CN116133549A

CN116133549A - Helmet attachment system and sunshade visor

Info

Publication number: CN116133549A
Application number: CN202180061097.5A
Authority: CN
Inventors: T·A·齐林格; P·W·麦卡锡; C·C·亚当斯; N·Z·萨默塞特; S·M·克莱因
Original assignee: Milwaukee Electric Tool Corp
Current assignee: Milwaukee Electric Tool Corp
Priority date: 2020-08-17
Filing date: 2021-08-10
Publication date: 2023-05-16
Also published as: US20220047033A1; AU2021328139A1; CA3188089A1; EP4195969A1

Abstract

A universal mounting system for a helmet is provided that includes a front mounting location and a rear mounting location and an auxiliary ridge on either side. The visor is coupled to the headgear mounting system in a manner that minimally impedes access to equipment attached to the mounting location and the ports in the auxiliary ridge from the visor. The various embodiments of the shield enable modular designs incorporating different materials and features of the shield. The parallel stretching regions are capable of folding and holding the opposite edges of the visor. The closed elastic region along the inside of the visor allows the user to reach the auxiliary ridge. Combinations of various accessories on a helmet are discussed as to how these accessories work together on a universal mounting system: such as the interaction between the visor, earmuffs, face shields and lights.

Description

Helmet attachment system and sunshade visor

Cross-reference to related patent applications

The present application claims the benefit and priority of U.S. provisional application No. 63/167,458 filed on 29 of 3 months 2021, U.S. provisional application No. 63/162,736 filed on 18 of 3 months 2021, U.S. provisional application No. 63/087,578 filed on 5 of 10 months 2020, and U.S. provisional application No. 63/066,561 filed on 17 of 8 months 2020, each of which is incorporated herein by reference in its entirety.

Background

The present invention relates generally to the field of helmets and helmets. The present invention relates in particular to visor and/or other safety device accessories attached to a helmet. Helmets are often used in noisy and brightly lit areas, such as construction sites on sunny days. The work environment at the various work sites may enable additional safety devices (e.g., earmuffs and/or facial protectors) to be used to provide additional protection to the user.

The sunshade visor can protect the face and/or neck of a user from sunburn and/or from debris falling overhead. The light or flashlight may aid vision in environments with insufficient light or low visibility or during a change from a lighted work environment to a dimmed work environment. Additional ear protection or earmuffs help to protect the user's hearing in a noisy environment.

Disclosure of Invention

One embodiment of the present invention relates to a headgear system that includes a headgear and a visor. The headgear includes a shell formed of a rigid material and an accessory mounting location positioned along an outer surface of the shell. The visor is reversibly coupled to the helmet. The visor includes a first portion and a second portion. The first portion extends circumferentially around at least a portion of the shell and extends radially outward from the shell to form a sun protection flange. The second portion is coupled to the first portion and is positioned adjacent to the accessory mounting location. The second portion is deformable relative to the first portion such that the second portion deforms to accommodate and cover a portion of an accessory coupled to the accessory mounting location, thereby allowing the accessory to extend from the accessory mounting location to below the second portion.

Another embodiment of the invention is directed to a headgear system that includes a headgear and a visor. The headgear includes a shell formed of a rigid material. The visor is reversibly coupled to the helmet. The visor includes a front portion and a rear portion. The front portion is movable between a covering configuration in which the front portion extends away from the front of the helmet in a forward direction and a stowed configuration in which the front portion extends away from the rear of the helmet in a rearward direction.

Another embodiment of the present invention is directed to a headgear system comprising: a headgear including a shell formed of a rigid material, a clip coupled to the headgear, and a shield. The clip includes an engagement portion including an upper surface and a lower surface. Each of the upper and lower surfaces faces in an upward direction. The clip is configured to be coupled to the helmet in a first position or in a second position. The upper surface engages the helmet when the clip is in the first position and the lower surface engages the helmet when the clip is in the second position. The upper surface is spaced above the lower surface. The visor is coupled to the clip such that the visor is reversibly supported to the helmet via the clip and extends circumferentially around a portion of the helmet.

One embodiment of the present invention relates to a headgear attachment system. The helmet includes a mounting location that includes opposing dovetail ridges that project outwardly on either side of the mounting location. Each ridge includes a transition to couple with a slot of a bracket and support an accessory (e.g., a light, a face guard, and/or a visor). Each ridge extends outwardly from the mounting location to create a protrusion that supports a mounted accessory. Sunshade shields (e.g., extended rims or shields) are coupled to the headgear at mounting locations or extended ridges to shield the eyes, face, and/or neck of the wearer from sunlight/UV rays and/or falling debris, etc.

Another embodiment of the invention relates to a visor configured for selective attachment to a helmet. The shield includes an inner diameter and an outer diameter. The visor includes a front edge and a rear edge. The front rim is positioned to extend outwardly from the front surface of the helmet and the rear rim is positioned to extend outwardly from the rear surface of the helmet. A tensile zone extends radially from the inner diameter to the outer diameter and is located between and interconnects the front and rear rims. A fastener is coupled to the tension zone and is configured to couple to an accessory ridge on the helmet to removably secure the visor to the cap. In some embodiments, the visor includes a bracket positioned to engage one or more mounting locations on the helmet to secure the visor to the helmet. In particular embodiments, a bracket is positioned on the front shield or the rear shield to engage the front mounting ridge or the rear mounting ridge of the helmet.

In various embodiments, the shield includes a single tension zone that allows the outer diameter of the shield to expand to accommodate different sized helmets. In this embodiment, a single stretch zone is located between opposite ends of the two visor sections, allowing the visor size/circumference/inner diameter to be adjusted to accommodate different sized helmets.

In various embodiments, the front edge includes a first end facing the first end of the rear shield and a second end facing the second end of the rear shield. In this arrangement, a first tension zone is coupled between the first ends of the front and rear shields, and a second tension zone is coupled between the second ends of the front and rear shields. In this arrangement, by having multiple tension zones, for example, on opposite sides of the visor section, a parallel-tensioned visor is provided that is tensioned in a direction between the front and rear rims, allowing the distance between the front and rear visor to expand between a minimum distance and a maximum distance. In this configuration, the flexibility of the material of the stretch zone also provides a folded position between the front and rear shields on each side of the shield. This allows the user to fold the front edge onto the rear edge and vice versa to customize the edge position of the visor.

Another embodiment of the invention is directed to a modular visor. The modular visor has a first module or rim section or rim segment that extends partially around the perimeter of the helmet. The modular shields enable a user to customize the combination of the rim segments and/or the accessories. For example, the user couples the rear modular rim section to a face guard located in the front of the helmet. The user customizes a first modular rim section made of translucent material at the front and couples it to a second modular rim section made of opaque material at the rear. Modular sunshade shields are used in variants with other accessories and/or segments. The segmentation of the modular visor enables a user to combine different modules made of different materials or features.

Another embodiment of the invention is directed to a helmet shield that includes a closed elastic region within the rim of the shield. The closed resilient area extends radially outwardly from the inner diameter toward the outer diameter of the shield and is located on opposite lateral sides of the rim. In particular, the closed elastic region is positioned adjacent to the auxiliary ridge of the helmet and extends outwardly from the auxiliary ridge a radial distance that is less than the distance to the outer diameter. In this way, the elastic zone does not extend over the entire radial length between the inner edge and the outer edge of the visor and forms an elastic inner edge coupled to the rigid outer edge. When the accessory is attached to the auxiliary ridge, the elastic region expands or deflects. For example, the support arm of the earmuff or facial shield is coupled to the port in the auxiliary ridge by deflecting the elastic region, but otherwise the visor need not be removed or adjusted. In this way, the earmuff is removed and rotated away from the user's ear without the need to remove or adjust either the safety helmet or visor.

Another embodiment of the present invention is directed to a visor for a sun shade having a front edge and a rear edge coupled by two opposing tension zones. The sunshade shield has a wire extending along an outer diameter. The front rim includes a translucent material and a liner along an inner diameter of the front rim. The cushion creates a bumper that deflects for different sizes or styles of headgear. The tension zone is coupled to the auxiliary ridge at a pivot joint that biases the shield around the outer perimeter of the helmet. The tension zone and cushion deflect to accept a change in the size of the accessory for attachment in the mounting location or port of the auxiliary ridge without the need to remove or adjust the shield. The cushion fits over and/or around an additional accessory (e.g., a face guard) attached at the mounting location of the headgear. The shield is folded about a spring-loaded joint or biased pivot to adjust the frictional grip of the inner diameter of the shield against the outer periphery of the helmet. The offset pivot also includes a joint coupling the visor to the mounting location or auxiliary ridge of the helmet.

