Patentable/Patents/US-20250344799-A1
US-20250344799-A1

Hard Hat Attachment System and Sun Visor

PublishedNovember 13, 2025
Assigneenot available in USPTO data we have
Inventorsnot available in USPTO data we have
Technical Abstract

A universal mounting system for a hard hat is provided that includes front and rear mounting locations and auxiliary ridges on either side. A visor is coupled to the hard hat mounting system in such a way as to provide access with minimal interference from the visor to the equipment attached to the mounting locations and ports in the auxiliary ridges. Various embodiments of visors enable modular designs that incorporate different materials and features of the visor. Parallel stretch zones enable folding and holding opposite brims of the visor. Enclosed elastic areas along the inner sides of visor provide user access to auxiliary ridges. Combinations of various accessories on hard hat and how the accessories work together on the universal mounting system are discussed: such as the interaction between visors, earmuffs, face shields, and lamps.

Patent Claims

Legal claims defining the scope of protection, as filed with the USPTO.

1

.-. (canceled)

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. A hard hat system comprising:

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. The hard hat system of, wherein the shell further comprises:

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. The hard hat system of, wherein the first stretch portion extends along an exterior surface of the first mounting ridge, wherein the second stretch portion extends along an exterior surface of the second mounting ridge.

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. The hard hat system of, wherein the second mounting ridge comprises a second port.

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. The hard hat system of, wherein the first stretch portion is formed from a material that is more elastic than the semi-transparent material of the front portion and is more elastic than a material of the rear portion.

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. The hard hat system of, wherein the first stretch portion overlaps with the first mounting ridge, and wherein the rear portion overlaps with the first mounting ridge.

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. The hard hat system of, wherein the rear portion of the visor is formed from an opaque material.

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. The hard hat system of, further comprising an elastic strap coupled to opposing sections of the front portion of the visor, the elastic strap extending under a front portion of the brim.

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. A hard hat system comprising:

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. The hard hat system of, further comprising a second stretch portion positioned on a second side of the visor, the second stretch portion extending between and connecting the front portion of the visor and the rear portion of the visor.

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. The hard hat system of, further comprising:

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. The hard hat system of, wherein the front portion and the rear portion of the visor are each formed from an opaque material.

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. The hard hat system of, wherein the front portion of the visor is formed from a semi-transparent material and wherein the rear portion of the visor is formed from an opaque material.

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. The hard hat system of, wherein the hard hat further comprises a brim extending radially outward from the exterior surface of the shell.

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. The hard hat system of, wherein the visor extends beyond an outermost edge of the brim.

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. A visor configured to be coupled to and support from a hard hat, the visor comprising:

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. The visor of, wherein the first portion of the visor is formed from a semi-transparent material, and wherein the second portion of the visor is formed from an opaque material.

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. The visor of, wherein the semi-transparent material is a plastic material and wherein the opaque material is fabric.

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. The visor of, wherein the first portion and the second portion of the visor are each formed from an opaque material.

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. The visor of, wherein the visor further comprising an elastic strap coupled to opposing sections of the first portion of the visor, wherein the first stretch zone and the second stretch zone are formed from a first material, wherein the first portion of the visor is formed from a second material and the second portion of the visor is formed a third material, and wherein the first material is more elastic than the second material and the third material.

Detailed Description

Complete technical specification and implementation details from the patent document.

The present application is a continuation of U.S. application Ser. No. 19/217,009, filed May 23, 2025, which is a continuation of U.S. application Ser. No. 17/461,163, now U.S. Pat. No. 12,336,586, filed Aug. 30, 2021, which is a continuation of International Application No. PCT/US2021/045405, filed Aug. 10, 2021, which claims the benefit of and priority to U.S. Provisional Application No. 63/167,458, filed on Mar. 29, 2021, U.S. Provisional Application No. 63/162,736, filed on Mar. 18, 2021, U.S. Provisional Application No. 63/087,578, filed on Oct. 5, 2020, and U.S. Provisional Application No. 63/066,561 filed on Aug. 17, 2020, each of which is incorporated herein by reference in their entirety.

