Abstract
A replacement rear strap assembly is provided for use on a helmet that has a headgear assembly. The headgear assembly has a front strap, a top strap, a pair of hubs between the front strap and top strap, and a pair of connection bosses extending from the pair of hubs. The replacement rear strap assembly includes a pair of adapter rings and a replacement strap extending between the pair of adapter rings. In some embodiments, each of the pair of adapter rings includes an adapter ring aperture. In some embodiments, each of the adapter ring apertures is sized and configured to be placed over a corresponding one of the pair of connection bosses.
Claims
1. A replacement rear strap assembly for use on a helmet that includes a headgear assembly that has a front strap, a top strap, a pair of hubs between the front strap and top strap, and a pair of connection bosses extending from the pair of hubs, the replacement rear strap assembly comprising: a pair of adapter rings; and a replacement strap extending between the pair of adapter rings.
2. The replacement rear strap assembly of claim 1, wherein each of the pair of adapter rings comprises an adapter ring aperture.
3. The replacement rear strap assembly of claim 2, wherein each of the adapter ring apertures is sized and configured to be placed over a corresponding one of the pair of connection bosses.
4. The replacement rear strap assembly of claim 3, wherein each of the pair of connection bosses is D-shaped.
5. The replacement rear strap assembly of claim 4, wherein each of the adapter ring apertures is D-shaped.
6. The replacement rear strap assembly of claim 1, wherein the replacement strap comprises stretchable fabric.
7. The replacement rear strap assembly of claim 1, wherein the headgear assembly further comprises a standard rear strap that extends between the pair of hubs.
8. The replacement rear strap assembly of claim 1, wherein the headgear assembly does not include a standard rear strap extending between the pair of hubs.
9. A method for adding a replacement rear strap assembly to a helmet that includes a standard headgear assembly that has a pair of hubs, a front strap extending between the pair of hubs, and a standard rear strap extending between the pair of hubs, the method comprising the steps of: removing the standard headgear assembly from the helmet; removing the standard rear strap from the standard headgear assembly to provide a modified headgear assembly; connecting the replacement rear strap assembly to the modified headgear assembly; and connecting the modified headgear assembly and replacement rear strap assembly to the helmet.
10. The method of claim 9, wherein the standard headgear assembly further comprises a pair of attachment bosses each extending from a corresponding one of the pair of hubs, and wherein the step of connecting the replacement rear strap assembly further comprises connecting an adapter ring of the replacement rear strap assembly over each of the pair of attachment bosses.
11. The method of claim 10, wherein the step of removing the standard rear strap from the standard headgear assembly further comprises severing the standard rear strap from the pair of hubs on the standard headgear assembly.
12. The method of claim 11, wherein the step of connecting the modified headgear assembly and replacement rear strap assembly to the helmet further comprises connecting the modified headgear assembly to the helmet with fasteners.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 provides a partial cutaway depiction of a PRIOR ART welding helmet with headgear assembly.
[0015] FIG. 2 is a perspective view of the PRIOR ART headgear assembly of FIG. 1.
[0016] FIG. 3 is a close-up view of the rear strap and adjustment mechanism from the PRIOR ART headgear assembly of FIG. 2.
[0017] FIG. 4 depicts a portion of the headgear assembly modified in accordance with an exemplary embodiment of the present invention.
[0018] FIG. 5 depicts an adapter ring and replacement strap of the replacement strap assembly.
[0019] FIG. 6 depicts the replacement strap assembly of FIG. 5 connected to the modified headgear assembly of FIG. 4.
[0020] FIG. 7 provides a top view of the replacement strap assembly and modified headgear assembly within the helmet.
[0021] FIG. 8 provides rear perspective view of the replacement strap assembly and modified headgear assembly within the helmet.
[0022] FIG. 9 depicts a welder wearing the helmet with the replacement strap assembly.
[0023] FIG. 10 depicts a rear view of the replacement strap assembly in accordance with an exemplary embodiment of the present invention.
