Support Structure for Headgear With Integrated Ventilation and Anchoring

This application claims the benefit of the filing date of U.S. Provisional Application No. 63/645,869, filed May 11, 2024, the disclosure of which is hereby incorporated herein by reference.

Individuals who regularly wear head coverings—including religious attire such as hijabs, protective gear like helmets, or fashion accessories such as hats and wigs—commonly experience a constellation of problems affecting both comfort and hair health. These issues include flattened, lifeless hair; excessive scalp moisture leading to unpleasant odors; insufficient ventilation causing discomfort during extended wear; and inadequate adherence of the headgear itself, resulting in frequent readjustment and diminished confidence. Despite the widespread nature of these concerns, existing solutions have failed to comprehensively address the full spectrum of needs for headgear wearers.

Current market offerings typically address these challenges in isolation rather than holistically. Volumizing products and inserts focus primarily on aesthetic appearance without addressing ventilation or grip; moisture-wicking liners manage sweat but provide minimal structural support; and traditional foundation pieces like wig caps and bonnets often compress hair rather than preserving its natural volume. Furthermore, these conventional solutions typically lack the structural integrity to support heavier head coverings while maintaining comfort, resulting in trade-offs between functionality and wearability that leave users without an optimal solution.

The limitations of existing products highlight an unmet need for an integrated approach-one that simultaneously provides structural support to maintain hair volume, strategic ventilation to promote scalp health, secure anchoring to prevent shifting, and versatile compatibility with various headgear types. Additionally, conventional manufacturing methods have constrained the development of products with the precise combination of rigidity, flexibility, and textural elements required for optimal performance across diverse head shapes and headgear styles. Therefore, further improvements are desirable.

The present disclosure provides a headgear support structure configured to address the challenges faced by individuals who regularly wear head coverings. In one embodiment, the headgear support structure includes a rim defining a perimeter with a front edge, a rear edge, and opposing side edges. A wall extends between these edges, featuring an exterior surface and an interior surface. The exterior surface comprises a plurality of ridges that define grooves between them, while ventilation openings extend through the wall. A plurality of pins extend from the interior surface, each having a pin base connected to the interior surface and angled relative to it, providing secure anchoring in the wearer's hair.

In various embodiments, the wall is curved in multiple planes to conform to the curvature of a wearer's head, with the interior surface being concavely curved and the exterior surface being convexly curved. The pins may be arranged in specific configurations, including front-to-back pin rows extending generally from the front edge toward the rear edge, and side pin rows positioned along opposing side sections of the support structure.

The support structure may be formed as a single integrated unit using an additive layer manufacturing process, which can create a microtextured surface in the 20-70 micron range to enhance grip on both hair and fabric. The pins may be angled at approximately 65 degrees relative to the interior surface, optimizing hair engagement while maintaining comfort.

In some embodiments, the support structure includes precise dimensional specifications, with the width of each groove between adjacent ridges being approximately 1.4 mm, the width of each ridge being approximately 1.0 mm, and the height of each ridge being approximately 0.7 mm. The ventilation openings may have a length of approximately 3.5 mm, with wall segments between adjacent openings of approximately 2.4 mm. The wall thickness may be approximately 0.8 mm, with the total distance from the interior surface to the peak of each ridge being approximately 1.5 mm.

The support structure may feature ridges arranged in an arc pattern, with each ridge extending in an arc that originates at the rear edge or a rear portion of a side edge, intersects a bisecting plane of the support structure, and curves back toward the rear edge or a rear portion of the opposite side edge, providing multi-directional friction.

In another embodiment, the front edge of the support structure has an undulating profile forming concave segments at opposite sides of a bisecting plane and a convex segment that intersects the bisecting plane to form a front edge apex. Similarly, the rear edge may have an undulating profile with concave segments, a convex segment, and angular transitions that form a rearward-sweeping profile.

