Quick Adjustable Headgear

This patent application is a continuation of, and claims priority to and the benefit of, International Patent Application No. PCT/US2024/017786, filed Feb. 29, 2024, entitled “Quick Adjustable Headgear”, having Attorney Docket No. 1485.0993i, which claims priority to and the benefit of U.S. Patent Application No. 63/487,966, filed Mar. 2, 2023, entitled “Quick Adjustable Headgear”, having Attorney Docket No. 1485.0993P. The entire disclosures of both of the two above-identified patent applications are incorporated herein by reference in their entirety for all purposes.

The present disclosure is directed to headgear and, in particular, a quick adjustable headgear for personal protective equipment (PPE).

In welding, head wearable PPE may include heavy components (e.g., a helmet, batteries, automatic darkening filters, a face shield, a mask, etc.). Generally, conventional headgearfor supporting such PPE, an example of which is shown in, typically has one to three “overhead straps” or “crown straps”that are connected to an adjustable headband. Each of these strapshas a length adjustment mechanism comprising snap-adjustments. This length adjustment mechanism enables the strap to be placed into several positions, but changing from one set length to another set length is a cumbersome task. Also, the length adjustment facilitates only step-wise adjustments, and wearers seldomly invest the required time to adjust the headgear to achieve a proper fit or sometimes are unable to reach one at all. While some conventional assemblies have the disadvantage that the overhead straps are oriented in set or fixed angles resulting in most users being unable to align the flat of the strap with their scalp, other conventional assemblies do provide some sort of adjustable solution. Either way, in conventional assemblies, one of the edges of the strap is in contact with the head and bears most of the load through the strap, thereby causing high surface pressure and discomfort as shown in.

Moreover, when removing or donning the headgear, the headbandneeds to be lengthened because of the geometry of a human skull. This lengthening leads to the adjustment mechanism (e.g., a ratchet) needing to be “released” every time the headgear is removed and “tightened” after the headgear is put on or donned. In one conventional product, the achieved setting of the adjustment mechanism is lost each time a user removes the headgear. This loss of the setting leads to an inconsistent fit each time the user wears the headgear and can result in user discomfort, body fatigue, and avoidance of removing the headgear. The inconsistent fits lead to the user wearing the headgear for longer periods, resulting in the user potentially suffering more body strain/fatigue. In other conventional products, overhead straps and the horizontal strap are not connected. Thus, the settings are separated.

The techniques presented herein provide a quick adjustable headgear for supporting PPE by quickly adjusting the headgear to conform a user's head and eliminating the need for resetting all of the many adjustments when removing and donning the headgear.

In one embodiment, an adjustable headgear comprises a crown strap assembly having a tensioning line and quick lock arrangement to adjust an over-the-crown fit of the adjustable headgear; and a circumferentially adjustable headband having a front section and a rear section, the rear section being adjustable with a tensioning mechanism, the circumferentially adjustable headband being coupled to the crown strap assembly, wherein the rear section is configured to elastically extend to slide relative to a user's head when removing or donning the adjustable headgear.

In another embodiment, the adjustable headgear can be quickly set to conform a user's head and eliminates any need of resetting any adjustments when removing and donning the adjustable headgear.

In another embodiment, the crown strap assembly includes a first strap and a second strap, the second strap being coupled to and movable with the first strap, the first strap and the second strap being coupled to the adjustable headband at a first pivot.

In another embodiment, the first strap and the second strap are pivotable relative to the adjustable headband about the first pivot.

In another embodiment, the first strap has a first strap portion and a second strap portion, the second strap portion being slidably coupled to the first strap portion, and an overall length of the first strap is determined by relative positions of the first strap portion and the second strap portion.

In another embodiment, the tensioning line is coupled to the first strap portion and is slidably coupled to the second strap portion, and application of a force on the tensioning line causes the second strap portion to move relative to the first strap portion and to change the overall length of the first strap.

In another embodiment, the second strap has a third strap portion and a fourth strap portion, the fourth strap portion being slidably coupled to the third strap portion, and an overall length of the second strap is determined by relative positions of the third strap portion and the fourth strap portion.

In another embodiment, the tensioning line is coupled to the fourth strap portion and is slidably coupled to the third strap portion, and application of the force on the tensioning line causes the third strap portion to move relative to the fourth strap portion and change the overall length of the second strap.

In another embodiment, the crown strap assembly includes a third strap and a fourth strap, the fourth strap being coupled to and movable with the third strap, the third strap and the fourth strap being coupled to the adjustable headband at a second pivot, the third strap and the fourth strap being pivotable relative to the adjustable headband about the second pivot.