In various additional embodiments, the visor is configured for use with any style or size of helmet or headgear (e.g., conventional style or climbing style) including a mounting location and/or auxiliary ridge. In this manner, a universal mounting system including mounting locations and auxiliary ridges is compatible with various accessories and is configured to work with the visor described herein. The visor may include a bracket coupled to the front mounting location or the rear mounting location. For example, a cutout on a face of the mounting location secures and removably locks the bracket against the mounting location. For example, the cutout may fit within an internal groove of the bracket to lock the bracket against the cutout at the mounting location. In another embodiment, the shield slides along the outer periphery of the helmet below the incision, and a bracket is coupled over the shield to compress the shield and securely lock the shield below the incision.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

Drawings

The present application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements, and in which:

fig. 1 is a front-edge-worn helmet with a forward accessory mounting location according to an exemplary embodiment.

Fig. 2 is a safety helmet with a rearward accessory mounting location, worn with a rim facing rearward, according to an exemplary embodiment.

Fig. 3 is a detailed view of a light attachment connected to a rigid bracket according to an exemplary embodiment not yet connected at a forward mounting position.

Fig. 4 is a comparison of a cap bill style helmet and a rim helmet supporting an earmuff according to an exemplary embodiment.

FIG. 5 is a cross-sectional comparison of the cap bill style helmet and rim helmet of FIG. 3, according to an exemplary embodiment.

Fig. 6 illustrates a mounting location of a headgear for mounting hardware (e.g., earmuffs) over a neck base according to an example embodiment.

Fig. 7 is two perspective views of a modular visor according to an exemplary embodiment.

Fig. 8 illustrates how the visor of fig. 7 is coupled to a bill-style helmet and a rim helmet according to an example embodiment.

Fig. 9 is a top perspective view of a visor that is supported on an outer perimeter of a helmet according to an exemplary embodiment.

Fig. 10 is a perspective side view of the visor for sunshade of fig. 9 according to an exemplary embodiment.

Fig. 11A is a perspective view of a visor having a parallel stretched visor with two stretching zones according to an exemplary embodiment.

Fig. 11B is a perspective view of a visor having one tension zone according to an exemplary embodiment.

Fig. 12 is a top perspective view of the parallel stretched visor of fig. 9 in a folded configuration according to an exemplary embodiment.

Fig. 13 is a top side view of the visor of fig. 9 in a folded configuration according to an exemplary embodiment.

Fig. 14 is a side view of the visor of fig. 9 in a folded configuration according to an exemplary embodiment.

Fig. 15 is a perspective view of another embodiment of a modular visor according to an exemplary embodiment.

Fig. 16 illustrates a modular visor and a folded visor located at the front and rear of a helmet, respectively, according to an exemplary embodiment.

Fig. 17 is a top perspective view of a modular visor coupled to a face guard attachment according to an exemplary embodiment.

FIG. 18 is a perspective view of a modular visor having a front translucent material segment coupled to a rear opaque material segment according to an exemplary embodiment; the modular shields are coupled to each other and to the headgear with a fastened joint.

Fig. 19 is a perspective view of a closed stretched elastic region within a rim of a visor and positioned adjacent to a secondary ridge of a helmet, according to an example embodiment.

Fig. 20 is a perspective view of the closed elastic region of the visor embodiment of fig. 19 according to an exemplary embodiment.

Fig. 21 is another embodiment of a multi-material visor according to an exemplary embodiment that includes a cushion, wire, and/or bracket for adjustably coupling the visor to a different size and shape headgear with a variety of different attached accessories (e.g., a face shield).

Fig. 22 is a perspective view of the visor of fig. 21 according to an exemplary embodiment.

Fig. 23 is a perspective view of a visor according to an exemplary embodiment.

Fig. 24 is a detailed perspective view of the visor of fig. 23 according to an exemplary embodiment.

Fig. 25 is a top view of a portion of the visor of fig. 23 according to an exemplary embodiment.

Fig. 26 is a perspective view of the visor of fig. 23 according to an exemplary embodiment.

Fig. 27 is a perspective view of the visor of fig. 23 according to an exemplary embodiment.

Fig. 28 is a side view of the visor of fig. 23 coupled to a helmet according to an exemplary embodiment.

Fig. 29 is a side view of the visor of fig. 23 coupled to a helmet according to an exemplary embodiment.

Fig. 30 is a detailed perspective view of a portion of the visor of fig. 23 according to an exemplary embodiment.

Fig. 31 is a detailed perspective view of a portion of the visor of fig. 23 according to an exemplary embodiment.

Fig. 32 is a perspective view of a portion of the visor of fig. 23 according to an exemplary embodiment.

Fig. 33 is a perspective view of the visor of fig. 23 according to an exemplary embodiment.

Fig. 34 is a cross-sectional view of a portion of the visor of fig. 23, according to an exemplary embodiment.

Fig. 35 is a perspective view of the visor of fig. 23 according to an exemplary embodiment.

Fig. 36 is a perspective view of the headgear and visor of fig. 31 according to an exemplary embodiment.

Fig. 37 is a perspective view of a headgear according to an exemplary embodiment.

Fig. 38 is a perspective view of a frame according to an exemplary embodiment.

Fig. 39 is a perspective view of the frame of fig. 38, according to an exemplary embodiment.

Fig. 40 is a perspective view of a headgear system including a face guard and a frame according to an exemplary embodiment.

Fig. 41 is a perspective view of a frame according to an exemplary embodiment.

Detailed Description

A headgear accessory system is shown and described with general reference to the accompanying drawings. Helmets include conventional edge style helmets and climbing style helmets having a small visor on the front only, for example. Unless specifically indicated, applicants use the term "headgear" to include both traditional style headgear and climbing style headgear, as well as any headgear or protective helmet design (including helmets having a universal mounting system with a mounting location and auxiliary ridge). Different sizes and styles of helmets present challenges to the size and dimensions of a consistent mounting system. The universal mounting system includes a front mounting location and a rear mounting location and auxiliary ridges on opposite sides. The mounting system provides a consistently sized attachment and location for mounting a variety of different accessories on a variety of different sizes and styles of helmets. Applicants have found that visor attachments mounted to a consistent mounting system can also provide operators with multiple points of access for mounting additional personal/safety devices at the mounting ridge and side ports. This enables the user to customize the headgear for job site and personal preferences, which enhances user compliance and proper use of the appropriate safety equipment based on job specifications. As used herein, an accessory typically includes a light (or headlight), a face guard, and/or an earmuff, but may also include a reflector, a magnetic tool holder or tool/fastener holder, a manual/power tool, and/or an eyeglass/goggles holder.

The visor expands the rim of the helmet to shield the eyes of the user, to protect the eyes of the user from direct sunlight at the construction site, to block/protect the eyes/front of the face from light debris and dust, etc. The mounting system of attaching a variety of different accessory attachments to the headgear sometimes prevents other previously installed equipment. For example, an operator may frequently wear and remove earmuffs at a job site, which would require the operator to adjust the shields and earmuffs up/down on the helmet. The applicant has found that the support on the mounting system for rotating the earmuff enables the user to frequently switch the wearing and storage of the earmuff when the earmuff is not in use (e.g. away from and behind the user's ear). The ability to switch between the use and storage positions enhances user comfort, particularly when the switch minimizes adjustment of other attached accessories such as shields. Thus, in various embodiments discussed below, applicants have developed an innovative modular shield that includes undulating portions (such as flexible expansion segments and/or portions that are less tensioned than adjacent portions) that allow a user to adjust the earmuff without removing the shield. The applicant has also developed an innovative modular visor that allows a user to fold the front and/or side portions of the visor towards the rear, allowing the user to attach other accessories and/or attachments to the front and/or side of the helmet without requiring the user to remove the visor.

Fig. 1 shows an operator wearing a helmet 10. Fig. 1 is a rim 12 style or conventional headgear 10 in that the rim 12 encircles and/or extends around the front 14 and rear 15 of the headgear 10. As used herein, the rim 12 is an extension on or attached to the helmet 10 to protect from the sun or debris. For example, sunshade shields are used to spread the rim 12 and create additional sun or debris protection. Generally, the headgear 10 is generally referred to as a rim (e.g., conventional) and visor (e.g., climbing helmet) style headgear 10, unless explicitly stated otherwise.

