Abstract:
The present invention generally relates to protective headgear worn by a user to protect his eyes, head, and face. More particularly, the present invention is directed to a protective headgear assembly used by welders and the like wherein a headgear strap can be tightened or loosened upon the ratcheting of a knob connected to the headgear strap. The headgear strap can also be automatically disengaged for removal of the headgear by pulling the knob away from the user&#39;s head.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to protective headgear worn by a user to protect his eyes, head, and face. More particularly, the present invention is directed to a protective headgear assembly used by welders wherein a headgear strap can be tightened or loosened upon the ratcheting of a knob connected to the headgear strap. The headgear strap can also be automatically loosened for removal of the headgear by pulling the knob away from the user&#39;s head. 
       BACKGROUND OF THE INVENTION 
       [0002]    It has become commonplace for protective headgear to be worn while a user is undertaking a number of different activities. Frequently, there are safety-related laws or standards that require certain types of protective headgear to be worn, depending on the occupation or activity a user performs. Different types of protective headgear are generally known in the art. Certain activities, such as welding, require the wearing of protective headgear, i.e., a welding helmet, to protect the user&#39;s head, neck, face, and eyes. Other examples of protective headgear include bicycle helmets, motorcycle helmets, or helmets used during sporting activities. 
         [0003]    Protective headgear used for different purposes can differ greatly in their design. Generally though, protective headgear will include: (1) a protective body, i.e., a helmet, to cover the user&#39;s head, (2) a type of headgear strap attached to the helmet to enable the headgear to remain on the user&#39;s head during use, and (3) a suspension system to separate the user&#39;s head from the helmet. Specifically with regard to welding, the user must also protect his eyes from dangerous sparks, heat, infrared and ultraviolet rays emitted when welding, while still remaining able to see in front of him. Accordingly, the protective headgear worn while welding further includes a face portion that acts to shield a user&#39;s face while allowing the user to see through the face portion to view his work. In addition, protective headgear worn while welding should enable the user to pivot the helmet portion of the headgear while the suspension system and headgear strap remain on the user&#39;s head. 
         [0004]    The headgear strap is typically adjustable to enable the user to change the length of the strap to conform to the circumference of the user&#39;s head. An adjustable headgear strap allows the protective headgear to fit comfortably and securely during use, which is imperative during dangerous practices such as welding. The strap can be of closed loop formation, or utilize a type of ratchet mechanism that enables the length of the strap to be adjusted manually. 
         [0005]    While ratchet mechanisms are generally known in the art and allow a user to manually loosen or tighten the headgear strap, none utilize a single mechanism that can allow for both adjustment of the size and fit of the headgear strap, and the ability to disengage the entire mechanism for automatic loosening of the headgear strap so that the protective headgear can be pulled off the user&#39;s head. Without a single quick-release mechanism, it can often be awkward and take needless time to ratchet the mechanism to loosen the headgear strap. Moreover, in the event of a need to remove the protective headgear quickly, such as in the event of an accident or other emergency, users, such as welders, should have a simple mechanism to free themselves of the oftentimes heavy and restrictive headgear. 
         [0006]    There is a need to provide a protective headgear assembly with a headgear strap that can be easily adjusted for length to enable a user to be able to wear the protective headgear assembly securely. 
         [0007]    There is also a need for a protective headgear assembly that can be removed in a simple, quick and efficient manner. 
         [0008]    There is also a need for a protective headgear assembly wherein the helmet can pivot from a closed position (during use) to an open position (when not in use) while the headgear strap and suspension system remain in place on the user&#39;s head. 
         [0009]    Accordingly, it is desirable to provide a protective headgear assembly wherein the headgear strap can be both adjusted for length and disengaged utilizing a single mechanism. By use of a single mechanism, a user can perform both actions in an easy and straightforward way. 
         [0010]    It is also desirable to provide a protective headgear assembly wherein the helmet is capable of pivoting from a closed position (during use) to an open position (when not in use) while the headgear strap and suspension system remain in place on the user&#39;s head. 
