Protective Headgear System

Abstract

A protective headgear may include a rigid outer shell including a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim may include an edge. At least a portion of the edge may include a groove. The rim may include at least one projection. A flexible cover may be retained on the protective headgear.

Description

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/084,443 entitled "Protective Headgear System" filed Jul. 29, 2008, which is incorporated by reference in its entirety.

BACKGROUND

[0002] Protective headgear is required to be worn by workers in particular industries and/or in particular work environments. Typical protective headgear, referred to as a "hard hat", includes a rigid outer shell having an internal cavity, and a suspension attached to the shell and positioned at least partially within the internal cavity. This protective headgear is designed to protect the wearer's head from injury when an impact is sustained on the headgear.

[0003] A wide variety of protective headgear is currently available, and numerous modifications have been developed to improve the usefulness of the headgear for specific industries or environments. In one example, a flexible cover may be worn over the protective headgear. A flexible cover may be decorative, such as a cover that identifies the wearer or that communicates a message. A flexible cover may be functional, such as a cover that protects the wearer and/or the protective headgear from contaminants. Flexible covers typically include an elastic material along the edge of the cover, to secure the cover to the headgear. In a specific example, a nonwoven fabric cover for protective headgear is typically used in the nuclear power industry to protect both the wearer and the headgear from radioactive contamination. The nonwoven fabric cover can be easily cleaned and disposed of, together with protective clothing made from similar materials.

[0004] A drawback to the use of a flexible cover on a protective headgear is that the headgear may become uncomfortable to the wearer. The elastic material at the edge of the cover can often migrate from the edges of the headgear to the head of the wearer. FIG. 1 is a bottom view of a conventional protective headgear 100 that includes a rigid outer shell 110 having an internal cavity, a suspension 120 attached to the shell and positioned at least partially within the cavity, and a flexible cover 130. The suspension 120 provides a space for the wearer's head. The flexible cover 130 includes an edge 132 and an elastic material along the edge. As illustrated in FIG. 1, the elastic material of the flexible cover 130 can contract so that the edge 132 is in contact with the wearer's head. The headgear 100 can become quite uncomfortable to the wearer if the flexible cover provides significant retention of heat and/or moisture.

[0005] One method to decrease the discomfort of protective headgear equipped with a flexible cover includes securing the edge of the cover to the edge of the headgear. For example, mechanical clips or adhesive tapes may be used at various points to keep the edge of the cover from moving away from the edge of the headgear and toward the wearer's head. However, this is a cumbersome approach that also introduces other drawbacks. For example, if the reason for wearing the flexible cover is to localize radioactive contaminants on a disposable cover, then a mechanical clip used to secure the cover may become contaminated, making waste disposal much more complicated and expensive. In another example, adhesive tapes may only secure the cover temporarily. Failure of adhesive tape may distract the wearer from a hazardous environment, and will gradually make the headgear more uncomfortable.

[0006] It would be desirable to provide a protective headgear that can retain the edges of a flexible cover worn on the headgear. Such a protective headgear ideally would provide the necessary protection to the worker's head, while also providing improved comfort relative to conventional covered headgear.

SUMMARY

[0007] In one aspect, the invention provides a protective headgear that includes a rigid outer shell including a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim includes an edge, and at least a portion of the edge includes a groove.

[0008] In another aspect, the invention provides a protective headgear that includes a rigid outer shell including a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim includes an edge and at least one projection.

[0009] In another aspect, the invention provides a protective headgear that includes a rigid outer shell including a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim includes a means for retaining an edge of a flexible cover for the protective headgear.

[0010] In another aspect, the invention provides a protective headgear that includes a rigid outer shell including a bottom opening and an internal cavity, and a suspension attached to the outer shell and positioned at least partially within the internal cavity. The improvement includes a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell, the rim including an edge. The rim includes at least one of a groove in at least a portion of the edge and at least one projection.

