U.S. patent application number 11/382448 was filed with the patent office on 2007-11-15 for protective helmet with flush pivoting ear cups.
Invention is credited to Peter Muller, Robert W. Wise.
Application Number | 20070261153 11/382448 |
Document ID | / |
Family ID | 38683665 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070261153 |
Kind Code |
A1 |
Wise; Robert W. ; et
al. |
November 15, 2007 |
PROTECTIVE HELMET WITH FLUSH PIVOTING EAR CUPS
Abstract
A helmet includes a shell with an impact resistant exterior
surface formed by an upper shell and a rear shell. The upper shell
is shaped to protect a top portion of a wearer's head, the rear
shell shaped to protect an occipital portion of the wearer's head.
A headset assembly, attached to the shell, includes dual ear cups
rotatable about an axis that is above the wearer's ears when the
helmet is worn. The ear cups have at least the following positions:
an extended position to cover the wearer's ears, and a retracted
position substantially abutting both upper and rear shell to the
rear of the wearer's ears. The ear cups are shaped so that they
form a surface substantially flush with the exterior surface while
the ear cups are in the retracted position.
Inventors: |
Wise; Robert W.; (Petaluma,
CA) ; Muller; Peter; (Woodside, CA) |
Correspondence
Address: |
GLENN PATENT GROUP
3475 EDISON WAY, SUITE L
MENLO PARK
CA
94025
US
|
Family ID: |
38683665 |
Appl. No.: |
11/382448 |
Filed: |
May 9, 2006 |
Current U.S.
Class: |
2/423 |
Current CPC
Class: |
A42B 3/166 20130101;
A42B 3/30 20130101; A42B 3/044 20130101; A42B 3/22 20130101 |
Class at
Publication: |
002/423 |
International
Class: |
A42B 1/08 20060101
A42B001/08 |
Claims
1. A helmet, comprising: a shell comprising an impact resistant
exterior surface formed by an upper shell and a rear shell, the
upper shell shaped to protect a top portion of a wearer's head, the
rear shell shaped to protect an occipital portion of the wearer's
head; a headset assembly attached to the shell, comprising: dual
ear cups rotatable about an axis that is above the wearer's ears
when the helmet is worn, the ear cups having at least the following
positions: an extended position to cover a wearer's ears, and a
retracted position substantially abutting both upper and rear shell
aft of the wearer's ears; where the ear cups are shaped to form a
surface substantially flush with the exterior surface while the ear
cups are in the retracted position.
2. The helmet of claim 1, further comprising: an electrical
connector configured for detachable electrical connection to
off-helmet electronics; audio speakers installed in the ear cups,
the speakers including signal inputs electrically coupled to the
connector.
3. The helmet of claim 1, further comprising: a first electrical
connector positioned proximate the rear shell; a second electrical
connector, detachably coupled to the first electrical connector,
the second electrical connector electrically attached via one or
more cables to one or more electronic components located apart from
the helmet; the electronic components including one or more
batteries and an audio source; audio speakers installed in the ear
cups, the speakers including signal inputs electrically coupled to
the first connector.
4. The helmet of claim 3, the shell includes a rear end proximate
the rear shell and a front end opposite the rear end, and the front
end includes a narrowed extension providing a visor; where the
audio source includes a two-way transceiver, and the helmet further
includes one or more visor-mounted microphones including signal
outputs electrically coupled to the first connector.
5. The helmet of claim 1, where: the shell includes a rear end
proximate the rear shell and a front end opposite the rear end, and
the front end of the shell includes a narrowed extension providing
a visor; the helmet further includes: audio speakers located in the
ear cups, at least one hands-free microphone attached to the visor,
at least one connector to electrically couple to a transceiver, and
one or more links connecting the connector with the microphone and
the speakers.
6. The helmet of claim 1, where: the shell includes a rear end
proximate the rear shell and a front end opposite the rear end, and
the front end includes a narrowed extension providing a visor; the
helmet further includes a light assembly internal to the visor and
protected by a brow lens substantially flush with the visor.
7. The helmet of claim 1, where: the shell includes a rear end
proximate the rear shell and a front end opposite the rear end; the
helmet further comprises an eye shield adjacent the front end, the
eye shield being slidably retractable upwardly into the helmet.
