Hard Hat with Impact Protection Layer

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

The present application claims the benefit of and priority to U.S. Provisional Application No. 63/725,282 filed on Nov. 26, 2024, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of protective equipment. The present invention relates specifically to various construction/work hard hat designs constructed with materials and/or layers to provide added protection to a user's head from impacts that could otherwise impart harmful forces to a wearer's head.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a protective helmet. The protective helmet includes an outer shell and an impact protection layer. The outer shell includes an exterior surface and an interior surface defining a cavity. The impact protection layer is positioned within the cavity and includes a plurality of projections spaced apart from each other and a plurality of connectors that attach each of the plurality of projections to one or more of the other plurality of projections. The protective helmet further includes a first bracket coupled to the outer shell and positioned along the interior surface of the outer shell. The first bracket includes a plurality of bores, each of the plurality of bores receives a portion of one of the plurality of projections.

Another embodiment of the inventions relates to a protective helmet. The protective helmet includes an outer shell and an impact protection layer. The outer shell includes an exterior surface, an interior surface defining a cavity, a crown portion positioned in a central area of the protective helmet, and a bottom segment defining a lower circumference. The impact protection layer is positioned within the cavity and includes a plurality of projections. Each of the plurality of projections has a tapered shape. The protective helmet further includes a perimeter bracket coupled to the outer shell and positioned along the interior surface of the outer shell. The impact protection layer is coupled to the outer shell via the perimeter bracket.

Another embodiment of the inventions relates to a protective helmet. The protective helmet includes an outer shell formed from a rigid material and an impact protection layer. The outer shell includes an exterior surface, an interior surface defining a cavity, a crown portion positioned in a central area of the protective helmet surrounding a center point, and a bottom segment defining a lower circumference. The impact protection layer is positioned within the cavity and includes a plurality of projections. The plurality of projections include a plurality of outer projections positioned along the bottom segment, a plurality of middle projections, a plurality of crown projections positioned in the central area, and a center projection. The plurality of middle projections are positioned between the plurality of crown projections and the plurality of outer projections. The plurality of crown projections are positioned between the center projection and the plurality of middle projections. The protective helmet further includes a bracket coupled to the outer shell and positioned along the interior surface of the outer shell. The impact protection layer is coupled to the outer shell via the bracket.

Additional features and advantages will be set forth in the detailed description which follows, and will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and/or shown in the accompany drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a perspective view of a hard hat on the head of a wearer, according to an exemplary embodiment.

FIG. 2 is a rear perspective of the hard hat shell of FIG. 1, according to an exemplary embodiment.

FIG. 3 is a bottom perspective view of the hard hat shell of FIG. 1, according to an exemplary embodiment.

FIG. 4 is a bottom view of a hard hat, according to another exemplary embodiment.

FIG. 5 is a detailed view of an impact layer for a hard hat, according to an exemplary embodiment.

FIG. 6 is a bottom perspective view of a hard hat, according to another exemplary embodiment.

FIG. 7 is a bottom view of a hard hat, according to another exemplary embodiment.

FIG. 8 is a cross-sectional view of the hard hat of FIG. 7 taken along line 8-8, according to an exemplary embodiment.

FIG. 9 is a detailed view of the impact layer for a hard hat of FIG. 7, according to an exemplary embodiment.

FIG. 10 is a is a detailed view of an impact layer for a hard hat, according to another exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a protective work/construction helmet, shown as a hard hat are shown. Various embodiments of the hard hat discussed herein include various impact layer designs that provide an improved ability to absorb impacts (e.g., force of impact of falling objects, lateral impact of objects, impact from tripping/falling) while being light weight. In various embodiments, the impact layer is formed from a rigid material having projections that are generally cone shaped. In specific embodiments, the impact layer includes projections that have a frustoconical shape. Applicant believes the shape of the impact layer provides for the improved energy absorption and increased durability relative to conventional protective layers (e.g., expanded polystyrene (EPS) foam).

Furthermore, the design of the impact layer, and more specifically having a plurality of projections rather than a uniform layer provides increased airflow within the hard hat increasing comfort for a wearer (e.g., reduced temperature). In various specific embodiments, the impact layer is coupled to the hard hat via a bracket, shown as a perimeter bracket. The perimeter bracket is positioned along an interior surface of the hard hat. In various specific embodiments, a center bracket is positioned on a side of the impact layer opposing the perimeter bracket. Applicant believes compared to conventional hard hat attachments that may require permanent couplers such as screws, hot melt adhesive, etc. the coupling of the impact layer discussed herein allows for secure attachment between the hard hat and impact layer without using couplers such as screws that may make replacing the impact layer difficult. In contrast, in various embodiments discussed herein, the perimeter bracket and center bracket have a snap fit design to couple to the hard hat and/or impact absorbing layer.

