Abstract:
A headgear support that comprises a headband and a pad. The headband has a first end and a second end and forms a substantially closed perimeter having a length which is selectively adjustable. The pad is pivotally connected to the headband such that the pad is disposed within the substantially closed perimeter and pivots relative to the headband about a pivot axis.

Description:
PRIORITY CLAIM 
     The present application is a Continuation Application of U.S. patent application Ser. No. 12/255,084, filed Oct. 21, 2008. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to devices for supporting a headgear, and more particularly, but not by way of limitation, to a headband with a pivotal pad. 
     2. Brief Description of Related Art 
     Protective headgear, for example construction hard hats, welding helmets, fire fighter helmets and the like, typically include headgear supports with headbands or head straps that are adjustable so that the headgear can be supported on any size head by the headband. The ability of a headgear to protect the head depends at least in part on the proper fitting of the helmet on a person&#39;s head. To accommodate different head sizes and head shapes of the general population, a headgear support typically has an adjustment mechanism, which includes adjustable straps that hold the helmet on the user&#39;s head and a head band that conforms to the circumference of the user&#39;s head. Although numerous adjustment mechanisms exist, the headband and/or the adjustment mechanisms do not tend to conform to the head of all users, particularly along the occipital region of the head, and thus can be uncomfortable to wear for an extended period of time. 
     To this end, a need exists for a headband that will readily conform to the head of a user. It is to such an apparatus that the present invention is directed. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a rear exploded, perspective view of a headband adjustment apparatus constructed in accordance with the present invention, shown with a portion of a headband. 
         FIG. 2  is a rear exploded, perspective view of the headband adjustment apparatus. 
         FIG. 3  is a front elevational view of an outer sleeve portion with a ratchet gear shown in an expanded position. 
         FIG. 4  is a front elevational view of the outer sleeve portion with the ratchet gear shown in a retracted position. 
         FIG. 5  is a front elevational view of the outer sleeve portion with another embodiment of a ratchet gear shown in an expanded position. 
         FIG. 6  is a rear perspective view of a pad shown pivotally connected to an inner sleeve of the headband adjustment apparatus. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Referring now to the drawings, and more particularly to  FIG. 1 , an exploded view of a headband adjustment apparatus  10 , a portion of a headband  12 , and a pad  90  is shown. The headband  12  is connectable to a protective headgear, such as a welding helmet shell (not shown). However, it will be appreciated that the welding helmet shell is only one example of the type of protective headgear with which the headband adjustment apparatus  10  may be used. For example, the headband adjustment apparatus  10  may be used with construction hard hats, fire-fighter helmets, military helmets, and other types of headgear. In addition, the headgear need not necessarily be protective of the user&#39;s head. 
     The headband  12  includes a first strap portion  16  and a second strap portion  18 . The first strap portion  16  is provided with an elongated slot  20 , which is provided with a row of teeth  22  along one side thereof. Likewise, the second strap portion  18  is provided with an elongated slot  24  with a row of teeth  26  provided along one side thereof such that the teeth  22  of the first strap portion are positioned in a substantially opposing relationship with respect to the teeth  26  of the second strap portion  18  when the first strap portion  16  overlaps the second strap portion  18  with the elongated slot  20  generally aligned with the elongated slot  24 . 
     Referring now to  FIGS. 1 and 2 , the headband adjustment apparatus  10  is designed to engage the teeth  22  and  26  so as to cause the first strap portion  16  and the second strap portion  18  to be moved relative to one another. The headband adjustment apparatus  10  includes an outer sleeve portion  28  and an inner sleeve portion  30  which cooperates with one another to form a sleeve for housing the first strap portion  16  and the second strap portion  18 . The outer sleeve portion  28  and the inner sleeve portion  30  are generally arc shaped so as to conform to the contour of the back of a user&#39;s head. The inner sleeve portion  30  includes a plurality of longitudinal ribs or ridges  34  for facilitating sliding movement of one of the first strap portion  16  or the second strap portion  18 . The ribs  34  are formed to have a flatted region  35  along the apex of the inner sleeve portion  30 . The inner sleeve portion  30  further includes a plurality of tabs  36  extending outwardly from a central location of the inner sleeve portion  30 . The tabs  36  spaced from one another so as to be inwardly flexible and to define a central opening  38 . Each tab  36  is provided with a catch  40  for engagement with a ratchet gear  42 . 
     The outer sleeve portion  28  is adapted to snap onto the inner sleeve portion  30  with the first strap portion  16  and the second strap portion  18  positioned between the outer sleeve portion  28  and the inner sleeve portion  30 . The outer sleeve portion  28  includes a ratchet wheel  44  formed on an outer side thereof. The ratchet wheel  44  defines an opening  45  and is provided with a plurality of teeth  46  formed along an inner surface thereof. Each of the teeth  46  has a tapered surface  48  and a locking surface  50 . 
