Specifically, the present invention provides for a headband for protective headgear, that allows rapid one-hand size adjustment, without the use of a ratchet, while the hard hat remains on a user's head.

Background of the Invention Protective helmets are commonly worn by people such as firefighters, construction workers, and athletes to shield their heads from flying or falling objects. The helmet usually includes a rigid protective shell of impact resistant material For some applications, the helmets may also include visors or face shields to protect the eyes or the entire face of the wearer, and may further include a respirator to protect the wearer's respiratory system.

Various government agencies and industry organizations define certain requirements and standards for protective gear, including helmets. In the United States, for example, the National Institute of Occupational Safety and Health (NIOSH) certifies certain safety equipment for the workplace and the American National Standards Institute (ANSI) recommends voluntary consensus industry standards. Other agencies and organizations around the world also establish safety standards for helmets. For protective helmets, some of these standards relate to impact energy attenuation, penetration resistance, force transmission, stiffness, flammability, and head coverage.

To meet these safety requirements and standards, protective helmets usually comprise a rigid outer shell of metal or plastic and a suspension system inside the shell. The suspension system serves many purposes, including providing a proper fit of the helmet to the wearer's head, holding the inner part of the helmet

away from the wearer's head, distributing the weight of the helmet over a larger area of the wearer's head, and attenuating the force transferred to the wearer's head upon impact of an object with the outer helmet shell. Suspension systems often comprise a headband attached to a crown support assembly which includes crisscrossing crown straps and sometimes, a crown pad. In some applications, however, additional protection may be desired. In these situations, a foam liner may be provided between the inner shelf and suspension of the helmet to provide additional impact protection.

Most types of protective headgear worn by workers to protect them from falling objects are held on the worker's head by a suspension system. The suspension system, along with the helmet itself, act to absorb the shock of a falling object striking the worker's head. The suspension system is also used to hold the helmet on the worker's head.

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 interior circumference of the helmet. A band is then 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's head, it is essential that the circumference of the headband be adjustable to fit the appropriate head size.

A napestrap is often attached at one end of the band to achieve these results.

In one type of standard adjustment means, commonly referred to as the"pin- lock"system described in U. S. Pat. No. 3,500, 474, the disclosure of which is incorporated herein by reference, an adjustable napestrap is manually adjusted by the wearer. This system is similar to a standard baseball cap.

The two ends of the napestrap are connected and held in place by a slot- and-teeth arrangement. One end of the napestrap is formed with parallel rows of teeth. The other end of the napestrap is formed with parallel rows of slots.

The size of the suspension can be adjusted by inserting the teeth of one end

of the strap into the slots formed in the other end of the strap at the desired length. Helmets using the pin-lock system generally must be removed from the head for adjustment. Adjustment is by way of trial and error, and further usually requires two hands to accomplish.

In another common system, entitled the ratchet system, as described in U. S.

Pat. No. 4,942, 628, the disclosure of which is incorporated herein by reference, has an adjustable napestrap wherein the ends of the strap are connected, held in place, and adjusted by a ratchet mechanism. The ratchet mechanism generally operates on a gear-and-teeth or rack-and-pinion arrangement. The adjustment knob of the ratchet mechanism has attached to it at one end of a set of cog teeth. These teeth are positioned inside a lateral section of the napestrap. The lateral section of the napestrap has rows of teeth formed along the inside of slots therein. By placing the cog teeth in contact with the slot, the size of the napestrap can be adjusted by turning the knob one direction to pull the strap ends closer together, or turning the knob the other direction to force the ends apart. A spring-activated detent mechanism is typically included to resist undesirable rotation of the adjustment knob.

In some situations the ratchet-type suspension is preferred over the slot-and-teeth suspension because the ratchet-type suspension generally can be adjusted more easily while on the head of the worker. There are, however, certain disadvantages to ratchet-type suspensions. For example, ratchet suspensions often have numerous component parts that must be assembled to operate the ratchet. The number of parts and the labor required to assemble the parts is quite costly.

Finally, ratchet-type suspensions sometimes do not prevent loosening of the headband after the user has adjusted the headband to the size of the user's head. In that regard, during normal use, protective headgear often experiences forces that tend to expand the size of or loosen the headband.