8. The helmet of claim 1, further comprising: an internal frame
coupled to the upper shell and rear shell; a headband assembly
coupled to the frame; an eye shield; a guide connected to the frame
and defining one or more slide slots to receive the eye shield and
permit slidable retraction and extension of the eye shield relative
to the guide; where one of the eye shield and guide include
includes a pawl and the other of the eye shield and guide includes
positioning notches, the pawl and notches positioned
complimentarily to provide ratcheting adjustment of the eye shield
in predefined positions affixed by engagement of the pawl and
notches.
9. The helmet of claim 1, further comprising: an internal frame
coupled to the upper shell and rear shell; a headband assembly
coupled to the frame; an eye shield; guide means for facilitating
slidable retraction and extension of the eye shield relative to the
helmet; means for ratcheting adjustment of the eye shield in
predefined positions.
10. The helmet of claim 1, where: the upper shell and rear shell
are positioned to define a gap therebetween; the helmet further
includes a rear-facing light assembly positioned to shine through
the gap when illuminated, and a lens covering the gap and
protecting the rear-facing light assembly.
11. The helmet of claim 1, further comprising: means for securing
the ear cups in the retracted position.
12. The helmet of claim 1, further comprising: an internal frame
coupled to the upper shell and rear shell; a headband assembly
coupled to the frame; where the ear cups are shaped to engage the
frame while in the retracted position, the engagement sufficient to
removably secure the ear cups in the retracted position.
13. The helmet of claim 1, further comprising: a switch, responsive
to position of the ear cups, to provide a higher volume to speakers
in the ear cups when the ear cups are retracted and a lower volume
to the speakers when the ear cups are extended.
14. The helmet of claim 1, further comprising: means for providing
a higher volume at speakers in the ear cups when the ear cups are
retracted and a lower volume when the ear cups are extended.
15. The helmet of claim 1, where: the shell includes a rear end
proximate the rear shell and a front end opposite the rear end, and
the front end of the shell includes a narrowed extension providing
a visor; the helmet further comprises: at least one hands-free
microphone attached to the visor; audio speakers installed in the
ear cups; at least one connector to electrically couple to a
transceiver; one or more links coupling the connector with the
microphone and the speakers, adjacent the front end, an eye shield
that is slidably retractable upwardly into the helmet, a light
assembly internal to the visor and protected by a brow lens
substantially flush with the visor.
16. A helmet, comprising: a shell comprising an impact resistant
exterior surface to protect top and occipital portions of a
wearer's head; a headset assembly attached to the shell,
comprising: dual ear cups rotatable about an axis that is
substantially above the wearer's ears when the helmet is worn, the
ear cups having at least the following positions: an extended
position to cover a wearer's ears, and a retracted position
substantially abutting both upper and rear shell aft of the
wearer's ears; where the ear cups form a surface substantially
flush with the exterior surface while the ear cups are
retracted.
17. A helmet, comprising: a headband assembly to receive a helmet
wearer's head; a frame coupled to the headband assembly; a shell
comprising an impact resistant exterior surface formed by an upper
shell and a rear shell separately coupled to the frame, the upper
shell shaped to protect a top portion of a wearer's head, the rear
shell shaped to protect an occipital portion of the wearer's lead;
a headset assembly attached to the shell, comprising: dual ear cups
rotatable about an axis that is substantially above the wearer's
ears when the headband assembly receives the wearer's head, the ear
cups having at least the following positions: an extended position
to cover a wearer's ears, and a retracted position substantially
abutting both upper and rear shell aft of the wearer's ears; where
the ear cups are shaped so that to form a surface substantially
flush with the exterior surface while the ear cups are in the
retracted position.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to safety helmets. More
particularly, the invention concerns a helmet with ear cups that
pivot into a position that is flush with the helmet, generally
above and behind the wearer's ears.
[0003] 2. Description of the Related Art
[0004] Today, there is a vast array of safety equipment available
to workers. Steel-toed boots protect the feet from heavy weights or
impact. Fire and heat resistant clothing helps protect the body
against flame. Eye goggles and face shields ward off debris and
bright lights to protect the eyes.
[0005] Probably one of the most common items of safety equipment is
a helmet or "hard hat." These are frequently used by construction
workers, building inspectors, shipbuilders, factory workers, and
others. However, conventional hard hats typically leave the
wearer's ears exposed and vulnerable to impact damage. Of course,
some people use ear plugs to protect their hearing, but this still
leaves their ears unprotected from possible impact. Other people
might use aftermarket ear muffs to protect against hearing loss,
and this might provide some incidental protection against impact
injury to the ears. However, aftermarket ear muffs can be difficult
to wear with a conventional hard hat. There are some products with
integrated hard hat and ear muffs, but these typically protrude
from the helmet in some direction, and necessitate an irregular
outer surface of the helmet. Therefore, they are vulnerable to
snagging on wiring, insulation, vehicle interior, brush, and other
features of the wearer's work environment.