         [0011]    Thus, it is an object of the present invention to provide a protective headgear assembly which effectively addresses the aforementioned shortcomings associated with prior apparatuses of this general type, as well as to provide the above-mentioned desirable features. 
       SUMMARY OF THE INVENTION 
       [0012]    The purpose and advantages of the present invention will be set forth in and apparent from the description that follows, as well as will be learned by practice of the invention. Additional advantages of the invention will be realized and attained by methods and systems particularly pointed out in the written description and claims thereof, as well as from the appended drawings. 
         [0013]    The present invention is generally embodied in a protective headgear assembly. The protective headgear assembly may be utilized for any application wherein a user desires to protect his eyes, head and face. In particular, the present invention is directed to a protective headgear assembly used to protect a user&#39;s eyes, head and face during work procedures. For example, the protective headgear assembly can be used by welders to protect the welders&#39; eyes, head and face during welding procedures. 
         [0014]    In accordance with one embodiment of the present invention, the protective headgear assembly comprises a protective body, a headgear strap, and a quick-release ratchet mechanism. In the preferred embodiment, the protective body is a helmet. It will be appreciated that the protective body can also be a face shield. 
         [0015]    The quick-release mechanism of the present invention comprises a gear system and an adjusting knob. The headgear strap fits around the circumference of a user&#39;s head in order to retain the protective headgear apparatus securely on the user&#39;s head. The quick-release mechanism is attached to the headgear strap and allows the user to: (1) manually adjust the length of the headgear strap, and (2) disengage the gear system in order for the user to automatically loosen the headgear strap and quickly take the protective headgear assembly off of his head. Specifically, the knob can be ratcheted clockwise or counterclockwise to adjust the length of the headgear strap to ensure a secure fit on the user&#39;s head. Turning the adjusting knob clockwise tightens the headgear strap and locks it to a selected size. Turning the knob counterclockwise loosens the headgear strap. In order for the user to disengage the gear system to unlock the selected size and allow for immediate headgear removal, the knob can be pulled away from the user&#39;s head. The same pulling action away from the user&#39;s head also can loosen the headgear strap to a selected size. 
         [0016]    In another embodiment of the present invention, the protective headgear assembly further comprises an attaching assembly. In this embodiment, the helmet is attached to the headgear strap by means of attaching assemblies well known in the art, such as, e.g., as described in U.S. Pat. No. 4,479,738, the entire contents of which is hereby incorporated by reference herein. 
         [0017]    In another embodiment of the present invention, the helmet can be attached to the headgear strap by means of a side-pivot device. The side-pivot device allows for the helmet to pivot from a closed position (during use) to an open position (when not in use) while the headgear strap remains in place on the operator&#39;s head. The side-pivot device limits the range of motion through which the helmet can pivot and also provides a positive dented stop at either end of the pivot path. The positive dented stops allow the helmet to rest in an open or closed position until adjusted by the user. The side-pivot device is distinctively a single piece that interacts with both the headgear strap and a pivot post that holds the device, strap and helmet together. It eliminates the need for a separate locking bolt. In addition, the headgear strap is able to accommodate the pivot device in two different positions. The positions move the helmet closer or farther from the front of the operator&#39;s head. The functionality of the pivot remains the same in either position. 
         [0018]    In yet another embodiment of the present invention, the helmet can be attached to the headgear strap by means of a multi-position stop construction on a first side of the helmet and a detent cap construction on a second side of the helmet. In this embodiment, a five-position stop pivots with the helmet. The five-position stop limits travel of the helmet in both directions as it interacts with the headgear strap. The closed position (during use) of the helmet is determined by the interaction between the five-position stop and a pin located on the helmet. In the detent cap construction of this embodiment of the present invention, a washer key and detent cap interact and lock together to keep the helmet locked in an open (not in use) position. The washer key and detent cap are unlocked when the helmet is in the closed position. 
         [0019]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and provided for purposes of explanation only, and are not restrictive of the invention, as claimed. Further features and objects of the present invention will become more fully apparent in the following description of the preferred embodiments and from the appended claims. 