The support structure may be manufactured using additive layer manufacturing processes such as selective laser sintering (SLS) or Multi Jet Fusion (MJF), and may be formed from materials such as nylon or thermoplastic polyurethane (TPU), selected for their specific performance characteristics with different hair types and headgear applications.

depict a headgear support structure(or crown) according to an embodiment of the present disclosure. Support structureis configured to be worn underneath various types of headgear to promote hair and scalp health while providing enhanced stability for the headgear. As shown, support structuregenerally includes a rim, a wallhaving an exterior surfaceand an interior surface, ridgesformed on the exterior surface, groovesbetween the ridges, ventilation openings, and pinsextending from the interior surface.

Support structureis defined by rimwhich forms a perimeter of the device. As depicted, rimis continuous and helps provide structural support and the overall shape of support structure. However, in some examples, rimmay be discontinuous at various points along the perimeter of support structure. Such discontinuities may be strategically placed for enhanced flexibility at certain locations, for example. Rimmay also include flared, thinned, or flexible edge zones to reduce pressure against the scalp and improve long-term comfort during wear. These comfort features may be particularly beneficial at contact points that experience greater pressure during extended periods of use. Rimincludes a front edge, a rear edge, and opposing side edges.

Front edgeis configured to be positioned just above the wearer's hairline when in use. As such, front edgehas a curved profile configured to conform to the wearer's hairline. In this regard, support structuremay have a slight undulating profile extending from side-to-side. Specifically, a plane P(see e.g.,) extends in a front-rear direction, intersects front edge, and bisects support structure. The undulating profile of front edgeforms concave curves(or concave segments) disposed at opposite sides of plane Pwhich merge with a convex curve(or convex segment) that intersects plane Pso as to form a front edge apex, as shown in.

Rear edgesimilarly features an undulating profile forming concave curves(or concave segments) at opposite sides of plane Pand a convex curve(or convex segment) intersecting plane Pto form a rear edge apex. In contrast to front edge, rear edgefurther includes angular transitionsthat forms a rearward-sweeping profile in a side view (see). In other words, each concave segmentof rear edgetransitions through angular transitioninto a rearward-sweeping segmentthat extends from the angular transitionto a corresponding side edge. These angular transitionsproduce an abrupt directional change in the rearward direction, as opposed to a smooth or gradual rearward curvature.

Side edgesextend between front edgeand rear edgein a generally front-to-rear direction. In the illustrated embodiment, side edgeshave a generally convex curvature. As shown in, angular transitionsat rear edgedirect a rear portionof side edgesupward to meet the rearward-sweeping segmentsof rear edge. This geometry further contributes to the rearward-sweeping profile of support structure.

Support structurecan be further divided into sections based on their position relative to the wearer's head. In this regard, support structuremay have a center sectionand opposing side sections. Center sectionextends across the mid-scalp of the wearer's head, while opposing side sectionsare positioned proximate the wearer's ears and rearward of the wearer's temples. Side sectionsare at least partially defined by side edgesand rearward-sweeping segmentssuch that side sectionsproject more rearward than the center section.

Wallextends between the front edge, rear edge, and side edgesof rim, and defines an exterior surfaceand an interior surface(see). Wallhas a thickness defined between exterior surfaceand interior surface. In one example, the wall thickness is approximately 0.8 mm. As illustrated, wallis spherically curved, such that exterior surfaceis convexly curved and interior surfaceis concavely curved. In this regard, wallexhibits curvature in two orthogonal planes. For instance, wallis curved in plane P, as shown in the cross-section of, and is also curved in a plane perpendicular to plane P, as best depicted in. This spherical curvature enables wall, and thus support structure, to conform to the curvature of a wearer's head.

Although walland support structureare shown with spherical curvature, in other embodiments they may be flat, which may simplify manufacturing. As described below, support structuremay be formed from a flexible polymer material, allowing a flat configuration to bend and conform to the shape of the wearer's head during use.

Exterior surfaceincludes a plurality of ridgesthat project outwardly to define a series of groovesbetween adjacent ridges (see). In the illustrated embodiment, ridgesare arranged in an arc pattern, radiating in a series of curved paths. Each ridgeextends in an arc that originates at rear edgeor a rear portionof a side edge, intersects the bisecting plane, and then curves back toward rear edgeor the rear portionof the opposite side edge, as best shown in. This arrangement of ridgesforms a grip surfacethat provides frictional resistance to inhibit slippage of overlying headgear during use. Additionally, the arc-shaped configuration of ridgesimparts multi-directional frictional characteristics, thereby reducing the likelihood of headgear slipping in any direction relative to support structure.