[0006] Thus, when selecting a safety helmet and ear protection
there are many different tradeoffs. Further complicating this,
certain users might wish to listen to audio signals while using a
safety helmet. Yet, finding an audio system that is compatible with
the helmet and ear protection can be difficult or impossible.
[0007] Consequently, known safety helmets are not completely
adequate for some applications due to certain unsolved
problems.
SUMMARY OF THE INVENTION
[0008] A helmet includes a shell with an impact resistant exterior
surface formed by an upper shell and a rear shell. The upper shell
is shaped to protect a top portion of a wearer's head, the rear
shell shaped to protect an occipital portion of the wearer's head.
A headset assembly, attached to the shell, includes dual ear cups
rotatable about an axis that is above the wearer's ears when the
helmet is worn. The ear cups have at least the following positions:
an extended position to cover the wearer's ears, and a retracted
position substantially abutting both upper and rear shell aft of
the wearer's ears. The ear cups are shaped so that they form a
surface substantially flush with the exterior surface while the ear
cups are in the retracted position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a right side plan view of a safety helmet.
[0010] FIG. 2 is a left side plan view of the safety helmet.
[0011] FIGS. 3A-3B are a rear views of the safety helmet.
[0012] FIG. 4 is an exploded top perspective view of the safety
helmet.
[0013] FIG. 5A is a partial, top perspective view of the safety
helmet.
[0014] FIG. 5B is a partial, bottom oblique view of the safety
helmet.
[0015] FIG. 6 is a perspective view of a headband assembly.
[0016] FIG. 7 is an exploded view of a headset assembly.
[0017] FIGS. 8A-8B are perspective views of an eye shield guide and
eye shield guide, respectively.
[0018] FIG. 9 is a perspective view of a rear shell and lens.
[0019] FIG. 10 is an underside perspective view of an electronics
module.
DETAILED DESCRIPTION
[0020] The nature, objectives, and advantages of the invention will
become more apparent to those skilled in the art after considering
the following detailed description in connection with the
accompanying drawings.
Hardware Components & Interconnections
Overall Structure
[0021] One aspect of the present disclosure concerns a safety
helmet. Although the safety helmet may be embodied by various
hardware components and interconnections, FIG. 1 shows one specific
example in the form of helmet 100.
[0022] Broadly, the helmet 100 comprises a safety helmet with ear
cups that pivot between an extended position and a retracted
position that is flush with the helmet, generally above (and also
behind) the person's ears. Although not part of the helmet 100, a
wearer 150 is shown for reference and perspective.
[0023] The helmet 100 includes a front end 102 and a rear end 104.
One part of the helmet is a rigid upper shell 105 to protect the
wear's head from impact injury. The upper shell 150 is made of a
suitable material for this purpose, such as polycarbonate or
another suitable reinforced or non-reinforced material.
[0024] Within the upper shell 105 are defined a number of vents
124, which in the illustrated example comprise aerodynamic channels
with apertures leading to the interior of the helmet 100. The vents
124 permit air exchange between the wearer's head and outside the
helmet without taking rain in.
[0025] The helmet 100 is shaped to form a visor 106, which
protrudes well forward of the wearer's face. The visor 106 affords
some protection of the wearer's face from sun, rain, and falling
debris. Integral with a lower side of the visor 106 is an
arc-shaped front lens 108, which protects a multiple beam light
(not shown in this view) such as an LED array. FIG. 1 reveals a
portion of an eye shield 107 (in retracted position). The shield
107 is illustrated and described in greater detail below.
[0026] At the rear 104 of the helmet 100, there is a rear shell 110
and a curved rear lens 114. Within the rear shell 110, there is an
electrical connector (not visible in FIG. 1) for attaching
electronic equipment of the helmet 100 to various off-helmet
electrical equipment. Components at the rear 104 of the helmet are
described in greater detail below.