As illustrated, the helmet 10 is oriented in a forward direction, with the front mounting location 16 above the visor, ridge, bill, or rim 12 of the front portion 14 of the helmet 10. In this configuration, the front edge 12 is located at the front 14 of the helmet 10, protecting the eyes of the operator from the sun, for example. In the illustrated position, the rear 15 of the helmet 10 is behind the user's head and provides a smaller rim 12 to conceal the user's neck.

Fig. 2 shows the reverse helmet 10 such that the front portion 14 is behind the user's head and the rear portion 15 is above the eyes. The rear mounting locations 16, which are the same or similar to the front 14 mounting locations 16, are reversed. In other words, the rear 15 mounting location 16 is located above the eyes of the user and may be used to attach an accessory 18 (fig. 3 and 9, e.g., a light 20 or a face guard 22) to the helmet 10. In both fig. 1 and 2, each attached accessory 18 (such as a headlight and/or a facial shield) includes a mounting bracket 24 (fig. 3) that is securely attached to a ridge 25 on the front 14 mounting location or the rear 15 mounting location 16 of the helmet 10.

Fig. 3 shows a bracket 24 at the mounting location 16 for attaching a headlight or lamp 20 to the helmet 10. In some embodiments, the attachment system includes a mounting bracket 24, a light 20, and a strap 28. The bracket 24 includes a clip or receiving slot 30 that engages a ridge 25 on the front or rear mounting location 16 of the helmet 10. The brackets 24 provide structural support for the lamp 20 and provide a rigid attachment location to secure the lamp 20 to the helmet 10. The strap 28 interconnects the lights 20 with the bracket 24 and provides a mechanism for attaching a variety of different lights 20 (including after market lights) with the strap 28 at the receiving support or mounting location 16 of the headgear 10.

The strap or band 32 is wrapped around the circumference of the helmet 10 without interfering with the mounting location 16 or the auxiliary ridge 26. For example, the strap 32 passes through an opening below the auxiliary ridge 26. The strap 32 supports a hand tool and/or other device suitable for storage along the rim 12 or auxiliary ridge 26 of the helmet 10. Similarly, a variety of different accessories 18 are attached or coupled to ports 34 in the auxiliary ridge 26 of the helmet 10. In some embodiments, the tool and/or other accessory 18 includes an insert, fastener, or receiving slot 30 coupled with one or more ports 34.

Figures 1 and 2 show different sized ports 34. The smaller port 34 accommodates a smaller accessory 18 (e.g., a tool or an eyeglass holder). Similarly, the larger port 34 is for a larger accessory 18 (e.g., earmuff 38). In some embodiments, the front, middle, and/or rear ports 34 may be interchangeable to receive and/or support a variety of different accessories 18. For example, the rear port 34 is positioned along the axial axis 40 and at the centerline of the operator's neck. When the accessory 18 is coupled to the rear port 34, the accessory 18 is aligned with the axial axis 40 to reduce moment or load on the user's neck.

Fig. 4 compares the left side white cap bill 42 style with the center green rim 12 style of the helmet 10. The cap bill 42 style of the helmet 10 has the cap bill 42 at the front 14 (e.g., above the user's eyes) but does not encircle the rim 12 of the side (e.g., ear) and/or rear 15 (e.g., neck) of the helmet 10. In contrast, the rim 12 style of headgear 10 has a rim 12 that at least partially encircles and extends around the front 14, rear 15 and/or sides of the headgear 10. For example, fig. 1-3 illustrate a safety helmet 10 in the form of a rim 12. Applicants have found that users have a preference for different styles of headgear 10. For example, the rim 12 pattern may be symmetrical/balanced from the front 14 to the rear 15, while the bill 42 pattern enables the user to rotate the earmuff further upward without interference from the surrounding rim 12. Different styles of helmets 10 having different geometries may have the same or similar mounting locations 16 supporting the same accessories 18.

On the left side of fig. 4, a composite image of the visor 42 and the rim 12 of the helmet 10 is shown. In this composite image, bai Maoshe (e.g., the white bill of a bill-style climbing helmet) extends farther in the front portion 14. The expanded rim 12 pattern (e.g., the conventional pattern) extends farther on the sides and rear 15 of the helmet 10. The bill 42 and rim 12 both the headgear 10 are shown supporting the earmuffs 38 in the rearward ports 34. As shown, the left white bill 42 does not interfere with rotation of the earmuff 38 to a position above and/or behind the user's ear. The intermediate image shows the earmuffs 38 stored behind the operator's ears but below the rim 12 to minimize interference with the earmuffs 38 at the rearward rim 12 of the helmet 10.

Typically, a user attaches a plurality of different accessories 18 at different locations (e.g., mounting locations 16 and/or ports 34) to maximize utility (e.g., accommodate more accessories 18) and/or comfort. The right side composite image shows the earmuffs 38 in the rear ports 34. In this position, when the earmuff 38 is in the illustrated operational position, the earmuff 38 extends substantially parallel to the axial axis 40 and over the user's ear. For example, the user places the earmuff 38 in the third or rear port 34 because this attachment location for the earmuff 38 is closer to the centerline or axial axis 40 of the operator's neck (e.g., the base of the user's head). Alternative locations of the appendage 18 may facilitate occlusion and/or muscle comfort, for example, by bringing the mass or CG as close as possible to the axial axis 40 at the centerline.

In other words, the accessory 18 fits differently on the helmet 10 in different styles and/or geometries. However, where the mounting locations 16 and/or the auxiliary ridges 26 are the same or similar for different helmets 10, they interchangeably receive the accessory 18 with the complementary mounting bracket 24 (or insert).

Fig. 5 is a cross-sectional comparison of the bill 42 style helmet of fig. 4 and the rim 12 style helmet 10. As shown, in various embodiments, the headgear 10 has a full rim 12 (e.g., a rim 12 pattern) or a large bill 42 (e.g., a bill 42 pattern) that does not encircle the rim 12. The mounting location 16 is different for the bill 42 style of helmet 10 and the rim 12 style of helmet. For example, a comparable size helmet 10 has an offset between the short edge 12 (brim 12 style) of the helmet 10 and the long bill 42 (bill 42 style) of the helmet at the mounting location 16.

Fig. 6 shows an expandable shield 48 that surrounds and clamps or is directly coupled to the auxiliary ridge 26 and/or the mounting location 16 on the helmet 10, e.g., similar to the strap 32. The shield 48 is coupled below the mounting location 16 and/or the auxiliary ridge 26 in a manner that leaves the port 34 and mounting location 16 available for the additional accessory 18. The shield 48 is made of a flexible material such as fabric, polymer, or plastic. In one embodiment, the visor 48 includes a front portion 50 and a rear portion 52 interconnected by a resilient section 54. The resilient section 54 enables a user to stretch the visor 48 around the auxiliary ridge 26 and the mounting location 16.

The shield 48 is coupled along the outer periphery 88 of the helmet 10 below the mounting location 16 and the auxiliary ridge 26. As shown in fig. 6, the shield 48 is deflected to rotate/move the earmuff 38 from an operative position 56 below the shield 48 to a storage position 58 of the earmuff 38 above the shield 48. Furthermore, the resilient section 54 enables the shield 48 to provide some slack when the earmuff 38 is moved from the operating position 56 over the shield 48 to the storage position 58. The flexible nature of the shield 48 and/or the resilient section 54 facilitates movement and return from a use position (e.g., the operational position 56) to the storage position 58.

Fig. 7 shows two perspective views of visor 60 with mounting bracket 24 attached to mounting location 16 on helmet 10. Visor 60 functions similarly to visor 48 for a particular accessory (e.g., face shield 22), but may be modular and segmented. For example, the visor 60 enhances the use of the face guard 22 with different styles and sizes of headgear 10. An additional outer mounting location 16 on the shield 60 supports the accessory 18 on the helmet 10 and an enlarged peak or ridge extension 62 projects radially outwardly between the mounting location 16 and the edge of the shield 60. In this manner, the shield 60 provides cross-compatibility between different helmets 10 (including the bill 42 and the rim 12) of different sizes and styles. In addition, the shield 60 provides additional mounting locations 16 for other accessories 18.