The present invention relates generally to the field of hard hats and helmets. The present invention relates specifically to a sun-visor and/or other safety equipment accessories attached to a hard hat. Hard hats are often used in loud and brightly illuminated areas, for example, a construction site on a sunny day. Work environments at various job sites may enable the use of added safety equipment (e.g., earmuffs and/or a face protector) to provide added

One embodiment of the invention relates to a hard hat system including a hard hat and a visor. The hard hat includes a shell formed from a rigid material and an accessory mounting location located along an outer surface of the shell. The visor is reversibly coupled to the hard hat. 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 forming a sun-blocking 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 allowing the accessory to extend from the accessory mounting location to below the second portion.

Another embodiment of the invention relates to a hard hat system including a hard hat and a visor. The hard hat includes a shell formed from a rigid material. The visor is reversibly coupled to the hard hat. The visor includes a front portion and a rear portion. The front portion is moveable between a covering configuration in which the front portion extends in a forward direction away from a front of the hard hat, and a stowed configuration in which the front portion extends in a rearward direction away from a rear of the hard hat.

Another embodiment of the invention relates to a hard hat system including a hard hat comprising a shell formed from a rigid material, a clip coupled to the hard hat, and a visor. The clip includes an engaging portion including an upper surface and a lower surface. Each of the upper surface and the lower surface face in an upward direction. The clip is configured to couple to the hard hat in a first position or in a second position. The upper surface engages with the hard hat when the clip is in the first position and the lower surface engages with the hard hat when the clip is in the second position. The upper surface is spaced a distance above the lower surface. The visor is coupled to the clips such that the visor is reversibly supported to the hard hat via the clip and extends circumferentially around a portion of the hard hat.

One embodiment of the invention relates to a hard hat attachment system. The hard hat includes a mounting location comprising opposite dovetailed ridges projecting outward on either side of the mounting location. Each ridge includes a transition to couple slots of a bracket and support an accessory (e.g., lamp, face shield, and/or visor). Each ridge extends outwardly from the mounting location to create projections that support the mounted accessory. A sun-visor, e.g., an extended brim or visor, is coupled to the hard hat at the mounting location or the extended ridge to shade a wear's eyes, face and/or neck, to protect the user from sun/UV rays and/or falling debris, etc.

Another embodiment of the invention relates to a visor configured for selective attachment to a hard hat. The visor includes an inner and outer diameter. The visor includes a front brim and a rear brim. The front brim is positioned to extend outward from a front surface of the hard hat, and the rear brim is positioned to extend outward from a rear surface of the hard hat. A stretch zone extends radially from the inner diameter to the outer diameter and is located between and interconnects the front and rear brims. A fastener is coupled to the stretch zone and is configured to couple to an accessory ridge on the hard hat to removably secure the visor to the hat. In some embodiments, the visor includes a bracket positioned to engage one or more mounting locations on the hard hat to secure the visor to the hard hat. In a specific embodiment, the bracket is positioned on the front or rear visor to engage a front or rear mounting ridge of the hard hat.

In various embodiments, the visor includes a single stretch zone allowing an outer diameter of the visor to expand to accommodate different sized hard hats. In this embodiment, the single stretch zone is located between opposing ends of two visor sections allowing the size/circumference/inner diameter of the visor to be adjusted to accommodate different sized hard hats.

In various embodiments, the front brim includes a first end facing a first end of the rear visor and a second end facing a second end of the rear visor. In this arrangement, a first stretch zone is coupled between the first ends of the front and rear visors, and a second stretch zone is coupled between the second ends of the front and rear visors. In this arrangement, by having a plurality of stretch zones, e.g., on opposite sides of the visor sections, a parallel stretch sun-visor is provided that stretches in a direction between the front brim and the rear brim allowing for a distance between front and rear visors be expanded between a minimum distance and a maximum distance. In this configuration, the flexibility of the material of the stretch zones also provides for folding locations located on each side of the visor between the front and rear visors. This allows the user to fold the front brim over onto the back brim, and vice versa, to customize the brim location of the visor.

Another embodiment of the invention relates to a modular visor. The modular visor has a first module or brim section or segment that partially extends around the hard hat's perimeter. The modular visor enables a user to customize combinations of brim segments and/or accessories. For example, the user couples the rear modular brim section to a face shield in the front of hard hat. The user customizes a first modular brim section made from a semi-transparent material in front and couples it to a second modular brim section made from an opaque material in back. The modular sun-visor is used in variation with other accessories and/or segments. Segmentation of the modular visor enables the user to combine different modules made from different materials or features.

