Hard hat and face shield

Abstract

A face protection system is provided in the form of a face shield attachable to a hard hat. An upper portion of the face shield includes at least one loop surrounding at least a portion of an opening. The opening is sized to allow at least a portion of a dome of the hard hat to fit upward therethrough, but small enough to keep the entire hard hat from passing therethrough, so that the upper portion of the face shield rests upon the hard hat. A mask extends down from the upper portion of the face shield and preferably includes a plurality of columns on a front side thereof in front of a face of a wearer of the hard hat. Preferably ribs extend laterally between the columns, with the columns and ribs together forming the mask. A visor can optionally be placed inboard of the mask.

Claims

1. A face protection system, comprising in combination: a hard hat having a dome and a brim, with a crease between said dome and said brim, said crease defining a transition angle between an outer surface of said dome and an upper surface of said brim, said brim extending to an edge defining a perimeter of said hard hat; at least one loop surrounding a majority of an opening, said opening at least as large as a portion of said dome, said opening smaller than said perimeter of said hard hat; said dome positioned at least partially up into said opening with said loop against and resting upon said hard hat; a mask coupled to said loop and extending down from said at least one loop, said mask located on a front side of said hard hat to protect from impacts coming from a forward direction; and wherein said opening is larger than all of said dome, such that said dome fits entirely up into said opening, at least portions of said brim larger than said opening, such that said brim cannot fit up through said opening and said at least one loop rests at least partially upon said brim of said hard hat.

2. The system of claim 1 wherein said opening matches said crease in size and shape.

3. The system of claim 1 wherein said at least one loop completely surrounds said opening.

4. The system of claim 1 wherein a chin strap is coupled to portions of said at least one loop at at least two locations on lateral sides of said hard hat, said chin strap having a length to extend under a chin of a wearer of the hard hat.

5. The system of claim 1 wherein a visor is removably attachable inboard of said mask.

6. A face protection system, comprising in combination: a hard hat having a dome and a brim, with a crease between said dome and said brim, said crease defining a transition angle between an outer surface of said dome and an upper surface of said brim, said brim extending to an edge defining a perimeter of said hard hat; at least one loop surrounding a majority of an opening, said opening at least as large as a portion of said dome, said opening smaller than said perimeter of said hard hat; said dome positioned at least partially up into said opening with said loop against and resting upon said hard hat; a mask coupled to said loop and extending down from said at least one loop, said mask located on a front side of said hard hat to protect from impacts coming from a forward direction; wherein said at least one loop completely surrounds said opening; and wherein said at least one loop defines a first loop, with a second loop coupled to said first loop and located outboard of said first loop, said second loop sized larger than said first loop and located below said first loop, and with said mask connected to said second loop and coupled to said first loop through said second loop.

7. The system of claim 6 wherein said mask includes a plurality of columns extending down from said second loop.

8. The system of claim 7 wherein a plurality of ribs extend laterally between said plurality of columns, said ribs joined to said columns.

9. The system of claim 8 wherein said columns, said ribs, said first loop and said second loop are each formed of wires.

10. A face protection system, comprising in combination: a hard hat having a dome and a brim, with a crease between said dome and said brim, said crease defining a transition angle between an outer surface of said dome and an upper surface of said brim, said brim extending to an edge defining a perimeter of said hard hat; at least one loop surrounding a majority of an opening, said opening at least as large as a portion of said dome, said opening smaller than said perimeter of said hard hat; said dome positioned at least partially up into said opening with said loop against and resting upon said hard hat; a mask coupled to said loop and extending down from said at least one loop, said mask located on a front side of said hard hat to protect from impacts coming from a forward direction; and wherein said brim of said hard hat is limited to a front of said hard hat, said mask connected to a front edge of said brim.

11. A face shield and hard hat comprising in combination: a hard hat; at least one loop surrounding a majority of an opening, said opening at least as large as a portion of a dome of the hard hat, said opening smaller than a perimeter of said hard hat, such that the dome can fit at least partially up into said opening with said loop against and resting upon the hard hat; a mask coupled to said loop and extending down from said at least one loop, said mask located on a front side of the at least one loop to protect from impacts coming from a forward direction; and wherein said at least one loop defines a first loop, with a second loop coupled to said first loop and located outboard of said first loop, said second loop sized larger than said first loop and located below said first loop, and with said mask connected to said second loop.