[0027] The helmet 100 also includes ear cups, one 116b of which is
visible in the view of FIG. 1. The ear cups pivot about respective
axes, such as the axis 120 of the ear cup 116b. The ear cups are
held in a retracted position, to the rear of the wearer's ears
(e.g., 152) by one of various mechanisms described below. In the
illustrated example, there is a friction fit between the ear cup
116b and an engaging feature 118 of a frame (not shown). The frame
is illustrated and discussed in greater detail below. In their
retracted position, the ear cups are substantially flush with the
upper/rear shells 105/110, and more particularly, they present a
surface that is substantially continuous with the arc and shape of
the rear shell 110 and upper shell 105. By minimizing any
protrusion from the helmet, the ear cups present a contiguous part
of the helmet when retracted.
[0028] FIG. 2 shows the helmet 100 from the wearer's left side.
This view demonstrates some of the helmet 100's movable parts.
Namely, the eye shield 107 and an ear cup 116a are shown in their
respective, extended positions.
[0029] FIGS. 3A-3B show the helmet 100 in rear view, in two
different configurations. In one configuration (302, FIG. 3A), ear
cups 116a-116b are extended. In another configuration (304, FIG.
3B), the ear cups 116a-116b are retracted. Both configurations
302-304 illustrate the rear 104 of the helmet, including features
such as the rear lens 114 and rear shell 110.
[0030] FIG. 4 shows an exploded view of the helmet 100 to better
illustrate the individual pieces' shapes and interconnections.
Optionally, the helmet 100 includes vent plugs 412. In one example,
the vent plugs 412 include apertures (not shown) that are pressed
over studs (not shown) protruding from the shell 105's inner
surface (i.e., the surface toward the wearer). In this example, the
vent plugs are secured in place with Tinnerman clips. Of course,
other means of attachment may be employed such as shape fit,
fasteners, clips, glue, press fit, screws, rivets, etc. Each vent
plug 412 comprises an elastomeric member with protrusions shaped to
fit inside corresponding holes of the vents 124. While the helmet
100 is not being worn, the wearer can insert/remove the vent plugs
412 into/from the vents 124 by bendably manipulating the plugs
412.
[0031] Beneath the shell 105 is a frame 408. The frame 408 serves
as a common attachment point for the upper shell 105, rear shell
110, rear lens 114, front lens 108, and other components described
below.
[0032] A number of additional components are coupled to the frame
408. One such component is the connector 112. The connector 112
comprises an electrical coupling for electrically attaching helmet
electronics (described below) to off-helmet electrical equipment.
In one example, the connector is a six position IEEE 1394
receptacle such as Molex part 53984-0611. In the illustrated
embodiment, the connector 112 is mounted to a printed circuit board
(PCB), which is attached to the frame 408.
[0033] The connector 112 is coupled to other electrical components
aboard the helmet 100, as described in greater detail below. Some
of these components include an electronics module and headset
assembly, and these may be electrically coupled to the connector
112 by one or more wiring harnesses, electrical buses, PCB traces,
wires, Bluetooth or other wireless links, etc. The connector 112
may be removably engaged with another connector (not shown),
electrically attached to various off-helmet components. Some
examples of these off-helmet components include a listen-only audio
source such as a flash-memory based music player (such as MP3,
iPod, etc.), AM/FM or satellite radio, CD player, etc. Another
example is a two-way transceiver, such as a wireless phone, two-way
radio, etc. As still another example, off-helmet components may
include an antenna, pack of one or more rechargeable or disposable
batteries, etc. In the illustrated example, the connector 112 is
compatible with a six position IEEE 1394 plug (not shown) such as a
Tyco part 787950-1. This female plug is compatible with a male
counterpart attached via cabling (not shown) to the off-helmet
electronics. At a remote end of this cabling, there may be one or
more 2.5 mm jacks to interface with audio equipment, cell phones,
etc.
[0034] Another component attached to the frame 408 is the
electronics module 406. Among other components, the module 406
includes a source of light that projects through the front lens 108
when the module 406 is mounted to the frame 408. Thus, in the
finished helmet 100, the module 406 and lens 108 are built into the
visor 106 of FIG. 1. The module 406 is mounted to the top side of
the frame 408, as viewed in FIG. 4.
[0035] Another component, attached to the frame 408, is an eye
shield guide 402. The guide 402 provides a base for slidable
movement of the eye shield 107, defines full up and down travel,
and removably secures the shield 107 in a user selected position.
The guide 402 and its attachment to the frame 408 are described in
greater detail below.
[0036] Another component, attached to the frame 408 is a headset
assembly 430. Primary components of the headset assembly are the
ear cups 116a-116b and the band 413, to which the ear cups
116a-116b are mounted. The assembly 430 and its attachment to the
upper shell 105 are described below.