     As shown in  FIGS. 3 and 4 , the ratchet gear  42  is positioned in the opening  45  of the ratchet wheel  44 . The ratchet gear  42  includes a plurality of arms  51  and a pinion  52 . The pinion  52  is adapted to engage the teeth  22  and  26  of the first strap portion  16  and the second strap portion  18 , respectively. Each of the arms  51  extend from a hub  58 . The hub  58  is provided with a central bore  60  which is adapted to receive the tabs  36  of the inner sleeve portion  30  whereby the catches  40  of the tabs  36  engage the hub  58  to secure the ratchet gear  42  to the sleeve formed by the outer sleeve portion  28  and the inner sleeve portion  30 . The ratchet gear  42  is rotated by a knob  62  so as to cause the pinion  52  to move the first strap portion  16  and the second strap portion  18  relative to one another. 
     As shown in  FIG. 3 , the arms  51  are intended to engage the locking surface  50  of the teeth  46  so as to prevent the first strap portion  16  and the second strap portion  18  from moving in a direction that enlarges a loop formed by the first strap portion  16  and the second strap portion  18 . In addition, the arms  51  are able to move over the tapered surfaces  48  of the ratchet wheel  44  when the ratchet gear  42  is rotated in a clockwise direction. Moreover, as shown in  FIG. 4 , the arms  51  are designed to be retracted so that the pinion  52  may be rotated in a counterclockwise direction to loosen the headband  12 . 
     More specifically, the arms  51  of the ratchet gear  42  each extend from the hub  58  in a counterclockwise spiral. Each arm  51  has a pawl  64  which is positionable between adjacent teeth  26  of the ratchet wheel  44 . A sliding surface  66  is configured to be substantially parallel to the tapered surface  48  of the teeth  46  to permit the pawl  64  to travel over the tapered surface  48  of the teeth  46  when the ratchet gear  42  is moved in a clockwise direction. In contrast, the pawl  64  is configured to engage the locking surface  50  of the teeth  46  in a substantially perpendicular relationship when the ratchet gear  42  is rotated in a counterclockwise direction thereby preventing counterclockwise rotation of the ratchet gear  42  when the arms  56  are in a retracted position with the pawls  64  positioned between adjacent teeth  46 . 
     To rotate the ratchet gear  42  in a clockwise direction, so that the pinion  52  causes a first strap portion  16  and the second strap portion  18  to move toward one another, the knob  62  is provided with a plurality of bosses  68  on the inner surface thereof. The bosses  68  are equally spaced about a central opening  70 . As shown in  FIG. 4 , the bosses  68  engage a lower end of the arms  51  in such a manner that causes the ratchet gear  42  to be rotated in a clockwise direction when the knob  62  is rotated in a clockwise direction. Furthermore, by positioning the bosses  68  at the lower end of the arms  51 , the flexibility of the arms  51  is maintained whereby the arms  51  may freely travel over the teeth  48  when the ratchet gear  42  is rotated in a clockwise direction. The knob  62  is rotated in a clockwise direction until the headband  12  has been adjusted to the desired size. As shown in  FIG. 4 , the pawl  64  of each arm  56  is equally spaced so that the pawls  64  each engage the locking surface  50  of the teeth  46  simultaneously. 
     Referring now to  FIG. 5 , another embodiment of a ratchet gear  42   a  is shown positioned in the ratchet wheel  44 . The ratchet gear  42   a  has a plurality of arms  51   a - 51   d . The arms  51   a - 56   d  are spaced apart from one another such that when the pawls  64  of the arms  51   a  and  51   c  are engaged with the locking surfaces  50  of the teeth  46 , the pawls  64  of the arms  51   b  and  51   d  are positioned on the tapered surfaces  48 . By spacing the arms  51   a - 56   d  in this manner, the adjustment increment is decreased. As such, finer adjustments to the size of the headband  12  are permitted. 