12. The face shield and hard hat of claim 11 wherein said opening is larger than all of the dome of the hard hat, such that the dome can fit entirely up into said opening, at least portions of a brim of the hard hat larger than said opening, such that the brim cannot fit up through said opening.

13. The face shield and hard hat of claim 11 wherein said at least one loop completely surrounds said opening.

14. The face shield and hard hat of claim 11 wherein said mask includes a plurality of columns extending down from said second loop.

15. The face shield and hard hat of claim 14 wherein a plurality of ribs extend laterally between said plurality of columns, said ribs joined to said columns and wherein said columns and said ribs are formed of wires.

16. The face shield and hard hat of claim 11 wherein a chin strap is coupled to portions of said at least one loop at least indirectly at at least two attachment locations on lateral sides of said at least one loop, said chin strap longer than a distance between said at least two attachment locations.

17. A method for protecting a face of a hard hat wearer, the method including the steps of: donning a hard hat having a dome and a brim, with a crease between the dome and the brim, the crease defining a transition in angle between an outer surface of the dome and an upper surface of the brim, the brim extending to an edge defining a perimeter of the hard hat; placing a face shield upon the hard hat, the face shield including at least one loop surrounding a majority of an opening, the opening at least as large as a portion of the dome of the hard hat, the opening smaller than the perimeter of the hard hat, such that the dome fits at least partially into the opening but the hard hat cannot fit entirely through the opening, wherein the at least one loop defines a first loop, with a second loop coupled to the first loop and located outboard of the first loop, the second loop sized larger than the first loop and located below the first loop, and with a mask connected to the second loop; and orienting the face shield so that the mask of the face shield extends down from the second loop on a front side of the second loop, the mask coupled to the first loop through the second loop, the mask located to be in front of a face of a wearer of the hard hat to protect the face from impacts coming at the face from a forward direction.

18. The method of claim 17 wherein the hard hat has the brim of the hard hat limited to a front of the hard hat, and wherein the mask of the face shield extends down from the edge of the hard hat in front of the brim of the hard hat.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front elevation view of the face shield of this invention shown in position upon a hard hat, with the hard hat shown in broken lines, and with an optional visor attached to the face shield.

(2) FIG. 2 is a rear elevation view of the face shield of FIG. 1, without the hard hat or visor shown.

(3) FIG. 3 is a top plan view of the face shield shown in FIG. 1, and without showing the hard hat or visor.

(4) FIG. 4 is a bottom plan view of that which is shown in FIG. 1, and showing details of a chin strap associated with the face shield.

(5) FIG. 5 as a side elevation view of that which is shown in FIGS. 1 and 4.

(6) FIG. 6 is a perspective view from above of that which is shown in FIGS. 1-5, and with the hard hat removed.

(7) FIG. 7 is a rear perspective view of a portion of the face shield of FIGS. 1-6, and particularly showing a visor accessory which can optionally be attached to the face shield inboard of a mask portion of the face shield.

(8) FIG. 8 is a rear perspective view of a portion of that which is shown in FIG. 6, and particularly revealing how fasteners removably hold the visor in position on the face shield.

(9) FIG. 9 is a front elevation view of an alternative embodiment of the face shield of FIG. 1, modified to accommodate hard hats which feature a prominent bill as at least a portion of a brim of the hard hat.

(10) FIG. 10 is a rear elevation view of that which is shown in FIG. 9.

(11) FIG. 11 is a top plan view of that which is shown in FIG. 9.

(12) FIG. 12 is a bottom plan view of that which is shown in FIG. 9.

(13) FIG. 13 as a side elevation view, slightly from above a midline, of that which is shown in FIG. 9.