Another embodiment of the invention relates to a hard hat visor including enclosed elastic areas within a brim of the visor. The enclosed elastic areas extends radially outwards from the inner diameter of the visor towards the outer diameter and are located on opposite lateral sides of the brim. Specifically, the enclosed elastic areas are located adjacent to the auxiliary ridges of the hard hat and extend outwards from the auxiliary ridge a radial distance that is less than the distance to outer diameter. As such, the clastic areas do not extend across the entire radial length of the visor between the inner and outer edges and form an elastic inner brim coupled to a rigid outer brim. The elastic area expands or deflects when accessories are attached to the auxiliary ridge. For example, support arms of earmuffs or face shields are coupled to ports in the auxiliary ridge by deflecting elastic areas, but otherwise without removing or adjusting the visor. In this way, the earmuffs are removed and rotated off the user's ear without removing or adjusting either the hard hat or the visor.

Another embodiment of the invention relates to a sun-visor with a front brim and a rear brim coupled with two opposite stretch zones. The sun-visor has a wire that extends along the outer diameter. The front brim includes a semi-transparent material and a pad along the inner diameter of the front brim. The pad creates a buffer that deflects for different sizes or styles of hard hats. The stretch zones couple to the auxiliary ridge at a pivot joint that biases the visor about an outer perimeter of the hard hat. The stretch zones and pad deflect to accept variations in sizes for accessories attached in the mounting locations or ports of the auxiliary ridge without removing or adjusting the visor. The pad fits over and/or around additional accessories attached at mounting locations of the hard hat (e.g., a face shield). The visor folds about a spring-loaded joint or biased pivot to adjust a frictional clamping force of an inner diameter of the visor against the outer perimeter of the hard hat. The biased pivot also includes a joint that couples the sun-visor to a mounting location or auxiliary ridge of the hard hat.

In various additional embodiments, the sun-visor is configured for any style or size of helmet or hard hat (e.g., a traditional or climbing style) that includes the mounting locations and/or auxiliary ridge. In this way a universal mounting system that includes mounting locations and auxiliary ridges is compatible with a variety of accessories and configured to work with the visors described herein. The visor can include a bracket that couples to a front or rear mounting location. For example, a notch located on a face of the mounting location secures and removably locks the bracket against the mounting location. For example, the notch can fit within an inner recess of bracket to lock bracket against the notch at the mounting location. In another embodiment, the visor slides under the notch along the outer perimeter of the hard hat and bracket is coupled over the visor to compress visor and securely lock the visor under the notch.

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

Referring generally to the figures, a hard hat accessory system is shown and described. Hard hats include both traditional brimmed style hard hats and climbing style helmets, e.g., with only a small bill in front. Unless specifically indicated, Applicant has used the term “hard hat” to include traditional and climbing style hard hats, as well as any hard hat or protective helmet design, including hard hats having a universal mounting system with mounting locations and auxiliary ridges. Different sizes and styles of hard hats present challenges to the uniform mounting system's size and dimensions. The universal mounting system includes both front and rear mounting locations and opposite side auxiliary ridges. The mounting system provides uniform sized attachments and locations to mount various accessories on various sizes and styles of hard hats. Applicant has found that a visor accessory mounted to the uniform mounting system can also provide the operator multiple access sites at the mounting ridges and side ports to mount additional personal/safety equipment. This enables a user to customize the hard hat for the job site and personal preferences, which enhances user compliance and the proper use of adequate safety equipment based on the job specifications. As used herein, accessories generally include lamps (or headlights), face shields, and/or earmuffs, but can also include a reflector, a magnetic tool carrier, or tool/fastener carrier, hand/power tools, and/or an eyeglass/safety glass holder.

