Abstract:
A headband for use in a headgear support includes a first end section having a plurality of spaced connectors and a second end section including a fastener attached adjacent the end thereof. The fastener includes a connecting member to which at least one cooperating connector is attached. The connecting member biases the cooperating connector in an engagement position with at least one of the plurality of connectors of the first end section to hold the headband in a selected loop configuration. The fastener further includes at least a first flexible release member. Upon application of a force to the first release member, the first flexible release member is movable to a release position (or range of positions) in which the first release member abuts the connecting member to cause the connecting member to flex to a disengage position (or range of positions) in which the cooperating connector is disengaged from the at least one the plurality of connectors of the first end section to enable increasing the size of the loop of the headband.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to adjustable headbands and, particularly, to adjustable headbands for use in headgear, including, for example, personal protective products such as protective helmets, faceshields and welding shields.  
       BACKGROUND OF THE INVENTION  
       [0002]     Most types of protective helmets worn by workers to protect them from falling objects have a suspension system. The suspension system or headgear support, along with the helmet shell, act to absorb the shock of a falling object striking the top of the worker&#39;s head. The suspension system also serves as a support that holds the helmet or faceshield on the worker&#39;s head.  
         [0003]     The suspension is often a web-like support system comprising two or more strips of material that are arranged to cross each other. The ends of the strips are, for example, attached at four or more points around the circumference of the helmet. A headband is then typically attached to the four or more points of the suspension to permit the helmet to be worn by the worker. To securely position the helmet on the worker&#39;s head, it is essential that the circumference of the headband be adjustable to fit the appropriate head size. An adjustable napestrap is often attached at one end of the headband to achieve these results. Such a suspension system is available from Mine Safety Appliances Company of Pittsburgh, Pa. under the trademark STAZ-ON® and is described in U.S. Pat. No. 5,896,586.  
         [0004]     U.S. Pat. No. 3,500,474, the disclosure of which is incorporated herein by reference, discloses a headband wherein the napestrap position of the headband is manually adjusted by the wearer to fit the appropriate head size. The two ends of the headband are connected and held in place by a slot-and-projection arrangement. One end of the headband is formed with parallel rows of projections or flanges. The other end of the headband is formed with parallel rows of slots. The size of the headband can be adjusted by inserting the projections of one end of the strap into the slots formed in the other end of the strap at the desired length. While this type of headband is relatively simple to manufacture (in part because separate mechanical fasteners or adjustment mechanisms are generally not required), users of such bands often have difficulty adjusting the band size while wearing the suspension. This inconvenience often results in the use of a different, more expensive type of suspension, such as a ratchet-type suspension system as, for example, described in U.S. Pat. No. 4,942,628.  
         [0005]     U.S. Pat. No.  5 , 896 , 586 , the disclosure of which is incorporated herein by reference, discloses a headband that is relatively simple to manufacture, while providing a fastening mechanism that is relatively easy to adjust. This headband can be fabricated from an integral or monolithic piece of polymeric material. The headband includes a first end and a second end which overlap. The first end includes a plurality of longitudinally spaced attachment members (for example, depressions, recesses or slots). The second end includes a resilient fastener having an opening or a channel to slidably receive the first end in overlapping engagement with the second end. The fastener also includes a fastener surface having at least one cooperating attachment member to cooperate with the attachment members of the first end of the band. The fastener surface is resiliently bowable in a direction away from the first end upon application of a compressive force to the fastener. Upon application of such compressive force, the attachment member of the first end of the band and the cooperating attachment member of the fastener disconnect so that the first end can be slid relative to the fastener (and thereby the second end). Unfortunately, it can be difficult to operate the bowable fastening mechanism of U.S. Pat. No. 5,896,586 with only one hand.  