[0011] In another aspect, the invention provides a rigid outer shell for a protective headgear that includes a bottom opening, an internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim includes an edge. The rim includes at least one of a groove in at least a portion of the edge and at least one projection.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.

[0013] FIG. 1 is a bottom view of a conventional protective headgear including a flexible cover.

[0014] FIG. 2 is a perspective view of a protective headgear including a rim having an edge that includes a groove.

[0015] FIG. 3 is a partial cross-section view of a protective headgear including a rim having an edge that includes a groove.

[0016] FIG. 4 is perspective view of a protective headgear including a rim having an edge that includes a groove, and including a flexible cover.

[0017] FIG. 5 is a side view of a protective headgear including a rim having an edge that includes a groove.

[0018] FIG. 6 is a top view of a protective headgear including a rim having an edge that includes a groove.

[0019] FIG. 7 is a perspective view of a protective headgear including a rim having an edge that includes a groove.

[0020] FIG. 8 is a perspective view of a protective headgear including at least one projection.

[0021] FIGS. 9A-9D are partial cross-section views of a protective headgear including a projection.

[0022] FIG. 10 is a perspective view of a protective headgear including a projection that circumscribes a bottom opening.

DETAILED DESCRIPTION

[0023] A protective headgear can be configured to retain a flexible cover for the headgear. The flexible cover may be retained in a groove that is present in at least a portion of an edge of a rim, where the rim extends from at least a portion of an outer shell of the headgear. The flexible cover may be retained by at least one projection that is part of the rim. The flexible cover may be retained at one or more points, or the entire circumference of the flexible cover may be retained.

[0024] FIG. 2 is a representation of a perspective view of a protective headgear 200 that includes a rigid outer shell 210, a suspension 220, and a rim 230. The rigid outer shell 210 includes a bottom opening 212 and an internal cavity 214. The suspension 220 is attached to the outer shell 210 and is positioned at least partially within the internal cavity 214. The rim 230 circumscribes at least a portion of the bottom opening 212, and extends laterally from the outer shell 210. The rim 230 includes an edge 232, and at least a portion of the edge 232 includes a groove 234.

[0025] The rigid outer shell 210 may include any rigid material. Examples of rigid materials include rigid thermoplastic polymers, thermoset polymers, composite materials, and metals. Examples of rigid thermoplastic polymers include high-density polyethylene, high-impact polystyrene, acrylonitrile-butadiene-styrene copolymer, polyamides (including KEVLAR), polycarbonates, polyesters, polysulfones, poly(phenylene oxide), and mixtures of these. Examples of rigid thermoset polymers include epoxy thermosets, phenolic thermosets, amino thermosets, polyester thermosets, allyl thermosets, polyurethane thermosets, dicyanate thermosets, bismaleimide thermosets, acrylate thermosets, and mixtures of these. A composite material includes a thermoplastic and/or thermoset polymer combined with a filler material. Examples of filler materials include particulate fillers, fibrous fillers, and shaped preforms. Specific examples of composite materials include fiberglass composites, fabric composites and graphite composites. Specific examples of metals include steel, aluminum, titanium, and combinations of these with other metals.

[0026] The suspension 220 includes flexible strips 222, a headband 224, and an optional adjustment mechanism 226. Preferably an internal dimension of the suspension can be adjusted. More preferably, the circumference of the headband 224 can be adjusted. Examples of headgear suspensions are disclosed, for example, in U.S. Pat. Nos. 7,296,305; 7,174,575; 6,862,747; 6,609,254; 6,481,023; 6,317,895; and 5,950,245.

[0027] The flexible strips 222 are attached to the rigid outer shell 210 and/or the headband 224, and are configured to cross each other. The flexible strips 222 thus can provide a crown portion of the suspension 220. Preferably the ends 223 of the flexible strips 222 are attached to the outer shell 210 at four or more points around the circumference of the internal cavity 214, near the bottom opening 212. The lengths of the flexible strips may be fixed, or they may be adjustable so as to adjust an internal dimension of the suspension 220.