     To move the arms  51  to a retracted position, and thus permit the ratchet gear  42  to be rotated in a counterclockwise direction to move the first strap portion  16  and the second strap portion  18  generally in a direction away from each other, the inner surface of the knob  62  is provided with a plurality of cams  72 . The cams  72  are positioned to interact with a hook portion  74  of the arms  51 . More specifically, the hook portion  74  has a cam surface  76  and a recess  78  for receiving the cam  72 . Upon rotation of the knob  62  in a counterclockwise direction, each cam  72  engages the cam surface  76  of a corresponding arm  56 . As the knob  62  continues to rotate in the counterclockwise direction, the engagement of the cam surface  76  with the cam  72  causes the arm  56  to move in an inward direction ( FIG. 4 ) so as to retract the pawl  64  and disengage the pawl  64  from the teeth  46 . Further rotation of the knob  64  causes the cam  72  to be lockingly received in the recess  78 . With the arms  51  in the retracted condition, the ratchet gear  42  may be freely rotated in the counterclockwise direction so as to cause the first strap portion  16  and the second strap portion  18  to be moved generally away from each other to increase the size of the headband  12 . Upon rotation of the knob  62  in the clockwise direction, the cams  72  are released from the recesses  78  thereby allowing the knob  68  to rotate relative to the ratchet gear  42  until the bosses  68  engage the lower end of the arms  51 . With the cams  72  released from the recesses  78 , the arms  51  return to the extended condition whereby the pawls  64  engage the teeth  46 . 
     To prevent the tabs  36  of the inner sleeve portion  30  from moving inwardly and thereby releasing the ratchet gear  42 , a cap  80 , provided with a plurality of prongs  82  ( FIG. 2 ), is positioned over the knob  62  with the prongs  82  disposed in the opening formed by the tabs  36 . As such, the cap  80  is held stationary relative to the knob  62  whereby the outer surface of the cap  80  may be utilized to display a trademark, a logo, or other informational indicia in such a manner that the indicia does not rotate with rotation of the knob  62 . 
     The knob  62  is rotatably connected to the ratchet wheel  44  via a plurality of flanges  84  extending radially from the ratchet wheel  44 . To facilitate turning of the knob  62 , the knob  62  is coated with a gripping material such as a rubber. 
     In the welding helmet application, in particular, the point of connection between the shell and the headgear is important because a welder will typically “nod” his helmet down in protective position with a sharp sudden movement of his head. With this “nodding” movement, the connection point provides a point of pivot for the protective shell which is independent of any headgear size adjustment. A drawback of the pivot connection between the headgear and the shell is that continuous movement will have a tendency to loosen the pivot point. Additionally, the welding helmet may vary in weight as the user adds, deletes, or changes filters or otherwise modifies his helmet configuration. Thus, a proper “nodding” movement will not be achieved should the weight of the shell be changed. Therefore, it is desirable to provide a pivot connection that allows the user to readily adjust the frictional engagement between the shell and the headgear to accommodate such changes in weight and personal preference. 
     Referring now to  FIGS. 1 ,  2 , and  6 , the pad  90  serves to increase the comfort to the user when the headband  12  is positioned on the user&#39;s head by providing a member that readily conforms to contour of the user&#39;s head. The pad  90  is shown to be pivotally connected to the inner sleeve portion  30  of the adjustment mechanism  10 . However, it should be appreciated that the pad  90  is not limited to being used with the adjustment mechanism  10 , but may be connected to a variety of adjustment mechanisms or directly to a headband. 
     The pad  90  includes a pad portion  92  and an extension portion  94 . The pad portion  92  has a front side  95 , a rear side  96 , an upper side  97 , a lower side  98 , a first lateral side  100 , and a second lateral side  102 . The pad portion  92  is preferably elongated and provided with an arcuate, curved, or otherwise contoured shape so as to at least partially correspond to the shape of a user&#39;s head and/or neck. In one embodiment, the front and rear sides  95  and  96  of the pad portion  92  are shaped to correspond to one another, as shown. In other embodiments, the front and rear sides  95  and  96  may be provided with different shapes. For example, the front side  95  may be contoured to at least partially correspond to the shape of a user&#39;s head and/or neck, and the rear side  96  may be provided with a substantially flat shape, such as to facilitate or reduce the cost of manufacturing the pad  90 . In yet further embodiments, the pad portion  92  may be provided with any suitable shape or size. 
     The pad portion  92  may be provided with a plurality of openings or perforations  103  extending between the front and rear sides  95  and  96  so as to promote air circulation through the pad portion  92  to the user&#39;s head. In this way, the pad portion  92  “breathes” so as to reduce moisture accumulation between the pad portion  92  and the user&#39;s head and/or neck, and thereby increase comfort to the user. Additionally, the openings  103  may help reduce slippage or sliding of the pad portion  92  relative to the user&#39;s head and/or neck. To further prevent slippage, the pad portion  92  may be provided with a textured surface elements  103   a . The textured surface elements  103   a  are illustrated in  FIG. 2  as being a plurality of bumps formed on the front side  95  of the pad portion  92 . The bumps may vary in size and shape, but it is preferred that the textured surface elements  103   a  be sized and shaped to provide a gripping function. To this end, it will be appreciated that the textured surface elements may be in the form of a wide variety of elements, such as ridges or a knurled surface. 