(14) FIG. 14 is a perspective view of that which is shown in FIGS. 9-13 and with a hard hat featuring a prominent bill on a forward portion thereof, shown in broken lines with an alternative embodiment face shield shown upon this hard hat.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(15) Referring to the drawings, wherein like reference numerals represent like parts throughout the various drawing figures, reference numeral 10 (FIGS. 1-6) is directed to a face shield which is conveniently removably attachable to a hard hat H. Most preferably, the face shield 10 or an alternate face shield 110 (FIGS. 9-14) fits upon either a hard hat H having a brim B circumscribing a perimeter of the hard hat H, or a hard hat H having a more prominent bill V on a forward portion of the hard hat H. The face shield 10 extends down through a forward portion of the hard hat H, to protect a face of a wearer of the hard hat H from being struck by objects approaching the face of the wearer from the front.

(16) In essence, and with particular reference to FIGS. 1 and 4-6, basic details of the face shield 10 are described, according to a representative embodiment. The face shield 10 includes an upper portion 20 configured to engage a hard hat H. The upper proportion 20 in this embodiment includes a top loop 30 surrounding an opening 35. A dome D of the hard hat H extends up through this opening 35. A second loop 40 is outboard of the top loop 30 and coupled to the top loop 30, with the second loop 40 extending past a perimeter edge of a brim B of the hard hat H. A forward portion 50 of the face shield 10 provides a preferred form of mask for the face shield 10 which extends down from the second loop 40 or otherwise from upper portion 20 of the face shield 10. This forward portion 50 includes a perimeter 55 and is preferably formed of a series of wire elements including columns 60 which preferably extend mostly vertically, and ribs 70 which preferably extend mostly horizontally. A chinstrap 80 can engage lateral sides of the upper portion 20 of the face shield 10 for extension beneath a chin of a wearer of the hard hat H upon which the face shield 10 is positioned. An optional visor 100 can be coupled to the face shield 10 inboard of the forward portion 50 of the face shield 10, with the visor providing protection from facial impact by particles and other debris which can pass through openings in the forward portion 50 of the face shield 10.

(17) More specifically, and with particular reference to FIGS. 3 and 6, particular details of the upper portion 20 of the face shield 10 are described, according to an exemplary embodiment of the face shield 10, and for engagement with the hard hat H. The upper portion 20 is specifically configured to best fit upon a hard hat H which has a brim B of substantially uniform shape and width, extending laterally from a lower portion of the dome D of the hard hat H. A crease C defines a transition between the brim B and the dome D, with the brim B extending from the crease C to the perimeter edge E, typically at a lesser angle away from horizontal than portions of the dome D above the crease C. This upper portion 20 of the exemplary embodiment could conceivably also work on hard hats H which have a more asymmetrical form, and including a bill B on a forward portion of the hard hat H, with the bill B extending out to a front edge F, as depicted in FIG. 14. Most preferably, however, hard hats H with such a bill B are provided with the alternate face shield 110 (FIGS. 9-14) to best match the geometry of such hard hats H with a bill B.

(18) The upper portion 20 includes a top loop 30 which extends at least partially around an opening 35. This opening 35 is sized to receive at least a portion of the dome D of the hard hat H extending upwardly therethrough, and with the top loop 30 resting upon the dome D or crease C or brim B, or some combination thereof. Most preferably, and in this exemplary embodiment, the top loop 30 completely circumscribes the top opening 35, but the top loop could surround only a majority or other portion of the opening 35. The top loop 30 preferably has a diameter and shape which generally matches a diameter and shape of the crease C of the hard hat H, which is typically an oval that is wider front to back than it is left to right. However, acceptable performance can be provided so long as the top loop 30 has a size which is not larger than the perimeter edge E of the brim B, so that the top loop 30 is prevented from passing entirely over the hard hat H, with a hard hat H extending entirely up through the opening 35 and with no engagement between the upper portion 20 and a hard hat H.

(19) The top loop 30 could be slightly smaller than the crease C, and still function according to this invention, provided that other parts of the upper portion 20 are sufficiently oversized to allow for the forward portion 50 of the face shield 10 to extend downwardly in front of forward portions of the edges of the brim B of the hard hat H.

(20) While the forward portion 50 of the face shield 10 could extend down from the top loop 30, perhaps with some initial lateral extension before extending downwardly, most preferably a second loop 40 is provided surrounding the top loop 30 as an additional part of the upper portion 20. This second loop 40 most preferably completely circumscribes the opening 35 and has a greater diameter than that of the top loop 30, but it could alternatively be less than a full loop. The second loop 40 in this embodiment extends from the top loop 30 with lateral elements 45 extending between the top loop 30 and second loop 40. These lateral elements 45 preferably angle downwardly diagonally from the top loop 30 to the second loop 40, at an angle generally matching an angle of an upper surface of the brim B of the hard hat H.