[0028] The headband 224 is attached to the rigid outer shell 210 and/or the flexible strips 222. The headband 224 and the flexible strips 222 together can provide a space for receiving a wearer's head. Preferably the circumference of the headband 224 is adjustable, so that the protective headgear 200 can be securely positioned on the wearer's head. The headband 224 may include an adjustable napestrap 225. The headband 224 may include the optional adjustment mechanism 226, which allows the circumference of the headband to be adjusted by the wearer while the headgear 200 is on the wearer's head.

[0029] The rim 230 may include any rigid material, such as the materials listed above for the rigid outer shell 210. The rim 230 and the outer shell 210 may be the same material, or they may include different materials. The rim 230 may be integral with the outer shell 210, or it may be formed separately and then attached to the outer shell 210. Preferably the rim 230 and the outer shell 230 are integral and are made of the same material.

[0030] In one example, the rim 230 circumscribes the entire bottom opening 212, extending at least one inch from the bottom opening. In another example, the rim 230 circumscribes the bottom opening only at the front of the headgear 200. In another example, the rim 230 circumscribes the entire bottom opening, such that the rim at the front of the headgear extends at least one inch from the bottom opening, and the rim at the sides and rear of the headgear extends less than 0.5 inch from the bottom opening.

[0031] The rim 230 includes an edge 232, which includes a groove 234. The groove 234 may be present along the entire edge 232, or it may be present only at one or more portions of the edge. In one example, a portion of the edge 232 at the front of the headgear includes a front groove, and a portion of the edge at the rear of the headgear includes a rear groove. In another example, portions of the edge 232 at the sides of the headgear each include a side groove. In another example, a portion of the edge 232 at the front of the headgear includes a front groove, a portion of the edge at the rear of the headgear includes a rear groove, and portions of the edge at the sides of the headgear each include a side groove.

[0032] The groove 234 may have a variety of dimensions. If the groove is present along the entire edge, then the width and depth may be uniform along the edge, or these dimensions may be different at different portions of the edge. If the groove is present only at one or more portions of the edge, then the individual grooves in the edge have lengths, widths and depths that may be the same or may be different from each other.

[0033] The groove 234 may be integral with the rim 230. The groove 234 instead may be present in a separate material attached to the rim 230. Thus, the separate material may form at least a portion of the edge 232. A separate material that includes the groove 234 may include a rigid material, such as the materials listed above for the rigid outer shell 210, or it may include a flexible material, such as an elastomer.

[0034] A rigid material that includes the groove 234 may be attached to the rim 230 by an adhesive. A rigid material that includes the groove 234 may be attached to the rim 230 mechanically. For example, a rigid material that includes the groove 234 may have a shape that mates with the shape of the edge 232 to provide a compression fit between the material and the rim, thus extending the edge 232. In one specific example, the rigid material may have two concave portions on opposite sides of the material, where one of the concave portions mates with and extends the edge 232, and the other concave portion is the groove 234.

[0035] A flexible material that includes the groove 234 also may be attached to the rim 230, either mechanically or by an adhesive. For example, an elastomeric material that includes the groove 234 may be shaped as a closed loop. The closed loop may be extended to be positioned around the rim 230, and then may be allowed to relax to provide a compression fit between the elastomeric material and the rim 230. Preferably, a flexible material that includes the groove 234 has enough stiffness that it can retain at least a portion of a flexible cover in the groove 234.

