Hard Hat with Strap System
A hard hat and related impact protection layer is shown. The hard hat includes one or more feature to improve support of the impact protection layer and coupling of the hard hat to the user. Various suspension mechanisms for hard hat outer shells and strap systems are described herein.
The present application is a continuation of International Application No. PCT/US2021/041941, filed on Jul. 16, 2021, which claims the benefit of and priority to U.S. Provisional Application No. 63/053,289, filed on Jul. 17, 2020, which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTIONThe present invention relates generally to the field of protective equipment. The present invention relates specifically to various hard hat designs with coupling, suspensions and adjustment mechanisms.
Hard hats are often used in construction or other environments/worksites where head protection is warranted. For example, hard hats are used in environments where there is a risk for head injury and act to provide added protection to a worker's head.
SUMMARY OF THE INVENTIONOne embodiment of the invention relates to a hard hat including an outer shell and a coupling system. The outer shell is formed from a rigid material. The coupling system is coupled to the outer shell. The coupling system includes a suspension system, a strap system, a clip, and a receiver. The strap system is configured to couple to the outer shell and is configured to couple the suspension system to a head of a person. The strap system includes a first strap. The clip is coupled to the first strap. The receiver is configured to mechanically and reversibly couple and decouple to the clip. The receiver is configured to rotatably couple to the clip such that the receiver is rotatable relative to the clip about a first axis when the receiver is coupled to the clip.
Another embodiment of the invention relates to a hard hat including an outer shell formed from a rigid material, and a coupling system coupled to the outer shell. The coupling system includes a strap system configured to couple a safety headwear to a head of a person. The strap system includes a first strap, a clip coupled to the first strap, and a receiver coupled to the outer shell. The clip includes a button. The receiver is configured to mechanically and reversibly couple to the clip to position the first strap below a chin of a user of the hard hat. The receiver includes a housing defining an opening. The button extends through the opening such that the housing peripherally surrounds the button of the clip when the receiver is coupled to the clip. The button actuates to decouple the clip from the receiver.
Another embodiment of the invention relates to a hard hat including an outer shell formed from a rigid material and a coupling system coupled to the outer shell. The coupling system includes a receiver coupled to the safety headwear, and a clip coupled to a first strap. The receiver defines a first longitudinal axis. The clip defines a second longitudinal axis. The clip is configured to mechanically and reversibly couple and decouple to the receiver. The clip includes a button that actuates along an axis perpendicular to the first and second longitudinal axes to decouple the clip from the receiver.
One embodiment of the invention relates to a helmet or hard hat. The hard hat includes an outer shell formed from a rigid material that includes an external surface and an internal surface that defines a cavity sized to receive the head of a wearer, an impact protection layer located within the cavity and coupled to the outer shell, the impact protection layer including an external surface that faces towards the shell and an opposing internal surface that faces away from the outer shell, an upper band coupled to the outer shell, a middle frame coupled to the upper band, and a lower band pivotably coupled to the middle frame. The lower band is adjustable to a plurality of lengths. In a specific embodiment, the upper band, the middle frame and the lower band collectively circumferentially surround a user's head, and the lower band is adjustable to accommodate a plurality of user head sizes. In a specific embodiment the middle frame is pivotably coupled to the upper band. In a specific embodiment a strap system is coupled to the outer shell at a plurality of connection points, at least two of which are pivotable with respect to the outer shell. In a specific embodiment the strap system includes a back strap that extends through a cavity defined by the adjustable lower ring.
One embodiment of the invention relates to a helmet or hard hat. The hard hat includes an outer shell formed from a rigid material and that includes an external surface and an internal surface that defines a cavity sized to receive the head of a wearer, a plurality of ribs extending from the internal surface of the outer shell into the cavity, the plurality of ribs defining a channel between at least two ribs of the plurality of ribs, and an impact protection layer located within the cavity and coupled to the outer shell. The impact protection layer includes an external surface that faces towards the shell and an opposing internal surface that faces away from the outer shell, and a protrusion extending from the external surface of the impact protection layer. The protrusion of the impact protection layer extends within the channel.
