Patent Document

This application is a Continuation-In-Part of application Ser. No. 12/216,278, filed on Jul. 2, 2008, now pending. The patent application identified above is incorporated here by reference in its entirety to provide continuity of disclosure. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to earmuffs and more particularly, to an earmuff assembly which allows convenient adjustment of the length of the headband and the angular positions of the ear cups to fit different wearing conditions, and is covered with a soft fabric material for optimal wearing comfort. 
     2. Description of the Related Art 
     In autumn and winter, people may dress in heavy clothes to protect the body against the cold. In addition to a fur coat, wind coat or snow coat, people may also wear a hat, gloves, scarf, muff and/or other accessories for warmth. However, the aforesaid warm-keeping devices cannot directly protect the ears against the cold. When exposing the ears to the cold weather, the ears may suffer from a freezing injury or become painful. More particularly, when the cold wind passes or when one is in a low temperature place, cold mountain or snowland area, exposing the ears to the freezing air may cause a serious injury. 
     U.S. Pat. No. 5,835,609 discloses an ear covering device, entitled “Ear Protection Device”. As illustrated in  FIG. 16 , this design of ear protection device comprises a headband A and two ear cups B on each end. The headband A is contemplated to be flexible so that the space between opposite ear cups B may be enlarged to permit attachment of the covering device onto the back of the head. Each ear cup B includes a frusto-conical frame portion having a central opening therein. Fabric C covers the frusto-conical portion of the ear cups B as well as the flexible headband A. 
     This design of ear protection device is still not satisfactory in function and has drawbacks as follows:
     1. The ear protection device can simply be attached to the user&#39;s head from the top side or the back.   2. The looped portions A 1  protrude over the bottom side of the headband A. When the user wears the ear protection device, the protruding looped portions A 1  are directly stopped against the user&#39;s head, causing the head to feel uncomfortable.   3. After adjustment of the length, the elements of the headband A may slip relative to the respective looped portions A 1 , and consequently, the ear cups B may fall from the ears accidentally.   4. The ear cups B are respectively fastened to the ends of the headband A by a respective small fastening member D. When the user adjusts the angle of each ear cup B relative to the ears, the connection area between the headband A and the ear cup B may break easily, losing the functionality of the ear protection device.   5. The ear cups B are not strong enough for positive positioning on the user&#39;s head around each ear to keep the ears well protected.   6. The ear cups B are respectively affixed to the ends of the headband A. When not in use, the ear protection device cannot be collapsed to reduce the size for storage. When storing or carrying the ear protection device, the ear protection device may be deformed or damaged accidentally by an external pressure.   7. The ear cups B are respectively affixed to the ends of the headband A and not detachable. The fabric C must be covered on the frusto-conical portion of the ear cups B and the flexible headband A prior to connection between the ear cups B and the flexible headband A, complicating the assembly process.   

     Therefore, it is desirable to provide an ear protection device, which eliminates the aforesaid drawbacks. 
     SUMMARY OF THE INVENTION 
     The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide an earmuff assembly, which allows convenient adjustment of the length of the headband and the angular positions of the ear cups to fit different wearing conditions, and is covered with a soft fabric material for optimal wearing comfort. 
     To achieve this and other objects of the present invention, an earmuff assembly comprises a length adjustable headband consisting of two headband elements, two ear cups, two connection devices that connect the coupling portions of the headband elements to the ear cups in such a manner that the angular positions of the ear cups are adjustable in the X-axis direction as well as in the Y-axis direction relative to the headband, and a soft fabric material covering the ear cups for optimal wearing comfort. Thus, the user can adjust the length of the headband and the angle of the ear cups subject to the actual wearing requirements, assuring positive contact between the ears and the ear cups. 
     Further, each headband element comprises two constraint lugs bilaterally located on one end and a coupling portion located on the opposite end. The coupling portion of one headband element is inserted through a groove on each constraint lug of the other headband element so that the combined length of the headband elements of the headband is conveniently adjustable. 