[0036] FIG. 3 is a representation of a partial cross-section view of a protective headgear 300 that includes a rigid outer shell 310 and a rim 330. The rim 330 includes an edge 332, at least a portion of which includes a groove 334, which may be the same as groove 234 of headgear 200. The groove 334 has a width 336 and a depth 338. Preferably the groove has a width 336 of from 0.5 to 3 millimeters (mm). More preferably, the groove has a width 336 of from 1 to 2.5 mm, and more preferably of from 1.5 to 2 mm. Preferably the groove has a depth 338 of from 1 to 5 mm. More preferably, the groove has a depth 338 of from 1.5 to 4 mm, and more preferably of from 2 to 3 mm. Preferably the groove has a width 336 of from 1 to 2.5 mm, and a depth 338 of from 1.5 to 4 mm. More preferably the groove has a width 336 of from 1.5 to 2 mm, and a depth 338 of from 2 to 3 mm. The preferred configuration and dimensions of the groove may depend on the properties of a flexible cover that is intended to be worn on the headgear.

[0037] Referring again to FIG. 2, the rigid outer shell 210 and the rim 230 may have a variety of shapes, sizes and configurations. For example, the outer shell and/or the rim may include air vents to allow air to flow more readily to and from the wearer's head. The outer shell and/or the rim may include shaped segments for attaching accessories to the headgear. Examples of accessories include face shields, ear protectors, sun shields, visors, head lamps, flashlights, wireless communication devices, cushioning inserts, perspiration absorbers, eye protection retainers, and chin straps.

[0038] Preferably the headgear 200 meets or exceeds the requirements of ANSI Z89.1-2003. The headgear 200 may electrically insulate the wearer, or it may provide little or no electrical insulation. The headgear may provide "Class G" protection, in which the headgear can insulate the wearer from 2,200 volts of electricity. The headgear may provide "Class E" protection, in which the headgear can insulate the wearer from 20,000 volts of electricity. The headgear may provide "Class C" protection, in which the headgear cannot insulate the wearer from 2,200 or more volts of electricity.

[0039] FIG. 4 is a representation of a perspective view of a protective headgear 400 that includes a rigid outer shell 410, a suspension 420, a rim 430, and a flexible cover 440. The rigid outer shell 410 includes a bottom opening 412 and an internal cavity 414. The suspension 420 is attached to the outer shell 410 and is positioned at least partially within the internal cavity 414. The rim 430 circumscribes at least a portion of the bottom opening 412, and extends laterally from the outer shell 410. The rim 430 includes an edge 432, and at least a portion of the edge 432 includes a groove (not shown). The flexible cover 440 includes an edge 442, at least a portion of which is retained by the groove.

[0040] The flexible cover 440 may be any flexible material. Examples of flexible materials include woven fabrics, nonwoven fabrics, flexible plastic sheets, mesh fabrics, and netting. In one example, the flexible cover 440 is a disposable cover for the protective headgear 400, such as a cover to protect the headgear from dust. In another example, the flexible cover 440 is a decorative cover, such as a cover to identify the wearer as an individual or as part of a particular group of people, or a cover used to communicate a message. For example, the flexible cover could have a camouflage pattern, particularly if the protective headgear is a military helmet. The flexible cover 440 may include an elastic material at least at a portion of the edge 442 of the cover. Preferably the flexible cover 440 includes an elastic material along the entire edge 442.

[0041] In one example, the flexible cover 440 includes a nonwoven fabric that prevents contaminants from the surrounding environment from contacting the exterior of the protective headgear 400. The nonwoven fabric may include poly(vinyl alcohol) (PVA). Nonwoven fabrics containing PVA can be designed to dissolve in hot water, and may also be broken down into carbon dioxide and water. An example of such a nonwoven fabric is OREX.TM. Certified Soluble T fabric, available from Eastern Technologies, Inc. (ETI, Ashford, Ala.). In this example, the flexible cover 440 includes an elastic material along the entire edge 442. An example of such a flexible cover is the OREX.TM. Hard Hat Cover (#CS1801), available from ETI.

