[1] Cross-Reference to Related Application

[2] The present specification claims priority to earlier filed U.S. Provisional

Application Mo. 62/050796, filed on September 16, 2014, the entire contents of which are incorporated herein by reference.

[3] Background

[4] The present specification relates to a headband of the type used in a head safety product such as a face shield, hardhat or welding helmet. More particularly, the specification is directed to a flexible headband with a self-adaptive functions to improve the fit, function, stability and comfort of the headgear.

[5] Summary of the Disclosure

[6] An improved headband includes a horizontal section configured to encircle the head and a first adjustment mechanism configured to adjust a circumference of the horizontal section. A nape-belt section depends from the horizontal section and is configured to cup the occipital area of the head. A flexible area is connected between the horizontal section and the nape-belt section. The flexible area provides spring-like or spring-biased action to pivotal movement of the nape-belt section relative to the horizontal section. A second adjustment mechanism is configured to adjust the nape- belt section.

[7] More specifically, the exemplary embodiment of an improved headband includes a flexible, spring-like section connected to the nape-belt section and a horizontal section of the headband to improve the fit, function, stability and comfort of the headband. The flexible section provides a spring-like flexibility to the nape-belt section, which extends downwardly from the horizontal section and has a concave rear surface contoured to conform to the shape of the head, The flexible, spring-like area is coupled between the nape-belt section and the horizontal section to buffer the tension between the headband and the head and more equally distribute pressure across the head. In an exemplary embodiment as illustrated, the flexible sectionis located in the forward of the nape-belt section and is preferably formed of a rubber layer through a double-injection molding process.

Accordingly, among the objectives of the improved headband are to provide a headband that improves fit, function, stability and comfort

Another objective is to provide flexible headband that can fit more head contours.

Yet another objective is to provide a flexible nape-belt of r a head band that micro-adjusts to meet various kinds of head shapes on the rear part of head contours.

Still another objective is to provide a cradle that cups the head below the equatorial region to provide an improved fit.

Yet another objective is to provide dynamic and self-adaptive adjustment happening at the same time of head movement especially head extension, which can reduce most interferences and discomforts, and maintain stability in these extreme movement.

Still another objective is to provide a headband that reduces the discomfort caused by ill-fitting for better wearing experience especially during long-term wearing,

Finally, it is yet another objective to provide a headband which is readily adaptable to both new headgear and headgear already deployed in the field and in various industries and consumer endeavors.

Other objects, features and advantages shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings. [16] Description of the Drawings

[17] An exemplary embodiment will now be described further by way of example with reference to the following examples and figures, which are intended to be illustrative only and in no way limiting upon the scope of the disclosure.

[18] Fig. 1 is a right side view of an exemplary embodiment of the headband on a hard hat;

[19] Fig. 2 is a right dies view of an exemplary embodiment of the headband in

isolation;

[20] Fig. 3 is a right side view thereof illustrating the mobility of the flexible nape- belt;

[21] Fig. 4 is a rear isometric view thereof, omitting the adjustment mechanism on the rear portion of the nape-belt section;

[22] Fig. 5 is a close up view of the flexible area;

[23] Fig. 6a is a right side view thereof in an initial state;

[24] Fig. 6b is a right side view thereof illustrating the difference between the initial state and the fully deflected state;

[25] Fig. 7a illustrates a person with a flat occipital area of the back of the head;

[26] Fig. 7b illustrates the deflection of the nape-belt on the person of Fig. 6a

[27] Fig. 8a illustrates a person with a rounded or bulged occipital area of the back of the head;

[28] Fig. 8b illustrates the deflection of the nape-belt on the person of Fig. 7a

[29] Fig. 9 shows an second exemplary embodiment of the headband, using a belt buckle style flexible area;

[30] Fig. 10 shows a third exemplary embodiment of the headband, using a spring as the flexible area; and

[31] Fig. llshows a fourth exemplary embodiment of the headband, using an elastic rubber area as the flexible area. Detailed Description of the Exemp!ary Embodiment