         [0020]    The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the method and system of the invention. Together with the description, the drawings serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    In describing the preferred embodiments, reference is made to the accompanying drawing figures wherein like parts have like reference numerals, and wherein: 
           [0022]      FIG. 1  is a perspective view of the protective headgear assembly during use in accordance with the present invention; 
           [0023]      FIG. 2  is an exploded perspective view of a quick-release mechanism made in accordance with the present invention; 
           [0024]      FIG. 3  is a perspective view of the quick-release mechanism of  FIG. 2 ; 
           [0025]      FIG. 4  is a detailed view of the quick-release mechanism of  FIG. 2 , illustrating lateral movement of the overlapping ends of the headgear strap caused by rotation of the adjusting knob; 
           [0026]      FIG. 5  is a detailed view of the quick-release mechanism of  FIG. 2 , illustrating movement of the overlapping ends caused by counterclockwise rotation of the adjusting knob; 
           [0027]      FIG. 6  is a perspective view of the quick-release mechanism of  FIG. 2 , illustrating movement of the adjusting knob and disengagement of the gear system caused by the pulling of the adjusting knob; 
           [0028]      FIG. 7  is a cut-away perspective view of the adjusting knob of the quick-release mechanism of  FIG. 2  when the adjusting knob is pulled, illustrating the disengagement of the gear system; 
           [0029]      FIG. 8  is an exploded perspective view of the multi-position stop construction made in accordance with the present invention; 
           [0030]      FIG. 9  is a perspective view of the protective headgear assembly illustrating the five-position stop engaged with the pin affixed to the helmet; 
           [0031]      FIG. 10  is an exploded perspective view of a detent cap construction made in accordance with the present invention; 
           [0032]      FIG. 11  is a perspective view of the detent cap construction of  FIG. 10 , illustrating the washer key and the detent cap in a locked position; 
           [0033]      FIG. 12  is a perspective view of detent cap construction of  FIG. 10 , illustrating the washer key and the detent cap in an unlocked position; 
           [0034]      FIG. 13  is an enlarged view of a side-pivot device made in accordance with the present invention; 
           [0035]      FIG. 14  is a perspective view of the side-pivot device of  FIG. 13  connected to the headgear strap of the present invention; 
           [0036]      FIG. 15  is a detailed view of the side-pivot device of  FIG. 13  in an open (not in use) position; 
           [0037]      FIG. 16  is a detailed view of the side-pivot device of  FIG. 13  in a closed (during use) position; 
           [0038]      FIG. 17  is a perspective view of the side-pivot device of  FIG. 13  utilizing the front mounting hole of the headgear strap; and 
           [0039]      FIG. 18  is a perspective view of the side-pivot device of  FIG. 13  utilizing the back mounting hole of the headgear strap. 
       
    
    
       [0040]    It should be understood that the present invention is not limited to the preferred embodiments illustrated. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0041]    Referring generally to  FIGS. 1-18 , and upon review of this description, it will be appreciated that the apparatus of the present invention generally may be embodied within numerous configurations. 
         [0042]      FIG. 1  is a perspective view of the protective headgear assembly  10  during use on a user&#39;s head. As shown in the preferred embodiment, the protective headgear assembly  10  generally includes: a helmet  15  to protect the user&#39;s head and eyes; a suspension system  12  to separate the user&#39;s head from the helmet; a headgear strap  20 ; and a quick-release mechanism  25 . It will be appreciated that the helmet  15  can be any type of protective body that protects a user&#39;s head and eyes, including, e.g., a face shield. It will also be appreciated that the helmet  15  of the protective headgear assembly  10  can be made of any hard material that resists impact. For example, among other hard materials, the helmet  15  can be made of metal, plastic, or resin fiber. The headgear strap  20  extends around the circumference of the user&#39;s head and provides for a secure and comfortable fit depending on the user&#39;s manual adjustments. The quick-release mechanism  25  preferably is integral to the headgear strap  20  and lies at the back of the user&#39;s head during use. 