In a specific embodiment, the impact protection layer defines a plurality of recesses that receive the plurality of ribs of the outer shell. In a specific embodiment, the outer shell defines a first plurality of apertures that extend between the internal surface and the external surface of the outer shell, and the impact protection layer defines a second plurality of apertures that extend between the internal surface and the external surface of the impact protection layer, the first plurality of apertures and the second plurality of apertures collectively providing fluid communication between the head of the wearer and the external surface of the outer shell. In a specific embodiment, the outer shell and the impact protection layer collectively define a plurality of lateral channels that provide fluid communication between at least two apertures of the second plurality of apertures of the impact protection layer.
Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.
The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments.
Referring generally to the figures, various embodiments of a hard hat are shown. As will be understood, hard hats are worn by users during activities where the user is frequently moving. Applicant has developed various mechanisms to securely and comfortably couple hard hats to the user's head even while the user works, moves around and speaks.
Applicant has developed hard hat securing mechanisms provide several that provide several advantages and improvements compared to previous designs. First, the hard hat securing mechanisms permit various aspects of the securing mechanisms, such as the back strap behind the user's head, to pivot towards more comfortable positions without requiring manual adjustment from the user. Second, the hard hat securing mechanisms provide improved coupling mechanism location between various straps to provide increased stability and comfort for the user. Third, the hard hat securing mechanisms are adjustable to a wide range of head sizes.
Applicant has developed hard hat systems configured to be comfortably worn by people with varying head sizes. For example, the hard hat includes a strap system with receivers and clips that are configured to rotate with respect to each other when the strap system is coupled to a hard hat on a user. Applicant has observed that allowing the straps to rotate at the location of coupling permits a more comfortable repositioning of the straps relative to the head of the user as compared to hard hat systems in which the straps are coupled via receivers and clips that do not rotate with respect to each other.
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Outer shell 20 includes an external surface 21 and an opposing internal surface 23 that defines a cavity 25 of outer shell 20. Outer shell 20 defines a plurality of venting apertures 22 and impact protection layer 40 defines a plurality of corresponding apertures 42. Apertures 22 and 42 collectively provide fluid communication between cavity 25 and ambient air proximate to external surface 21 of outer shell 20. Front brim 24 of outer shell 20 projects outwardly from a front 16 of outer shell 20.
Outer shell 20 includes recess 26 positioned between front 16 and rear 18 of outer shell 20, proximate the ears of a user wearing hard hat 10. In a specific embodiment recess 26 extends height 28 above lower surface outer shell 20 in front of recess 26.
Outer shell includes coupling components 36 that couple outer shell 20 to crown 12. Outer shell 20 includes apertures 30 proximate recess 26. Apertures 30 are configured to receive coupling mechanisms, such as clips, which may be used to couple objects to outer shell 20. Outer shell 20 includes apertures 32 to which strap system 14 can be coupled. As will be described in more detail below, strap system 14 secures outer shell 20 to a user's head.
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Impact protection layer 40 includes apertures 42 that provide fluid communication between cavity 25 and outer shell 20. Impact protection layer 40 includes a plurality of recesses 44 that receive ribs 34 of outer shell 20. When impact protection layer 40 is coupled to outer shell 20, protrusions 46 project into channels 38 of outer shell 20. In a specific embodiment an adhesive is applied between protrusions 46 and channels 38 to couple impact protection layer 40 to outer shell 20. Ribs 34 retain the adhesive within channel 38, reducing the chances of adhesive extruding out of channel 38 and becoming visible and/or interfering with the fluid communication provided by apertures 42 and apertures 22. This method of securing impact protection layer 40 to outer shell 20 permits an easier method of manufacture compared to over molding the outer shell 20 around the impact protection layer 40.
In a specific embodiment the adhesive is a liquid adhesive. In a specific embodiment the impact protection layer 40 includes an expanded polystyrene (EPS) foam.
Impact protection layer 40 includes a plurality of recesses 50. When impact protection layer 40 is coupled to outer shell 20, recesses 50 provide fluid communication between one or more apertures 42 of impact protection layer 40.
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Outer shell 80 includes multiple connection points 56 and 58 to couple to back clips 54. Upper connection points 58 are height 60 higher than lower connection points 56. In a specific embodiment, height 60 is between 0.5 inches and 3 inches, and more specifically between 0.75 inches and 2 inches, and more specifically height 60 is 1 inch.