Referring to FIG. 1, a perspective view of a protective work or construction helmet, shown as hard hat 10, is shown according to an exemplary embodiment. Hard hat 10 includes an outer shell 12. In a specific embodiment, outer shell 12 is formed from a rigid material, such as a rigid polymer material. In various specific embodiments, outer shell 12 is formed from one of high density polyethylene (HDPE), acrylonitrile-butadine-styrene (ABS), polycarbonate (PC), polycarbonate/acrylonitrile-butadine-styrene (PC-ABS), and polypropylene (PP). Outer shell 12 includes an exterior surface 14 and an interior surface 16 (see e.g., FIG. 3). Interior surface 16 defines a cavity 18 (see e.g., FIG. 3) sized to receive a head of a user and/or wearer 20. Outer shell 12 includes a crown portion 22 and a bottom segment 24 defining a lower circumference of hard hat 10. In various embodiments, crown portion 22 is positioned in a central area of the hard hat 10 surrounding a center point. In various embodiments, a brim 26 extends radially outward from a portion of the lower circumference. In a specific embodiment, brim 26 extends radially outward from the front 28 of hard hat 10 and specifically outer shell 12.

Hard hat 10 includes a suspension system 30 and a chin strap 32 to support and secure hard hat 10 to the wearer's 20 head. In specific embodiment, outer shell 12 includes a plurality of apertures or vents 34. Vents 34 extend through outer shell 12 providing fluid communication between cavity 18 and the ambient air proximate to exterior surface 14 of outer shell 12. Outer shell 12 further includes recess 25 positioned between front 28 and rear 68 (see e.g., FIGS. 2-3) of hard hat 10 proximate to the ears of wearer 20. In a specific embodiment, recess 25 extends a height above a portion of bottom segment 24 proximate to front 28 and/or rear 68 of hard hat 10.

In various embodiments, hard hat 10 includes one or more mounting ridges configured to couple to and/or support hard hat accessories. A side accessory support ridge or auxiliary mounting ridge 36 is coupled to a lateral side of outer shell 12 along the bottom segment 24. In specific embodiments, hard hat 10 includes a pair of side accessory ridges along opposing lateral sides of outer shell 12. Auxiliary mounting ridge 36 includes a first end and a second end opposing the first end. A plurality of apertures or slots 38 are positioned along auxiliary mounting ridge 36 between the first end and the second end. Slots 38 are configured to receive a coupling mechanism, such as clips, or a portion of a hard hat accessory to couple the accessory to outer shell 12. Auxiliary mounting ridge 36 supports accessories for hard hat 10, such as ear muffs, tool or eyeglass holders, lamp supports, face shields, and/or reflectors, etc.

Hard hat 10 further includes a front mounting ridge 56 positioned on the front 28 of outer shell 12. Front mounting ridge includes a right edge 58 protruding outwardly from the front mounting ridge 56 and a left edge 60 opposing the right edge and protruding outwardly from the front mounting ridge 56. In a specific embodiment, front mounting ridge 56 includes a detent (see e.g., 62 in FIG. 2) positioned between the right edge 58 and the left edge 60 and configured to interface with an accessory mounting bracket 64 (see e.g., FIG. 1) and/or an accessory. The right edge 58 and left edge 60 of the front mounting ridge 56 each extend toward the bottom segment 24 of the outer shell 12. The right edge 58 and left edge 60 each include a portion with an increased width as the right edge 58 and left edge 60 approach the bottom segment and/or the brim 26.

Referring to FIGS. 2-3, hard hat 10 is shown according to an exemplary embodiment. A hard hat system and/or hard hat 10 includes an impact absorbing portion, shown as impact absorbing layer or impact protection layer 140 (see e.g., FIG. 4), is positioned within outer shell 12 and specifically within cavity 18. Interior surface 16 of outer shell 12 at least partially defines cavity 18 which receives and supports an impact absorbing layer 140. In various embodiments, the hard hat 10 includes a second or rear mounting ridge 66 located along at the rear 68 of the hard hat 10. This allows a user to attach accessories and/or accessory mounting brackets to both the front 28 and rear 68 of hard hat 10. Rear mounting ridge 66 is substantially the same as front mounting ridge 56.