The visor 60 provides a space or bridge for the accessory 18 (such as the light 20) to remain attached to the helmet 10 as the operator moves the face guard 22 from the operational position 56 to the storage position 58 and back. Visor 60 also provides a reliable structural abutment or seal between face guard 22 and any style of headgear 10, wherein mounting locations 16 (or auxiliary ridges 26) are configured for brackets 24 on visor 60. In this manner, visor 60 facilitates coupling welding face guard 22 and lamp 20 to mounting location 16. As a specific example, this configuration is beneficial when welding because the conventional welding face guard 22 is dark to protect the eyes from arcing, but is typically too dark to be seen in ambient light. Operators often find it difficult to see and manipulate work piece objects when the face guard is in the operative position but the welding arc is not lit. The lamp 20 may provide sufficient light to the operator to see and manipulate the welding workpiece before and after the welding process without arcing.

Visor 60 provides a structural and spatial bridge between helmet 10 and face guard 22 for structural support of the other attached accessory 18. This enables two accessories 18 (e.g., a welding mask and a headlight) to be coupled at the mounting location 16 of the helmet 10. Ridge extensions 62 on shield 60 (e.g., brackets 24 of shield 60) provide a structured offset or bridge from helmet 10 to shield 64 to accessory 18.

The shield 60 has a bracket 24 with repeated mounting locations 16 on the exterior of the shield 60 to accommodate the mounted accessory attachment 18. For example, on one side (e.g., the inner surface) of the visor 60 is a mounting bracket 24 (similar to the lamp 20) having a ridge 25. When the bracket 24 of the visor 60 is coupled to the mounting location 16, the opposite exposed side (e.g., outer surface) of the visor 60 forms an available external mounting location 16 to receive and support an additional accessory 18, such as a light 20, mounted on the helmet 10.

To support the accessory 18 and/or visor 60, each mounting location 16 has side ridges 25 on either side of the mounting location 16. The mounting bracket 24 has complementary side receiving slots 30 on either side of the mounting bracket 24. The side receiving groove 30 is configured to couple to the ridge 25 at the mounting location 16. For example, the coupling of the receiving groove 30 to the ridge 25 mounts the visor 60 to the helmet 10, and similarly mounts the lamp 20 to the visor 60 (fig. 18). In this manner, the shield 60 acts as a bridge between the accessory 18 and the mounting location 16 of the helmet 10 of different sizes and styles.

Applicants have found that having the mounting location 16 for the face guard 22 with the same or similar ridge extension 62 dimensions ensures proper abutment of the face guard 22 against the visor 64 in the operative position 56 protecting the eyes and/or face of the user. The ridge extension 62 structurally interconnects the face guard 22 to the rim 12 of the helmet 10. In one embodiment, the ridge extension 62 and the face guard 22 abut to form a seal, such as a watertight seal or an airtight seal. The seal protects the user from the ingress or egress of liquids or debris.

Different users prefer different geometries of the bill 42, the rim 12, and/or the helmet 10. Different geometries may also be advantageous for a variety of different job sites and/or operations. For example, the same user may have one helmet 10 with a large visor 42 for an outdoor work site and a second helmet 10 with a small surrounding rim 12 for an indoor work site to support the lamp 20.

Applicants have found that the use of the intermediate modular shield 60 enables a user to attach a face shield 22 that reliably abuts and/or seals against the rims 12 of the various helmets 10. The shield 60 provides a secure fit regardless of the style, size or geometry of the upper rim 12 or bill 42 of the helmet 10. In this way, an operator with two helmets 10 can attach, abut, and/or seal the same face guard 22 to the visor 60, and then interchangeably attach and detach the visor 60 and the face guard 22 to and from the helmets 10 that the operator prefers. This enables an operator to customize the helmet 10 for a particular environment or job. Alternatively, the same user attaches a welding face guard 22 for a welding operation and then attaches a different protective eyewear face guard 22 for the carpenter. In other words, the visor 60 bridges a variety of different helmets 10 (or face shields 22) of different sizes and shapes and allows one face shield 22 to be used to fit a variety of different sized helmets 10 having complementary mounting locations 16.

In one embodiment, visor 60 includes rectangular locking projection 66 in mounting location 16. An overhang 68 on the bracket 24 engages a cutout or cutout 69 to lock the shield 60 in the mounting position 16 of the helmet 10. When visor 60 is coupled to helmet 10, the coupled cutout 69 and overhang 68 prevent inadvertent impact or jostling of accessory 18.

Fig. 8 shows a perspective view, a top view and a bottom view, respectively, of visor 60. The connection of the visor 60 to the helmet 10 creates a ridge extension 62 that covers both the helmet 10 and the helmet with the bill 42 and rim 12 patterns. The top row shows visor 60 attached to visor 42 (left side climbing helmet) helmet 10 and to the brim 12 style (right side-traditional brim style) helmet.

Visor 60 attaches to both styles and creates a uniform ridge extension 62 with a consistent rim width W. The rim width W extends between the mounting location 16 of the helmet 10 to the edge of the ridge extension 62 on the visor 60. As shown, the rim width W is greater than the size of either the bill 42 or the rim 12. The middle row shows how visor 60 creates a uniform attachment for accessory 18 or face guard 22. The bottom row shows how the rim width W is longer than the extension of either the bill 42 pattern or the rim 12 pattern. Specifically, the black shield 60 is longer than either the bill 42 (left) or the rim 12 (right) of either helmet 10.

Fig. 9 is a top perspective view of an embodiment of a visor or shield 70 having a bracket 24 on the helmet 10. Visor 70 is identical or similar to visor 48 and/or visor 64 except that visor 70 includes one or more attachment mechanisms (shown as tabs 72 and/or brackets 24) to securely but removably couple visor 70 to mounting location 16 or auxiliary ridge 26 of helmet 10.

In a particular embodiment, the headgear system 8 includes a headgear 10 that includes a shell 11 formed of a rigid material and a shield 70 that is reversibly coupled to the headgear 10. The housing 11 includes an accessory mounting location 16 positioned along the outer surface 7 of the housing 11.

In various embodiments, the visor 70 includes a first portion 130 and a second portion 132. The first portion 130 extends circumferentially around at least a portion of the shell 11 and extends radially outward from the shell 11 to form a sun protection flange. The second portion 132 is coupled to the first portion 130 and is positioned adjacent to the accessory mounting location 16. The second portion 132 is deformable relative to the first portion 130 such that the second portion 132 deforms to accommodate and cover a portion of an accessory 18 (e.g., an earmuff) coupled to an accessory mounting location, shown as one of the front port 80, the intermediate port 82, or the rear port 84. The deformation of the second portion 132 allows the accessory 18 to extend from an accessory-mounting location (e.g., the front port 80, the middle port 82, or the rear port 84) to below the second portion 132.

In various embodiments, the second portion 132 is formed from a material that is more resilient than the material of the first portion 130. In various embodiments, the second portion 132 includes a first region 134 at a first side 136 of the housing 11 and a second region 138 at a second side 140 of the housing 11 opposite the first side 136. In a particular embodiment, the first side 136 is the left side of the housing 11 and the second side 140 is the right side of the housing 11. In various embodiments, a fastener, shown as a tab 72, couples the shield 70 to the left side of the housing 11, while a second fastener, shown as a tab 72, couples the shield 70 to the right side of the housing 11. In various embodiments, the second portion 132 includes a third region 142 and a fourth region 144 separated by a bridge 78, and both the third region 142 and the fourth region 144 are positioned on a first side of the housing 11 (e.g., left side of the housing 11, right side of the housing 11). The bridge 78 is formed of a material that is less elastic than the material forming the second portion 132.

As described in detail below, the visor 70 enables a user to fold the rim 12, such as front to back or back to front, and maintain the fold. The visor 70 is coupled to the mounting locations 16 and/or the ports 34 of the auxiliary ridge 26 on different styles and sizes of rims 12, helmets 10 and/or visors 42 helmets (e.g., climbing style helmets and conventional helmets 10). Fig. 10 shows a rear view of the helmet 10, wherein the visor 70 is coupled to the rear mounting ridge via the bracket 24, as illustrated in fig. 9.