A visor extends the brim of hard hat to shade the user's eyes, to protect the user's eyes from direct sunlight at a construction site, to block/shield the eyes/front of the face from light debris and dust, etc. Attachment of various additional accessories to the mounting system of hard hat can sometimes interfere with other previously mounted equipment. For example, an operator may frequently wear and take off earmuffs at the job site, which would require the operator to adjust both the visor and the earmuffs on/off the hard hat. Applicant has found that support on the mounting system for the rotation of earmuffs when not in use, e.g., off and behind the user's ears, enables the user to switch frequently wear and storage of the earmuffs. The ability to switch between a use and stored position enhances user comfort, particularly when the switch minimizes the adjustments to other attached accessories, such as a visor. Thus, in various embodiments, discussed below, Applicant has developed an innovative modular visor which includes relief portions, such as flexible expanding segments and/or portions that are less taut than neighboring portions, which allows the user to adjust earmuffs without needing to remove the visor. Applicant has also developed an innovative modular visor that permits the user to fold a front and/or side portion of the visor towards the rear, thus permitting the user to attach other accessories and/or attachments to a front and/or side of the hard hat without requiring the user to remove the visor.

shows an operator wearing a hard hat.is a brimstyled or traditional hard hatbecause a brimsurrounds and/or extends around a frontand rearof hard hat. As used herein, a brimis an extension on or attached to hard hatto protect from sun or debris. For example, a sun-visor serves to extend the brimand create additional sun or debris protection. Hard hatgenerally refers generically to both brim (e.g., traditional) and bill (e.g., climbing helmet) styled hard hatsunless expressly noted otherwise.

As illustrated, hard hatis oriented in a forward-facing direction with a front mounting locationabove a visor, ridge, bill, or brimof the frontof hard hat. In this configuration, front brimis located at the frontof hard hat, shields the operator's eyes, e.g., from the sun. In the illustrated position, a rearof hard hatis in the back of the user's head and provides a smaller brimto shade to the user's neck.

shows a reversed hard hat, such that the frontis at the back of the user's head, and the rearis above the eyes. A rear mounting location, the same as or similar to the frontmounting location, is reversed. In other words, the rearmounting locationis located above the user's eyes and available for attachment of an accessory(, e.g., a lampor face shield) to hard hat. In both, each attached accessory, such as a headlamp and/or face visor, includes a mounting bracket() that securely attaches to ridgeson frontor rearmounting locationsof hard hat.

illustrates bracketattachment of a headlamp or lampat mounting locationon hard hat. In some embodiments, the attachment system includes mounting bracket, lamp, and a strap. Bracketincludes clips or receiving slotsthat interface with ridgeson front or rear mounting locationsof hard hat. Bracketprovides structural support to lampand provides a rigid attachment location to secure lampon hard hat. Strapinterconnects lampto bracketand provides a mechanism to attach various lamps, including aftermarket lamps with strapat receiving support locations or mounting locationsof hard hat.

A strap or bandwraps around the circumference of hard hatwithout interfering with the mounting locationsor auxiliary ridges. For example, bandpasses through openings under auxiliary ridges. Bandsupports hand tools and/or other equipment suitable for storage along brimor auxiliary ridgesof hard hat. Similarly, various accessoriesattach or couple to portsin an auxiliary ridgeof hard hat. In some embodiments, tools and/or other accessoriesinclude an insert, fastener, or receiving slotthat couples with one or more ports.

show different sized ports. A smaller portaccommodates a smaller accessory(e.g., tool or eyeglass carrier). Similarly, a larger portis used for a larger accessory(e.g., earmuffs). In some embodiments, a front, middle, and/or rear portare interchangeable to receive and/or support various accessories. For example, a rear portis located along an axial axisand located at a centerline of the operator's neck. When an accessoryis coupled, the rear port, the accessoryis aligned with the axial axisto reduce the moment or load on the user's neck.

compares a white billstyle on the left and a green brimstyle hard hatin the middle. Billstyled hard hatshave a billin front(e.g., over the user's eyes), but no brimsurrounding the sides (e.g., ear) and/or rear(e.g., neck) of hard hat. In contrast, brimstyled hard hatshave a brimat least partially surrounding and extending about the front, rear, and/or sides of hard hat. For example,show a brimstyled hard hat. Applicant has found that users have preferences for different styles of hard hats. For example, brimstyles can be symmetric/balanced from frontto rear, whereas billstyles enable a user to rotate earmuffs further upwards without interference from the surrounding brim. Different hard hatstyles with different geometries can have the same or similar mounting locationsto support the same accessories.

The composite image of billand brimhard hatsis shown on the left of. In this composite image, the white bill(e.g., of a bill styled climbing helmet) extends further in the front. The extended brimstyle (e.g., traditional style) extends further on the sides and rearof hard hat. Both billand brimhard hatsare shown supporting earmuffsin the rearward port. As shown, white billhard hat, on the left, does not interfere with rotation of earmuffsto a position above and/or behind the user's ear. The middle image shows earmuffstored behind the operator's ear, but under brimto minimize interference with earmuffat the rearward brimof hard hat.