[0042] FIG. 5 is a representation of a side view of a protective headgear 500 that includes a rigid outer shell 510, a suspension 520, and a rim 530. The rigid outer shell 510 includes a bottom opening (not shown) and an internal cavity (not shown). The suspension 520 is attached to the outer shell 510 and is positioned at least partially within the internal cavity. The rim 530 circumscribes at least a portion of the bottom opening, and extends laterally from the outer shell 510. The rim 530 includes an edge 532, and at least a portion of the edge 532 includes a groove. In this example, the edge 532 includes at least one front groove 534, at least one rear groove 536 and at least one side groove 538.

[0043] FIG. 6 is a representation of a top view of a protective headgear 600 that includes a rigid outer shell 610, a suspension (not shown), and a rim 630. The rigid outer shell 610 includes a bottom opening (not shown) and an internal cavity (not shown). The rim 630 circumscribes the entire bottom opening, and extends laterally from the outer shell 610. The rim 630 includes an edge 632, and at least a portion of the edge 632 includes a groove. In this example, the entire edge 632 includes a groove 634.

[0044] FIG. 7 is a representation of a protective headgear 700 that includes a rigid outer shell 710, a suspension 720, and a rim 730. The rigid outer shell 710 includes a bottom opening 712 and an internal cavity 714. The suspension 720 is attached to the outer shell 710 and is positioned at least partially within the internal cavity 714. The rim 730 circumscribes at least a portion of the bottom opening 712, and extends laterally from the outer shell 710. The rim 730 includes an edge 732, and at least a portion of the edge 732 includes a groove. In this example, the edge 732 includes a front groove 734, a rear groove 736 and at least one side groove 738.

[0045] FIG. 8 is a representation of a perspective view of a protective headgear 800 that includes a rigid outer shell 810, a suspension 820, and a rim 830. The rigid outer shell 810 includes a bottom opening 812 and an internal cavity 814. The suspension 820 is attached to the outer shell 810 and is positioned at least partially within the internal cavity 814. The rim 830 circumscribes at least a portion of the bottom opening 812, and extends laterally from the outer shell 810. The rim 830 includes an edge 832, and at least one projection. The rigid outer shell 810, the suspension 820, and the rim 830 may be as described above for the outer shells, suspensions and rims of FIGS. 2 and 4-7.

[0046] The at least one projection may include at least one front projection 840 at the front of the rim 830. The at least one projection may include at least one rear projection (not shown) at the rear of the rim 830. The at least one projection may include at least one side projection 844 at a side of the rim 830. The at least one projection may circumscribe the bottom opening 812. The at least one projection may be positioned between the bottom opening 812 and the edge 832.

[0047] The at least one projection may have a variety of shapes and dimensions. If the projection circumscribes the bottom opening 812, then the height of the projection may be uniform, or the height may be different at different portions of the rim 830. If the at least one projection includes two or more projections, then the individual projections may have heights, lengths and thicknesses that may be the same or may be different from each other. The preferred number of the projections, and their configurations and dimensions, may depend on the properties of a flexible cover that is intended to be worn on the headgear. For example, a projection may extend from the main portion of the rim 830 to a height of from 1 to 50 mm, including a height of from 1 to 10 mm, from 2 to 7 mm, from 3 to 5 mm, from 5 to 50 mm, from 7 to 40 mm, or from 10 to 30 mm. For example, a projection that does not circumscribe the bottom opening may have a length of from 0.5 to 20 centimeters (cm), including a length of from 1 to 10 cm, from 2 to 5 cm, or from 5 to 15 cm.

[0048] The at least one projection may be integral with the rim 830. The at least one projection instead may be present in a separate material attached to the rim 830. A separate material that includes the at least one projection may include a rigid material, such as the materials listed above for the rigid outer shell 210, or it may include a flexible material, such as an elastomer.

[0049] A rigid material that includes the at least one projection may be attached to the rim 830 by an adhesive. A rigid material that includes the at least one projection may be attached to the rim 830 mechanically. In one example, a rigid material that includes the at least one projection may have a shape that mates with the shape of the edge 832 to provide a compression fit between the material and the edge. In another example, a rigid material that includes the at least one projection may include at least one portion that mates with at least one hole in the rim 830. In another example, the rim 830 may include at least one portion that mates with at least one hole in a rigid material that includes the at least one projection.