In another embodiment, the first strap and second strap are pivotable about the first pivot independently from movement of the third strap and the fourth strap about the second pivot.

In another embodiment, the third strap has a fifth strap portion and a sixth strap portion, the sixth strap portion being slidably coupled to the fifth strap portion, and an overall length of the third strap is determined by relative positions of the fifth strap portion and the sixth strap portion.

In another embodiment, the crown strap assembly includes a second tensioning line engageable with the fifth strap portion and with the sixth strap portion, and application of a force on the second tensioning line causes the sixth strap portion to move relative to the fifth strap portion and to change the overall length of the third strap.

In another embodiment, the tensioning mechanism is a ratchet that can be manipulated to change the tension in the second tensioning line.

In another embodiment, the quick lock arrangement permits limited slipping of the tensioning line so that it absorbs some of a force of impact applied to a hardhat coupled to the adjustable headgear.

In an alternative embodiment, an adjustable headgear to which a hard hat can be coupled comprises a crown strap assembly having a first tensioning line, a second tensioning line, and a locking mechanism to adjust an over-the-crown fit of the adjustable headgear, the crown strap assembly including a plurality of adjustable straps; and a circumferentially adjustable headband coupled to the crown strap assembly, the adjustable headband including a tensioning mechanism, wherein the tensioning mechanism and the locking mechanism are manipulatable to set and hold a fit of the adjustable headgear so that it can slide relative to a user's head when removing or donning the adjustable headgear.

In an alternative embodiment, the plurality of adjustable straps includes a first strap and a second strap being coupled to and movable with the first strap, the first strap and the second strap being coupled to the adjustable headband at a first pivot, and the first tensioning line is engageable with the first strap and the second strap.

In an alternative embodiment, the locking mechanism permits limited slipping of the first tensioning line so that it absorbs some of a force of impact applied to a hardhat coupled to the adjustable headgear.

In another embodiment, an adjustable headgear to which a hard hat can be coupled comprises a crown strap assembly having a first tensioning line, a second tensioning line, and a locking mechanism to adjust an over-the-crown fit of the adjustable headgear, the crown strap assembly including a first strap coupled to a second strap and movable about a first pivot, and a third strap coupled to a fourth strap and movable about a second pivot, the first tensioning line being engageable with the first strap and the second strap, and the second tensioning line being engageable with the third strap and the fourth strap; and a circumferentially adjustable headband coupled to the crown strap assembly, the adjustable headband including a tensioning mechanism, wherein the tensioning mechanism and the locking mechanism are manipulatable to set and hold a fit of the adjustable headgear so that it can slide relative to a user's head when removing or donning the adjustable headgear, and the locking mechanism permits limited slipping of the first tensioning line so that it absorbs some of a force of impact applied to a hardhat coupled to the adjustable headgear.

In an alternative embodiment, the first strap has a first strap portion and a second strap portion, the second strap portion being slidably coupled to the first strap portion, and an overall length of the first strap is determined by relative positions of the first strap portion and the second strap portion which are adjustable by manipulating the first tensioning line.

In an alternative embodiment, the first strap and second strap are pivotable about the first pivot independently from movement of the third strap and the fourth strap about the second pivot.

The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the invention. Embodiments of the invention will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the present invention.

Generally, the present application is directed to PPE for welding operations (e.g., a helmet, welding mask, welding face shield, etc.) with a quick adjustable headgear that conforms to a user's head. That is, the headgear supports the PPE when worn on a user's head. In one embodiment, the headgear includes two parts. The first part is a crown strap assembly having a tensioning line and quick lock arrangement to adjust an over-the-crown fit of the headgear. The second part is a circumferentially adjustable headband having a rear section that can quickly adjust with a tensioning mechanism and/or elastically extend to slide over a user's head when removing or donning the headgear. Consequently, the user can set the fit of headgear once, then iteratively wear and remove it without needing to reset all of the adjustments. Also, this headgear is easier to set because it has fewer individual settings and the straps may be set at any desired position and/or tension to conform to the user's head. This functionality results in settings that fully adapt to a wider range of skull-shapes as compared current headgear solutions. Therefore, the headgear according to the present invention provides an improved fit over conventional headgear.

Referring to, illustrations of an embodiment of an over the crown strap assembly(e.g., the first part of a headgear assembly) is shown. The strap assemblyreplaces the crown straps of a conventional headgear design. That is, the lateral sides of the strap assemblyattach to, or are connected to, a circumferential headband that is configured to extend along the circumference of a user's head and couple to a PPE.