     Further, each headband element comprises two sliding grooves bilaterally extending along the length between the two opposite ends thereof. Further, each headband element has a thickness gradually increasing in direction from the constraint lugs toward the coupling portion. When the two headband elements are arranged together, the constraint lugs of one headband element fit the sliding grooves of the other headband element, avoiding protrusion of the constraint lugs over the surface of the headband and keeping the outwardly curved outer surface and inwardly curved inner surface of each of the headband elements in a smoothly arched condition to fit the user&#39;s head positively and comfortably. When adjusting the length of the headband, no stress concentration will occur, avoiding headband deformation. 
     Further, the coupling portion of each headband element has a through hole pivotally connected to a pivot hole on each of two parallel ends of a U-shaped connection plate of one respective connection device by a respective pivot member such that each ear cup is biasable with the U-shaped connection plate of the respective connection device relative to the headband horizontally (X-axis) to one of 90°, 0° and 180° positions. 
     Further, the coupling portion of each headband element has chamfered edges so that each ear cup may be biased with the U-shaped connection plate of the respective connection device relative to the headband horizontally (in the X-axis direction) to any one of 90°, 0° and 180° positions. 
     Further, each ear cup comprises an elongated base frame, a rim, an insertion hole cut through two distal ends of the elongated base frame, and a plurality of locating holes transversely formed in the elongated base frame across the insertion hole. Each connection device comprises a substantially U-shaped connection plate pivotally connected to one headband element of the headband by a pivot member, and an elongated connection strip coupled to the U-shaped connection plate and fastened to the insertion hole of the elongated base frame of the respective ear cup. The elongated connection strip is inserted through an insertion slot on the U-shaped connection plate, having a round rod transversely located on and formed integral with one end thereof and pivotally positioned in a round rod groove in the U-shaped connection plate, and also having a plurality of locating teeth transversely located on and spaced along each of two opposite sides thereof remote from the round rod and selectively engaged with the locating holes of the elongated base frame of the respective ear cup. 
     Further, the two ear cups are detachably connected to the headband elements of the headband by the connection devices. Thus, the soft fabric material can be wrapped about the ear cups and the headband either after or before connection between the headband and the ear cups. 
     As the length of the headband is adjustable and the ear cups may be biased relative to the headband in the X-axis direction as well as the Y-axis direction, the earmuff assemblies can be received in a received condition with the two ear cups closely attached together to reduce the size, saving storage space and avoiding accidental damage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevational view of an earmuff assembly in accordance with the present invention (the soft fabric material excluded). 
         FIG. 2  is an exploded view of the earmuff assembly shown in  FIG. 1 . 
         FIG. 3  is a schematic drawing of a part of the present invention, illustrating a length adjustment of the headband. 
         FIG. 4  is a schematic sectional view of the present invention, illustrating the mounting arrangement between the connection device and the headband. 
         FIG. 5  is a schematic sectional view of the present invention, illustrating the mounting arrangement between the connection device and the ear cup. 
         FIG. 6  is a schematic sectional view of the present invention, illustrating angular adjustment of the ear cup in the X-axis direction relative to the headband. 
         FIG. 7  is a schematic sectional view of the present invention, illustrating angular adjustment of the ear cup in the Y-axis direction relative to the headband. 
         FIG. 8  is a schematic elevational view of the present invention, illustrating the earmuff assembly received in a first received condition (the soft fabric material excluded). 
         FIG. 9  is a schematic elevational view of the present invention, illustrating the earmuff assembly received in a second received condition (the soft fabric material excluded). 
         FIG. 10  is a schematic exploded view of the present invention, illustrating one mounting arrangement of the soft fabric material. 
         FIG. 11  is a schematic sectional view of the present invention, illustrating another mounting arrangement of the soft fabric material. 
         FIG. 12  is a schematic perspective view of the present invention, illustrating still another mounting arrangement of the soft fabric material. 
         FIG. 13  is a schematic perspective view of the present invention, illustrating still another mounting arrangement of the soft fabric material. 
         FIG. 14  is a schematic perspective view of the present invention, illustrating still another mounting arrangement of the soft fabric material. 
         FIG. 15  is a schematic applied view of the earmuff assembly in accordance with the present invention. 