(21) Both the top loop 30 and second loop 40 are shown in this exemplary embodiment as form of elongate circular cross-section wire formed of a high strength material with limited flexibility under normal operating conditions. Various alloys of steel would be one suitable material. Typically, the diameter of these wire elements would be uniform throughout the face shield 10, but could optionally be varied. As an option to wire, the upper portion could be formed as a surface with an opening therein having a similar size and function to the opening 35 of the various embodiment and options identified above.

(22) While the face shield 10 could be provided with some form of fastener for attaching to the hard hat H, such as utilization of an adhesive, mechanical fasteners, magnets, hook and loop fasteners, or other fasteners for securing the face shield 10 to the hard hat H, most preferably, the face shield 10 merely rests upon the hard hat H, with the top loop 30 engaging a portion of the dome D or brim B, such as near the crease C of the hard hat H, and with the weight of the face shield 10 then carried by the hard hat H.

(23) To keep the face shield 10 in place, especially when the forward portion 50 thereof is impacted from the front, a chinstrap 80 is preferably provided. This chin strap 80 can extend downwardly from eyelets 47 coupled to the second loop 40, or otherwise to other parts of the upper portion 20. The chinstrap 80 can include ends 82 engaging each of these eyelets 47. If multiple eyelets 47 are provided at ends 82 of the chinstrap 80, junctions 84 are preferably provided which bring these multiple ends 82 together, before spanning a space under a chin of the wearer as a single length of flexible material. Most preferably, an adjuster 86 is provided to adjust the length of the chinstrap 80. A clasp 88 is also preferably provided for opening and closing the chinstrap 80 (along arrow A of FIG. 4). A button 89 can be provided on the clasp 88 which can be pushed manually to cause the clasp 88 male portion to selectively engage or release a female portion of the clasp 88. Various other forms of chinstraps 80 could alternatively be provided, such as elongate length of elastic material with no clasp or adjuster. The chinstrap 80 could be utilized alone or along with a chinstrap for the hard hat H, if such a chinstrap is provided with the hard hat H.

(24) With particular reference to FIGS. 1, 5 and 6, details of the forward portion 50 of the face shield 10 are described, according to this exemplary embodiment. The forward portion 50 provides a preferred form of mask for protecting a face of a wearer from objects which might strike the face of the wearer from the front. This forward portion 50 preferably includes a perimeter 55 which defines lateral sides and a lower edge of the forward portion 50. This perimeter 55 is preferably sufficiently large to protect a face of a wearer fully. In this exemplary embodiment, the lateral width of the forward portion 50 is similar to a diameter of the upper portion 20. While the forward portion 50 could be formed in a variety of different ways, in this exemplary embodiment the forward portion 50 is formed by wire elements similar to how the upper portion 20 is formed, but with different orientations for the individual wire elements. In this embodiment, the forward portion 50 include columns 60 which preferably extend substantially within vertical planes, and with ribs 70 extending laterally relative to the columns 60. Joints between the ribs 70 and columns 60 can be welded together or otherwise coupled if desired. In this exemplary embodiment, three columns 60 are provided within the forward portion 50 and inboard of the perimeter 55, and two ribs 70 are provided which extend substantially horizontally, or otherwise extend laterally from the columns 60. As an alternative, one or more of the columns 60 or ribs 70 could be formed in a manner other than from wire, such as molded composite elements, such as formed of fiberglass, carbon fiber, high strength plastic, or other suitable materials for protecting a face of a wearer from impact by objects from the front.