The strap assemblyincludes flexible top straps or padsA andB (in one embodiment, rectangular portions) that conform to the top of the user's head, and flexible side strapsA andB (V-shaped portions) that may overlap with a portion of the top strapsA andB. In one implementation, top strap or padA is a front top strap or pad, and rear strap or padB is a rear top strap or pad. In addition, side strapA is a right side strap, and side strapB is a left side strap. The side strapsA andB are configured to be disposed on either side of the user's head and to connect to a circumferential headband (not shown).

An elongate member or line(e.g., an inelastic string, strip, cord, etc.) extends through the rear top padB through a right, or first, side strapA to the front top strapA through a left, or second, side strapB, and back to the rear top strapB. The two ends of the elongate member or lineare fed through a spring-loaded lockfor easy length adjustment and setting (e.g., locking and unlocking of the line), and thus, ensuring the strap assemblyand the headgear properly rests on the user's head. The length and/or tension of the linemay be locked with the spring-loaded lock. That is, a tension in the linemay be set to adjust how the strap assemblyrests/fits on the user's head.

Each of the support components (i.e., top strapsA andB, side strapsA andB, and line) may be flexible in one or more axes. That is, each of the support components may bend and/or twist to conform to the user's head and distribute the weight of the headgear (and any attached PPE) across the strapsA,B,A, andB. Accordingly, the top strapsA andB, and the side strapsA andB distribute the weight to the user's head. As a result, the strap assemblymay be easily set by adjusting a length of the lineto comfortably conform to the user's head and support the headgear (and PPE), to thereby reduce user strain/fatigue. In some instances, the side strapsA may extend from the right side of the user's head and overlap with the side strapsB extending from the left side of the user's head. The top strapsA andB may individually cover, surround, and/or wrap the overlapping side strapsA andB. In an alternative embodiment, the top strapsA andB may be absent.

Now turning to the second part of the design, an adjustable headband is coupled to the strap assemblydescribed above to support the headgear (and PPE) on a user's head. For example, the flexible side strapsA andB may be coupled to opposing lateral sides of the headband. A PPE (not shown) may be coupled to the headband to protect the wearer during a welding operation.

Referring to, an embodiment of some components of a headband according to the present invention is illustrated. The headbandincludes an elongate member, which may be an elastic member, such as an elastic line, an elastic string, a cord, a band, or the like, coupling a front portionof the headbandto a rear portionof the headband. In an alternative embodiment, the elongate membercan be a strap. The strap assemblyofand one or more PPE components may be attached to the front portion(e.g., near a pivot). The attached PPE component(s) may move with the front portionand the user's head.

In the depicted embodiment, the elongate membercircumscribes a portion of a pivot pointconnected to the front portionand extends to the rear portion. The elongate membermay extend from lateral sideto a lateral side (not shown) of the headbandopposite to lateral sideto circumscribe a second pivot (not shown). The rear portionmay include a flexible pad that may conform to a contact surface (e.g., a user's head at or below an occipital ridge). Tension in the elongate memberpulls the rear portiontowards the front portionsuch that the headbandgrips the user's head and the flexible pad of the rear portionconforms to the shape of the wearer's head at or below the ridge of the occipital bone. That is, when the headgear is worn by the user, the tension of the elongate memberbetween the front portionand the rear portionsecures the headbandto the user's head. The tension of the elongate membermay be adjusted by changing a length of the elongate memberbetween the rear portionand the front portion.

The length of the elongate membermay be adjusted by a ratchetdisposed at the rear portion. In the depicted embodiment, the ratchetmay be manipulated by a user, such as by rotation thereof, to extend or shorten the length of the elongate memberbetween the rear portionand the front portionand adjust its tension to achieve a comfortable and secure fit. When removing or donning the headgear (and any attached PPE components), the elasticity of the elongate memberallows the user to stretch and release the headbandso that it can pass over the largest circumference of the wearer's head (e.g., between the forehead and the occipital ridge) without releasing and/or adjusting the tension. Consequently, the user sets the tension of the headbandonce and can iteratively remove and securely don the headgear without needing to adjust the tension in the headbandand/or strap assembly. In some alternative implementations, the elongate membermay be substantially inelastic, and the user may adjust the ratchetto set the tension of the elongate memberwhen removing and donning the headgear.