         [0043]    Referring now to a preferred embodiment illustrated in  FIGS. 2 and 3 , the quick-release mechanism  25  comprises: (1) an adjusting knob  28  that enables a user to adjust the length of the headgear strap  20 ; (2) a housing  30  to define an internal cavity for receiving the headgear strap  20 ; and (3) a gear system  32  for manipulation of the length of the headgear strap  20 . In this exemplary embodiment, the adjusting knob  28  has a first end  28   a  and a second end  28   b . The first end  28   a  provides a component that the user can manipulate to adjust the length of the headgear strap  20 . The second end  28   b  includes a cylindrical opening that receives a cylindrical covering  29  of the gear system  32 . The cylindrical covering  29  is positioned on the exterior side of an outer housing section  30   a . The second end  28   b  also comprises ratchet teeth (not shown) that engage ratchet teeth  29   a  of the cylindrical covering  29 . The outer housing section  30   a  and an inner housing section  30   b  join to form the housing  30 , as shown in  FIG. 3 , and collectively define the internal cavity for receiving the headgear strap  20 . It will be appreciated that the housing  30  can be arc-shaped to fit securely around the user&#39;s head. The quick-release mechanism  25  is preferably held together by means of a river pin  26  that enters through the first end  28   a  of the adjusting knob  28 . The pin  26  holds the knob  28  adjacent to a lock gear  34  with a spring  31  interspersed between. 
         [0044]    In the preferred embodiment, as illustrated in  FIG. 2 , the gear system  32  of the quick-release mechanism  25  is comprised of a drive gear  33  and the lock gear  34 . The drive gear  33  comprises two integral sides  33   a  and  33   b . A first side  33   a  of the drive gear  33  preferably has radially inward projecting teeth which cooperate with radially outward projecting teeth of the lock gear  34 . A second side  33   b  of the drive gear  33  preferably is a cog that engages two overlapping ends  20   a  and  20   b  of the headgear strap  20 . The first end  20   a  and second end  20   b  of the headgear strap each include lateral slots  21 ,  22  that have gripping teeth formed along the periphery of each slot. The quick-release mechanism  25  further preferably comprises the spring  31  positioned within the cylindrical covering  29  which abuts a flange disposed on the cylindrical covering  29  on one end, and the lock gear  34  at the other end. The spring  31  biases the lock gear  34  into engagement with the inward projecting teeth of the first side  33   a  of the drive gear  33 . 
         [0045]    The ratchet teeth  29   a  of the cylindrical covering  29  engaged with the ratchet teeth of the second side of the adjusting knob  28   b  restrict movement of the adjusting knob  28  by means of the spring  31 . The lock gear  34  is rigidity connected to the adjusting knob  28 . Accordingly, manual turning of the adjusting knob  28  by a user (see  FIG. 3 ) causes the gear system  32  to turn and engage the gripping teeth of the two lateral slots  21 ,  22  of the headgear strap  20 , as shown in  FIG. 4 . Specifically, when the user turns the adjusting knob  28  clockwise, the first overlapping end  20   a  and the second overlapping end  20   b  of the headgear strap  20  move toward one another laterally to decrease the circumference of the headgear strap  20 . Similarly, as shown in  FIG. 5 , when the user turns the adjusting knob  28  counterclockwise, the first overlapping end  20   a  and the second overlapping end  20   b  move away from one another laterally to increase the circumference of the headgear strap  20 . The user must overcome sufficient torque provided by the spring  31  on the adjusting knob  28  in order to once again change the selected size of the headgear strap  20 . The gripping teeth of the two lateral slots  21 ,  22  of the headgear strap  20  allow for incremental tightening of the headgear strap  20 . The user is accordingly able to adjust the headgear strap  20  so as to have a secure fit around his head. Once the user stops turning the adjusting knob  28  in either direction, the ratchet teeth  29   a  of the cylindrical covering  29  engaged with the ratchet teeth of the second side of the adjusting knob  28   b  prevents lateral movement of the overlapping ends  20   a ,  20   b  of the headgear strap  20  and therefore locks the headgear strap  20  into a selected size and fit around the user&#39;s head. 