         FIG. 16  illustrates the outer appearance of an earmuff assembly according to the prior art. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 ,  2  and  10 , an earmuff assembly in accordance with a first embodiment of the present invention is shown comprising a headband  1 , two ear cups  3  for covering the user&#39;s ears respectively, two connection devices  2  that connect the ear cups  3  to the two distal ends of the headband  1 , and a soft fabric material  4 . 
     The headband  1  consists of two reversed headband elements  11 . Each headband element  11  comprises two constraint lugs  12  bilaterally located on one end thereof, an insertion groove  121  defined in each of the two constraint lugs  12 , a coupling portion  13  located on the other end thereof, and two sliding grooves  14  bilaterally extending along the length between the two opposite ends thereof. The coupling portion  13  has two chamfered edges  131  bilaterally located on the distal end thereof, and a through hole  130  spaced between the two chamfered edges  131 . 
     Each connection device  2  consists of a substantially U-shaped connection plate  21 , an elongated connection strip  22  and a pivot member  23 . The U-shaped connection plate  21  comprises a flat positioning space  210  defined between the two parallel ends thereof, a pivot hole  211  cut through each of the two parallel ends across the flat positioning space  210 , a round rod groove  212  transversely located on the middle part thereof inside the flat positioning space  210  and an insertion slot  2120  cut through the middle part. The elongated connection strip  22  comprises a strip body  222  insertable through the insertion slot  2120  of the U-shaped connection plate  21 , a round rod  221  transversely located on and formed integral with one end of the strip body  222  for positioning in the round rod groove  212  of the U-shaped connection plate  21 , and a plurality of locating teeth  223  transversely located on and spaced along each of the two opposite sides of the strip body  222  remote from the round rod  221 . 
     Each ear cup  3  comprises an elongated base frame  31 , a rim  33 , an insertion hole  311  cut through two distal ends of the elongated base frame  31 , a plurality of locating holes  312  transversely formed in the elongated base frame  31  across the insertion hole  311 , a stop block  313  located on one end of the insertion hole  311  near the center of the respective ear cup  3 , a plurality of ribs  32  extending in transverse and radial directions and connected with one another between the elongated base frame  31  and the rim  33 , a rounded accommodation space  34  surrounded by the rim  33  and the ribs  32 , a straight cutting edge  35  located on the periphery of the rim  33  adjacent to one end of the insertion hole  311  and remote from the stop block  313 , and a plurality of plug holes  36  defined in between the rim  33  and the ribs  32 . 
     The soft fabric material  4  is wrapped about each of the two connection devices  2  and each of the two ear cups  3  for direct contact with the user&#39;s ears. 
     The assembly process of the earmuff assembly will be described hereinafter with reference to  FIGS. 3-5 . At first, attach the two headband elements  11  of the headband  1  together, and insert the coupling portion  13  of one headband element  11  through the insertion grooves  121  of the constraint lugs  12  of the other headband element  11  to have the respective sliding grooves  14  be relatively slidably coupled to the respective insertion grooves  121  (see  FIG. 3 ), and then insert the strip bodies  222  of the elongated connection strips  22  of the connection devices  2  through the insertion slots  2120  of the associating U-shaped connection plates  21  to have the round rods  221  of the respective the elongated connection strips  22  be positioned in the round rod grooves  212  of the associating U-shaped connection plates  21 . Then insert the coupling portions  13  of the headband elements  11  of the headband  1  into the flat positioning spaces  210  of the U-shaped connection plates  21  of the connection devices  2  respectively, and then fasten the respective pivot members  23  to the pivot holes  211  of the U-shaped connection plates  21  of the connection devices  2  and the through holes  130  of the coupling portions  13  of the headband elements  11  of the headband  1  respectively to pivotally connect the headband elements  11  to the U-shaped connection plates  21  of connection devices  2  respectively (see  FIG. 4 ). Then insert the strip bodies  222  of the elongated connection strips  22  of the connection devices  2  into the insertion holes  311  of the elongated base frames  31  of the ear cups  3  respectively to have the strip bodies  222  be respectively stopped against the respective stop blocks  313  in the respective elongated base frames  31  and the transversely extending locating teeth  223  of the strip bodies  222  be respectively engaged into the respective locating holes  312  (see  FIG. 5 ). 