Referring to, another embodiment of a headband according to the present invention is shown. The headbandcomprises an elongate member, such as an elastic band, (which alternatively may be a strap, a belt, a ribbon, a chord, etc.) coupling a rear portionof the headbandto a front portionof the headband. The rear portionmay be flexible and conform to a contact surface (e.g., a user's head at or below the occipital ridge). The front portionmay be substantially rigid and may include one or more elastic portionsconfigured to align with the temples of the user's head. The front portionincludes a connection portion, which receives the strap assemblydescribed above. That is, the strap assemblycouples to the connection portionof the headband. In some implementations, PPE may couple to the connection portionas well.

When the headbandis worn on the user's head, the elastic bandand one or more clastic portionspull the front portionand the rear portiontogether to grip the user's head. In some implementations, a length of the bandmay be adjusted with a length adjustment mechanism (e.g., a ladder lock, a slider lock, a buckle, etc.). Consequently, a user can set a tension in the headbandto comfortably grip or cradle the user's head and align the PPE with the user's head. For example, the length and tension of the band(and one or more elastic portions) may be set to align the connection portionof the headbandwith the user's ears. When combined, the headbandand the strap assemblydefine a headgear for supporting welding PPE on the user's head. Further, the headbandallows for easy donning and removal of the headgear (and PPE) without having to reset the strap assemblyand/or tension in the elastic band.

Now referring to, a headgearaccording to another embodiment of the present invention is illustrated. In the depicted embodiment, the headgearincludes a headbandhaving a front portionA and a rear portionB and a plurality of flexible over-the-crown straps,,, and. The rear portionB may be defined by a rear strapand the rearmost over-the-crown strap. In some implementations, the rear portionB may be defined by a pad disposed on the rear strap.

Still referring to, a first or frontmost over-the-crown strapmay extend from the front portionA of the headband. A second over-the-crown strapand a third over-the-crown strapmay be pivotably coupled to the front portionA of the headbandvia a pivot. The fourth or rearmost over-the-crown strapand the rear strapmay couple to the front portionA of the headbandvia another pivot. The pivotsandallow strapsand, and strapsandto rotate with respect to the headbandand align with the user's head. In some implementations, one or more of the straps,,, andmay be individually wrapped in an absorbent material (e.g., a cloth, sponge, etc.) to capture sweat from the user's head. An absorbent material may also cover, attach to, and/or wrap around at least a portion of the headband.

The headgearfurther includes an attachment portionoperably coupled to the front portionA to support a portion of a PPE for protecting the user's head/face during a welding operation. In one embodiment, the PPE includes a face shield or visor part, as well as a headgear. That is, the attachment portionoperably couples the face shield or visor part to the headgear. The attachment portionmay translate up, down, forward and/or backward along the headbandto adjust a position of the face shield or visor part with respect to the headgearand the user's head. In one embodiment, the attachment portionmay slide along a strap portion coupled to the headband.

To securely support the PPE, the fit of the headgearon the user's head may be adjusted by one or more lines or elongate membersand. A first lineextends along the first, second and third over-the-crown straps,, andand the first pivot. The linemay run through a plurality of guideson or defined by the over-the-crown straps,, andand may be fixed to one end of the headgear. The pivotmay grip or lock the first lineat a desired tension. Tensioning the first linewhen worn on a user's head causes the first, second, and third over-the-crown straps,, andto conform to the user's head and distribute weight from the headgear(and PPE) along the straps,,and the user's head. The pivotmay further include an unlock feature to release or adjust the tension of the first line.

The second lineextends along the fourth over-the-crown strapand the rear strapand adjusts the fit of the rear portionB. The second linemay run through a plurality of guideson, or otherwise defined by, the over-the-crown strapand the rear strap. A ratchetdisposed on the rear strapmay be used to adjust the tension in the second line. Tensioning the second linewith the ratchetsets or adjusts the fit of the second portionB and the headbandon the user's head. That is, the tension in the second linepulls the first portionA and the second portionB of the headgeartogether to grip the user's head. In some instances, the second linemay be elastic to allow the user to loosen and slip the rear strapover the occipital ridge when the user dons or removes the headgearfrom their head without changing the setting of the ratchet.

Alternatively, the second linemay be substantially inelastic, and the user may adjust the ratchetto set the tension in the second linewhen removing and donning the headgear (and any attached PPE). In some implementations, the first lineand the second linemay be coupled together, or comprise a single line tensioned by the ratchetor other tensioning mechanisms. Further, in some implementations, the first lineand/or the second linemay be elastic or inelastic (e.g., a string or braided cord made from nylon, polyester, etc.).