[0037] Still another component of the helmet 100 is the headband
assembly 414. The assembly 414 provides an adjustable harness to
provide a snug fit to the wearer's head, which supports the helmet
100 during use. The assembly 414 mounts to the frame 408 by four
supports 416-419. The assembly 414 and its attachment to the frame
408 are discussed below.
[0038] FIGS. 5A-5B illustrate some of the components of FIG. 4 in
assembled form. Namely, FIG. 5A shows a top perspective view of the
frame 408, headband assembly 414, supports 416-419, eye shield
guide 402 (with eye shield 107 removed), and electronics module
406. FIG. 5B shows a bottom oblique view of the helmet 100, where
the following components are visible: the frame 408, headband
assembly 414, lens 108, guide 402, eye shield 107, support 416, ear
cups 116a-116b, rear shell 110, vent plugs 412, connector 112, and
upper shell 105.
Headband Assembly
[0039] FIG. 6 shows the headband assembly 414 in greater detail. As
mentioned above, the headband assembly 414 provides an adjustable
harness so that the wearer's head can comfortable and securely
support the helmet 100. In one example, the assembly 414 includes a
headband base 602 coupled to crisscrossing straps 610, 612. The
straps 610, 612, in one example, comprise nylon webbing. The base
602 includes mechanism 614 to adjust the base to fit different head
sizes.
[0040] In the illustrated example, the headband assembly 414 is
attached to the base 408 at the supports 416-419. More
particularly, the supports 416-419 are attached by fasteners,
clips, glue, press fit, screws, rivets, detent or other shape fit,
etc. The headset assembly 430 attaches to the shell 105 as
discussed above. The base 408 attaches to the shell 105 by
fasteners, clips, ultrasonic bonding, glue, press fit, screws,
rivets, detent or other shape fit, etc. Thus, in the final
construction, the headset assembly 430 is positioned over the
headband assembly 414, permitting the assembly 414 to comfortably
direct the weight of the helmet 100 upon the wearer's head.
Headset Assembly
[0041] FIG. 7 shows the headset assembly 430 in greater detail.
Broadly, the assembly 430 includes the ear cups 116a-116b, which
pivotably attach to the band 413. The band 413 includes studs 704
about which the ear cups 116a-116b are free to rotate, as discussed
below. In one example, the band 413 is made of spring steel, and
the studs 704 include Press-in studs such as PEM part THFS-632-6.
The band 413 also includes holes 724 for use in attaching the band
413 to the upper shell 105. For example, the band 413 may be
screwed or riveted to the shell 105 via holes 724. In a different
example, the holes 724 may receive barbed studs (not shown)
projecting from the shell 105, in order to secure the band 413 to
the shell 105. Of course, other arrangements may be used such as
fasteners, clips, glue, press fit, shape fit, etc.
[0042] Each ear cup is comprised of an ear pad 710, inner shell
712, acoustic foam 714, and outer shell 716. The shells 712, 716
comprise plastic or another material providing suitable protective
strength and light weight. In one example, the shells 712, 716 are
bonded to each other using ultrasonic welding, solvent bond, epoxy,
or other permanent seal. In one example, the ear cushion 710
comprises water impenetrable material such as GORE-TEX.RTM.
material surrounding padding of neoprene foam. In another example,
the ear cushions 710 are gel or foam filled plastic or another
durable yet soft material to provide cushioning between the
wearer's head and the assembly 430.
[0043] Each inner shell 712 includes a pivot housing 723 to permit
free rotation of the respective ear cup about an axis 722 through
the pivot housing 723. In one example, each pivot housing 723 is
implemented by a drilled or tooled or vacuum molded hole the shell
712. A stud 704 protrudes through each such hole, enabling the ear
cup can to pivot about this hole. The ear cups 116a-116b are held
in place by fasteners 706, such as nuts with spring steel washers,
and the fasteners 706 are cosmetically disguised by caps 708. As an
alternative, the pivot housings 723 may be implemented by other
arrangements such as bearings, bushings, axles, etc. Furthermore,
instead of permitting free rotation of the ear cups 116a-116b about
their respective studs 704, the pivot housings 723 and/or studs 704
may be defined to provide rotation under friction, ratcheting
movement, detent holding ear cups in position until forcibly
overcome, etc.