         [0006]     U.S. Pat. No. 6,341,382 also discloses a one-piece adjustable headband which is constructed of lightweight material such as a plastic. The strap is constructed with an integral adjustment or fastening mechanism to adjust the fit of the strap around the head of wearer, purportedly using a single hand. The headband includes a first end, a second end, an interior surface, and an exterior surface. A plurality of ratchet teeth extend from the exterior surface of the headband adjacent the first end thereof. Each of the ratchet teeth has a tapered surface and a locking surface. A clasp is resiliently connected to the exterior surface of the headband adjacent the second end thereof. The clasp includes a pawl which is biased in a locking position wherein the pawl is engageable with the locking surface of one of the ratchet teeth to hold the headband in a selected loop configuration. The clasp is movable to a release position upon application of a force generally normal to the plane of the headband whereby the pawl is moved away from the ratchet teeth to permit the loop configuration of the headband to be increased in size.  
         [0007]     Although a number of fastening or adjusting mechanisms have been developed for headbands or head straps for use in headgear, and especially in personal protective equipment such as protective helmets, faceshields and welding shields having a headgear support, it remains desirable to develop improved headbands and adjusting mechanism for use therein, and preferably ones which can be adjusted using only one hand, and more preferably which can also be adjusted with one hand while a user is wearing the protective headgear support.  
       SUMMARY OF THE INVENTION  
       [0008]     In one aspect, the present invention provides a headband for use in a headgear support including a first end section having a plurality of spaced connectors and a second end section including a fastener attached adjacent the end thereof. The fastener includes a connecting member to which at least one cooperating connector is attached. The connecting member biases the cooperating connector in an engagement position with at least one of the plurality of connectors of the first end section to hold the headband in a selected loop configuration. The fastener further includes at least a first flexible release member. Upon application of a force to the first release member, the first flexible release member is movable to a release position (or range of positions) in which the first release member abuts the connecting member to cause the connecting member to flex to a disengage position (or range of positions) in which the cooperating connector is disengaged from the at least one of the plurality of connectors of the first end section to enable increasing the size of the loop of the headband.  
         [0009]     In one embodiment, the plurality of connectors on the first end section are slots. The at least one cooperating connector can, for example, be a projection. More than one projection can attached to the connecting member. In another embodiment, each of the projections includes a first surface which is angled to facilitate sliding of the projections over the slots of the first end section when the first end section and the second end section are moved relative to each other to decrease the size of the loop of the headband. In this embodiment, each of the projections also includes a second surface that is angled to abut one of the slots of the first end section when in the engagement position and to provide resistance to movement of first end section and second end section relative to each other in a direction to increase the size of the loop of the headband when in the engagement position.  
         [0010]     A generally lateral force can, for example, be applied to the first release member to place the first release member in the release position. The first release member can, for example, include a sloped surface which abuts the connecting member. The headband can further include a second release member that is movable to a release position upon application of a force to the second release member in which the second release member abuts the connecting member to cause the connecting member to flex to the disengage position. In one embodiment, the first release member is positioned on one lateral side of the fastener, and the second release member is positioned on the other side of the fastener.  
         [0011]     In another aspect, the present invention provides a headband for use in a headgear support including a first end section having a plurality of spaced slots and a second end section including a fastener attached adjacent the end thereof. The fastener includes a flexible connecting member and at least one cooperating connector attached to the connecting member and biased by the connecting member in an engagement position with at least one of the plurality of slots of the first end section to hold the headband in a selected loop configuration. The connecting member is movable to a disengage position upon application of a generally lateral force to the fastener to cause the cooperating connector to disengage from the at least one of the plurality of slots of the first end section to enable increasing the size of the loop of the headband.  
         [0012]     The at least one cooperating connector can, for example, be a projection. As described above, the projection can include a first surface which is angled to facilitate sliding of the projections over the slots of the first end section when the first end section and the second end section are moved relative to each other to decrease the size of the loop of the headband. In this embodiment, the projection can further include a second surface that is angled to abut one of the slots of the first end section when in the engagement position and to provide resistance to movement of first end section and second end section relative to each other in a direction to increase the size of the loop of the headband when in the engagement position.  