Often the user attaches various accessoriesat different locations (e.g., mounting locationand/or ports) to maximize utility (e.g., accommodate more accessories) and/or comfort. The composite image on the right shows earmuffsin the rear port. In this position, earmuffextends substantially parallel to axial axisand over the user's ears, when earmuffsare in the shown operating position. For example, a user places earmuffin the third or rear portbecause this attachment location for earmuffis closer to a centerline, or axial axis, of the operator's neck (e.g., the base of the user's head). Alternative positions for accessoriesmay aid with shade and/or muscle comfort, e.g., by keeping the mass or CG as close to the axial axisat the centerline.

Stated differently, accessoriesfit differently on hard hatsof different styles and/or geometries. However, where the mounting locationsand/or auxiliary ridgesare the same, or similar, for different hard hats, they interchangeably receive accessorieswith a complimentary mounting bracket(or insert).

is a cross-sectional comparison of the billstyle and the brimstyle hard hatsof. As shown, in various embodiments, hard hathas a full brim(e.g., brimstyle) or a large billwithout a surrounding brim(e.g., billstyle). Mounting locationsfor the billand brimstyle hard hatsare different. For example, comparably sized hard hatshave an offset between the mounting locationon the short brim(brimstyle) and long bill(billstyle) hard hat.

shows an extendible visorthat surrounds and clamps or directly couples to auxiliary ridgesand/or mounting locationson hard hat, e.g., similar to band. Visorcouples under mounting locationsand/or auxiliary ridgesin such a way as to leave portsand mounting locationsavailable for additional accessories. Visoris made from a flexible material, such as a fabric, polymer, or plastic. In one embodiment, visorincludes a front portionand a rear portioninterconnected by an elastic section. Elastic sectionenables a user to stretch the visoraround the auxiliary ridgeand mounting locations.

Visorcouples under mounting locationsand auxiliary ridgealong an outer perimeterof hard hat. Visordeflects to rotate/move earmufffrom below the visorin an operation positionto a stored positionfor earmuffabove the visor, as shown in. In addition, the clastic sectionenables the visorto provide some slack when earmuffis moved over visorfrom an operation positionto a stored position. The flexible nature of visorand/or clastic sectionfacilitates the movement from use (e.g., operation position) to stored positionand back.

shows two perspective views of a visorwith a mounting bracketthat attaches to the mounting locationson hard hat. Visoracts like a visorfor specific accessories, e.g., face shield, but can be modular and segmented. For example, visorenhances face shieldfor different styles and sizes of hard hats. Additional outer mounting locationson visorsupport accessorieson hard hat, and a distending peak or ridge extensionprotrudes radially outward between the mounting locationand an edge of visor. As such, visorprovides cross-compatibility between different hard hatsof different sizes and styles, including billsand brims. In addition, visorprovides additional mounting locationsfor other accessories.

Visorprovides a space, or bridge, for accessories, such as lamp, to remain attached to hard hatwhen an operator moves the face shieldfrom an operation positionto a stored positionand back. Visoralso provides a reliable structural abutment, or seal, between the face shieldand any style of hard hatwith mounting locations(or auxiliary ridges) configured for the bracketon visor. In this way, visorfacilitates coupling a welding face shieldand a lampto the mounting location. As a specific example, this configuration is beneficial when welding, since traditional welding face shieldsare dark to protect the eyes from the arc, but often too dark to see in ambient light. Operators often find it difficult to see and manipulate work-piece objects when the face shield is in the operating position but the welding arc is not illuminated. Lampcan provide sufficient light for the operator to see and manipulate the welding work-pieces before and after the welding process in the absence of the arc.

Visorprovides a structural and spatial bridge between hard hatand face shieldfor structural support of another attached accessory. This enables two accessories(e.g., a welding mask and a headlamp) to be coupled at the mounting locationof hard hat. Ridge extensionson visor(e.g., bracketof visor) provide a structural offset or bridge from hard hatto visorto accessory.