     Referring to  FIGS. 4 and 5  again, each transverse locating tooth  223  has a beveled guide face  2231  located on the front side thereof and a vertical stop edge  2232  located on the rear side thereof. When inserting the strip bodies  222  of the elongated connection strips  22  of the connection devices  2  into the insertion holes  311  of the elongated base frames  31  of the ear cups  3 , the beveled guide faces  2231  of the transversely extending locating teeth  223  facilitates forward movement of the respective strip bodies  222  in the respective insertion holes  311  relative to the respective elongated base frames  31 . When the beveled guide face  2231  of one transverse locating tooth  223  is moved over one end of one respective insertion hole  311  of the elongated base frames  31 , the vertical stop edge  2232  prohibits the respective transverse locating tooth  223  from backward movement with the respective elongated connection strip  22  relative to the respective elongated base frames  31 . 
     Subject to the sliding coupling arrangement between the respective sliding grooves  14  and the respective insertion grooves  121 , the two headband elements  11  can be moved axially relative to each other to adjust the length of the headband  1 . Further, each headband element  11  has a thickness gradually increasing in direction from the constraint lugs  12  toward the coupling portion  13 , enabling the two headband elements  11  to fit the user&#39;s head positively and comfortably. Further, thinning the wall thickness of the two opposite lateral sides of each of the headband elements  11  form the sliding grooves  14 . When the two headband elements  11  are arranged together, the constraint lugs  12  of one headband element  11  fit the sliding grooves  14  of the other headband element  11 , avoiding protrusion of the constraint lugs  12  over the surface of the headband  1  and keeping the outwardly curved outer surface  111  and inwardly curved inner surface  112  of each of the headband elements  11  in a smoothly arched condition. 
     Further, as stated above, the two pivot members  23  are respectively fastened to the pivot holes  211  of the U-shaped connection plates  21  of the connection devices  2  and the through holes  130  of the coupling portions  13  of the headband elements  11  of the headband  1  to pivotally connect the headband elements  11  to the U-shaped connection plates  21  of the connection devices  2 . Thus, the headband elements  11  can be respectively turned about the respective pivot members  23  in the horizontal (X-axis) direction to selectively adjust the ear cups  3  to any one of the 0°, 90° and 180° positions (see  FIG. 6 ). Subject to the design of the chamfered edges  131  of the of the headband elements  11  for stopping against the periphery of the round rods  221  of the elongated connection strips  22  of the respective connection devices  2 , the ear cups  3  can be positively positioned in one of the 0°, 90° and 180° positions. Further, subject to the pivotal connection between the round rod  221  of the elongated connection strip  22  of each connection device  2  and the round rod groove  212  of the associating U-shaped connection plate  21 , each ear cup  3  can be biased with the connected elongated connection strip  22  relative to the associated U-shaped connection plate  21  and the headband  1  in the vertical (Y-axis) direction (see  FIG. 7 ). Thus, the user can adjust the angles of the ear cups  3  relative to the headband  1  conveniently when wearing or storing the earmuff assembly. 
     Referring to  FIGS. 8 and 9 , when the earmuff assembly is not used, it can be arranged in one of two received conditions. The user can shorten the combined length of the headband elements  11  of the headband  1 , and then bias one ear cup  3  with the connected elongated connection strip  22  relative to the associated U-shaped connection plate  21  and the headband  1  to have the two ear cups  3  be attached together in a reversed manner (see  FIG. 8 ). Alternatively, the user can shorten the combined length of the headband elements  11  of the headband  1 , and then bias the ear cups  3  to have one ear cup  3  be received in the other ear cup (see  FIG. 9 ). Subject to the functioning of the connection devices  2 , the user can conveniently adjust the angular positions of the ear cups  3  relative to the headband  1  to fit different wearing requirements, assuring wearing comfort. The user can also conveniently receive the earmuff assembly in a received condition to reduce space occupation, avoiding structural damage or deformation during storage. 