[0024] FIG. 11 depicts two adapter rings and a strap clip in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0025] In accordance with an exemplary embodiment, FIG. 4 depicts a modified headgear assembly 100. The modified headgear assembly 100 includes the front strap 208, top strap 212, hubs 214 and attachment bosses 230 common to the prior art standard headgear assembly 206, but the standard rear strap 210 and rear strap adjustment mechanism 218 have been removed. In some embodiments, the standard rear strap 210 can be removed simply by severing the standard rear strap 210 from both hubs 214. Scissors, utility knives or other cutting tools can be used to remove the standard rear strap 210 from the hubs 214. In other embodiments, a standard headgear assembly 206 may be modified during initial manufacture to omit the standard rear strap 210.
[0026] FIGS. 5-7 depict a replacement rear strap assembly 102. The replacement rear strap assembly 102 includes a pair of adapter rings 104 and a replacement strap 106 that extends between the pair of adapter rings 104. In some embodiments, a 3-D printing process is used to create each adapter ring 104 from any material suitable for a 3-D printer. In a preferred embodiment using a 3-D printing process, each adapter ring 104 is made from polycarbonate. It will be appreciated, however, that each adapter ring 104 may be made by any other suitable manufacturing processes and materials. Further, each adapter ring 104 may be made through the combination of one or more processes and from one or more materials. For example, each adapter ring 104 may be made from any suitable plastic, metal, wood, fabric or textile or any combination thereof.
[0027] Each adapter ring 104 includes an adapter ring aperture 108 that is designed to fit around a corresponding one of the attachment bosses 230. As illustrated in FIG. 4, the attachment boss 230 is “D-shaped” and as illustrated in FIG. 5, the adapter ring aperture 108 is congruently “D-shaped” and sized to closely fit over the attachment boss 230, such that the adapter ring aperture 108 corresponds to the outer perimeter of the attachment boss 230. It will be appreciated, however, that the adapter ring aperture 108 can be configured in any shape to match or accommodate the outer perimeter of a corresponding attachment boss 230, which may take on a variety of shapes and configurations.
[0028] Each adapter ring 104 further includes an upper surface 105, a lower surface 107 positioned opposite of the upper surface 105, and outer side surfaces 109 that extend from edges of the upper surface 105 to corresponding edges of the lower surface 107 and define an outer perimeter of the adapter ring 104. As shown in FIG. 11, the upper surface 105 may include a fillet 111 at its edges. In some embodiments, the fillet 111 is between 1 mm to 2 mm in width. In several embodiments, the fillet 111 is 1.2 mm in width. As illustrated in FIGS. 5-6 and FIGS. 10-11, the outer perimeter of each adapter ring 104 may be a streamlined shape with obtuse angles, curves, and straight edges.
[0029] Notwithstanding these exemplary embodiments, it will be appreciated that the outer perimeter of each adapter ring 104 can be configured in any shape or size to accommodate the adapter ring aperture 108. In some embodiments, the outer perimeter may include sharp angles rather than curves. As illustrated in FIG. 11, each adapter ring 104 may have a shape and size mirroring that of the other. However, it is appreciated that the adapter rings 104 in some embodiments can have a different shape and size from each other.
[0030] Each of the adapter rings 104 can include a strap slit 110 that is sized to permit the replacement strap 106 to be passed through the strap slit 110. In some embodiments, the strap slit 110 has a height that the same as the width of the replacement strap 106. In other embodiments, the strap slit 110 has a height that is greater than the width of the replacement strap 106. In a first preferred embodiment, the replacement strap 106 has a width of 2 inches. In a second preferred embodiment, the replacement strap 106 has a width of 1.5 inches. The replacement strap 106 of FIGS. 7 and 10 may be manufactured to any width and length that is suitable for securely fastening the modified headgear assembly 100 to a user's head during use. The replacement strap 106 has a short end 114 that passes through the strap slit 110 of a first adapter ring 104 and is then attached by stitching or by other suitable attachment devices, such as adhesive, snaps, buttons, clips or other closure mechanisms, to a first position on the replacement strap 106 that is proximate to the first adapter ring 104. The replacement strap 106 of FIGS. 7 and 10 also has a long end 116 that passes through the strap slit 110 of a second adapter ring 104 and is then attached by stitching or by other suitable attachment devices to a second position on the replacement strap 106 that is distant from the second adapter ring 104.