In one example, the distance between adjacent ridges(i.e., the width of each groove) is approximately 1.4 mm. Each ridgehas a width of approximately 1.0 mm and a height of approximately 0.7 mm. Accordingly, the total distance from interior surfaceof wallto the peak of each ridgeis approximately 1.5 mm. This specific ridge configuration is configured to optimize both the frictional interface and the flexibility of support structure, while maintaining wearer comfort.

While the arc pattern of ridgesdescribed above provides enhanced multi-directional friction, in alternative embodiments, ridgesmay be arranged in different patterns to achieve varied functional or aesthetic objectives. For example, in one embodiment, ridgesmay be oriented linearly in a parallel configuration extending in a front-rear direction across exterior surface. In another embodiment, ridgesmay be arranged in a concentric pattern centered about a point on support structure, such as the apexof front edgeor the apexof rear edge, to create a radial grip effect.

In yet another embodiment, ridgesmay be arranged in an intersecting grid pattern, forming a network of raised intersections that provide omni-directional friction and increased surface texture. Alternatively, ridgesmay follow a wave-like or sinusoidal pattern that undulates across exterior surface, which may increase surface flexibility and dynamic grip properties. The arrangement, spacing, and shape of ridgesmay also be varied across different regions of support structureto provide zone-specific grip or structural characteristics.

Additionally, in some embodiments, ridgesmay be discontinuous, forming segmented or interrupted patterns that provide selective frictional zones. The ridge geometry may also be modified. For example, the cross-sectional shape of each ridgemay be rounded, triangular, trapezoidal, or otherwise contoured to optimize friction, compressibility, or comfort based on the intended application or overlying headgear configuration.

Within the groovesformed between ridgesare a series of ventilation openings. These openingsextend completely through wall, from interior surfaceto exterior surface. Ventilation openingscollectively form a ventilation system configured to promote airflow to the wearer's scalp, thereby reducing moisture accumulation and improving comfort during extended wear of headgear. In the illustrated embodiment, the ventilation openingsare rectangular in shape. In one example, each ventilation openinghas a length of approximately 3.5 mm, and each wall segment between adjacent openings may have a length of approximately 2.4 mm.

In alternative embodiments, the ventilation openingsmay have other shapes and arrangements. For example, openingsmay be circular, oval, hexagonal, or slot-shaped, depending on desired airflow characteristics and manufacturing considerations. Openingsmay also vary in size or density across different regions of support structureto provide zone-specific ventilation. In one embodiment, ventilation openingsare concentrated near front edgeto increase airflow where heat accumulation is greatest. In another embodiment, openingsmay be staggered or arranged in a diagonal or honeycomb pattern to enhance both structural integrity and airflow distribution.

In some embodiments, the ventilation openingsmay intersect ridgesrather than being located entirely within grooves. In yet another embodiment, ventilation openingsmay be selectively angled or contoured to direct airflow in a preferred direction relative to headgear movement or orientation.

Interior surfaceincludes a plurality of pinsarranged in multiple pin rows, which function as hair organization elements configured to engage and direct the wearer's hair. In the illustrated embodiment, pinsare arranged in various row configurations provided as examples. These include a plurality of front-to-back pin rows(see), which, in one example, comprises ten rows arranged in parallel pairs and generally extending from front edgeto rear edge. The configuration also includes a plurality of side pin rows(see), which, in one example, comprises four rows positioned along each side section of support structure. Additionally, at least one front edge pin row(see) follows the contour of front edgeand extends partially along the side sections to provide frontal and lateral hair guidance. The number, spacing, and orientation of the pin rows may vary in alternative embodiments to achieve desired performance characteristics and accommodate different wearer needs.