When back clips 54 are coupled to upper connection points 58, back straps of strap system 14 are pulled tighter against a user's head. This provides a more secure fit for users, which can be more comfortable for users with smaller heads. When back clips 54 are coupled to lower connection points 56, back straps of strap system 14 are permitted more slack. A silhouette of back strap 59 is depicted in
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Middle frame 108 is pivotably coupled to upper band 106 and pivots with respect upper band 106 around axis 110. The positioning of axis 110 between middle frame 108 and upper band 106 closer to the back of the user's head (compared to other designs) permits easier rotation of crown 100 with respect to the user's head as the user's head moves.
Middle frame 108 defines apertures 114, which couple to securing component, shown as ratchets 112. Ratchets 112 can be loosened with respect to middle frame 108 to permit middle frame 108 to be adjusted to the shape of a user's head. When the adjustment has been made to conform to the user's head, ratchets 112 can be tightened to fixedly couple upper band 106 to middle frame 108 such that upper band 106 no longer pivots with respect to middle frame 108. If further adjustments need to be made, then ratchets 112 can once again be selectively loosened and tightened.
Adjustable band 120 is coupled to middle frame 108 and pivots with respect to middle frame 108 about axis 116. The pivotable coupling between adjustable band 120 and middle frame 108 contributes to user comfort by permitting adjustable band 120 to more easily alter its position and/or configuration as the user is moving around. For example, if the user pivots his head back to look straight up, the back of the user's neck will correspondingly arch backwards. When the user's neck is in that configuration, adjustable band 120 pivots downwards with respect to middle frame 108 to match the contours of the user's neck, thereby avoiding and/or mitigating the adjustable band 120 digging into the user's neck and negatively affecting the user's comfort.
Adjustable band 120 includes first arm 122, which is coupled to middle frame 108, and second arm 124, which is also coupled to middle frame 108. First arm 122 and second arm 124 can be adjusted with respect to body 146 of adjustable band 120, thereby extending or retracting the overall length of adjustable band 120 along arcuate axis 154. A user can adjust the positioning of first arm 122 and second arm 124 with respect to body 146 by actuating an interface, shown as button 140. As shown in
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Chin strap 206 extends underneath a front portion of user's face, such as underneath the user's chin. Side straps 202, back straps 204, and chin strap 206, are coupled together via coupler 208. In a specific embodiment, chin strap 206 includes adjustor 218, which can be actuated by a user to extend or retract a total distance of chin strap 206, thereby adjusting the position of coupler 208 with respect to outer shell 20 and the user's face. In a specific embodiment, coupler 208 permits chin strap 206 to rotate with respect to coupler 208 (similar to the functionality of clip 546, shown in
In various embodiments back straps 204 extend through cavity 164 of adjustable band 160. Adjustable band 160 is substantially similar to adjustable band 120, except as shown and depicted herein. Ratchet 166 of adjustable band 160 permits the user to adjust the position of first and second arms of adjustable band 160 with respect to the body, thereby extending or retracting the length of adjustable band 160.
Extending back straps 204 through cavity 164 of adjustable band 160 provides several advantages. First, extending back straps 204 through cavity 164 facilitates managing the strap system 200 while donning or removing the helmet (e.g., the straps are less likely to be tangled or knotted because the straps are biased towards a perimeter of the hard hat). Second, extending back straps 204 through cavity 164 secures pad 162 against the user's head while the hard hat is being worn. Third, extending back straps 204 through cavity 164 routs the straps further from the user's ears compared to other designs, thereby increasing the user's comfort.
Adjustable band 160 includes pad 162, which interfaces against the back of the user's head and neck area. In a specific embodiment, pad 162 is a single piece, rather than a series of different pads.
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Chin strap 206 of strap system 400 includes a buckle 410 that is configured at or near coupler 208 on one side of user's face (shown in
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Clip 546 rotates with respect to receiver 542 over range 554. In a specific embodiment, range 554 is between 60 degrees and 150 degrees, and more specifically between 90 degrees and 135 degrees, and more specifically is 120 degrees. In a specific embodiment, range 554 is at least 60 degrees, and more specifically is at least 90 degrees, and more specifically is at least 120 degrees. The pivotable range 554 of clip 546 with respect to receiver 542 improves the ability of straps to reposition as needed while the user is moving and working.