[0044] Each inner shell 712 further includes a tab 720 designed to
interact with a corresponding engaging feature 118 of the frame
408, which is most clearly shown in FIGS. 1, 2, and 4A. In this
example, the point of rotation of the ear cups 116a-116b is defined
relative the frame 408 so that increasing movement of the ear cups
116a-116b into their stowed position places the tabs 720 into
increasingly firm contact with their respective engaging features
118. This holds the ear cups 116a-116b firmly in place by friction
between the tabs 720 and engaging features 118. Further force
applied to the ear cups 116a-116b in this direction more firmly
engages the ear cups with the frame. Alternatively, the helmet 100
may employ other means to hold the ear cups 116a-116b in place,
such as springs, snaps, hooks, clips, magnets, etc.
[0045] The foam 714 comprises acoustically absorbent material such
as that typically used in conventional and industrial headsets. The
outer shell 716 includes a speaker assembly 718 electrically
coupled to the connector 112. One example of the speakers is a
circumaural type speaker.
Eve Shield and Guide
[0046] FIG. 8A-8B highlight the guide 402 and eye shield 107,
respectively. In one embodiment, the shield 107 is made of a clear
or intentionally tinted material that meets or exceeds OSHA, UL,
and/or CSA requirements for safety glasses. For example, the shield
107 may be made of polycarbonate, acrylic, or another suitable
material. The guide 402 is made of a material suitable to provide
self-lubrication e.g. nylons and others.
[0047] Although the shield 107 and guide 402 are shown separately,
the shield rides in a path defined and limited by the guide 402.
When coupled to the guide 402, the shield 107 is slidable in
generally upward and downward movements, allowing the wearer to
retract and extend the shield (respectively).
[0048] The shield 107 includes a number of features that help
establish and limit its position with respect to the rest of the
helmet 100. In this respect, the shield 107 includes down catches
810. Each catch 810 includes a protrusion that engages a
corresponding feature of the guide 402 to stop extension of the
shield 107. Positioning notches 812 are defined in the shield 812
to engage a corresponding pawl of the guide 402 and thereby hold
the shield 107 one of these positions under adjustment by the
wearer. Channels 814 defined in the shield 107 engage corresponding
features of the guide 402 to help stop retraction of the shield
107.
[0049] The guide 402 includes foldover flaps 808 defining slide
slots 809 that receive and accommodate the shield 107. Up-stops 802
stop retraction of the shield 107 by engaging the channels 814. The
stops 802 include protrusions that are biased toward the shield 107
by their size, position, and the natural springiness of the guide
402 material. Pedestals 804 are provided for mounting of the guide
402 to the frame 408 by barbed studs, fasteners, clips, glue, press
fit, screws, rivets, detent or other shape fit, etc. A pawl 806
engages with the positioning notches 812 to hold the shield 107 in
place, or releasably permit the extension or retraction of the
shield 107 when the wearer applies sufficient force to slide the
shield 107 and thereby disengage and reengage the pawl 806 from the
notches 812 one at a time. Notches 807 are engaged by the down
catches 810 to stop extension of the shield 107. Alternatively, the
notches 807 may be omitted, with the upper edge of the guide 402
serving to engage the down catches 810, albeit at an earlier point
than the notches 807 would, and thereby not permitting as much down
travel.
Rear Panel & Lens
[0050] FIG. 9 shows the rear shell 110 and lens 114 in greater
detail. In the rear shell, a notch 902 is defined to accommodate
the connector 112, which is attached to the frame 408 as shown
above. Aligners 910 permit the shell 110 to be accurately
positioned with respect to the frame 408. As shown, each of the
aligners 910 is a base with a hole defined therein. Mounting to the
frame 408 occurs by the aligner hole's receipt of a screw, rivet,
barbed stud, or other fastener. Alternatively, another means of
securing may be used such as glue, ultrasonic bonding, clips,
etc.
[0051] The shell 110 bears attachment pegs 904 shaped to engage
corresponding holes 906 in the rear lens 114 and thereby secure the
lens relative to the shell 110. The shell 110 and lens 114 may be
attached by a press fit between the pegs 904 and holes 906 and/or
additional means such as ultrasonic welding, solvent bond, epoxy,
etc. Along these lines, the lens 114 includes knobs 908 to affix
the lens 114 with respect to the frame 408.
[0052] A number of rear-facing light sources (not shown) may be
attached to the frame 408 at a suitable position to be aligned with
the lens 114. For example, four LEDs of type T1 may be used. Or,
instead of multiple light sources, a single light may be used with
beam splitters, lenses, or other modification. These light sources
serve a safety function, to make the wearer more visible to people
behind him/her. Optionally, the rear-facing light sources may be
red in color, or use a blinking pattern. The light sources receive
power from the electronics module 406 via one or more wiring
harnesses, electrical buses, PCB traces, wires, Bluetooth or other
wireless links, etc.