Visorhas a bracketwith a duplicate mounting locationon an exterior of visorto accommodate the additional mounted accessory. For example, on one side (e.g., an inner surface) of visoris a mounting bracketwith ridgessimilar to lamp. When this bracketof visorcouples to mounting location, an opposite, exposed side (e.g., outer surface) of visorforms an available external mounting locationto receive and support an additional mounted accessory, such as a lamp, on hard hat.

To support accessoryand/or visor, each mounting locationhas side ridgeson both sides of mounting location. Mounting brackethas a complimentary side receiving slotson both sides of mounting bracket. Side receiving slotsare configured to couple to ridgesat the mounting locations. For example, the coupling of receiving slotsto ridgesmounts visorto hard hatand similarly mounts a lampto visor(). In this way, visorserves as a bridge between an accessoryand the mounting locationsof different sizes and styles of hard hats.

Applicant has found that having a mounting locationfor the face shieldwith the same, or similar, ridge extensiondimensions ensures the proper abutting visorposition for the face shieldin the operation positionto protect a user's eyes and/or face. Ridge extensionstructurally interconnects face shieldover the brimof hard hat. In one embodiment, ridge extensionand face shieldabut to form a seal, such as a watertight or hermetic seal. The seal then protects the user from intruding or splashed liquids or debris.

Different users prefer different bills, brims, and/or hard hatgeometries. Different geometries are also advantageous for various worksites and/or jobs. For example, the same user may have one hard hatwith a large billfor outdoor worksites and a second hard hatwith a small surrounding brimto support a lampfor indoor job sites.

Applicant has found that using an intermediary modular visorenables the user to attach one face shieldthat reliably abuts and/or seals against the brimof a variety of hard hats. Visorcreates a reliable fitment regardless of the style, size, or geometry of the brimor billon the hard hat. In this way, an operator with two hard hatscan attach, abut, and/or seal the same face shieldto visor, and then interchangeably attach and detach the visorand face shieldto the operator's preferred hard hat. This enables the operator to customize the hard hatfor a particular environment or job. Alternatively, the same user attaches a welding face shieldfor a welding job and later attaches a different protective eyeglass face shieldfor woodworking. In other words, visorbridges different sizes and shapes of various hard hats(or face shields) and permits the use of one face shieldto fit various sizes of hard hatswith complimentary mounting locations.

In one embodiment, visorincludes an oblong locking protrusionin mounting location. An overhangon bracketengages a notch or notchto lock visoron mounting locationsof hard hat. The coupled notchand overhangprotect against inadvertent bumping or jostling of accessorieswhen visoris coupled to hard hat.

shows perspective, top, and bottom views, respectively, of visor. The connection of visorto hard hatcreates a ridge extensionthat covers both hard hatsand helmets with billand brimstyles. The top row shows visorattachment to both bill(left climbing helmet) and brimstyled (right-traditional brim style) hard hats.

Visorattaches to both styles and creates a uniform ridge extensionwith a consistent brim width W. The brim width W extends between the mounting locationof hard hatto an edge of the ridge extensionon visor. As shown, the brim width W is greater than either billor brimdimensions. The middle row shows how the visorcreates a uniformly sized attachment for an accessoryor face shield. The bottom row shows how brim width W is longer than either extension of billor brimstyles. Specifically, the black visoris longer than either the bill(left) or brim(right) of either hard hat.

is a top perspective view of an embodiment of a sun-visor or visorwith a bracketover hard hat. Visoris the same as or similar to visorand/or visor, except visorincludes one or more attachment mechanism, shown as jointand/or a bracket, to securely but removably couple visorto mounting locationsor auxiliary ridgesof hard hat.

In a specific embodiment, hard hat systemincludes hard hatincluding a shellformed from a rigid material and visorreversibly coupled to hard hat. The shellincludes an accessory mounting locationlocated along an outer surfaceof shell.

In various embodiments, visorincludes a first portionand a second portion. The first portionextends circumferentially around at least a portion of the shelland extends radially outward from the shellforming a sun-blocking flange. The second portionis coupled to the first portionand positioned adjacent to the accessory mounting location. The second portionis deformable relative to the first portionsuch that the second portiondeforms to accommodate and cover a portion of an accessory(e.g., an ear muff) coupled to an accessory mounting location, shown as one of front port, middle port, or rear port. The deformation of second portionallows accessoryto extend from the accessory mounting location (e.g., front port, middle port, or rear port) to below the second portion.