Receiver 542 defines a longitudinal axis 543, and clip 546 defines a longitudinal axis 547. In various embodiments, receiver 542 rotates over range 555 (e.g., at least 30 degrees, at least 45 degrees, at least 60 degrees) with respect to clip 546 in a first rotational direction from a starting position of the first longitudinal axis and the second longitudinal axis being aligned (see
In various embodiments, receiver 542 is rotatably coupled to clip 546 allowing rotation in a first rotational direction 533 such that longitudinal axis 547 of clip 546 is able to form at least a 30 degree angle relative to longitudinal axis 543 of receiver 542, and more specifically at least a 45 degree angle, and more specifically at least a 60 degree angle, and more specifically at least a 90 degree angle. In various embodiments, receiver 542 is rotatably coupled to clip 546 allowing rotation in a second rotational direction 535 opposite the first rotational direction 533 such that the longitudinal axis 547 of clip 546 is able to form at least a 30 degree angle relative to the longitudinal axis 543 of receiver 542, and more specifically at least a 45 degree angle, and more specifically at least a 60 degree angle. In various embodiments, receiver 542 is rotatably coupled to clip 546 restricting rotation in a second rotational direction 535 opposite the first rotational direction 533 such that the longitudinal axis 547 of clip 546 forms an angle no more than 5 degrees relative to the longitudinal axis 543 of receiver 542.
In various embodiments, receiver 542 has a more limited rotational range with respect to clip 546. In particular, receiver 542 rotates over range 556 (e.g., less than 5 degrees, less than 1 degree) with respect to clip 546 in the second rotational direction, opposite the first rotational direction, from a starting position of the first longitudinal axis and the second longitudinal axis being aligned (see
In a specific embodiment, receiver 542 defines a longitudinal axis 543, clip 546 defines a longitudinal axis 547, and button 552 actuates along an axis 543 perpendicular to the first and second longitudinal axes 543, 547 to decouple the clip 546 from the receiver 542.
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The ability of clip 562 to rotate with respect to receiver 566 permits back strap 572 to maintain a flat interface or nearly flat interface against the back of the user's neck. As a result, back strap 572 is less likely to be uncomfortable for the user (e.g., by chaffing and/or digging into the user's skin).
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In use, lower aperture 964 receives a pen (best shown
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In a specific embodiment, coupling system 600 for safety headwear includes a suspension system (e.g., suspension system 640), a strap system (e.g., strap system 610 or strap system 200 in
The strap system is configured to couple the suspension system to a head of a person. Strap system 200 includes a first strap (e.g., back strap 204). A clip, such as clip 546, is coupled to the first strap.
In a specific embodiment, coupling system 600 includes a strap system, a clip, and a receiver. The strap system is configured to couple the suspension system to a head of a person.
It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction 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, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.
Various embodiments of the invention relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above.
Claims
1. A hard hat comprising:
- an outer shell formed from a rigid material;
- a coupling system coupled to the outer shell, the coupling system comprising: a suspension system configured to couple to the outer shell; a strap system configured to couple the suspension system to a head of a person, the strap system comprising a first strap; a clip coupled to the first strap; and a receiver, the receiver configured to mechanically and reversibly couple and decouple to the clip, the receiver is configured to rotatably couple to the clip such that the receiver is rotatable relative to the clip about a first axis when the receiver is coupled to the clip.
2. The coupling system of claim 1, wherein the receiver defines a first longitudinal axis and the clip defines a second longitudinal axis, and wherein the receiver is rotatably coupled to the clip allowing rotation in a first rotational direction such that the second longitudinal axis is able to form at least a 60 degree angle relative to the first longitudinal axis.
3. The coupling system of claim 1, the receiver defines a first longitudinal axis and the clip defines a second longitudinal axis, wherein the receiver is rotatably coupled to the clip allowing rotation in a first rotational direction such that the second longitudinal axis is able to form at least a 30 degree angle relative to the first longitudinal axis.