Referring to fig. 9 and 10, visor 70 includes a front portion (shown as front rim section 74) and a rear portion (shown as rear rim section 76) interconnected by opposing tension zones 77. Front and

rear rim segments

74, 76 are similar to front and rear portions 50, 52 of visor 48. A fastener, shown as joint 72, couples two parallel tension zones 77 to ports 34 on auxiliary ridge 26 to secure visor 70. In one embodiment, the front rim section 74 and/or the rear rim section 76 include brackets 24 that couple the visor 70 to the mounting locations 16 (or the auxiliary ridge 26) on the helmet 10. The inelastic material or bridge 78 between the stretch zones 77 is integrally formed with the joint 72 (fig. 9) or is a separate component coupled to the joint 72 and supporting the joint (fig. 10).

The front rim section 74 is movable between a covered configuration in which the front rim section 74 extends away from the front portion 14 of the helmet 10 in the forward direction 71, and a stowed configuration in which the front rim section 74 extends away from the rear portion 15 of the helmet 10 in the rearward direction 73. The front rim section 74 engages the rear rim section 76 when the front rim section 74 is in the stowed configuration.

In various embodiments, the clip 24 is coupled to the rear rim section 76, and the clip 24 couples the visor 70 to the helmet 10 (fig. 9). In various embodiments, the clip 24 is coupled to the front rim segment 74, and the clip 24 is coupled to the rear portion 15 of the headgear 10 when the front rim segment 74 of the visor 70 is in the stowed configuration. In various embodiments, the clip 24 couples the front rim segment 74 to the front 14 of the helmet 10 when the front rim segment 74 of the visor 70 is in the covering configuration. In various embodiments, the clip 24 is coupled to the front rim section 74 of the visor 70, and the clip 24 is coupled to the front 14 of the helmet 10 when the visor 70 is in the covering configuration.

In various embodiments, the fitting 72 is coupled to the port 34 in the auxiliary ridge 26. For example, as shown in fig. 9, the fitting 72 is coupled to the front port 80. Fig. 10 shows a fitting 72 coupling visor 70 to intermediate port 82. Similarly, the joint 72 may be coupled to any port 34 (e.g., the rear port 84) of the auxiliary ridge 26 and/or the front or rear mounting location 16 on the helmet 10. The position of the fitting 72 in the front port 80, the middle port 82, or the rear port 84 determines the folded position 86 of the visor 70. In addition, the use of a particular port 34 (e.g., front port 80, middle port 82, or rear port 84) facilitates the attachment of other accessories 18 to any of the other ports 34 in the mounting location 16 and/or auxiliary ridge 26. For example, attaching the face guard 22 and/or visor 70 using the anterior port 80 facilitates attaching the earmuff 38 at the medial port 82 or the posterior port 84 of the auxiliary ridge 26.

In various embodiments, the bracket 24 is coupled directly to the visor 70 (fig. 9) or coupled at the mounting location 16 on the visor 70 (fig. 10). Fig. 9 shows the bracket 24 coupled to the visor 70 and securely coupled to the rear mounting location 16 on the helmet 10. In contrast, fig. 10 shows the visor 70 wrapped around the outer perimeter 88 of the helmet 10. The outer periphery 88 includes the transition periphery of the front and rear mounting locations 16 and the side auxiliary ridge 26 toward/adjacent the rim 12 of the helmet 10. The shield 70 has a hollow oval shape (elongate ring shape) extending radially from an inner diameter 90 (e.g., adjacent the outer periphery 88 of the helmet 10) to an outer diameter 92. The bracket 24 is coupled to the rear mounting location 16 and clamps the visor 70 between the rim 12 of the helmet 10 and the bracket 24 about the outer periphery 88 (e.g., below the cutout 69 of the helmet 10 but above the rim 12). The bracket 24 includes the external mounting location 16 and/or the cutout 69 to further support and/or couple the additional accessory 18. An elastic member or strap 94 extends under the front edge 12 to fold the edge 12 and maintain the folded configuration.

Fig. 11A and 11B compare an axially or parallel stretched shield 70 (fig. 11A) having two stretched regions 77 on opposite sides of the shield 70 with a radially stretched shield 70 (fig. 11B) having only one stretched region 77. As shown in fig. 11A and 11B, the radially stretched shield 70 expands the inner diameter 90 of the shield 70 to open the radial circumference of the inner diameter 90 and fit the shield 70 onto the helmet 10 and/or accessory 18 of different sizes, shapes, and configurations. The parallel stretched shields 70 include stretched regions 77 on opposite sides of the shield 70 (e.g., adjacent the auxiliary ridge 26). The parallel stretched shields 70 are foldable and may include a folding position 86 so that a user may fold the shields 70. For example, the folded shield 70 expands the rim 12 on the front or rear half while providing unobstructed access to the mounting system (mounting location 16 and port 34 on the auxiliary ridge 26) on the other half of the helmet 10. The parallel stretched shields 70 also allow a user to access the ports 34 of the auxiliary ridge 26 on opposite sides of the helmet 10.

Fig. 12-14 illustrate different views of the visor 70 of fig. 9 in a folded configuration. A pivot is provided at the fold locations 86 on opposite sides of the visor 70 to allow a user to flip over the front (or rear) edge 12 of the visor 70 and attach an accessory to the mounting location 16 on the front of the helmet 10. The bracket 24 slides over the flipped rim 12 to clamp and hold the rotated rim 12 in the folded configuration. The strap 94 rotates about the two edges 12 (e.g., the front and rear edges 12) to hold the edges 12 together in the folded configuration shown. This configuration allows the user to reach the mounting location 16 and/or the auxiliary ridge 26 without being obstructed by the visor 70 and allows the user to modify the visor 70 according to the user's preferences and conditions.

In various embodiments, the visor 70 includes a first folded position 86 on a first side 81 of the visor 70 and a second folded position 87 on a second side 79 of the visor 70 opposite the first side 81. In various embodiments, the first fold location 86 includes a stretch zone 77 that is more elastic than an adjacent portion of the visor 70 (e.g., a portion of the visor 70 adjacent to the stretch zone 77).

Fig. 15 illustrates another embodiment of a modular visor 100. Except for the differences described, modular shield 100 is identical or similar to shields 48, 64, and 70. The modular visor 100 includes separate modules or rim segments (e.g., front rim segment 74 and rear rim segment 76) coupled together about the outer perimeter 88 of the helmet 10. In this manner, modular visor 100 may include different materials, shapes, and/or accessories 18 to provide different functions based on user preferences. As shown, the front rim section 74 comprises a translucent plastic that, for example, blocks UV radiation from reaching the user's eyes, but allows some visible light to pass through. The joint 72 couples the front rim segments 74 to interconnect the rear rim segments 76. The rear rim section 76 comprises two stretched zones 77 and an opaque plastic material rim 12.

The strap 94 may be coupled to the front rim section 74 and/or the rear rim section 76. The joints 72 may be biased or unbiased to provide a folded position 86 that rotates either modular segment. The joint 72 couples the front rim section 74 to the rear rim section 76. The connector 72 also couples the modular visor 100 to the auxiliary ridge 26. In other embodiments, the compressive force caused by the tension zone 77 expanding around the outer perimeter 88 holds the visor 100. A plurality of different shims 104 are positioned about outer perimeter 88 to adjust the size, shape, and/or style of modular visor 100.

In some embodiments, the tab 72 includes mating protrusions 106 and grooves 108 between the front and

rear rim segments

74, 76. For example, the protrusion 106 couples or snaps into the slot 108 to couple the front section 74 and the rear section 76 of the modular visor 100. In various embodiments, the tabs 72 include other mechanisms for temporarily and securely joining segments of the modular visor 100, such as hook and loop tabs, pressure/friction-inducing tabs, metal and/or plastic quick release tabs, fasteners, buckles, and/or adhesives.

Fig. 16 is a perspective view of the modular visor 100 of fig. 15 coupled to the front portion 14 and the folded visor 70 of fig. 9 and to the rear portion 15 of the helmet 10. Bridge 78 and/or joint 72 couple/form fold locations 86 in opposing, parallel stretch zones 77. For example, the joint 72 couples the stretch zone 77 to the front port 80, leaving the intermediate port 82 and the rear port 84 available for coupling the attachment 18. In other words, the modular visor 100 is independently coupled to the front portion 14 of the helmet 10, such as by clamping friction generated by a friction fit or the bracket 24 or inserted fasteners. In some embodiments, a single segment (e.g., front edge segment 74) includes multiple materials, such as a first translucent material 110 and a second opaque material 112. Because the modules or segments of modular visor 100 are independent, front section 74 and rear section 76 may also be manufactured from different materials to exhibit different characteristics and functions. Alternatively, one segment (e.g., either of segments 74 or 76) may be used in combination with another accessory 18, such as face guard 22.