Unless the ratchet mechanism provides suitable resistance to such forces, the headband will loosen, requiring constant adjustment by the user.

It is, therefore, desirable to provide an easily adjustable headband, without a ratchet mechanism, that is inexpensive to make and assemble and can be easily tightened, while still providing adequate resistance to loosening of the headband during use thereof.

Summary of the Invention The present invention provides a suspension system that may be interchangeable between helmets having liners and helmets without liners.

The suspension system is provided with connectors for attaching the suspension system to helmets and for properly positioning the suspension system and helmet on a wearer's head.

In one aspect of this invention, a suspension system for a helmet is provided, wherein the suspension system comprises a crown support assembly having a center portion and a plurality of strap portions extending radially from the center portion. The suspension system further comprises a headband and a plurality of connectors, wherein at least one of the plurality of connectors comprises an anchor portion for attaching the suspension system to a helmet, a first support member extending from the anchor portion and attached to one of the plurality of strap portions, a second support member spaced from the first support member, extending from the anchor portion, and attached to the headband.

The present invention also provides an adjustable headband. The adjustable headband comprises a band having a first end and a second end which overlap. The first end has a first elongated slot, and the second end has a second elongated slot. The first elongated slot and the second elongated slot are in general alignment when the first end and the second end of the band overlap. A first row of teeth is formed in a first edge of the first elongated slot,

while a second row of teeth is formed in a second edge of the second elongated slot. The first row of teeth preferably oppose the second row of teeth.

The adjustable headband further comprises two protruding tabs, on different parts of the band thereby providing gripping members to assist a user with adjusting the bands. The two tabs can both be grasped simultaneously by one hand of a user and squeezed together, thus reducing the size of the headband to the appropriate size.

Brief Description of the Drawings Figure 1 is a perspective view of a headband.

Figure 2 is a perspective view of the suspension assembly installed in a hard hart shown from the outside in the engaged position; Figure 3 is a perspective view of the suspension assembly installed in a hard hat shown from the inside in the disengaged position.

Detailed Description of the Invention In order to more clearly understand the present invention part numbers as assigned in the following parts list will be used: Part Number Description 10 Helmet 12 Inner Shell 14 Outer Shell 16 Suspension Assembly 22 Slots 30 Straps 32 Headband 33 First End of Headband

34 Connectors 35 Second End of Headband 38 Center Area 40 Tabs Referring now to the Figures, wherein the components are labeled with like numerals throughout the several Figures, and initially to FIG. 2, one preferred embodiment of a helmet 10 is illustrated, which basic components include an inner shell 12, a rigid outer shell 14 spaced from inner shell 12, and a helmet suspension assembly 16.

FIG. 1 shows the headband 32 removed therefrom. Multiple slots 22 are provided for engagement with the suspension assembly 16, as described below.

With additional reference now to FIG. 3, the helmet suspension assembly 16 generally comprises an adjustable headband 32, and a plurality of connectors 34 for releasably attaching the suspension assembly 16 to helmet 10.

Preferably, four flexible strap portions 30 are used, however any suitable number of straps that can properly support the helmet on the wearer's head may be used. Straps 30 are preferably constructed of a strong web material, such as nylon, and are arranged for resting comfortably on a wearer's head.

As illustrated, the four strap portions 30 preferably extend radially from a center area 38. In the embodiment shown, a single piece of strap material is sewn and arranged in one possible configuration. However, the straps may instead comprise multiple pieces of material attached to each other, such as by sewing. Other configurations of straps or strap portions arranged into a cap or crown support are also considered to be within the scope of the present invention.

A crown pad (not shown) may also be provided in the center area of the cap, and may be connected thereto, to provide additional comfort and cushioning between the straps 30 and the wearer's head.

In order to properly position the helmet 10 on the wearer's head, it is preferable that headband 32 is adjustable in circumference to accommodate various head sizes and shapes. In addition, it is preferable that the headband 32 be made of a flexible material, such as polyethylene, polypropylene, polyester, polyvinyl, and the like, that can easily conform to the size and shape of the wearer's head. The headband 32 may also include a sweat band or covering (not shown) to increase the comfort of the wearer.