[0053] As an alternative to the rear shell 110 and lens 114 that
are separate from the upper shell 105 as illustrated, these
features may be integral with the upper shell 105, thereby forming
a larger, contiguous combined upper/rear shell.
Electronics Module
[0054] FIG. 10 shows the electronics module 406 in greater detail.
As mentioned above, the electronics module 406 includes a source of
light that projects through the front lens 108 when the module 406
is mounted to the frame 408. In one example, the module 406 may be
mounted to the frame 408 by fasteners, clips, glue, press fit,
screws, rivets, detent or other shape fit, etc. In the finished
helmet 100, the module 406 and lens 108 are built into the visor
106 of FIG. 1.
[0055] One example of the module 406 includes an array of LEDs 1002
mounted to a printed circuit board 1003. In the illustrated
example, six white LEDs of type T1-3/4 may be used. The LEDs 1002
may be aimed in the same direction (as shown), or at various angles
to enhance the overall presentation of light around the wearer's
workspace. Optionally, the LEDs 1002 may even be distributed to
provide peripheral lighting in addition to straight-ahead
illumination respective to the wearer's face and normal field of
view. Instead of multiple separate beams (as shown), the same or
similar effect may be accomplished with beam splitters, lenses,
etc.
[0056] The module 406 may include further electronics. In one
example, the module 406 includes brow microphones 1004 enabling the
wearer of the helmet 100 to conduct hands free communications
utilizing an off-helmet audio module coupled to the connector 112.
As an example, 6 mm directional microphones may be used to
effectively define a "beam" of heightened sound reception aimed at
the site of an average wearer's mouth. The microphones 1004 may
include a moisture barrier, such as GORE-TEX.RTM. or a similar
material.
[0057] As shown, the module 406 also includes a photo sensor 1008,
such as a Perkin Elmer part A9060. Optionally, circuitry of the
board 1003 may automatically activate the LEDs 1002 and/or the rear
light when the sensor 1008 finds that ambient light is less than a
given threshold.
[0058] In order to provide more intelligent functionality to the
helmet 100, the module 406 may also accommodate various circuitry
in the form of discrete circuit elements, integrated circuits,
ASICs, and the like. For example, the module 406 may include
Fortemedia brand FM1072LP chips in order to aid processing of audio
signals received at the microphones 1004, prevent feedback between
the microphone and speakers, etc. As a further example, the module
406 may include circuitry to convert mobile phone signals to a
speakerphone and headset function for send and receive, and to
provide a stereo amplifier for the speakers 718.
[0059] The module 406 further includes hand-operated dual switches
1006, such as E-Switch part EG2305A. The dual switches 1006 may be
attached to permit the wearer to selectively deactivate the LEDs
1002, rear light, microphones 1004, and/or other electronic
equipment.
[0060] Optionally, through the switches 1006 or on-board circuitry,
the module 406 may automatically or manually adjust the volume of
the ear cup speakers. For instance, the module 406 may utilize a
softer volume while the ear cups are extended, and use a louder
"speakerphone" volume while the ear cups are retracted. As a more
particular example of the automatic embodiment, the ear cups
116a-116b may actuate a switch mounted to the frame 408 or other
structure, where this switch is activated by a raised feature of
one or both ear cups 116a-116b close to the pivot point when ear
cups are extended. Without any intended limitation, some specific
examples of this raised feature include one or both of the tabs
730-731 (FIG. 7). In this example, the switch is de-activated when
the ear cups are retracted, and activated when the ear cups are
extended. In one example, the switch connects the speakers to
different amplifier circuitry depending upon whether the switch is
activated or deactivated. In another example, the switch provides
an input signal to a controller of the electronics module 406,
which regulates volume accordingly.
Helmet Features
[0061] As described above, the helmet 100 offers a variety of
useful features in one package. The helmet 100 provides MP3, CD
player, radio, cell phone, two-way radio, or other audio to the
wearer by virtue of the speaker assemblies 718 in ear cups
116a-116b. And, with the directional brow microphones 1004, the
helmet 100 enables the wearer to conduct mobile, hands free speech
through an attached, off-helmet wireless phone or two-way radio
transceiver. Audio signals are conveyed to/from remote electronics
by the connector 112 and appropriate cabling (not shown). Moreover,
the wearer's eyes are protected by the retractable eye shield 107.