As shown, there is no physical connection between modular visor 100 and folded visor 70. This configuration enables functional coupling or mating of modular visor 100 and folded visor 70. The modular visor 100 is used in combination with other accessories 18 and/or sunshade visors (e.g., visors 48, 67 and/or visor 70, or another visor described herein). For example, two or more modular shields 100 (e.g., front rim section 74 and rear rim section 76) combine to extend completely around the outer perimeter 88 of the helmet 10. The front and

rear rim segments

74, 76 of the modular visor 100 may be of different materials and/or have different transparency (e.g., transparent, translucent, or opaque). Further, the front and/or

rear rim segments

74, 76 may be interchangeably removed and replaced with one or more accessories 18 to adapt to operator preferences, safety, and/or use at a particular job site.

Fig. 17 is a top perspective view of modular visor 100 coupled to accessory 18 of face shield 22. The face guard 22 includes a bracket 24 coupled to the front 14 mounting location 16 on the helmet 10. The face guard 22 extends around the face of the user. In various embodiments, the face guard 22 may create a seal between the user's face (e.g., eyes, nose, and/or mouth). An optional shield 114 (e.g., a shield sized for the face shield 22) extends outwardly to form a seam 115 along the junction between the face shield 22 and the shield 114. In various embodiments, the seam 115 is an airtight, watertight, or another fixed seal to prevent debris (e.g., hot/molten metal in a welder's helmet) from entering around the face of the user. The bracket 24 on the face guard 22 includes an outer mounting location 116 having side ridges 125 and cutouts 169 that are the same or similar in geometry to the mounting location 16. Thus, the mounting system can use additional mounting locations 116 to attach another accessory 18 (e.g., a light and/or an eyeglass holder).

Fig. 18 is a top perspective view of front modular visor 100 made of translucent material coupled to rear modular visor 100 made of opaque material. The front section 74 and the rear section 76 are coupled to form a modular visor 100 that is coupled to the helmet 10 with a joint 72. The fitting 72 includes a protrusion 106 coupled to a slot 108 to adjust the side of the inner diameter 90 of the combined modular shield 100 (e.g., a shield joined by a front modular shield and a rear modular shield 100). This feature enables a user to modify the size of the inner diameter 90 to accommodate the size, style, and/or dimensions of the mounting locations 16 and/or the auxiliary ridges 26. As shown in fig. 18, the outer diameter 92 may increase from a solid line to the dashed outer diameter 92 based on the change in the inner diameter 90. Front rim segment 74 is made of a different material than rear rim segment 76 to form multi-material modular visor 100. For example, the front rim section 74 comprises a translucent colored plastic material. The rear rim section 76 includes an opaque fabric material coupled to the polymeric center. Modular visor 100 has a front rim section 74 and a rear rim section 76 and includes different material characteristics.

In some embodiments, the modular visor 100 includes one or more materials and/or a tension zone 77 to adjust the frictional grip of the inner diameter 90 of the visor 100 on the outer diameter 92 of the helmet 10. In various embodiments, the friction grip and/or the bracket 24 couples the visor 100 to the helmet 10. The bracket 24 either forms part of (e.g., is attached to) the

rim segment

74 or 76 or fits over the rim segment 74 and/or 76 and clamps the rim segment against the helmet 10 (e.g., does not join, but rather approaches the segments 74 and 76).

Fig. 19 shows another embodiment shield 150 having a closed resilient region 152 in rim 12. The shield 150 is the same as or similar to other shields described herein (e.g., shields 48, 64, 70 and/or modular shield 100), but combines features and modifications that are different from those shields. For example, the closed spring region 152 of the shield 150 extends from the inner diameter 90 of the rim 12, but does not extend across the rim 12 to the outer diameter 92. Unlike the tension zone 77 of the visor 70, the spring zone 152 is closed within the rim 12 and adjacent to the auxiliary ridge 26. The closed elastic region 152 is surrounded by an inelastic region 154 of the rim 12 on the shield 150. Thus, the outer diameter 192 is fixed (e.g., non-expandable or not flexible), but deflection near the sides of the headgear 10 (e.g., near the auxiliary ridge 26) allows access to the ports 34 in the auxiliary ridge 26.

Visor 150 also couples rear rim segment 76 to both front port 80 and rear mounting location 16. This configuration creates a stable visor 150 connection and also allows an operator to insert and attach earmuff 38 to auxiliary ridge 26 through elastic region 152. Specifically, the operator links through a four-bar support arm 156 for either the face guard 22 or the earmuff 38. The support arm 156 passes into or through the resilient region 152 and couples an insert 158 (at the end of the support arm 156) into the remaining intermediate or

rear ports

82, 84 of each opposing auxiliary ridge 26 (fig. 20). Coupling the rear rim section 76 to the front port 80 and the rear mounting location 16 improves the ergonomic attachment of the earmuff 38 to either the middle port 82 or the rear port 84, which results in the most comfortable arrangement over the ear of the individual user.

Fig. 20 shows different views of closing the elastic region shield 150 and inserting 158 the earmuff 38 and the support arm 156 coupled into the rear port 84. As described above, some users may choose to use the intermediate port 82 to ergonomically fit the earmuff 38 directly over their ear. In contrast, the rear port 84 may be better adapted to other users. The modular configuration of the shield 150 coupled to the front port 80 enables the user to selectively select the most ergonomic and most comfortable configuration. This configuration also makes another port 34 on each side of the auxiliary ridge 26 available for another accessory 18 (e.g., reflector, eyeglass holder, or tool holder).

Fig. 21 shows another embodiment of a visor 160 having a hybrid material. Visor 160 includes different materials having a rigid outer perimeter or outer diameter 92 and a soft fabric inner diameter 90 to accommodate the size, style and/or dimensions of a variety of different helmets 10 or helmets having differently sized mounting locations 16 or auxiliary ridges 26. For example, visor 160 includes two tension zones 77 interconnecting front and rear rims 12. Rim 12 includes a cushion 162 and brackets 24 to couple visor 160 to different sized and shaped headgear 10 and/or attached accessories 18 (e.g., face shield 22).

In various embodiments, the face guard 22 may be a convertible face guard 22 that attaches to the helmet 10 when the visor 100 is folded toward the rear 15 of the helmet 10 (fig. 17). Alternatively, face shield 22 is coupled to rear section 74 of modular shield 150. Visor 160 combines a variety of different features of the visors (e.g.,

visors

48, 64, 70, 100, and/or 150) previously described herein to further customize the attachment of different accessories 18 (e.g., face guard 22) to mounting locations 16 and/or auxiliary ridge 26.

The visor 160 is mounted around the perimeter 88 of the helmet 10 with the accessory 18 (the face shield 22) coupled at the front mounting location 16 of the helmet 10. This configuration reveals how the features and/or materials of visor 160 interact with a variety of different attached attachments 18 (e.g., four bar links, support arms, and/or inserts) at mounting locations 16 and/or auxiliary ridges 26. Fig. 22 is an isolated perspective view of the visor 160 of fig. 21.

As illustrated in fig. 21-22, the bracket 24 includes an external mounting location 116 that is the same as or similar to the mounting location 16 on the helmet 10. In some embodiments, the bracket 24 includes an external mounting location 116 having a ridge 125. In this manner, the bracket 24 serves as a bridge coupling the first accessory 18 (e.g., the face guard 22) to the front mounting location 16 of the headgear 10 and provides a second outer mounting location 116 to attach the second accessory 18. In other words, the bracket 24 forms a connecting bridge that enables stacking of multiple accessories 18 onto a single mounting location 16 of the helmet 10.