Generally, an improved headbandas illustrated and described herein includes a flexible, spring-like section connected to the nape-belt section and a horizontal section of the headband to improve the fit, function, stability and comfort of the headband. The flexible section provides a spring-like flexibility to the nape-belt section, which extends downwardly from the horizontal section and has a concave rear surface contoured to conform to the shape of the head.The flexible, spring-like area is coupled between the nape-belt section and the horizontal section to buffer the tension between the headband and the head and more equally distribute pressure across the head. In an exemplary embodiment as illustrated, the flexible sectionis located in the forward of the nape-belt section and is preferably formed of a rubber layer through a double-injection molding process. However, as shown in the other exemplary embodiments, other configurations of the headband are also contemplated where a similar flexible, springlike section could be located rearward of the nape-belt section.

Referring to Fig. 1, the first exemplary embodiment of the headband is embodied in a hard hat product indicated at 12, to secure the hard hat 10 to a wearer's head. While the first exemplary embodiment is illustrated in conjunction with a hard hat product 10, it should also be understood that the exemplary headband 12 is

contemplated for use in other head safety products, including but not limited to face shields, welding helmets, head lamps, medical head gear and products, wearable head equipment, and consumer headgear and products.

Referring to Figs. 2-6b, the headbandl2 components are preferably molded from a resilient plastic material and generally comprise the horizontal sectionl4that encircles the head, a nape-belt sectionis extending downwards and rearwards to cup the occipital area of the head, anadjustment mechanisml4a for sizing the horizontal section 14to a desired circumference to achieve a desired fit on the user's head, and a rack and pinion adjusting mechanism 18 for sizing the nap-belt section 16 to a desired fit on the user's head. A flexible area20 is located in the forward of the nape-belt section 16 and connected to the horizontal section 14.

The horizontal section 14 includes a front portion 22that extends across a forehead area. The front portion 34 of the headband 10 preferably includes a cushioned padextending across the brow area for the wearer's comfort.

The adjusting mechanism 14a of the horizontal section 14 is located on the front portion 22 of the horizontal section 14 and includes overlapping portions, which can be adjusted and secured for a proper size and fit against the wearer's forehead and temples.

The rack and pinion adjusting mechanism 18 of the nape-belt sectionl6 is centrally located on a rear portionof the nape-belt sectionl.6 and has a well-known construction for sizing the nape-belt section l6 to a desired fit.As is well known, opposing sides of the rear portion of the nape-belt section l6 overlap at the rear and are captured within the adjusting mechanism IS.Turning the adjustment knob 24 in one direction pulls the band ends closer while turning the knob 24in the other direction forces them apart.

The horizontal section 14 and nape-belt section 16 of the headband 10 are preferable molded from plastic.

Referring to Figs, 5, 6a and 6b, connected between the horizontal section 14 and nape-belt section 16 and forward of the nape-belt section 16 is a flexible area 20. The flexible area 20 may be formed by over-molding or a double molding a rubber layer onto the plastic horizontal and nape-belt sectionsl4, 16 of the headband 10. The flexible area 20 is resilient and functions as a spring. At rest, as shown in Fig. 5a, the flexible area 20 draws the nape-belt section 16 inwards. However, as shown in Fig. 5b, the flexible area 20 permits the nape-belt section 16 to be deflected outwardly to accommodate to fit various contours of the human head. For instance, Fig. 7a shows a wearer having a head 24 with a relatively flat back occipital region 26. As shown in Fig. 7b, when the headband 10 is placed on the head 24, the flexible area 20 draws the nape-belt section 14 inwards, providing a more secure and comfortable fit to the wearer.

As shown in Fig. 8a, a wearer having a head 24b with a rounded or protruding occipital area 26b requires a different fit. Referring to Fig. 8b, when the headband 10 is placed on this wearer's head 24b, the flexible area 20 allows the nape-belt section 16 to deflect outwardly to accommodate the rounded or protruding occipital area 26b of the wearer's head 24b, providing a more secure and comfortable fit to the wearer.