[0050] A flexible material that includes the at least one projection also may be attached to the rim 830, either mechanically or by an adhesive. For example, an elastomeric material that includes the at least one projection may include a closed loop. The closed loop may be extended to be positioned around the edge 832, and then may be allowed to relax to provide a compression fit between the elastomeric material and the edge. Preferably, a flexible material that includes the at least one projection has enough stiffness that the projection can retain at least a portion of a flexible cover.

[0051] FIGS. 9A-9D are representations of partial cross-section views of different configurations of protective headgear 900. In each configuration, protective headgear 900 includes a rigid outer shell 910 and a rim 930, where the rim includes an edge 932 and at least one projection. In FIG. 9A, a projection 941 includes a tab extending from the rim 930 between the edge 932 and a bottom opening of the headgear. In FIG. 9B, the at least one projection 943 includes a hook extending from the rim 930 between the edge 932 and a bottom opening of the headgear. In FIG. 9C, the at least one projection 945 includes a panel extending from the bottom of the rim 930. In FIG. 9D, the at least one projection 947 includes a panel extending from the top of the rim 930. The panels 945 and 947 independently may be set back from the edge 932, they may extend to the edge, or they may extend past the edge. Any of these projections may circumscribe the bottom opening, or they may be present at various positions around the rim. The shape and/or position of the projection may help to retain a flexible cover on the headgear 900.

[0052] FIG. 10 is a representation of a protective headgear 1000 that includes a rigid outer shell 1010, a suspension 1020, and a rim 1030. The rigid outer shell 1010 includes a bottom opening 1012 and an internal cavity 1014. The suspension 1020 is attached to the outer shell 1010 and is positioned at least partially within the internal cavity 1014. The rim 1030 circumscribes at least a portion of the bottom opening 1012, and extends laterally from the outer shell 1010. The rim 1030 includes an edge 1032, and at least one projection between the bottom opening 1012 and the edge 1032. In this example, the projection 1034 circumscribes the bottom opening 1012.

[0053] A protective headgear may include a rigid outer shell including a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell, where the rim includes a means for retaining an edge of a flexible cover for the protective headgear. The means for retaining an edge of a flexible cover for the protective headgear may include at least one groove and/or at least one projection. The means for retaining an edge of a flexible cover for the protective headgear may be integral with the rim, or it may be present in a separate material attached to the rim. A separate material that includes the means for retaining an edge of a flexible cover for the protective headgear may include a rigid material, such as the materials listed above for a rigid outer shell, or it may include a flexible material, such as an elastomer.

[0054] In one example, the means for retaining an edge of a flexible cover for the protective headgear includes a groove such as a groove 234 of FIG. 2, a groove 334 of FIG. 3, or a groove 634 of FIG. 6. In another example, the means for retaining an edge of a flexible cover for the protective headgear includes more than one groove, such as two or more of a front groove 534, a rear groove 536 and a side groove 538 of FIG. 5, or two or more of a front groove 734, a rear groove 736 and a side groove 738 of FIG. 7. In another example, the means for retaining an edge of a flexible cover for the protective headgear includes more than one projection, such as two or more of a front projection 840, a side projection 844 and a rear projection of FIG. 8. In another example, the means for retaining an edge of a flexible cover for the protective headgear includes a projection such as a tab 941 of FIG. 9A, a hook 943 of FIG. 9B, or a panel 945 or 947 of FIGS. 9C and 9D, respectively. In another example, the means for retaining an edge of a flexible cover for the protective headgear includes a projection such as a projection 1034 of FIG. 10.

[0055] A method of making a protective headgear may include forming a rigid outer shell, and attaching a suspension to the rigid outer shell. The rigid outer shell may include a bottom opening, an internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell. The rim includes an edge, and includes a groove in at least a portion of the edge and/or includes at least one projection. The outer shell may be configured as an outer shell described above.