     As shown in  FIG. 1 , the extension portion  94  extends from the rear side  96  of the pad portion  92 , as shown. The extension portion  94  preferably supports a pair of posts  106  a distance from the rear surface  96  of the pad portion  92  so as to provide an axis about which the pad  90  is able to pivot. In the preferred embodiment, the posts  106  are preferably integrally formed with the extension portion  94 . In other embodiments, the posts  106  may be formed by a single rod cooperating with the extension portion  94 , for example, a single rod could be pressed, threaded, or glued into an aperture in the extension portion  94  so as to extend from both sides of the extension portion  94  to provide the pair of posts  106  extending from the extension portion  94 . In yet further embodiments, the posts  106  and the extension portion  104  may be formed or constructed in any suitable configuration that permits the pad  90  to function as described herein. 
     In the embodiment shown, the ends of the posts  106  are provided with notches such that the posts  106  are characterized as having a pair of tines  108  and  109  which are inwardly flexible. The end of each of the tines  108  and  109  is preferably tapered on a side away from the pad  90  to facilitate connection with the inner sleeve portion  30  of the headband adjustment apparatus  10  in a manner to be discussed below. 
     The inner sleeve portion  30  is provided with a pair of openings  110  ( FIG. 2 ). Each opening  110  is adapted to receive one of the posts  106  of the pad  90 . To support the posts  106 , the inner sleeve  30  is provided with a pair of bearing portions  112 . Each bearing portion  112  has a semi-circular profile and defines a bearing surface  114  ( FIG. 2 ) that is generally oriented along a tangent of the inner sleeve  30  and against which at least a portion of the posts  106  may rotate. An outer portion of the openings  110  is tapered inwardly to define a retaining wall  116  ( FIG. 1 ) against which the tines  108  and  109  of the posts  106  contact when positioned through the openings  110 . The inward flexibility of the tines  108  and  109  permits the tines  108  and  109  to move past the retaining wall  116  when connecting the pad  90  to the inner sleeve  30  or disconnecting the pad  90  from the inner sleeve  30  should it be desired to use the headband  12  without the pad  90 . In the preferred embodiment, the posts  106  are received in the openings  110  to permit the pad  90  to rotate relative to the inner sleeve portion  30  about the rotational or longitudinal axis of the posts  106 . The extension portion  104  preferably maintains an offset or spaced-apart relationship between the pad portion  92  and the inner sleeve portion  30  so as to further enable rotational movement therebetween and about the axis of the posts  106 . 
     The range of rotational motion is generally limited by the distance between the rear side  96  of the pad portion  92  and the inner sleeve portion  30 . For example, a greater distance therebetween will permit a greater degree of rotation, while a smaller distance therebetween will permit a smaller degree of rotation. In some embodiments, it is desirable to apply this principle to limit the degree of rotation between the pad portion  92  and the inner sleeve portion  30 . In one such embodiment, the total sweep of rotation of the pad  90  relative to the inner sleeve portion  30  is preferably limited to about 45 degrees. However, a greater range of motion may be preferred, or it may be desired to limit rotation more in one direction than the other direction by any suitable means, such as, for example, by providing protrusions or the like from either of the pad  90  and the inner sleeve portion  30  to limit the range of rotation therebetween. For instance, the pad may be permitted to rotate relative to a rotational or longitudinal pivot axis of the adjustment assembly in an angular range of between about 5 degrees and about 45 degrees. In further embodiments, the pad  90  may be provided with one or more springs, shock absorbers, and/or resilient elements (not shown), such as, for example, to bias the rotation of the pivot pad  90  in a given direction, to increase comfort to a user by reducing shocks transmitted to the user by sudden rotations between the pad  90  and the inner sleeve portion  30 , any combination thereof, and/or the like. 
     Although the pad  90  is described in conjunction with the headband adjustment assembly  10 , it should be understood that the principles, structure and function of the pad  90  described herein may be incorporated with any type of headband, headgear, helmets, hats, hard hats, or the like so as to improve fit, function, comfort, or the like. It should be further understood that the element that forms the axis of pivot for the pad  90  may be connected to, or formed as a part of, the adjustment assembly or the headband, rather than be a part of the pad  90  as has been described in detail above, and the pad  90  may be formed to receive the element that forms the axis of pivot. 
     From the above description, it is clear that the present invention is well adapted to carry out the objects and to attain the advantages mentioned herein, as well as those inherent in the invention. While a presently preferred embodiments of the invention have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the invention disclosed and described in the appended claims.