4. The coupling system of claim 3, wherein the receiver is rotatably coupled to the clip allowing rotation in a second rotational direction opposite the first rotational direction such that the second longitudinal axis is able to form at least a 30 degree angle relative to the first longitudinal axis.
5. The coupling system of claim 3, wherein the receiver is rotatably coupled to the clip restricting rotation in a second rotational direction opposite the first rotational direction such that the second longitudinal axis forms an angle no more than 5 degrees relative to the first longitudinal axis.
6. The coupling system of claim 1, wherein the receiver is coupled to the safety headwear.
7. The coupling system of claim 1, wherein the receiver is rigidly coupled to the safety headwear.
8. The coupling system of claim 1, wherein the clip comprises a circular element that interfaces with the receiver when the clip rotates with respect to the receiver.
9. The coupling system of claim 8, wherein the receiver comprises a housing that peripherally surrounds the circular element of the clip when the clip is coupled to the receiver.
10. A hard hat comprising:
- an outer shell formed from a rigid material;
- a coupling system coupled to the outer shell, the coupling system comprising: a strap system configured to couple a safety headwear to a head of a person, the strap system comprising a first strap; a clip coupled to the first strap, the clip comprising a button; and a receiver coupled to the outer shell, the receiver configured to mechanically and reversibly couple to the clip to position the first strap below a chin of a user of the hard hat, the receiver comprising a housing defining an opening, wherein the button extends through the opening such that the housing peripherally surrounds the button of the clip when the receiver is coupled to the clip, wherein the button actuates to decouple the clip from the receiver.
11. The coupling system of claim 10, wherein the receiver is rigidly coupled to the safety headwear.
12. The coupling system of claim 10, the receiver defines a first longitudinal axis and the clip defines a second longitudinal axis, wherein the clip is rotatably coupled to the receiver allowing rotation in a first rotational direction such that the second longitudinal axis is able to form at least a 45 degree angle relative to the first longitudinal axis.
13. The coupling system of claim 12, wherein the clip is rotatably coupled to the receiver allowing rotation in a second rotational direction, opposite the first rotational direction, such that the second longitudinal axis is able to form at least a 45 degree angle relative to the first longitudinal axis.
14. The coupling system of claim 12, wherein the clip is rotatably coupled to the receiver restricting rotation in a second rotational direction, opposite the first rotational direction, such that the second longitudinal axis forms an angle no more than than 1 degree with respect to the first longitudinal axis.
15. A hard hat comprising:
- an outer shell formed from a rigid material;
- a coupling system coupled to the outer shell, the coupling system comprising:
- a receiver coupled to the safety headwear, the receiver defining a first longitudinal axis;
- a clip coupled to a first strap, the clip defining a second longitudinal axis, the clip configured to mechanically and reversibly couple and decouple to the receiver, the clip comprising a button that actuates along an axis perpendicular to the first and second longitudinal axes to decouple the clip from the receiver.
16. The coupling system of claim 15, wherein the receiver is rigidly coupled to the safety headwear.
17. The coupling system of claim 15, wherein the clip is rotatably coupled to the receiver allowing rotation in a first rotational direction such that the second longitudinal axis is able to form at least a 90 degree angle relative to the first longitudinal axis.
18. The coupling system of claim 15, wherein the button interfaces with the receiver when the clip rotates with respect to the receiver.
19. The coupling system of claim 15, wherein the receiver comprises a housing that peripherally surrounds the button of the clip when the clip is coupled to the receiver.
20. The coupling system of claim 15, the clip is rotatably coupled to the receiver allowing rotation in a first rotational direction such that the second longitudinal axis is able to form at least a 30 degree angle relative to the first longitudinal axis, and further allowing rotation in a second rotational direction, opposite the first rotational direction, such that the second longitudinal axis is able to form at least a 30 degree angle relative to the first longitudinal axis.
Type: Application
Filed: Jul 22, 2021
Publication Date: Jan 20, 2022
Inventors: Caleb C. Adams (Milwaukee, WI), Joseph R. Worple (Wauwatosa, WI), Todd Andrew Zeilinger (Wauwatosa, WI), Scott D. Eisenhardt (Milwaukee, WI)
Application Number: 17/383,144