In various embodiments, second portionis formed from a material that is more elastic than a material of the first portion. In various embodiments, second portionincludes a first zoneon a first sideof shell, and a second zoneon a second sideof shellopposite the first side. In a specific embodiment, the first sideis a left side of the shelland the second sideis a right side of the shell. In various embodiments, a fastener, shown as joint, couples the visorto the left side of the shelland a second fastener, shown as joint, couples the visorto the right side of the shell. In various embodiments, second portionincludes a third zoneand a fourth zoneseparated by a bridge, and the third zoneand the fourth zoneare both positioned on a first side of the shell(e.g., a left side of the shell, a right side of the shell). The bridgeis formed from a material that is less elastic than a material forming the second portion.

As described in detail below, visorenables a user to fold a brim, e.g., front over the back or back over the front, and retain the fold. Visorcouples to mounting locationsand/or portsof auxiliary ridgeon different styles and sizes of brimand/or billhard hats(e.g., climbing styled helmets and traditional hard hats).shows a rear view of hard hatwith visorcoupled to the rear mounting ridge via bracket, as illustrated in.

With reference to, visorincludes a front portion, shown as front brim segment, and a rear portion, shown as rear brim segment, that are interconnected by opposite stretch zones. Front brim segmentand rear brim segmentare similar to front and rear portionsandof visor. A fastener, shown as joint, couples two parallel stretch zonesto a porton the auxiliary ridgeto secure visor. In one embodiment, the front brim segmentand/or rear brim segmentincludes bracketthat couples visorto mounting locations(or auxiliary ridges) on hard hat. A non-clastic material or bridgebetween stretch zonesforms integrally with joint() or is a separate component that couples to and supports joint().

Front brim segmentis moveable between a covering configuration in which the front brim segmentextends in a forward directionaway from a frontof hard hat, and a stowed configuration in which the front brim segmentextends in a rearward directionaway from a rearof the hard hat. Front brim segmentinterfaces with the rear brim segmentwhen the front brim segmentis in the stowed configuration.

In various embodiments, clipis coupled to rear brim segmentand clipcouples visorto hard hat(). In various embodiments, clipis coupled to front brim segment, and clipcouples to rearof hard hatwhen the front brim segmentof visoris in the stowed configuration. In various embodiments, clipcouples front brim segmentto frontof hard hatwhen front brim segmentof visoris in the covering configuration. In various embodiments, clipis coupled to the front brim segmentof visor, the clipcouples to a frontof the hard hatwhen the visoris in the covering configuration.

In various embodiments, jointcouples to a portin auxiliary ridge. For example, as shown in, jointcouples to a front port.shows jointcoupling visorto a middle port. Similarly, jointcan couple to any port(e.g., rear port) of auxiliary ridgeand/or a front or rear mounting locationon hard hat. Jointlocation in a front port, middle port, or rear portdetermines a fold locationof visor. Also, the use of a particular port(e.g., front port, middle port, or rear port) facilitates the attachment of other accessoriesto either the mounting locationand/or other portsin auxiliary ridge. For example, using a front portto attach a face shieldand/or visorfacilitates earmuffattachment at a middle or rear portorof auxiliary ridge.

In various embodiments, bracketis coupled directly to visor() or over visor() at the mounting location.shows bracketcoupled to visorand securely coupled to a rear mounting locationon hard hat. In contrast,shows visorwrapped around an outer perimeterof hard hat. Outer perimeterincludes the transition perimeter of the front and rear mounting locationsand the side auxiliary ridgestowards/adjacent the brimof hard hat. Visorhas a hollowed elliptical shape (elongated donut) that extends radially from an inner diameter(e.g., adjacent outer perimeterof hard hat) to an outer diameter. Bracketcouples to a rear mounting locationand captures visoraround the outer perimeter, between the hard hatbrimand bracket(e.g., under notchbut over brimof hard hat). Bracketincludes exterior mounting locationsand/or a notchto further support and/or couple an additional accessory. An elastic or strapextends under front brimto fold the brimsand hold the folded configuration.

Patent Metadata

Filing Date

Unknown

Publication Date

November 13, 2025

Inventors

Unknown

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Cite as: Patentable. “Hard Hat Attachment System and Sun Visor” (US-20250344799-A1). https://patentable.app/patents/US-20250344799-A1

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