To fully illuminate the wearer's workspace with minimal intrusion,
the front-facing light assembly 1002 is provided internal to the
visor 106 and protected by a brow lens 108 that is flush with the
visor 106. For added safety, the rear-facing light makes sure that
the helmet is visible from behind. Furthermore, the ear cups
116a-116b are particularly convenient because they are retractable.
Moreover, they are unlikely to catch on wiring, insulation, vehicle
interior, brush, or other features of the wearer's work
environment, since the ear cups 116a-116b when retracted are flush
with helmet's exterior surface, namely, the upper shell 105 and the
rear shell 110. Despite the collective benefit of these features,
the helmet still provides significant utility if one or more of
these are omitted.
Helmet Operation
[0062] In preparation for use of the helmet 100, the wearer uses
the mechanism 614 to adjust the headband base 602. The wearer also
couples the connector 112 to the desired electrical equipment, such
as one-way or two-way audio equipment, battery pack, etc. When the
wearer dons the helmet 100, the axis 722/120 is generally just
above the wearer's ears. Thus, the ear cups 116a-116b when
retracted rest above and generally behind the wearer's ears, flush
with the outer surface of the shells 105, 110. The ear cups
116a-116b are secured in the stowed position by friction between
the tab 720 of the headset assembly 430 and the engaging feature
118 of the frame 408. In this position, recognizing that the ear
cups are stowed, the helmet 100 may automatically provide an
increased "speaker phone" volume to the ear cup speakers.
[0063] When the helmet 100 is being worn, the wearer operates the
switches 1006 to configure electrical features such as the front
lights, rear lights, audio on/off, microphone mute, and the like.
To extend the ear cups 116a-116b, the wearer applies downward force
to the ear cups 116a-116b, which disengages the tabs 720 from the
engaging features 118. The ear cups 116a-116b then hang in a free
pivoting mode, or they may be held in place by a feature (not
shown) such as a catch, detent, ratchet, clasp, etc. In this
position, recognizing that the ear cups are extended, the helmet
100 may automatically select a decreased volume for ear cup
speakers.
[0064] To retract the ear cups 116a-116b again, the wearer pivots
the ear cups rearward, ultimately engaging the tabs 720 with the
features 118. Greater force applied to the ear cups in this way
more snugly engages them with the frame 408 in tighter fit.
Other Embodiments
[0065] While the foregoing disclosure shows a number of
illustrative embodiments, it will be apparent to those skilled in
the art that various changes and modifications can be made herein
without departing from the scope of the invention as defined by the
appended claims. Accordingly, the disclosed embodiment are
representative of the subject matter which is broadly contemplated
by the present invention, and the scope of the present invention
fully encompasses other embodiments which may become obvious to
those skilled in the art, and that the scope of the present
invention is accordingly to be limited by nothing other than the
appended claims.
[0066] All structural and functional equivalents to the elements of
the above-described embodiments that are known or later come to be
known to those of ordinary skill in the art are expressly
incorporated herein by reference and are intended to be encompassed
by the present claims. Moreover, it is not necessary for a device
or method to address each and every problem sought to be solved by
the present invention, for it to be encompassed by the present
claims. Furthermore, no element, component, or method step in the
present disclosure is intended to be dedicated to the public
regardless of whether the element, component, or method step is
explicitly recited in the claims. No claim element herein is to be
construed under the provisions of 35 USC 112, sixth paragraph,
unless the element is expressly recited using the phrase "means
for" or, in the case of a method claim, the phrase "step for."
[0067] Furthermore, although elements of the invention may be
described or claimed in the singular, reference to an element in
the singular is not intended to mean "one and only one" unless
explicitly so stated, but shall mean "one or more". Additionally,
ordinarily skilled artisans will recognize that operational
sequences must be set forth in some specific order for the purpose
of explanation and claiming, but the present invention contemplates
various changes beyond such specific order.
[0068] The previous description of the disclosed embodiments is
provided to enable any person skilled in the art to make or use the
present invention. Various modifications to these embodiments will
be readily apparent to those skilled in the art, and the generic
principles defined herein may be applied to other embodiments
without departing from the spirit or scope of the invention. Thus,
the present invention is not intended to be limited to the
embodiments shown herein but is to be accorded the widest scope
consistent with the principles and novel features disclosed
herein.
* * * * *