Referring to Fig. 9, a second exemplary embodiment of a headband is shown generally at 100. The headband 100 includes a fixed distance adjustment section 102 connected to the nape-belt section 16 and a horizontal section 14 of the headbandlOO to improve the fit, function, stability and comfort of the headband 100. The nape-belt section 16 includes a narrowed portion 104, or neck, connecting the nape-belt section 16 to the horizontal section 14, forming a recess. Depending from a rear portion of the horizontal section 16 and into the recess is an adjustment structure 106 with a mating formation, such as a pin, extending inwardly therefrom. A receiving structure 108 extends from the nape-belt section and into the recess, towards the horizontal section and the depending support structure 104. The mating formation of the support structure 104 is received in to one of a number of reciprocal mating formations 110, such as adjustment holes, on the receiving structure 106, whereby deflection of the nape-belt 16 relative to the horizontal section 14 is fixed at a desired fit for the wearer.

Referring to Fig. 10, a third exemplary embodiment of a headband is shown generally at 200. The headband 200 includes a spring 202 connected to the nape-belt section 16 and a horizontal section 14 of the headband200 to improve the fit, function, stability and comfort of the headband 200. The nape-belt section 16 includes a narrowed portion 204, or neck, connecting the nape-belt section 16 to the horizontal section 14, forming a recess. Because the neck 204 on the nape-beit section 16 is narrowed it provides flex to the nape-beit section 16. The spring 202 extends across the recess formed in the nape-belt sectionl6 to the horizontal section 14, connecting the two sections 14,16together. The spring 202 buffers the tension between the headband 200 and the head and more equally distribute pressure across the head.

Referring to Fig. 11, a fourth exemplary embodiment of a headband is shown generally at 300. The headband 300 includes an elastic rubber layer 302 connected to the nape-belt section 16 and a horizontal section 14 of the headband300 to improve the fit, function, stability and comfort of the headband 300. The nape-belt section 16 includes a narrowed portion 304, or neck, connecting the nape-belt section 16 to the horizontal section 14, forming a recess. Because the neck 304 on the nape-belt section 16 is narrowed it provides flex to the nape-belt section 16. The elastic rubber layer 302 extends across the recess formed in the nape-belt section 16, bridging the nape-belt section 16 and the horizontal section 14. The spring-like action of the elastic rubber layer 302 buffers the tension between the headband 300 and the head and more equally distribute pressure across the head.

In summary, it can be appreciated from the foregoing description and illustrations that the shape and position of the nape-bet section 16is such that it gently cups the head below the equatorial region of the head and gently grips around the mastoid bone area {occipital area) creating a more secure fit for various shaped heads. The nape-belt sectionl6 configuration is completely passive and requires no additional effort by the end user to use or adjust, once the adjustment mechanisms 14a, 18 are set to the appropriate width. The adjustmentmechanisms 14a, 18are the same as currentl known by the user and thus requires no additional training. In use, the nape-belt section 16defiects the appropriate amount depending on the shape of the wearer's head. The nape-belt sectionl6 is self-adjusting and aligning allowing it to gently conform in shape to the user's head and seat itself in a manner that equally distributes contact and pressure on the rear of the user's head. Because the nape-belt section 16 works in a cupping manner securely below the equatorial region of the head, it provides a secure fit and feeling with far less tension and pressure than a standard headgear arrangement.

Accordingly, among the objectives of the improved headbandare to provide a headband that improves fit, function, stability and comfort; to provide flexible headband that can fit more head contours, to provide a flexible nape -belt of a head band that micro-adjusts to meet various kinds of head shapes on the rear part of head contours;to provide dynamic and self-adaptive adjustment happening at the same time of head movement, especially head extension, which can reduce most interferences and discomforts, and maintain stability in these extreme movement; to provide a headband that reduces the discomfort caused by ill-fitting for an improved wearing experience especially during long-term wearing; and to provide a headband which is readily adaptable to both new headgear and headgear already deployed in the field and in various industries and consumer endeavors.

For these reasons, the present flexible headbandwith self-adaptive functions is believed to represent significant advancements in the art, which have substantial commercial merit.

While there is shown and described herein certain specific structure

embodying the flexible headband, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claim.