The front liner 162 along the inner diameter 90 of the front transparent rim section 74 provides a tolerance 165 to fit the visor 160 on a variety of different accessories, helmets 10 and helmets of different sizes and shapes. Two opposing and parallel stretching regions 77 are positioned adjacent the auxiliary ridge 26 and extend from an inner diameter 90 to an outer diameter 92 of the rim 12. The spring-loaded or biased fastener creates a biased pivot 164 (e.g., similar to joint 72) that couples the tension zone 77 of the shield 160 to the port 34 (e.g., front port 80, middle port 82, or rear port 84) on the auxiliary ridge 26. The biased pivot 164 generates a biasing force or spring force against the shield 160 such that an operator applies a downward force on the shield 160 to create a clamping friction force at the inner diameter 92 on the rim 12. The stretch zone 77 comprises a stretch flexible material that extends from an inner diameter 90 to an outer diameter 92 to create a compressive force on the outer periphery 88 and enable the liner 162 and visor 160 to deflect for different sizes, shapes and styles of headgear 10. The wire 166 extends along the outer diameter 92 of the shield 160 to create a rigid outer diameter 92.

The optional bracket 24 is coupled to the rear section 76 of the visor 160. The bracket 24 couples or clamps the visor 160. The gasket 162 slides under the cutout 69 at the mounting location 16 of the helmet 10. As illustrated, the mounting location 16 is coupled to the face guard 22, and the cushion 162 fits under the cutout 169 to couple to the outer periphery 88 of the helmet 10 with the attached accessory 18. The tension zone 77 is elastic/flexible adjacent the auxiliary ridge 26, but the wire 166 forms the rigid/firm outer diameter 92 of the shield 160. This configuration enables a variety of materials in the translucent or colored front and

rear sections

74, 76, the stretch zone 77, and the liner 162 to form an expandable feature at the junction between the outer periphery 88 of the helmet 10 and the inner diameter 90 of the visor 160. In contrast, outer diameter 92 is relatively rigid and strong through a variety of different materials due to wire 166. In one embodiment, the stretch zone 77 extends over and/or deflects around both the support arm 156 and the insert 158 of the attached face guard 22 and/or earmuff 38.

Referring to fig. 23-27, a variety of different aspects of the visor 220 are shown. Except for the differences discussed herein, shield 220 is substantially identical to shield 48, shield 60, shield 64, shield 67, shield 70, shield 100, or shield 150. Visor 220 includes a rear portion 224 that is coupled to helmet 210 via frame 240. The side portions 222 extend from the rear portion 224 and extend circumferentially around the helmet 210. The folded portion 232 is coupled to the rear portion 224 via a folded position 230 at a connection portion 236. In particular embodiments, the rear portion 224 and the folded portion 232 are formed from a fabric or fabric-like material.

The frame 240 is coupled to a safety headgear, shown as a helmet 210, at one of a plurality of mounting slots along a side of the helmet 210. In the particular embodiment shown, the frame 240 is coupled to the intermediate port 214 of the helmet 210. In particular embodiments, the frame 240 is formed in an arch, U-shape, or horseshoe shape, and is formed of a plastic material.

The folded portion 232 includes a front undulating portion, shown as front flap 226, that is configured to receive a variety of different accessories, such as arms of an earmuff. Similarly, the side portions 222 include a rear undulating portion, shown as a rear flap 228, that is configured to receive a variety of different accessories, such as arms of an earmuff. In use, the front portion 234 and the folded portion 232 can be folded up and over the dome of the helmet 210 and back toward the rear portion 224 (see fig. 27). In this position, the front portion 234 and/or the fold portion 232 may be coupled to a coupling element, such as a clip 242 (fig. 24), to retain the portions of the visor 220 in the folded position.

In a particular embodiment, the shield 220 includes a first portion 221 and a second portion 223. Similar to the various embodiments of visor 70, second portion 223 is more deformable than first portion 221 such that second portion 223 deforms to accommodate and cover a portion of an accessory (e.g., an arm of an earmuff) coupled to the accessory mounting location that is located below second portion 223. In various embodiments, the second portion 223 is less tensioned than the first portion 221. In various embodiments, the second portion 223 includes a front flap 226 and a rear flap 228. For example, the second portion 223 may be more deformable when not stretched than the first portion 221 (e.g., because the second portion has additional fabric that is not stretched). As another example, the second portion 223 extends upward and slackens upward against the exterior of the shell (see fig. 26). In particular embodiments, the rear portion 224 includes an undulating portion, shown as a rear flap 228, that is less tensioned than a portion of the visor 220 adjacent the rear flap 228, and the rear flap 228 is positioned below the front portion 234 and/or the folded portion 232 when the visor 220 is in the stowed configuration.

With further reference to fig. 25-27, when the shield 220 is unfolded (fig. 26), an accessory such as an arm of an earmuff extends through the rear flap 228. When the shield 220 is folded (fig. 27), an accessory such as an arm of an earmuff extends through the front flap 226 and the rear flap 228. In particular embodiments, the shield 220 includes one or more flexible portions, shown as flex points 238, that allow the shield 220 to be formed into a variety of different shapes to accommodate a variety of different accessories that are covered, wrapped around, or passed under the front flap 226 and/or the rear flap 228. In various embodiments, the front portion of the shield 220 includes a front flap 226 that is less tensioned than a portion of the shield 220 adjacent the front flap 226, and the rear portion includes a rear flap 228 that is less tensioned than a portion of the shield 220 adjacent the rear flap 228. In particular embodiments, the front flap 226 is positioned above the rear flap 228 when the visor 220 is in the stowed configuration (e.g., when the front portion of the visor 220 is folded back, such as shown in fig. 12).

Referring to fig. 28-30, a variety of different aspects of a visor 220 coupled to different safety headsets are shown. The coupling of the frame 240 to some safety headgear (as shown by helmet 212 in fig. 28) is higher than to other safety headgear (as shown by helmet 210 in fig. 29). If left untreated, this results in portions of the frame 240 and visor 220 extending from the helmet 212 at a steeper angle than the frame 240 and visor 220 coupled to the helmet 210.

To compensate for this, the frame 240 includes clips 244. The clip 244 includes an engagement portion 258 that includes a first surface, such as an upper surface (shown as an upper step surface 256), and a second surface, such as a lower surface (shown as a lower step surface 254), each of the upper step surface 256 and the lower step surface 254 facing in an upward direction 257. In use, when clip 244 is coupled to helmet 212, either upper step surface 256 or lower step surface 254 is coupled to helmet 212. In particular, the clip 244 is coupled to the helmet 210 in a first position or in a second position. The upper step surface 256 engages the helmet 210 when the clip 244 is in the first position and the lower step surface 254 engages the helmet 210 when the clip 244 is in the second position. In a particular embodiment, the upper step surface 256 is spaced a distance 253 above the lower step surface 254. Thus, the clip 244 inserts lower into the body of the helmet 212 than the helmet 210, and thus, the angle of the frame 240 and visor 220 provides greater consistency when coupled to different embodiments of the safety headgear. In a particular embodiment, the engagement portion 258 is biased in a horizontal direction against the helmet 210.

Referring to fig. 28-29, when the clip 244 is coupled to the helmet 210 in a first position, the shield 220 extends from the helmet 210 at a first angle 247 relative to horizontal, and when the clip 244 is coupled to the helmet 210 in a second position, the shield 220 extends from the helmet 210 at a second angle 248 relative to horizontal. In particular embodiments, first angle 247 is different from second angle 248, and more particularly, first angle 247 is greater than second angle 248. In various embodiments, angles 247 and 248 are measured from the front of the helmet 210. In various embodiments, the lower step surface 254 is spaced a second distance 259 closer to the center 218 of the helmet 210 than the upper step surface 256.

In various embodiments, the headgear system 208 includes a headgear 210, a clip 244 coupled to the headgear 210, and a shield 220 coupled to the shield 220 such that the shield 220 is reversibly supported to the headgear 210 via the clip 244 and extends circumferentially around a portion of the headgear 210.

Referring to fig. 31-32, various aspects of visor 220 are shown, such as enabling multiple objects to be coupled to the same general area of helmet 212. In a particular embodiment, the frame 240 includes a coupling element, shown as a rear slot 250. The rear slots 250 are configured to double the coupling capability of the rear portion of the helmet 212, thereby allowing the user to "daisy-chain" the elements to the same general area of the helmet 212. For example, a user may couple the frame 240 to the helmet 212 and use the rear slot 250 to couple additional accessories such as a headlight battery 252.

Referring to fig. 33-35, in various embodiments, the visor 220 includes components that provide flexibility to couple to safety headgear of different sizes. In such an embodiment, the front portion 234 of the visor 220 is coupled to the rim 216 of the helmet 212 via the clip 246. In a particular embodiment, the clips 246 are formed of a plastic material.