     Referring to  FIG. 10 , after connection between the headband  1  and the connection devices  2 , the soft fabric material  4  is wrapped about the headband  1  and the connection devices  2  to let the elongated connection strips  22  of the connection devices  2  be exposed to the outside of the soft fabric material  4 . During the assembly process, two pieces of the soft fabric material  4  are respectively attached to the front and back sides of each of the ear cups  3 , and then peripherally stitched together. A finding tape  41  is seamed to the peripheral edges of the stitched pieces of the soft fabric material  4 , and then an opening  42  is made on one piece of the soft fabric material  4  corresponding to the insertion hole  311  of the elongated base frame  31  of the associating ear cup  3 . After connection between the headband  1  and the connection devices  2  is completed, the strip body  222  of each connection device  2  is directly inserted through the opening  42  of the soft fabric material  4  at each ear cup  3  into the insertion hole  311  of the elongated base frame  31  of the associating ear cup  3  to connect the associating ear cup  3  to the headband  1  (see  FIG. 10 ). Because the soft fabric material  4  is separately made and then fastened to the ear cups  3  of the earmuff assembly, different designs of the soft fabric material  4  can be selectively used. 
     Referring to  FIG. 11 , two pieces of the soft fabric material  4  can be peripherally stitched together to form a pocket that fits the configuration of the ear cups  3 , and then each pocket thus made is turned inside out and sleeved onto one respective ear cup  3 . The opposing unstitched border edges around the opening of each pocket are turned inwards and selectively inserted into the plug holes  36  between the rim  33  and ribs  32  of the associating ear cup  3 . The unstitched border edges of each pocket can be inserted into the plug holes  36  of the associating ear cup  3  adjacent to the straight cutting edge  35 . Alternatively, the unstitched border edges of each pocket can be inserted into the plug holes  36  of the associating ear cup  3  opposite to the straight cutting edge  35 . 
     Referring to  FIG. 12 , the soft fabric material  4  can simply cover the ear cups  3  to let a part of each of the elongated connection strips  22  of the connection devices  2 , the U-shaped connection plates  21  of the connection devices  2 , and the headband  1  be exposed to the outside. Pieces of the soft fabric material  4  can be stitched together, overedge seamed, and then put on each ear cup  3 . Alternatively, pieces of the soft fabric material  4  can be stitched together and then turned inside out, and then put on each ear cup  3 . 
     Referring to  FIG. 13 , two narrow elongated pieces of the soft fabric material  4  can be stitched together to form a fabric tube  43  for surrounding the headband  1 . The soft fabric material  4  can be spandex. Alternatively, the fabric tube  43  can be made in the form of an extendable bellows structure that fits length adjustment of the headband  1 . 
     Referring to  FIG. 14 , two pieces of the soft fabric material  4  can be attached to the top and bottom sides of the earmuff assembly and then peripherally stitched together to surround the headband  1 , connection devices  2  and ear cups  3  of the earmuff assembly. Alternatively, two pieces of the soft fabric material  4  can be stitched together to form an earmuff covering with a small part of the peripheral edges of the pieces of the soft fabric material  4  left unstitched. The earmuff covering is turned inside out and then the earmuff is inserted into the earmuff covering. The unstitched peripheral edges around the opening at each of the two distal ends of the earmuff covering are respectively turned inwards and selectively inserted into the plug holes  36  of the ear cups  3 . 
     Referring to  FIG. 15 , subject to the connection arrangement of the connection devices  2  between the headband  1  and the ear cups  3 , the user can conveniently adjust the angle of the ear cups  3  relative to the headband  1 . For example, the user can attach the headband  1  to the forehead or the back or the top of the head, and then bias the ear cups  3  relative to the headband  1  to have the ear cups  3  be capped on the ears. By means of adjusting the combined length of the headband elements  11  of the headband  1  and the angles of the ear cups  3  relative to the headband  1 , the earmuff assembly fits many hairstyles and satisfies many wearing requirements. When one is wearing a head covering, the earmuff assembly can be adjusted and worn over the head covering. 
     Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.

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