Rear mounting ridge includes a right edge 63 protruding outwardly from the rear mounting ridge 66 and a left edge 65 opposing the right edge and protruding outwardly from the rear mounting ridge 66. In a specific embodiment, rear mounting ridge 66 includes a detent 62 positioned between the right edge 63 and the left edge 65 and configured to interface with an accessory mounting bracket 64 (see e.g., FIG. 1) and/or an accessory. The right edge 63 and left edge 65 of the rear mounting ridge 66 each extend toward the bottom segment 24 of the outer shell 12. The right edge 58 and left edge 60 each include a portion with an increased width as the right edge 63 and left edge 65 approach the bottom segment 24.

Referring to FIG. 4, details of hard hat 110 and impact absorbing layer 140 are shown according to an exemplary embodiment. Hard hat 110 is substantially the same as hard hat 10 except for the differences discussed herein. In various specific embodiments, outer shell 112 does not include vents or apertures (see e.g., 34 in FIG. 1) extending through outer shell 112.

Impact absorbing layer 140 includes a plurality of projections 142 and connectors 146 that connect projections 142. In specific embodiments, the projections 142 extend between one or more of the plurality of projections. In specific embodiments, connectors 146 extend in a radial arrangement. In various embodiments, impact absorbing layer 140 is formed from a rigid polymer material. In specific embodiments, impact absorbing layer is formed from at least one of polycarbonate (PC), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), acrylonitrile butadiene styrene (ABS), and nylon.

In various specific embodiments, the plurality of projections 142 form an array with groups of projections 142 positioned at various locations of cavity 118. In various specific embodiments, each of the plurality of projections 142 are spaced apart from adjacent projections 142. In other words, adjacent projections 142 do not interface against each other and/or are not in contact with each other. As previously discussed, impact absorbing layer 140 includes a plurality of unobstructed air channels 141 allowing for improved comfort and reduced temperatures around a user's head.

In a specific embodiment, impact absorbing layer 140 includes a plurality of outer projections 152 positioned adjacent to bottom segment 24 along interior surface 116, a plurality of middle projections 154, a plurality of crown projections 156, and a center projection 158. Middle projections 154 are positioned between crown projections 156 and outer projections 152. Crown projections 156 are positioned between middle projections 154 and the center projection 158. In various specific embodiments, the plurality of outer projections 152, the plurality of middle projections 154, and the plurality of crown projections 156 are each positioned in a generally circular arrangement along interior surface 116 of outer shell 112. Center projection 158 is positioned in a generally central position within impact absorbing layer 140 such that the crown projections 156, middle projections 154, and outer projections 342 are all positioned radially outward relative to center projection 158.

In various embodiments, the impact layer 140 includes a plurality of projections 142 that are generally cone shaped. In specific embodiment, impact layer 140 includes a plurality of projections 142 that are tapered in shape. In specific embodiments, the impact layer 140 includes projections 142 that have a frustoconical shape. In specific embodiments, the projections 142 are truncated cones. As previously discussed, Applicant believes the shape of impact layer 140 and specifically projections 142 allows for improved energy absorption while being a light weight layer.

In various embodiments, each of the plurality of projections 142 is a thin walled projection. In specific embodiments, each projection 142 has a wall thickness less than a maximum wall thickness.

As previously discussed, Applicant believes the shape of impact layer 140 and specifically projections 142 allows for improved energy absorption. In various embodiments, the impact layer 140 has a weight less than a maximum weight.

As shown in FIG. 4, a bracket shown as perimeter bracket 148 is used to couple impact layer 140 to hard hat 110. Perimeter bracket 148 is positioned along interior surface 116. In specific embodiments, perimeter bracket 148 is positioned between outer shell 112 and impact layer 140. Impact layer 140 and specifically projections 142 are held in shape (e.g., a curved shape) along interior surface 116 and within cavity 118. In various embodiments, perimeter bracket 148 is formed by injection molding. In various embodiments, perimeter bracket 148 has a snap fit design.

In specific embodiments, a center bracket 150 is coupled to one or more projections 142 to allow for mounting an additional layer or comfort liner over projections 142. In various embodiments, perimeter bracket 148 is coupled to an exterior or outward facing portion of impact layer 140 while center bracket 150 is coupled to an interior or inward facing portion of impact layer 140. In specific embodiments, center bracket 150 is coupled to at least some middle projections 154, crown projections 156, and center projection 158. In various embodiments, center bracket 150 has a snap fit design.

Referring to FIG. 5, a detailed view of impact absorption layer 140 is shown. When impact absorption layer 140 is formed, impact absorption layer 140 is molded in a flat pattern. As can be seen, connectors 146 extend outward and away from center projection 158. In specific embodiments, connectors 146 form a radial arrangement, such that connectors 146 extend radially outward from center projection 158. As previously discussed, perimeter bracket 148 supports impact layer 140 and secures impact absorbing layer 140 in shape and against interior surface of hard hat 110.