In particular embodiments, the connecting portion 236 resiliently couples the front portion 234 and the rear portion 224. The resilience of the connecting portion 236 allows the visor 220 to be securely coupled to a variety of differently sized embodiments of the safety headset (compare fig. 33 and 35).

Referring to fig. 36, a variety of different aspects of the coupling element shown as spring clip 262 are illustrated. The spring clips 262 help to retain the visor on the rear retention feature of the safety headset. The spring clip 262 includes an interface element, shown as tab 264. The user may interact with the tab 264 to pull in the direction 260 and thereby disengage the spring clip 262.

Referring to fig. 37, a variety of different aspects of a safety headset shown as a helmet 310 are shown. The helmet 310 is similar to the helmet 210 except for the differences described herein. The helmet 310 includes a first coupling feature (shown as front mount 312) at a front portion and a second coupling feature (shown as rear mount 316) at a rear portion of the helmet 310 opposite the front portion. The helmet 310 includes a coupling element 314 at the front of the helmet 310. The helmet 310 includes a centrally located coupling element (shown as slot 322) on the side of the helmet 310 between the rear slot 320 and the front slot 324. It is contemplated herein that the headgear 310 may be engaged with one or more elements described herein (such as, for example purposes only, the shield 220).

Referring to fig. 38-39, a variety of different aspects of the frame 420 are shown. Frame 420 is substantially identical to frame 240 except for the differences discussed herein.

The frame 420 is coupled to a safety headgear such as a helmet via a coupling mechanism shown as hooks 422 (e.g., hooks 422 engage with ridges 25 of the mounting location 16 of the helmet 10, see fig. 3). One or more tabs 448 engage with protrusions extending from the front of the helmet, such as under the protrusions.

The frame 420 includes one or more coupling elements shown as engaging portions 460. The engagement portion 460 is substantially identical to the engagement portion 258, except for the differences discussed herein. In particular, the engagement portion 460 includes an extension that extends vertically above the body of the engagement portion 460.

In use, the hook 422 is slidably engaged with the helmet to limit the frame 420 to vertical movement relative to the helmet, and the tab 448 biases the frame 420 from moving upward and out of engagement with the helmet. To remove the frame 420 from the helmet, the user pulls the lever 440 in an upward direction 442. In response, pivot 446 engages against the helmet, which forces tab 448 away from the helmet until tab 448 does not engage with a protrusion extending from the helmet. Thus, the user can slide the frame 420 upward relative to the headgear to disengage the frame 420 from the headgear.

Referring to fig. 40, a variety of different aspects of a headgear system 508 are illustrated. The headgear system 508 includes a face guard 510 and a frame 520. The headgear system 508 is substantially identical to the headgear system 8 except as discussed herein, and the frame 520 is substantially identical to the frame 420 except as discussed herein. In particular, the hooks 522 of the frame 520 extend further along the inner circumference of the frame 420 than the hooks 422 of the frame 420.

Referring to fig. 41, a variety of different aspects of the frame 620 are shown. Frame 620 is substantially identical to frame 420 or frame 520 except for the differences discussed herein. In particular, the frame 620 includes a structure 624 above the hooks 622 that extends outwardly from the headgear to which the frame 620 is coupled.

It is to be understood that the drawings illustrate exemplary embodiments in detail, and it is to be understood that the application is not limited to the details or methodology set forth in the description or illustrated in the drawings. It is also to be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Other modifications and alternative embodiments of the various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, the description is to be construed as illustrative only. The constructions and arrangements shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logic algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present inventions.

For the purposes of this disclosure, the term "coupled" means that two components are directly or indirectly joined to one another. Such linkages may be fixed in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional members being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

Although this application recites a particular combination of features in the appended claims, various embodiments of the invention are directed to any combination of any features described herein (whether or not such combination is presently claimed), and any such combination of features may be claimed in this or a future application. Any feature, element, or component of any example embodiment discussed above may be used alone or in combination with any feature, element, or component of any other embodiment discussed above.

In various exemplary embodiments, as shown in the figures, the relative dimensions, including angle, length, and radius, are to scale. Actual measurements on the drawings will reveal the relative sizes, angles, and proportions of the various exemplary embodiments. The various exemplary embodiments extend to the various different ranges around the absolute and relative dimensions, angles, and proportions that may be determined from the figures. The various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the figures. Further, the actual dimensions not explicitly stated in the present specification may be determined by using the dimensional ratios measured in the drawings in combination with the explicit dimensions stated in the present specification. Additionally, in many different embodiments, the present disclosure extends to various ranges surrounding any absolute or relative dimension disclosed herein or determinable from the figures (e.g., plus or minus 30%, 20%, or 10%).

Claims

1. A headgear system comprising:

a safety helmet, the safety helmet comprising:

a shell formed of a rigid material; and

an accessory mounting location positioned along an outer surface of the housing; and

a visor reversibly coupled to the helmet, the visor comprising:

a first portion extending circumferentially around at least a portion of the shell and extending radially outwardly from the shell to form a sun protection flange; and

a second portion coupled to the first portion and positioned adjacent to the accessory mounting location, wherein the second portion is deformable relative to the first portion such that the second portion deforms to accommodate and cover a portion of an accessory coupled to the accessory mounting location, thereby allowing the accessory to extend from the accessory mounting location to below the second portion.

2. The headgear system of claim 1, the second portion being formed of a material that is more elastic than the material of the first portion.

3. The headgear system of claim 1, the second portion comprising a first region on a first side of the shell and a second region on a second side of the shell opposite the first side.

4. The headgear system of claim 3, wherein the first side is a left side of the shell and the second side is a right side of the shell.

5. The headgear system of claim 4, comprising a first fastener coupling the shield to the left side of the shell and a second fastener coupling the shield to the right side of the shell.

6. The headgear system of claim 1, the second portion comprising a third region and a fourth region separated by a bridge formed of a material that is less elastic than the second portion, wherein the third region and the fourth region are both positioned on a first side of the shell.

7. The headgear system of claim 1, wherein the second portion is less tensioned than the first portion.

8. A headgear system comprising:

a helmet comprising a shell formed of a rigid material; and

a visor reversibly coupled to the helmet, the visor comprising a front portion and a rear portion, the front portion being movable between a covered configuration in which the front portion extends away from the front of the helmet in a forward direction and a stowed configuration in which the front portion extends away from the rear of the helmet in a rearward direction.

9. The headgear system of claim 8, wherein the front portion engages the rear portion when the front portion is in the stowed configuration.

10. The headgear system of claim 8, comprising a clip coupled to a rear portion of the shield, the clip coupling the shield and the headgear.

11. The headgear system of claim 8, comprising a clip coupled to a front portion of the visor, the clip coupled to a front portion of the headgear when the visor is in the covering configuration.

12. The headgear system of claim 8, the shield comprising a first folded position on a first side of the shield and a second folded position on a second side of the shield opposite the first side.

13. The headgear system of claim 12, the first folded position being formed of a material that is more elastic than a portion of the shield adjacent the first folded position.

14. The headgear system of claim 8, the rear portion comprising an undulating portion that is less tensioned than a portion of the shield adjacent the undulating portion.

15. A headgear system comprising:

a helmet comprising a shell formed of a rigid material;

a clip coupled to the helmet, the clip having an engagement portion, the engagement portion comprising an upper surface and a lower surface, each of the upper surface and the lower surface facing in an upward direction, the clip configured to be coupled to the helmet in a first position or in a second position, the upper surface being engaged with the helmet when the clip is in the first position and the lower surface being engaged with the helmet when the clip is in the second position, wherein the upper surface is spaced a distance above the lower surface; and

A shield coupled to the clip such that the shield is reversibly supported to the helmet via the clip and extends circumferentially around a portion of the helmet.

16. The headgear system of claim 15, wherein the shield extends from the headgear at a first angle relative to horizontal when the clip is coupled to the headgear in the first position, and wherein the shield extends from the headgear at a second angle relative to horizontal when the clip is coupled to the headgear in the second position, the first angle being different from the second angle.

17. The headgear system of claim 16, the first angle being measured at a front of the headgear and the second angle being measured at a front of the headgear.

18. The headgear system of claim 16, the first angle being greater than the second angle.

19. The headgear system of claim 15, the lower surface being spaced a second distance closer to the center of the headgear than the upper surface.

20. The headgear system of claim 15, the engagement portion being biased horizontally against the headgear.