# US 2017/0280804 A1 · Hybrid sports shock absorbing cap > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0280804 A1 - Document ID: US20170280804A1 - Status: Published application - Kind: A1 - Application number: 15/626,950 - Filed: 2017-06-19 - Published: 2017-10-05 - Earliest claimed: 2015-11-25 - Assignees: The Ctfot Group LLC - Applicants: The CtFOT Group LLC - Inventors: Donna L. Avery - Web page: https://patentgrep.com/patent/US20170280804A1 ## CPC - A42B 1/08: with protection against blows - A42B 3/063: {using layered structures} - A42B 3/10: Linings (A42B3/16 takes precedence) - A42B 3/127: {with removable or adjustable pads} - A42C 1/00: Manufacturing hats - A63B 71/10: for the head ({A63B71/081 takes precedence } ; in the form of caps or hats A42B1/08; helmets A42B3/00) - D04C 3/00: Braiding or lacing machines - A63B 2243/007: American football - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) - A42C: MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS - A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H) - D04C: BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE (machines for making soles from strips of material A43D29/00; cane working B27J1/00) ## Abstract A shock absorbing cap provides shock abortion in the space between the interior of a traditional safety helmet and the head of the wearer. The cap has a first region next to the scalp which is made of 100% knitted cotton for comfort and the absorption of sweat. A second region is made of 100% wool fleece braided fiber bundles that extend alternately in longitudinal and lateral directions sufficiently to nearly fill the space. The outermost region is made of one or more layers of braided 100% carbon fiber bundles, which run the opposite direction of the last wool lock. In an alternative, the first region is used but the second region completely fills the space with woven aramid and carbon fiber squares laid on top of each other and sewn together. The uppermost portion is laser cut for a tight but comfortable fit under the helmet. ## Claims ### Claim 1 A cap that provides additional force or shock abortion between the interior of a safety helmet and the head of the wearer, comprising: a first region, which is next to the head of the wearer, being formed as a ground cap, said first region being made from at least a first layer of knitted fiber bundles that extend either longitudinally or laterally of the wearer's head, said first region being substantially made of cotton fibers; a second region attached to the ground cap, said second region being made of a plurality of second layers of braided fiber bundles laid densely together so as to interlock with each other, said second layers of fiber bundles being substantially made of wool fleece and extending alternately either longitudinally or laterally of the wearer's head so as to nearly fill a space between the ground cap and the interior of the helmet; and a third region attached to the uppermost layer of the second region and which is the outermost region of the cap, said third region being adapted to engage the interior of the helmet, said third region being made of at least one third layer of braided fiber bundles that run either longitudinally or laterally of the wearer's head, said third layer of fiber bundles being substantially made of carbon fibers. ### Claim 2 (depends on 1) The cap of claim 1 wherein the first layer of fiber bundles is made of 100% cotton fibers. ### Claim 3 (depends on 1) The cap of claim 1 wherein the second layer of fiber bundles is made of 100% wool fleece. ### Claim 4 (depends on 1) The cap of claim 1 wherein the third layer of fiber bundles is made of 100% carbon fibers. ### Claim 5 (depends on 1) The cap of claim 1 further including a fourth layer between the first layer ground cap and the head of the wearer, said fourth layer being formed with a padded scrim to prevent exposed threads of the first layer from contacting the head of the wearer. ### Claim 6 (depends on 5) The cap of claim 5 wherein the fourth layer is made of knitted 100% cotton fibers. ### Claim 7 (depends on 1) The cap of claim 1 wherein the number of second layers in the second region is sufficient to provide cushioning of the wearer's head against impacts on the helmet and are located so as to compensate for the distance between variations in the user's head and the interior of the helmet. ### Claim 8 (depends on 1) The cap of claim 1 wherein a lowermost second layer of the second region extends in a direction orthogonal to an uppermost first layer of the first region and a lowermost third layer of the third region extends in a direction orthogonal to an uppermost second layer of the second region. ### Claim 9 A method for making a shock absorbing cap that provides additional force or shock abortion between a safety helmet and the head of the wearer, comprising the steps of: forming a ground cap by cutting two knitted cotton cloths to fit the outline of the scalp and the head, said ground cap being a first region of the cap with at least one knitted cotton layer; braiding clean wool fleece to form a second layer; densely laying together a plurality of second layers of braided fiber bundles so they interlock with each other and form a second region of the shock absorbing cap; attaching a lowermost second layer of the second region to an uppermost first layer of the first region; braiding carbon fibers to form at least one third layer as a third region; and attaching the third region to an uppermost layer of the second region. ### Claim 10 (depends on 9) The method of claim 9, wherein the shock absorbing cap is custom made, further including the steps of: placing a plastic cape on the wearer to cover the wearer's scalp, eyes and ears; placing a helmet on the head of the wearer, which helmet has holes; pouring a molding material into the holes so as to create a 3D mold of the space between the head of