[0056] A method of making a protective headgear may include modifying an outer shell of a protective headgear to include a groove in an edge of a rim of the headgear, and/or to include a projection between the bottom opening of the outer shell and the edge of the rim. For example, the outer shell of a commercially available headgear may be modified to include a groove in the edge of the rim of the headgear, and/or to include a projection between the bottom opening of the outer shell and the edge of the rim. Examples of commercially available protective headgear include models C30, C33 S51, S51R, S61, S61R, S62, S62R, S71, S71R, 911H, 911HR, 911C, 911CR, S51 MT, S51 MTR, A1, A2, Vector-C and Vector CRT, available from BULLARD, Cynthiana, Ky. Examples of commercially available protective headgear include Skullgard.RTM., Advance.RTM., Topgard.RTM., Topgard.RTM. HTE, V-Gard.RTM., SmoothDome.TM., Thermalgard.RTM., Comfo Cap.RTM., and Vanguard II.RTM., available from MINE SAFETY APPLIANCES COMPANY (MSA), Pittsburgh, Pa.

[0057] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that other embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Claims

1. A protective headgear, comprising: a rigid outer shell comprising a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell; where the rim comprises an edge, and at least a portion of the edge comprises a groove.

2. The protective headgear of claim 1, where a portion of the edge at the front of the headgear comprises a front groove, and a portion of the edge at the rear of the headgear comprises a rear groove.

3. The protective headgear of claim 2, where portions of the edge at the sides of the headgear each comprise a side groove.

4. The protective headgear of claim 1, where the entire edge comprises the groove.

5. The protective headgear of claim 1, where the groove has a width of from 0.5 to 3 mm.

6. The protective headgear of claim 5, where the groove has a depth of from 1 to 5 mm.

7. The protective headgear of claim 1, where the groove is integral with the rim.

8. The protective headgear of claim 1, where the edge comprises a separate material attached to the rim, the separate material comprising the groove.

9. The protective headgear of claim 1, where the groove is integral with the rim, the entire edge comprises the groove, the groove has a width of from 1 to 2.5 mm, and the groove has a depth of from 1.5 to 4 mm.

10. The protective headgear of claim 9, where the groove has a width of from 1.5 to 2 mm, and the groove has a depth of from 2 to 3 mm.

11. A protective headgear, comprising: a rigid outer shell comprising a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell; where the rim comprises an edge and at least one projection.

12. The protective headgear of claim 11, where the at least one projection comprises a front projection at the front of the rim.

13. The protective headgear of claim 12, where the at least one projection further comprises a rear projection at the rear of the rim.

14. The protective headgear of claim 13, where at least one projection further comprises a side projection at a side of the rim.

15. The protective headgear of claim 11, where the at least one projection circumscribes the bottom opening.

16. The protective headgear of claim 11, where the at least one projection comprises at least one of a tab, a hook, or a panel.

17. The protective headgear of claim 11, where the at least one projection is integral with the rim.

18. (canceled)

19. A protective headgear, comprising: a rigid outer shell comprising a bottom opening and an internal cavity, a suspension attached to the outer shell and positioned at least partially within the internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell; where the rim comprises a means for retaining an edge of a flexible cover for the protective headgear.

20.-22. (canceled)

23. In a protective headgear, comprising a rigid outer shell comprising a bottom opening and an internal cavity, and a suspension attached to the outer shell and positioned at least partially within the internal cavity; the improvement comprising: a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell, the rim comprising an edge, and at least one of a groove in at least a portion of the edge, and at least one projection.

24. A rigid outer shell for a protective headgear, comprising: a bottom opening, an internal cavity, and a rim circumscribing at least a portion of the bottom opening and extending laterally from the outer shell; where the rim comprises an edge, and at least one of a groove in at least a portion of the edge, and at least one projection.