Referring to FIG. 6, details of an impact absorbing layer 240 positioned within hard hat 110 is shown according to another exemplary embodiment. Impact absorbing layer 240 is substantially the same as impact absorbing layer 140 except for the differences discussed herein.

Impact absorbing layer 240 includes a plurality of projections 242. Impact absorbing layer 240 is coupled to hard hat 110 via perimeter bracket 248. Perimeter bracket 248 includes a plurality of bores 252 sized and configured to receive a projection 242. One or more additional brackets 246 are coupled to one or more projections 242.

In specific embodiments, a second bracket shown as center bracket 250 is coupled to one or more projections 242 to allow for mounting an additional layer or comfort liner over projections 242. In various embodiments, perimeter bracket 248 is coupled to an exterior or outward facing portion of impact layer 240 while center bracket 250 is coupled to an interior or inward facing portion of impact absorbing layer 240. In other words, center bracket 250 is coupled to an interior or inward facing surface of projections 242.

In various embodiments, perimeter bracket 248 is coupled to a first end of each of the plurality of projections 242 and center bracket is coupled to a second end of each of the plurality of projections 242. In specific embodiments, the second end of the projections 242 has a reduced dimension compared to the first end. In other words, when each of the plurality of projections has a tapered shape, a first end of the projection 242 has a first dimension and the second opposing end of the projection 242 has a second dimension. In such embodiments, the second dimension is different than the first dimension. In specific embodiments, the second dimension is less than the first dimension. In specific embodiments, the first dimension and the second dimensions are diameters of the projection 242.

Referring to FIGS. 7-8, details of an impact absorbing layer 340 positioned within hard hat 110 is shown according to another exemplary embodiment. Impact absorbing layer 340 is substantially the same as impact absorbing layer 140, 240 except for the differences discussed herein.

Impact absorbing layer 340 includes a plurality of projections 342. In various embodiments, the plurality of projections 342 are generally cone shaped. In specific embodiments, the impact layer 340 includes projections 342 that have a frustoconical shape. Impact absorbing layer 340 is coupled to hard hat 110 via one or more brackets 348, 346. A perimeter bracket 348 is positioned along bottom segment 124 of hard hat 10 and includes a plurality of bores 360 sized and configured to receive a projection 342. Bracket 348 is coupled to snaps or protrusions 349 that extend inward from interior surface 116 of outer shell 112. A second bracket 346 are coupled to one or more projections 342 and positioned along the crown portion 122 of hard hat 110. Second bracket 346 includes a plurality of bores 362 sized and configured to receive a projection 342 of impact absorbing layer 340.

In a specific embodiment, impact absorbing layer 340 includes a plurality of outer projections 352 positioned adjacent to bottom segment 124 along interior surface 116, a plurality of middle projections 354, a plurality of crown projections 356, and a center projection 358. Middle projections 354 are positioned between crown projections 356 and outer projections 352. Crown projections 356 are positioned on crown portion 122 of hard hat 110 between middle projections 354 and the center projection 358. In various specific embodiments, the plurality of outer projections 352, the plurality of middle projections 354, and the plurality of crown projections 356 are each positioned in a generally circular arrangement along interior surface 116 of outer shell 112. Center projection 358 is positioned in a generally central position on crown portion 122 and within impact absorbing layer 340 such that the crown projections 356, middle projections 354, and outer projections 352 are all positioned radially outward relative to center projection 358.

In specific embodiments, a center bracket 350 is coupled to one or more projections 342 to allow for mounting an additional layer or comfort liner over projections 342. In various embodiments, perimeter brackets 348, 346 are coupled to an exterior or outward facing portion of impact layer 340 while center bracket 350 is coupled to an interior or inward facing portion of impact absorbing layer 340. In other words, center bracket 350 is coupled to an interior or inward facing surface of projections 342.

Referring to FIG. 9, details of projections 342 of impact absorbing layer 340 are shown. Unlike projections 142 of impact absorbing layer 140 that have connectors 146 that extend radially, projections 342 are produced as single, integral components. In other words, projections 342 are manufactured individually or as discrete components rather than in a connected form.

Referring to FIG. 10, details of projections 442 for an impact absorbing layer 440 are shown according to another exemplary embodiment. Impact absorbing layer 440 and specifically projections 442 can be utilized with hard hats 10, 110 and brackets 348, 346. Impact absorbing layer 440 includes a plurality of projections 442 and connectors 446 extending between and connecting adjacent projections 442. Projections 442 and connectors 446 are produced in a strip arrangement. In other words, projections 442 are arranged in a line (e.g., linear, curved line, etc.).

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.

Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one.

For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.