the wearer and the interior of the helmet; removing the helmet and measuring the dimensions of the mold; determining the number of second layers of braided fiber bundles to be used to fill the space between the head of the user and the interior of the helmet, giving regard to the thickness of the first region and the third region. ### Claim 11 (depends on 10) The method of claim 10, wherein the molding material is Plaster of Paris. ### Claim 12 (depends on 10) The method of claim 10, further including the steps of placing the mold in a container, surrounding it with another molding material, and after solidification of the second molding material the first molding materials is removed leaving a void that replicates the void between the head of the user and the interior of the helmet. ### Claim 13 (depends on 12) The method of claim 12 wherein molding material is wax and the second molding material is plaster of Paris. ### Claim 14 (depends on 9) The method of claim 9, wherein the shock absorbing cap is made in standard sizes, further including the steps of: forming different sizes by varying the number of second layers of braided fiber bundles to form the second region. ### Claim 15 (depends on 9) The method of claim 9, wherein the step of forming a ground cap involves trimming the ground cap to fit the wearer's head in the fashion that a lace front is fitted for a wig. ### Claim 16 (depends on 9) The method of claim 9 wherein the step of braiding the carbon fibers to form a third layer, comprises the steps of: making the wool into wool roving; braiding the wool, looping it and locating it on long smooth tubes; clipping the wool to retain its shape; washing, scouring and rinsing the wool to remove impurities; and immersing the wool into hot water to lock the braids and combing it. ### Claim 17 (depends on 9) The method of claim 9 wherein the step of braiding clean wool fleece to form a second layer, comprises the steps of: teasing the strands of carbon fiber yarn; and braiding the yarn to form a layer. ### Claim 18 (depends on 9) The method of claim 9 further including the step of: securing a cotton scrim to the interior of the ground cap so as to prevent the threads of the ground cap from being exposed and irritating the scalp of the user. ### Claim 19 (depends on 18) The method of claim 18 wherein after the step of securing the cotton scrim, a lace front is applied to the ground cap. ### Claim 20 A cap that provides additional force or shock abortion between the interior of a safety helmet and the head of the wearer, comprising: a first region, which is next to the head of the wearer, being formed as a ground cap, said first region being made from at least a first layer of knitted fiber bundles that extend either longitudinally or laterally of the wearer's head, said first region being substantially made of cotton fibers; and a second region attached to the ground cap, said second region being made of a plurality second layers of woven squares of a yarn mixture of 100% aramid as the filling and 100% carbon in the warp, said squares being laid densely together so as to interlock with each other to form a triaxial weave, and extending so as to nearly fill a space between the ground cap and the interior of the helmet. ### Claim 21 (depends on 20) The cap of claim 20 wherein the woven squares are alternating layers of 2-ply 100% aramid warp yarns mixed with 4 to 8-ply 100% carbon filling yarn fiber. ### Claim 22 A method for making a shock absorbing cap that provides additional force or shock abortion between a safety helmet and the head of the wearer, comprising the steps of: forming a ground cap by cutting two knitted cotton cloths to fit the outline of the scalp and the head, said ground cap being a first region of the cap with at least one knitted cotton layer; densely laying together a plurality of woven squares of a yarn mixture of 100% aramid as the filling and 100% carbon in the warp, said plurality of woven squares being a second region of the cap; attaching a lowermost second layer of the second region to an uppermost first layer of the first region; and laser cutting at least the top most layers of the second region to shape the cap to fit in a space between a safety helmet and the head of the wearer. ### Claim 23 A cap that provides additional force or shock abortion between the interior of a safety helmet and the head of the wearer, comprising: a first region, which is next to the head of the wearer, being formed as a ground cap, said first region being made from at least a first layer of knitted fiber bundles that extend either longitudinally or laterally of the wearer's head, said first region being substantially made of cotton fibers; and a second region attached to the ground cap, said second region being made of a plurality of second layers laid densely together so as to interlock with each other, said second layers extending so as to nearly fill a space between the ground cap and the interior of the helmet. ### Claim 24 (depends on 23) The cap according to claim 23 wherein the second layers are made of wool fleece braided fiber bundles extending substantially alternately either longitudinally or laterally of the wearer's head; and further including a third region attached to the uppermost layer of the second region and which is the outermost region of the cap, said third region being adapted to engage the interior of the helmet, said third region being made of at least one third layer of braided fiber bundles that run either longitudinally or laterally of the wearer's head, said third layer of fiber bundles being substantially made of carbon fibers. ### Claim 25 (depends on 23) The cap according to claim 23 wherein said second region is made of a plurality of woven squares of a yarn mixture of 100% aramid as the filling and 100% carbon in the warp, said squares being interlocked with each other to form a triaxial weave.