The headband 32 is attached to the helmet 10 by the connectors 34 that may also be used to attach the suspension assembly 16 to helmet 10. More specifically, connectors 34 are used both to attach the straps 30 to the headband 32, and to removably attach the entire suspension assembly 16 to the helmet 10. Thus, there should be one connector 34 corresponding to each strap in order to connect the shell (12 and 14) to the headband 32. In the illustrated embodiment, there are four connectors 34 to correspond to the four strap portions 30.

In operation, the suspension system is mounted in a helmet that may or may not have a liner by simply sliding the anchor portion (not shown) of each of the connectors 34 into a corresponding slot in the periphery of the helmet so that the connector locks in place. The suspension system is then secured to the helmet. The suspension system may be removed from the helmet by pulling the connectors from their corresponding slots. The suspension system may then be reinstalled in another or the same helmet, with or without a liner, by repeating the above process.

The head suspension should be flexible to easily conform to the wearer's head and should be light and comfortable. The helmet is preferably manufactured from plastic, such as a thermoplastic, a thermoset, or an elastomeric material. Thermoplastic material is the most preferred. Helmet 10 can be manufactured by molding, preferably by injection molding.

Various optional features may be included in head suspension 16 to increase the wearer's comfort, to improve worker conditions, and to provide a secure fit of the head suspension onto the wearer's head. For example, headband 32 and any straps 30 may be padded to provide a more comfortable and conformable fit. Low-density foam is a preferred material. Headband 32, in particular the forehead portion, may include an absorbent material, for example terry cloth or other'sweatband'type material to absorb perspiration.

It may be preferable that the absorbent material is easily removable and replaceable throughout the useful life of the headband 32.

In order for the improved head suspension to optimally function the helmet should securely fit onto the wearer's head. The helmet should not rotate, slide, or otherwise undesirably move in relation to the head. An adjustable headband and crown improves the secureness of the fit.

The headband 32 has a first end 33 and a second end 35. Each of the two ends are appropriately sized and configured to be releasably interconnected with each other. To fasten the two ends 33 and 35 of the headband 32 together, the first end 33 is inserted into the second end 35. The operation is similar to engaging the two ends of a belt. Once the two ends are engaged they can be locked in place by engaging a series of closely-spaced teeth or notches on each end. The rows of teeth are opposed so they interlock. The system is designed to lock in place and resist the two ends sliding apart once the helmet is on a user's head. The configuration does allow the two ends of the headband to easily slide together for adjustment, thereby reducing the total circumference of the adjusted headband.

To assist with adjusting the headband 32 tabs 40 are provided that protrude from appropriately placed locations on each end 33 and 35, of the headband. Each end is provided with its own headband tab 40.. In this manner a user can grasp two tabs 40 with one hand and squeeze them together to easily adjust the size of the cap while on the head.

To enlarge the size of the headband the two ends of the headband 33 and 35 must be bent so that the curvature is opposite the curvature of the headband when normally worn so that the interlocking teeth release allowing the two ends to easily slide apart.

In addition to increasing comfort, foam padding can conform the head suspension to the wearer's head. The compressible foam is typically able to compensate for extra space between the headband and the wearer's head.

A chinstrap can be added to the head suspension to improve the stability on the wearer's head.

The helmet 10 described above is typically worn by a person to shield his or her head from falling or flying objects. However, the helmet may also be provided with additional features for different environments and applications.

For one example (not shown), the helmet may be used in a respirator assembly which includes a face shield, a welding shield, or the like for protecting the eyes and respiratory system of the. wearer. In this example, the helmet of the respirator typically has a generally dome-shaped passageway or chamber between the inner and outer shells of the helmet, a rear opening or receptacle designed to accept an air supply hose, and a front opening designed to allow the supplied air to escape into the face area and breathing zone of the wearer. Thus, it will be appreciated by those skilled in the art that the suspension system of the present invention may be used in many different applications where a person's head needs protection.

The present invention has now been described with reference to several embodiments thereof. The foregoing detailed description has been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by the structures described by the language of the claims and the equivalents of those structures.