The tension from the linesandadjusts the length of the individual straps,,,, and, respectively. For example, each strap,,,, andincludes two telescoping portions that operably engage one another. Tensioning the linesandsets an overall length of each strap,,,, andby pulling corresponding strap portions forming each strap together. That is, the telescoping portions of each strap,,,, andtranslate or slide with respect to one another in response to the tension in the linesand, respectively.

Example telescoping portions of the over-the-crown straps,,,, andare described with reference to the second and third over-the-crown strapsandthat are illustrated in. Referring to, each of the over-the-crown strapsandincludes a first portionA orA and a second portionB orB. The distal ends of the first portionsA andA include receiving elementsto receive distal endsof the second portionB andB, respectively. Each of the distal endsof the second portionsB andB includes engagement elementsconfigured to slidably engage lateral edges of the first portionsA andA. The telescoping portionsA,B,A, andB translate in response to a change in the tension in line. The tension in both of the lines,may be set based on a length adjusting mechanism discussed below.also shows part of the front portionA of the headband, an exemplary guide, and a pivot.

Referring to, a length adjustment mechanism according to an embodiment of the present invention is illustrated. The depicted adjustment mechanism may be representative of how each of the straps,,,, andis adjusted. In, the first portionA of the third over-the-crown strapis operatively coupled to the second portionB of the third over-the-crown strapin a telescoping manner. In particular, the distal endof the second portionB of the third over-the-crown strapextends through an opening in the receiving elementand overlaps with a section of the first portionA. Meanwhile, the engagement elementsengage lateral sides and the upper surface of the first portionA. The first linehas a first endA coupled to a guideof the second portionB and extends through additional guidesalong the second portionB and the first portionA. When tension is applied to the first line, the first endA pulls and translates the second portionB towards the first portionA, thereby shortening the overall length of the strap. Additionally, when the tension is released, the line first endA and the second portionB are free to translate away from the first portionA, thereby increasing the length of the strap.

A length of each of the straps,,,, andmay be adjusted in a similar manner to conform to the user's head. In some implementations, the linemay be fixed at a first or a second portion of a strap,,,, andand be threaded through two or more of the straps,,,, andsuch that tensioning a second end of the lineadjusts a length of multiple ones of the straps,,,, and. In yet another implementation, the linemay be a closed loop, and the tension in the loop may pull the telescoping portions of all the straps together simultaneously.

With reference to, the pivotsandmay assist in aligning and conforming one or more of the straps,,, andwith the user's head. In the depicted embodiment, each of the pivotsandincludes a resilient, V-crown bandhaving a plurality of radially extending teeth. The teethare configured to engage one or more tabsextending from the headband. The bandresiliently engages the tabwith the teethto maintain a desired angular orientation between the one or more straps,,andand the headband. Consequently, the user may easily set the straps,,,, andto conform to their head and the pivotsandmay maintain the positioning of the straps when the user removes the headgear.

According to the techniques presented herein, a user may tension a first line and/or a second line to fit a headgear to the user's head. The headgear is configured to support and secure a PPE on the user's head. Additionally, the user may remove and don the headgear without adjusting the first line and/or second line, thereby avoiding inconsistencies in fit of the headgear and reducing fatigue/strain.

In an alternative embodiment, either one or both of the tensioning linesandcan move or slip in a controlled manner to provide a “crumble zone” for the headgear. In one implementation, the headgear can be coupled to a hardhat. Turning to, a schematic block diagram of a locking mechanism that can be used in the headgear is illustrated. In this embodiment, the locking mechanismincludes a first memberand a spaced apart second memberthat is biased toward the first memberby a biasing member, such as a spring, along the direction of arrow “D”. The properties of the biasing membercan be selected to control the amount of the biasing force applied to one of the tensioning linesorthat is located between membersand. In the event of a vertical impact on the hardhat to which the headgear is coupled, the locking mechanismwould allow “slowed down” and limited slipping of the tensioning lineorbetween membersand, based on the biasing force of the biasing member. In particular, the biasing force applied by the biasing membercan be selected based on how tightly the membersandare to grip and lock the respective tensioning line. As the biasing force is increased, the grip by membersandis tighter on the tensioning line. The force of the biasing membercan be selected so that it permits movement of the tensioning line when a force reaching a certain level is applied to the hardhat. In an alternative embodiment, both memberand membermay be biased toward each other by one or more biasing mechanisms.