         [0013]     The headband can further include at least a first flexible release member which is movable to a release position upon application of a generally lateral force thereto. In the release position, the first release member abuts the connecting member to cause the connecting member to flex to the disengage position. In one embodiment, the headband further includes a second release member which is movable to a release position upon application of a generally lateral force to the second release member. In the release position thereof, the second release member abuts the connecting member to cause the connecting member to flex to the disengage position. The first release member can, for example, be positioned on one lateral side of the fastener, and the second release member can be positioned on the other side of the fastener.  
         [0014]     In one embodiment, a generally lateral force is applied directly to the connecting member to cause the connecting member to move to the disengage position.  
         [0015]     In still a further aspect, the present invention provides a headband for use in a headgear support including a first end section having a plurality of spaced slots and a second end section including a fastener attached adjacent the end thereof. The fastener includes a flexible connecting member and at least one projection attached to the connecting member and biased by the connecting member in an engagement position with one of the plurality of slots of the first end section to define a selected loop configuration of the headband. The fastener further including a first flexible release member on a first lateral side of the fastener. The first flexible release member is movable to a release position upon application of a force to the first release member. In the release position thereof, the first release member abuts the connecting member to cause the connecting member to flex to a disengage position in which the projection is disengaged from the at least one the plurality of connectors of the first end section to enable increasing the size of the loop of the headband., The fastener also includes a second flexible release member on a second lateral side of the fastener. The second flexible release member is movable to a release position upon application of a force to the second release member. In the release position thereof, the second release member abuts the connecting member to cause the connecting member to flex to the disengage position. Each of the first release member and the second release member can, for example, include a sloped surface to abut the connecting member. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1  illustrates a perspective view of an embodiment of a headband of the present invention having a first end section and a second end section thereof in a disconnected state.  
         [0017]      FIG. 2A  illustrates an enlarged perspective view of the first end section of  FIG. 1 .  
         [0018]      FIG. 2B  illustrates an enlarged perspective view of the second end section of  FIG. 1 .  
         [0019]      FIG. 2C  is an enlarged perspective view of a portion of the fastener of the second end section.  
         [0020]      FIG. 3A  illustrates another perspective view of the first end section of  FIG. 1 .  
         [0021]      FIG. 3B  illustrates another perspective view of the second end section of  FIG. 1 .  
         [0022]      FIG. 4A  illustrates a perspective view of the headband of  FIG. 1  with the first end section and the second end section in a connected state.  
         [0023]      FIG. 4B  illustrates an enlarged view of the fastener in the orientation of  FIG. 4A .  
         [0024]      FIG. 4C  illustrates a cross-sectional view of the connecting member of the fastener in a connecting or a locking state wherein the projections or flanges of the connecting member are in operative connection with the slots of the first end section.  
         [0025]      FIG. 4D  illustrates a cross-sectional view of the connecting member of the fastener in a stressed or release state wherein the projections or flanges of the connecting member are raised out of operative connection with the slots of the first end section.  
         [0026]      FIG. 5  illustrates a perspective view of the headband of  FIG. 1  with the first end section and the second end section in a connected state wherein the headband is rotated approximately 90° from the view of  FIG. 4A .  
         [0027]      FIG. 6A  illustrates a front perspective view of another embodiment of a headband of the present invention with the first end section and the second end section connected.  
         [0028]      FIG. 6B  illustrates tightening of the fit the headband of  FIG. 6A .  
         [0029]      FIG. 6C  illustrates application of-force to a release member in the form of a lever arm of the fastener of the headband of  FIG. 6A  to loosen the fit of the headband.  
         [0030]      FIG. 6D  illustrates a front plan view of the headband of  FIG. 6A .  
         [0031]      FIG. 6E  illustrates a cross-sectional view of the headband of  FIG. 6A .  