[0031] As illustrated in FIGS. 7 and 10, the replacement strap 106 can include a strap clip 112 that permits the replacement strap 106 to be lengthened or shortened. It is understood, however, that other mechanisms may be used to permit the replacement strap 106 to be lengthened or shortened, such as a hook and loop fastener or a double ring closure. In some of the embodiments, a 3-D printing process is used to create the strap clip 112 from any material suitable for a 3-D printer. In a preferred embodiment using a 3-D printing process, the strap clip 112 is made from polycarbonate. It will be appreciated, however, that the strap clip 112 may be made by any other suitable manufacturing processes and materials and, in fact, may be made through the combination of one or more processes and from one or more materials. For example, the strap clip 112 may be made from any suitable plastic, metal, wood, fabric or textile or any combination thereof. As shown in FIG. 11, the strap clip 112 may have two strap apertures 113 that are sized to permit the replacement strap 106 to be passed through the strap apertures 113. In other embodiments, the strap clip 112 may instead have only one strap aperture 113. In several embodiments, the replacement strap 106 may have multiple strap clips 112. For example, the replacement strap 106 may have two strap clips 112, each strap clip 112 having only one strap aperture 113. The strap clip 112 may also include a fillet 111 at its edges. In some embodiments, the fillet 111 is between 1 mm to 2 mm in width. In several embodiments, the fillet 111 is 1.2 mm in width.
[0032] In some embodiments, the replacement strap 106 is manufactured from an elastic material that stretches in one or more directions. Suitable strap material is commonly found in the straps used on standard ski goggles and headlamps. In some embodiments, the replacement strap 106 may include a non-slip silicone strip. In several embodiments, an additional reinforcing material, such as leather or rubber, may be used to provide more structure to the replacement strap 106. The replacement strap 106 may be patterned, colored, or textured to alter the visual appearance.
[0033] As illustrated in FIGS. 7-9, the replacement rear strap assembly 102 is attached to the modified headgear assembly 100 by removing the standard headgear assembly 206 from the helmet 200, removing the standard rear strap 210 from the standard headgear assembly 206 to provide the modified headgear assembly 100, securing the replacement rear strap assembly 102 to the modified headgear assembly 100 by placing each of the adapter rings 104 over a corresponding one of the attachment bosses 230, and then attaching the modified headgear assembly 100 to the face shield 202 with the fasteners 222. In this way, the adapter rings 104 are captured on the attachment bosses 230 between the hubs 214 and the interior of the face shield 202. The attachment bosses 230 on worn-out or older headgear may develop rough edges that make it difficult to slide hardware over the outer perimeter of the attachment bosses 230. Therefore, depending on the condition of the standard headgear assembly, it may be necessary to sand or file down these rough edges on the attachment bosses 230 before placing each of the adapter rings 104 over a corresponding one of the attachment bosses 230. It will be appreciated that the fasteners 222 may be made from any suitable material, including but not limited to metal, plastic, or wood. In most embodiments, the outer side surfaces 109 of the adapter rings 104 have approximately the same width as the side surfaces 234 of the attachment bosses 230, such that the adapter rings 104 are captured tightly between the hubs 214 and the interior of the face shield 202 during use. In other embodiments, the outer side surfaces 109 of the adapter rings 104 have a smaller width than the side surfaces 234 of the attachment bosses 230, such that the adapter rings are more loosely captured between the hubs 214 and the interior of the face shield 202. The replacement rear strap assembly 102 provides an inexpensive, durable, and comfortable modification to the standard rear strap 210 found in conventional headgear assemblies.
[0034] Although the use of the replacement rear strap assembly 102 has been illustrated in connection with the welding helmet 200, it will be understood that the replacement rear strap assembly 102 can also be used on other hats and helmets, including, but not limited to, hard hats, climbing helmets, ski helmets, bicycle helmets, and motorcycle helmets. Additionally, although the replacement rear strap assembly 102 is designed to replace the standard rear strap 210 of the standard headgear assembly 206, it will be appreciated that the replacement rear strap assembly 102 can be used in addition to, and without removing, the standard rear strap 210. In some embodiments, the standard headgear assembly 206 or modified headgear assembly 100 may not include attachment bosses 230. For those applications, the adapter rings 104 can otherwise be connected to the modified headgear assembly 100 or standard headgear assembly 206 using the fasteners 222 and a smaller adapter ring aperture 108.
[0035] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.