         [0046]    Referring now to a preferred embodiment in  FIGS. 6 and 7 , the adjusting knob  28  of the quick-release mechanism  25  can further be manually pulled in a direction away from the housing  30  to disengage the gear system  32 . When a user pulls the adjusting knob  28  in a direction away from the user&#39;s head, the lock gear  34  is forced to separate from the drive gear  33 , causing the drive gear  33  to be able to freely rotate and unlock the headgear strap  20  from the selected size. As a result, the first overlapping end  20   a  and the second overlapping end  20   b  of the headgear strap  20  are able to move away from one another without any ratcheting of the adjusting knob  28 . The user can simply pull the protective headgear assembly  10  off of his head. 
         [0047]    It will be appreciated that various attachment means can be employed to affix the headgear strap  20  to the helmet  15 . Referring now to a preferred embodiment in  FIGS. 8-10 , the protective headgear assembly  10  comprises a multi-position stop construction  40  on a first side of the helmet  15 , and a detent cap construction  50  on a second side of the helmet  15 . As shown in  FIGS. 8 and 9 , the multi-position stop construction  40  comprises a knob  41 , a washer  42 , a washer key  43 , and a five-position stop  44 , all connected to the headgear strap  20  by means of a pivot post  45 . The five-pivot stop  44  comprises five adjustment holes  44   a  and pivots with the helmet  15 . It will be appreciated that any number of adjustment holes  44   a  can be used in accordance with the present invention. The adjustment holes  44   a  determine the position of the helmet  15  with respect to the suspension system  12  and headgear strap  20 . A pin  46  is affixed to the helmet in order to receive an adjustment hole  44   a . The helmet  15  can be positioned closer or farther from the face of the user depending on the placement of the pin  46  into an adjustment hole  44   a.    
         [0048]    As shown in  FIG. 10 , the detent cap construction  50  on the second side of the helmet  15  comprises a knob  51 , a washer  52 , a washer key  53 , and a detent cap  54 , all connected to the headgear strap  20  by means of a pivot post  55 . The detent cap  54  is preferably comprised of at least one notch that matches and interacts with at least one notch on the washer key  53 . The washer key  53  and the detent cap  54  rotate relative to each other. In order to lock the helmet  15  into an open position, the user lifts the helmet  15  until the washer key  53  and the detent cap  54  lock together, as shown in  FIG. 11 . The user must overcome the force necessary to unlock the washer key  53  and the detent cap  54  by pulling the helmet  15  down into a closed position, see  FIG. 12 . 
         [0049]    Referring now to an alternative embodiment illustrated in  FIGS. 13-18 , it will be appreciated that the helmet  15  of the present invention can also be attached to the headgear strap  20  by means of a side-pivot device  60 , a pivot post  64 , and a knob  65 . As shown in  FIGS. 15 and 16 , the side-pivot device  60  comprises a pair of spring arms  60   a ,  60   b  that interact with a series of pins  61  on the headgear strap  20  to provide a dented stop at either end of the pivot path. The spring arms  60   a ,  60   b  restrain the helmet  15  in either an open (not in use) position (see  FIG. 15 ), or a closed (in use) position (see  FIG. 16 ) until adjusted by the user. Further, as shown in  FIGS. 17 and 18 , in this alternative embodiment, the headgear strap  20  can accommodate the side-pivot device  60  in two different positions by means of a pair of mounting holes  62 ,  63 . The mounting holes  62 ,  63  are provided on the headgear strap  20  so that the helmet  15  may be selectively positioned closer or farther from the front of the user&#39;s face. For example,  FIG. 17  illustrates the side-pivot device  60  attached to the headgear strap  20  by means of the pivot post  64  received through the front mounting hole  62  of the headgear strap  20 , thereby positioning the helmet  15  farther in front of the operator&#39;s head than if the side-pivot device  60  was affixed to the back mounting hole  63  (see  FIG. 18 ). The functionality of the side-pivot device  60  remains the same in either position. 
         [0050]    It should be appreciated that merely preferred embodiments of the invention have been described above. However, many modifications and variations to the preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.