         [0032]      FIG. 7A  illustrates a front perspective view of another embodiment of a headband of the present invention with the first end section and the second end section connected.  
         [0033]      FIG. 7B  illustrates tightening of the fit the headband of  FIG. 7A .  
         [0034]      FIG. 7C  illustrates application of force to a connecting member of the fastener of the headband of  FIG. 7A  to loosen the fit of the headband.  
         [0035]      FIG. 7D  illustrates a front plan view of the headband of  FIG. 7A .  
         [0036]      FIG. 7E  illustrates a cross-sectional view of the headband of  FIG. 7A . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0037]      FIG. 1  illustrates an embodiment of a headband or head strap  110  of the present invention for use in a headgear support. Headband  110  is, for example, a flexible member that can be molded from one or more suitable polymeric materials to extend around the head of the user. Headband  110  can, for example, be formed from an integral or monolithic piece of polymeric material or can, for example, be co-molded or otherwise fabricated from two or more polymeric materials. A first end  120  and second end  160  overlap, preferably at the back of the wearer&#39;s head (see, for example,  FIGS. 4A and 4B ). Headband  110  may be straight from end to end, in which case first end  120  and second end  160  will overlap on the head of the user. On the other hand, first end  120  and second end  160  may extend downwardly in the rear portion of headband  110  across the nape of the neck. The latter embodiment is illustrated in  FIGS. 1 through 5 . Regardless of which type of headband  110  is used, overlapping ends  120  and  160  are connected in the same manner.  
         [0038]     First end  120  includes a connection mechanism  125  that, in the embodiment of  FIGS. 1 through 5 , comprises a plurality of longitudinally spaced connective elements such as spaced slots  130 . Second end  160  includes a cooperating fastener  170  which includes at least one cooperating connective element that forms an operative connection with at least one of the spaced connective elements of connection mechanism  125  to form an adjustable overlapping connection between first end  120  and second end  160 . In  FIG. 1 , arrow A 1  represents a generally latitudinal direction as such term is used herein, whereas arrow A 2  represents a generally longitudinal direction as such term is used herein.  
         [0039]     First end  120  is maintained in slidable connection with fastener  170  and second end  160  via retaining members  172  (see, for example,  FIG. 4B ) on an interior side thereof (that is, the side closest to the wearer&#39;s head while donned) of fastener  170 . Each of retaining member  172  also includes a projecting flange or ridge  172   a  which abuts the sides of first end section  120  when first end section  120  is in operative connection with second end section  160 . First end section  120  passes through an opening or notch  174  formed in fastener  170 . Retaining members  172  and opening  174  form a channel through which first end section  120  is slidable to adjust the loop formed by headband  110  (see, for example,  FIGS. 4A and 5  for an example of the loop configuration). Opening  174  includes recesses  174   a  through which ridges  122  formed on the lateral sides of first end section  120  pass. Ridges  122  can, for example, add strength or stiffness to first end section  120 .  
         [0040]     Fastener  170 , for example, includes a flexible connecting member or arm  180  having at least one cooperating abutment member or tooth  178  (see, for example,  FIGS. 2B and 4C ) attached thereto. Each of abutment members  178  extends into one of slots  130  (see, for example,  FIG. 4C ) to form an operative connection between first end section  120  and second end section  160 .  
         [0041]     In the embodiment of  FIGS. 1 through 5 , abutment members  178  are in the form of projections or flanges and include a first surface  178   a  (see  FIGS. 4C and 4D ) that is sloped to facilitate sliding of first end  120  through fastener  170  to reduce the size of headband  110  (thereby tightening the fit thereof). For example, application of an appropriate force to first end  120  (and/or second end  160 ) to tighten headband  110  causes sloped surfaces  178   a  of projections  178  to “slide over” or past slots  130 . Projections  178  further include a second surface  178   b  (see  FIGS. 4C and 4D ) that is generally vertical. Surfaces  178   b,  in cooperative connection with slots  130 , provide substantial resistance to movement of first end  120  away from second end  160  (which would result in loosening of the fit of headband  110 ). In that regard, loosening of the fit of headband  170  typically requires placement of flexible connecting member  180  into a release or bowed state as illustrated in  FIG. 4D  to move projections  178  out of operative abutting connection with slots  130 .  