(25) With particular reference to FIGS. 1 and 4-8, details of an optional visor 100 are described according to one form of this exemplary embodiment. The visor 100 provides protection for flying particles which would pass between columns 60 and ribs 70 or other parts of the forward portion 50 of the face shield 10, such as sparks, splinters, pebbles, fragments of items being cut, or other debris. The visor 100 is depicted as including a mesh 108 of fine wire or fabric elements, which are sufficiently thin and loosely attached to each other to allow for viewing therethrough. As an alternative to this mesh 108, a clear plastic layer could be provided, or clear layer of some other material. This mesh 108 or other at least partially transparent protective layer is preferably supported by an upper band 102 and a perimeter band 106 extending from the upper band 102 to provide lateral sides and a lower edge to the overall visor 100.

(26) Fastener ports 104 are preferably located within the upper band 102. Fastener posts 105 are coupled to brackets 107 affixed to the second loop 40 of the upper portion 20, or otherwise attached to some part of the upper portion 20. These fastener posts 105 preferably have an asymmetrical shape and the fastener ports 104 preferably have a corresponding asymmetrical shape. The fastener posts 105 are preferably rotatable relative to the brackets 107 (along arrow G of FIG. 8). The faster posts 105 can thus be rotated into and out of alignment with a geometry of the fastener ports 104. A first and a second fastener post 105 on the upper portion 20 can pass through two fastener ports 104 in the upper band 102 of the visor 100 at the right place to align with the two posts 105 of the upper portion 20 of the face shield 10, and then the fastener posts 105 can be rotated (along arrow G of FIG. 8) to capture the visor 100 adjacent to the upper portion 20 of the face shield 10. The visor 100 can thus be held in place inboard of the forward portion 50 of the face shield 10. For removal of the visor 100, this procedure can be reversed.

(27) With particular reference to FIGS. 9-14, details of an alternative face shield 110 are described. This alternative face shield 110 is configured to best accommodate a hard hat H which has a brim B which is wider at a bill V extending from the crease C to a front edge F on a forward portion of the hard hat H (FIG. 14). This alternate face shield 110 is similar to the face shield 10 of the first exemplary embodiment, except where particularly distinctly described herein. An upper portion 120 can be provided in a variety of different configurations, but in this embodiment includes a top loop 130 surrounding an opening 135. A front loop segment 140 extends forward of the top loop 130, but only on a forward portion of the top loop 130, and preferably slightly below the top loop 130. Lateral elements 145 extend from the top loop 130 to the front loop segment 140 to more securely hold the front loop segment 140 to the top loop 130. The front loop segment 140 preferably is shaped and sized to follow a perimeter of the bill B on a forward portion of the brim B of the hard hat H, so that the front loop segment 140 generally follows the front edge F of the bill B. Eyelets 147 can be provided on portions of the top loop 130 and/or front loop segment 140 to accommodate a chinstrap 80 such as that described above.

(28) The forward portion 150 is generally similar to the forward portion 50 of the first exemplary embodiment described above. This forward portion 150 includes a perimeter 155 and includes columns 160 which are preferably oriented within mostly vertical planes and ribs 170 which are preferably oriented extending lateral to the columns 160 and shown extending generally horizontally in this one embodiment of the alternate face shield 110. If desired, the perimeter 155 can be swept rearwardly in a more pronounced fashion on the forward portion 150 then is provided for the perimeter 55 associated with the forward portion 50 of the face shield 10 of the first exemplary embodiment. In this way, even though the front edge F of the bill V of the hard hat H places upper parts of the forward portion 150 more forwardly relative to a face of a wearer of the hard hat H, by sweeping back lateral sides of the perimeter 155, this allows for greater protection for sides of a face of the wearer then would be the case if the perimeter 155 were not swept back in a pronounced fashion at lateral sides thereof.

(29) This disclosure is provided to reveal a preferred embodiment of the invention and a best mode for practicing the invention. Having thus described the invention in this way, it should be apparent that various different modifications can be made to the preferred embodiment without departing from the scope and spirit of this invention disclosure. When embodiments are referred to as exemplary or preferred this term is meant to indicate one example of the invention, and does not exclude other possible embodiments. When structures are identified as a means to perform a function, the identification is intended to include all structures which can perform the function specified. When structures of this invention are identified as being coupled together, such language should be interpreted broadly to include the structures being coupled directly together or coupled together through intervening structures. Such coupling could be permanent or temporary and either in a rigid fashion or in a fashion which allows pivoting, sliding or other relative motion while still providing some form of attachment, unless specifically restricted.