Each pinincludes a pin basethat is integrally formed with interior surfaceand a pin tipconfigured to engage the wearer's hair. A fillet is provided at the junction between pin baseand interior surfaceto create a smooth transition and reduce localized stress, thereby enhancing structural integrity and wearer comfort. Pin tipsare rounded or gently tapered to minimize discomfort and reduce the risk of scalp irritation during use. Pinsare angled relative to interior surfaceby a pin angle θ, which in one example is approximately 65 degrees, as shown in. The length of each pinis about 3 mm, for example. Minor variations in pin angle and length may be implemented in specific regions of the support structureto optimize hair alignment and accommodate variations in scalp shape. In this regard, the pin angle θ may vary within each row or from row-to-row.

In alternative embodiments, the arrangement of pinsmay vary to accommodate different hair types, densities, or user preferences. For example, pinsmay be arranged in a spiral or radial pattern to direct hair away from a central point or in a staggered configuration to enhance engagement across variable scalp contours. In another embodiment, pin rows may be non-linear, following contoured or arcuate paths that mirror natural hair growth patterns or conform to ergonomic scalp topography. Additionally, pin density may vary across the interior surface. For instance, a higher concentration of pinsmay be provided near front edgeto provide stronger retention, while fewer pinsmay be used near rear edgeor sides edgesto enhance comfort.

As described, support structureis configured to be compatible with a wide range of headgear types, each presenting unique functional requirements. With religious head coverings such as hijabs, support structureprovides volume maintenance while ensuring the fabric drapes naturally without slippage. For turbans, support structureoffers a stable foundation that maintains the wrapped fabric's position throughout daily activities. When used with wigs or hairpieces, support structure creates natural volume while securing the hairpiece firmly in place. For protective gear such as helmets, support structure provides additional comfort and stability while enhancing air circulation to reduce moisture buildup during extended wear. Fashion accessories such as hats benefit from improved positioning and reduced pressure against the scalp. The multi-directional friction provided by ridgesis helps accommodate the varying weights, textures, and draping characteristics of these different headgear types, making support structurea versatile solution across diverse cultural, professional, and recreational contexts.

The exemplary support structuredescribed herein may be formed layer-by-layer using an additive layer manufacturing (ALM) process (i.e., 3D printing) such that all of its components are formed together as a single, integrated unit without assembly requirements. ALM refers to any manufacturing process where objects are built by adding material layer upon layer, as opposed to subtractive manufacturing methods where material is removed from a solid block or blank of a base material. In some examples, ALM processes are powder-bed based and involve one or more of selective laser sintering (SLS), selective laser melting (SLM), and electron beam melting (EBM). Other methods of ALM, which can be used to form the herein described support structure, include stereolithography (SLA), fused deposition modeling (FDM), Multi Jet Fusion (MJF), and continuous liquid interface production (CLIP).

When employing powder-bed based technologies, articles are produced in layer-wise fashion according to a predetermined digital model of such articles by heating (e.g., using a laser or an electron beam) multiple layers of powder, which may be a polymer powder, that are dispensed one layer at a time. The application of laser energy directed in raster-scan fashion sinters the powder in the case of SLS technology or melts it in the case of SLM technology, targeting portions of the powder layer corresponding to a cross section of the article. After the sintering or melting of the powder on one particular layer, an additional layer of powder is dispensed, and the process repeated, with sintering or melting taking place between the current layer and the previously laid layers until the article is complete. The powder layers similarly may be heated with EBM technology.

Support structuremay be made from one or more polymer materials using at least one of the aforementioned ALM processes. Such materials may be selected to provide for various advantages for wearing particular type of headwear, such as hijabs and the like, and/or to accommodate certain characteristics of the wearer. For example, support structuremay be made from nylon which may be suitable for wearers with normal to thick hair as it can provide a porous, spongy texture and a level of friction suitable to prevent slippage of lightweight, smooth fabrics. Nylon's balanced combination of rigidity and lightweight properties helps maintain the desired shape of the headgear while allowing sufficient air circulation to prevent heat buildup during extended wear periods, and its dimensional stability ensures the support structure maintains its form over time. In another example, support structuremay be made from thermoplastic polyurethane (TPU) which offers greater flexibility than nylon and may be more beneficial for individuals with thin or low-density hair. TPU's enhanced elasticity allows it to conform more closely to the head's contours, creating a more secure fit, while its higher coefficient of friction helps prevent slippage even with minimal hair contact, and its resilience enables it to return to its original shape after compression for consistent performance. In both of these examples, the material of support structuremay feature a microtexture in the 20-70-micron range that enhances the device's ability to interact with both hair and headgear fabrics without causing discomfort. Such texturing creates thousands of microscopic contact points that interact with individual hair strands and fabric fibers to help prevent slippage and to help distribute pressure evenly across contact surfaces.

Variations of support structuremay be configured to accommodate specific user groups and scalp types. For individuals with sensitive scalps, the pinsmay feature softer tips, reduced density, or alternative geometries to minimize irritation while maintaining functionality. Pediatric versions may incorporate scaled dimensions, gentler pin angles, and enhanced flexibility to accommodate the unique head shapes and comfort requirements of children. For users with thicker hair or chemically treated hair types, pin configurations may be optimized with greater length, altered spacing, or specialized tip geometries to provide adequate engagement without tangling or causing damage to the hair structure.

In use, as illustrated in, support structureis positioned on the wearer's head such that the front edgesits just above the hairline, side sectionsare proximate the ears and rearward of the wearer's temples, and center sectionextends across the mid-scalp region of the head. Pinspickup hair and nestle comfortably within it to produce a comfortable grip that helps secure support structurein place. Pinsalso help organize hair patterns to promote scalp aeration. Support structure, and particularly ridges, functions to elevate headgear away from direct contact with the hair and scalp, creating space for the hair to maintain volume and allowing air circulation via ventilation openingsfor improved scalp health. Additionally, ridgesprovide friction to prevent the overlying headgear from slipping, enhancing wearer confidence and comfort during extended use.

After support structureis securely positioned on the head, headgear such as a hijab, for example, may be applied. When applying a hijab, the fabric is typically draped over the support structure, beginning at the front edgeand extending rearward to cover the entire support structure. The wearer may then secure or style the hijab according to personal preference or cultural requirements. During this application process, the ridgesimmediately engage with the inner surface of the hijab fabric, creating multiple contact points that generate friction and prevent slippage in any direction. This engagement is particularly beneficial when turning or tilting the head, as the multi-directional grip pattern maintains the hijab's position without the need for excessive tightness or additional pins. The ventilation openingscontinue to allow air circulation between the scalp and the hijab, reducing heat and moisture buildup that would otherwise accumulate during extended wear. The elevated structure created by support structuremaintains the natural contour and volume of both the hair and the hijab, providing an aesthetically pleasing appearance while ensuring long-term comfort and confidence for the wearer. Additionally, the spacing of ridgednot only promotes air circulation and grip, but also provides a flat appearance even for thin fabrics draped over support structure.

In some embodiments, an additional surface layer may be affixed or printed onto ridgesof exterior surfaceto enhance grip on low-friction materials such as silk or chiffon. This layer may comprise a higher-friction material, a specialized texture, or a polymer coating specifically configured to interact with smooth fabrics that would otherwise be prone to slippage. The additional layer may be applied selectively to specific regions of the exterior surface/ridges, or it may cover the entire ridged area, depending on the intended application and headgear compatibility requirements.

In another embodiment, support structuremay comprise a partial arc extending across only a portion of the scalp, configured for use in sports or low-profile applications. This reduced-size version maintains various features of the full-sized embodiment—including the ridged exterior surface, ventilation openings, and angled pins—while covering a smaller area of the head. Such a configuration is particularly suitable for wearers with shorter hair, athletes requiring minimal headgear support during physical activities, or any application where a lower profile is preferred.

In some embodiments, support structuremay include or accommodate attachable modular elements, such as hair-securing clips, fabric overlays, or scarf anchors, affixed through mechanical or adhesive interfaces. These modular elements may be configured to enhance functionality, provide additional security, or adapt the support structure for specific types of headgear or hair configurations. The support structuremay include specialized connection points, indentations, or receptacles configured to receive these modular elements in a secure and user-friendly manner

Although the subject matter disclosed herein has been described with reference to specific embodiments, these are merely illustrative of the principles and applications discussed. Numerous modifications can be made to these embodiments, including combining features from different embodiments. Therefore, the exemplary embodiments are not intended to be exhaustive or to limit the disclosed subject matter.