         [0042]     In the embodiment of  FIGS. 1 through 5 , fastener  170  includes a first end  170   a  and a second end  170   b.  Connecting member  180  is attached at a first end thereof to first end  170   a  of fastener  170  and at a second end thereof to second end  170   b  of fastener  170 . Flexible connecting member  180  includes a raised section  180   a  generally in the center thereof. Fastener  170  further includes first and second (or upper and lower, in the orientation of, for example,  FIG. 4A ) flexible release members  184   a  and  184   b,  respectively, on each lateral side thereof. First and second flexible release members  184   a  and  184   b  are attached at a first end thereof to first end  170   a  of fastener  170  and at a second end thereof to second end  170   b  of fastener  170  and can flex about those points of attachment.  
         [0043]     To place connecting member  180  in its bowed or release position or state as illustrated in  FIG. 4D , the wearer of headband  110  reaches behind the wearer&#39;s head and applies (for example, with a single hand) a generally latitudinal compressing force F (see  FIG. 4B ) to each of flexible release member  184   a  and  184   b.  For example, the wearer can place the wearer&#39;s thumb on lower release member  184   a  and the wearer&#39;s index finger on the upper release member  184   b  and squeeze upper and lower release member  184   a  and  184   b  toward each other. Each of flexible release members  184   a  and  184   b  includes a sloped abutment member  186   a  and  186   b  (see, for example,  FIGS. 3B and 4B ), respectively, in operative connection therewith. As release members  184   a  and  184   b,  and thereby sloped abutment members  186   a  and  186   b,  are forced toward each other, abutment of sloped abutment members  186   a  and  186   b  with raised section  180   a  of connecting member  180  forces connecting member  180  into its release state as illustrated in  FIG. 4D . As abutment members  186   a  and  186   b  are forced toward each other, inward projecting contact members  188   a  and  188   b  on an inner side of abutment members  186   a  and  186   b  contact and slide along the outer surface of first section  120 , thereby reducing or eliminating bending of abutment member  186   a  and  186   b  relative to connecting member  180 . Rearward motion of first section  120  relative to fastener  170  and connecting member  180  is prevented by contact of the inner surface of first section  120  with retaining members  172 . In the release state or position of connecting member  180 , projections  178  are out of contact with slots  130 , and first section  120  can be moved relative to second section  160  and fastener  170 . When compressive force as described above is removed from release members  184   a  and  184   b,  release members  184   a  and  184   b  (and abutment members  186   a  and  186   b ) return to their unstressed or locking state as illustrated in  FIGS. 4B and 4C , allowing connecting member  180  to return to its locking or connecting state as illustrated in  FIG. 4C . Even in its locking state, connecting member  180  can be flexed and not fully relaxed so that it biases projections  178  in operative connection with slots  130  of first end  120 .  
         [0044]     Actuation of release members  184   a  and  184   b  is typically required only to loosen or enlarge headband  110 . In that regard, projections  178  provide little resistance to motion of first end section  110  relative to second end section  160  and fastener  170  in a tightening direction. To tighten the fit of headband  110 , the user can readily reach behind his or her head, place the user&#39;s fingers in contact with tab  150  on first end  120  and with tab  190  on fastener  170 , and force tabs  150  and  190  toward each other to tighten the fit of headband  110 .  
         [0045]     As illustrated, for example, in  FIG. 4A , second end section  160  also includes an extending member  188  extending from second end  170   b  of fastener  170 . Extending member  188  contacts first end section  120  and assists in maintaining that portion of first end section  120  that projects through fastener  170  in close proximity to second end section  160 .  
         [0046]     As described above, all components of fastener  170  can, for example, be fabricated as a monolithic unit (via, for example, molding) from a resilient polymeric material wherein connecting member  180  flexes about its attachment points with first end  170   a  and second end  170   b  of fastener  170  and release member  184   a  and  184   b  flex about their attachment points with first end  170   a  and second end  170   b  of fastener  170 . Likewise the entirety of headband  110  can be fabricated as a monolithic unit from a resilient polymeric material. Alternatively, one or more components of headband  110  can be fabricated from different materials via, for example, a co-molding process as known in the art. One or more components of headband  110  can alternatively be fabricated separately and later assembled to form headband  110 . Resilient polymeric materials suitable for use in the present invention include, but are not limited to, polypropylene, high density polyethylene and/or nylon.  
         [0047]      FIGS. 6A through 6E  illustrate another embodiment of a headband  310  of the present invention. Like headband  110 , headband  310  includes a first end section  320  and a second end section  360 . First end section  320  includes a plurality of slots  334  formed in an upper or outer surface  328  thereof. Second end section  360  includes a fastener  370 . Fastener  370  includes tabs or flanges  372  (see  FIG. 6E ) on a rearward side thereof and an opening  372   a  through which first end  320  passes to assist in maintaining first end  320  in operative connection with fastener  370  and first end  360 . Fastener  370  includes a cantilevered connecting member or arm  384  including a downward oriented abutment member such as a projection  386  on an end thereof. Projection  386  operatively cooperates with slots  334  to adjust the fit of headband  310 . Projection  386  can, for example, include a sloped surface  386   a  proximal to or facing first end  320  (which causes little resistance to tightening of headband  310 ) and a generally vertical surface  386   b  (which provides substantial resistance to loosening of headband  310 ).  
         [0048]     Fastener  370  further includes a single release member in the form of a lever arm  374  including a beveled or sloped surface  374   a  which is adapted to contact a lower edge  388  of flexible connecting member  384 . Application of force to finger contact  378  of release member  374  (as illustrated in  FIGS. 6C and 6E ) causes release member  374  to move or flex latitudinally upward (in the orientation of  FIG. 6D ). Sloped surface  374   a  of release member  374  forces cantilevered connecting member  384  to swing outward, away from first end  320 , thereby removing projection  386  from operative connection with slots  334  (see, for example,  FIG. 6E ). A finger contact  380  (see  FIG. 6C ) opposite to finger contact  378  can be provided to facilitate operation of release member  374 . Tabs  350  and  390  can be used in the manner described above in connection with tabs  150  and  190  of headband  110  to facilitate tightening of headband  310 . Use of tabs  350  and  390  to tighten headband  310  is illustrated in  FIG. 6B .  
         [0049]      FIGS. 7A through 7E  illustrate another embodiment of a headband  410  of the present invention in which a first end  420  includes a plurality of slots  434  formed in an outer surface thereof. Second end  460  includes a fastener  470  In this embodiment, fastener  470  includes a flexible connecting member in the form of a lever arm  484  including an abutment member such as a projection  486  which forms an operative connection with one of slots  434  to control the fit of headband  410 . In the embodiment of  FIGS. 7A through 7E , force is applied by the wearer directly to an outward projecting flange or tab  484   a  of connecting member  484  to place release member  484  in a release state. In that regard, a generally lateral force can be applied to release member  484  as illustrated in  FIGS. 7C and 7E  to cause release member  484  to swing outward as illustrated in  FIG. 7E  to remove projection  486  from operative connection with slots  434  to enable loosening of headband  410 . Projection  486  can, for example, include a sloped surface and a generally vertical surface as described above to provide little resistance to tightening the fit of headband  410  while providing substantial resistance to loosening of the fit of headband  410 . Tabs  450  and  490  can be used in the manner described above to facilitate tightening of headband  410  as illustrated in  FIG. 7B .  
         [0050]     The foregoing description and accompanying drawings set forth preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope.