16, the same as or similar to the front 14 mounting location 16, is reversed. In other words, the rear 15 mounting location 16 is located above the user's eyes and available for attachment of an accessory 18 (FIGS. 3 and 9, e.g., a lamp 20 or face shield 22) to hard hat 10. In both FIGS. 1 and 2, each attached accessory 18, such as a headlamp and/or face visor, includes a mounting bracket 24 (FIG. 3) that securely attaches to ridges 25 on front 14 or rear 15 mounting locations 16 of hard hat 10.

FIG. 3 illustrates bracket 24 attachment of a headlamp or lamp 20 at mounting location 16 on hard hat 10. In some embodiments, the attachment system includes mounting bracket 24, lamp 20, and a strap 28. Bracket 24 includes clips or receiving slots 30 that interface with ridges 25 on front or rear mounting locations 16 of hard hat 10. Bracket 24 provides structural support to lamp 20 and provides a rigid attachment location to secure lamp 20 on hard hat 10. Strap 28 interconnects lamp 20 to bracket 24 and provides a mechanism to attach various lamps 20, including aftermarket lamps with strap 28 at receiving support locations or mounting locations 16 of hard hat 10.

A strap or band 32 wraps around the circumference of hard hat 10 without interfering with the mounting locations 16 or auxiliary ridges 26. For example, band 32 passes through openings under auxiliary ridges 26. Band 32 supports hand tools and/or other equipment suitable for storage along brim 12 or auxiliary ridges 26 of hard hat 10. Similarly, various accessories 18 attach or couple to ports 34 in an auxiliary ridge 26 of hard hat 10. In some embodiments, tools and/or other accessories 18 include an insert, fastener, or receiving slot 30 that couples with one or more ports 34.

FIGS. 1 and 2 show different sized ports 34. A smaller port 34 accommodates a smaller accessory 18 (e.g., tool or eyeglass carrier). Similarly, a larger port 34 is used for a larger accessory 18 (e.g., earmuffs 38). In some embodiments, a front, middle, and/or rear port 34 are interchangeable to receive and/or support various accessories 18. For example, a rear port 34 is located along an axial axis 40 and located at a centerline of the operator's neck. When an accessory 18 is coupled, the rear port 34, the accessory 18 is aligned with the axial axis 40 to reduce the moment or load on the user's neck.

FIG. 4 compares a white bill 42 style on the left and a green brim 12 style hard hat 10 in the middle. Bill 42 styled hard hats 10 have a bill 42 in front 14 (e.g., over the user's eyes), but no brim 12 surrounding the sides (e.g., ear) and/or rear 15 (e.g., neck) of hard hat 10. In contrast, brim 12 styled hard hats 10 have a brim 12 at least partially surrounding and extending about the front 14, rear 15, and/or sides of hard hat 10. For example, FIGS. 1-3 show a brim 12 styled hard hat 10. Applicant has found that users have preferences for different styles of hard hats 10. For example, brim 12 styles can be symmetric/balanced from front 14 to rear 15, whereas bill 42 styles enable a user to rotate earmuffs further upwards without interference from the surrounding brim 12. Different hard hat 10 styles with different geometries can have the same or similar mounting locations 16 to support the same accessories 18.

The composite image of bill 42 and brim 12 hard hats 10 is shown on the left of FIG. 4. In this composite image, the white bill 42 (e.g., of a bill styled climbing helmet) extends further in the front 14. The extended brim 12 style (e.g., traditional style) extends further on the sides and rear 15 of hard hat 10. Both bill 42 and brim 12 hard hats 10 are shown supporting earmuffs 38 in the rearward port 34. As shown, white bill 42 hard hat 10, on the left, does not interfere with rotation of earmuffs 38 to a position above and/or behind the user's ear. The middle image shows earmuff 38 stored behind the operator's ear, but under brim 12 to minimize interference with earmuff 38 at the rearward brim 12 of hard hat 10.

Often the user attaches various accessories 18 at different locations (e.g., mounting location 16 and/or ports 34) to maximize utility (e.g., accommodate more accessories 18) and/or comfort. The composite image on the right shows earmuffs 38 in the rear port 34. In this position, earmuff 38 extends substantially parallel to axial axis 40 and over the user's ears, when earmuffs 38 are in the shown operating position. For example, a user places earmuff 38 in the third or rear port 34 because this attachment location for earmuff 38 is closer to a centerline, or axial axis 40, of the operator's neck (e.g., the base of the user's head). Alternative positions for accessories 18 may aid with shade and/or muscle comfort, e.g., by keeping the mass or CG as close to the axial axis 40 at the centerline.

Stated differently, accessories 18 fit differently on hard hats 10 of different styles and/or geometries. However, where the mounting locations 16 and/or auxiliary ridges 26 are the same, or similar, for different hard hats 10, they interchangeably receive accessories 18 with a complimentary mounting bracket 24 (or insert).

FIG. 5 is a cross-sectional comparison of the bill 42 style and the brim 12 style hard hats 10 of FIG. 4. As shown, in various embodiments, hard hat 10 has a full brim 12 (e.g., brim 12 style) or a large bill 42 without a surrounding brim 12 (e.g., bill 42 style). Mounting locations 16 for the bill 42 and brim 12 style hard hats 10 are different. For example, comparably sized hard hats 10 have an offset between the mounting location 16 on the short brim 12 (brim 12 style) and long bill 42 (bill 42 style) hard hat 10.

FIG. 6 shows an extendible visor 48 that surrounds and clamps or directly couples to auxiliary ridges 26 and/or mounting locations 16 on hard hat 10, e.g., similar to band 32. Visor 48 couples under mounting locations 16 and/or auxiliary ridges 26 in such a way as to leave ports 34 and mounting locations 16 available for additional accessories 18. Visor 48 is made from a flexible material, such as a fabric, polymer, or plastic. In one embodiment, visor 48 includes a front portion 50 and a rear portion 52 interconnected by an elastic section 54. Elastic section 54 enables a user to stretch the visor 48 around the auxiliary ridge 26 and mounting locations 16.

Visor 48 couples under mounting locations 16 and auxiliary ridge 26 along an outer perimeter 88 of hard hat 10. Visor 48 deflects to rotate/move earmuff 38 from below the visor 48 in an operation position 56 to a stored position 58 for earmuff 38 above the visor 48, as shown in FIG. 6. In addition, the elastic section 54 enables the visor 48 to provide some slack when earmuff 38 is moved over visor 48 from an operation position 56 to a stored position 58. The flexible nature of visor 48 and/or elastic section 54 facilitates the movement from use (e.g., operation position 56) to stored position 58 and back.

FIG. 7 shows two perspective views of a visor 60 with a mounting bracket 24 that attaches to the mounting locations 16 on hard hat 10. Visor 60 acts like a visor 48 for specific accessories, e.g., face shield 22, but can be modular and segmented. For example, visor 60 enhances face shield 22 for different styles and sizes of hard hats 10. Additional outer mounting locations 16 on visor 60 support accessories 18 on hard hat 10, and a distending peak or ridge extension 62 protrudes radially outward between the mounting location 16 and an edge of visor 60. As such, visor 60 provides cross-compatibility between different hard hats 10 of different sizes and styles, including bills 42 and brims 12. In addition, visor 60 provides additional mounting locations 16 for other accessories 18.

Visor 60 provides a space, or bridge, for accessories 18, such as lamp 20, to remain attached to hard hat 10 when an operator moves the face shield 22 from an operation position 56 to a stored position 58 and back. Visor 60 also provides a reliable structural abutment, or seal, between the face shield 22 and any style of hard hat 10 with mounting locations 16 (or auxiliary ridges 26) configured for the bracket 24 on visor 60. In this way, visor 60 facilitates coupling a welding face shield 22 and a lamp 20 to the mounting location 16. As a specific example, this configuration is beneficial when welding, since traditional welding face shields 22 are dark to protect the eyes from the arc, but often too dark to see in ambient light. Operators often find it difficult to see and manipulate work-piece objects when the face shield is in the operating position but the welding arc is not illuminated. Lamp 20 can provide sufficient light for the operator to see and manipulate the welding work-pieces before and after the welding process in the absence of the arc.

Visor 60 provides a structural and spatial bridge between hard hat 10 and face shield 22 for structural support of another attached accessory 18. This enables two accessories 18 (e.g., a welding mask and a headlamp) to be coupled at the mounting location 16 of hard hat 10. Ridge extensions 62 on visor 60 (e.g., bracket 24 of visor 60) provide a structural offset or bridge from hard hat 10 to visor 64 to accessory 18.

Visor 60 has a bracket 24 with a duplicate mounting location 16 on an exterior of visor 60 to accommodate the additional mounted accessory 18. For example, on one side (e.g., an inner surface) of visor 60 is a mounting bracket 24 with ridges 25 similar to lamp 20. When this bracket 24 of visor 60 couples to mounting location 16, an opposite, exposed side (e.g., outer surface) of visor 60 forms an available external mounting location 16 to receive and support an additional mounted accessory 18, such as a lamp 20, on hard hat 10.

To support accessory 18 and/or visor 60, each mounting location 16 has side ridges 25 on both sides of mounting location 16. Mounting bracket 24 has a complimentary side receiving slots 30 on both sides of mounting bracket 24. Side receiving slots 30 are configured to couple to ridges 25 at the mounting locations 16. For example, the coupling of receiving slots 30 to ridges 25 mounts visor 60 to hard hat 10 and similarly mounts a lamp 20 to visor 60 (FIG. 18). In this way, visor 60 serves as a bridge between an accessory 18 and the mounting locations 16 of different sizes and styles of hard hats 10.

Applicant has found that having a mounting location 16 for the face shield 22 with the same, or similar, ridge extension 62 dimensions ensures the proper abutting visor 64 position for the face shield 22 in the operation position 56 to protect a user's eyes and/or face. Ridge extension 62 structurally interconnects face shield 22 over the brim 12 of hard hat 10. In one embodiment, ridge extension 62 and face shield 22 abut to form a seal, such as a watertight or hermetic seal. The seal then protects the user from intruding or splashed liquids or debris.

Different users prefer different bills 42, brims 12, and/or hard hat 10 geometries. Different geometries are also advantageous for various worksites and/or jobs. For example, the same user may have one hard hat 10 with a large bill 42 for outdoor worksites and a second hard hat 10 with a small surrounding brim 12 to support a lamp 20 for indoor job sites.

Applicant has found that using an intermediary modular visor 60 enables the user to attach one face shield 22 that reliably abuts and/or seals against the brim 12 of a variety of hard hats 10. Visor 60 creates a reliable fitment regardless of the style, size, or geometry of the brim 12 or bill 42 on the hard hat 10. In this way, an operator with two hard hats 10 can attach, abut, and/or seal the same face shield 22 to visor 60, and then interchangeably attach and detach the visor 60 and face shield 22 to the operator's preferred hard hat 10. This enables the operator to customize the hard hat 10 for a particular environment or job. Alternatively, the same user attaches a welding face shield 22 for a welding job and later attaches a different protective eyeglass face shield 22 for woodworking. In other words, visor 60 bridges different sizes and shapes of various hard hats 10 (or face shields 22) and permits the use of one face shield 22 to fit various sizes of hard hats 10 with complimentary mounting locations 16.

In one embodiment, visor 60 includes an oblong locking protrusion 66 in mounting location 16. An overhang 68 on bracket 24 engages a notch or notch 69 to lock visor 60 on mounting locations 16 of hard hat 10. The coupled notch 69 and overhang 68 protect against inadvertent bumping or jostling of accessories 18 when visor 60 is coupled to hard hat 10.

FIG. 8 shows perspective, top, and bottom views, respectively, of visor 60. The connection of visor 60 to hard hat 10 creates a ridge extension 62 that covers both hard hats 10 and helmets with bill 42 and brim 12 styles. The top row shows visor 60 attachment to both bill 42 (left climbing helmet) and brim 12 styled (right-traditional brim style) hard hats 10.

Visor 60 attaches to both styles and creates a uniform ridge extension 62 with a consistent brim width W. The brim width W extends between the mounting location 16 of hard hat 10 to an edge of the ridge extension 62 on visor 60. As shown, the brim width W is greater than either bill 42 or brim 12 dimensions. The middle row shows how the visor 60 creates a uniformly sized attachment for an accessory 18 or face shield 22. The bottom row shows how brim width W is longer than either extension of bill 42 or brim 12 styles. Specifically, the black visor 60 is longer than either the bill 42 (left) or brim 12 (right) of either hard hat 10.

FIG. 9 is a top perspective view of an embodiment of a sun-visor or visor 70 with a bracket 24 over hard hat 10. Visor 70 is the same as or similar to visor 48 and/or visor 64, except visor 70 includes one or more attachment mechanism, shown as joint 72 and/or a bracket 24, to securely but removably couple visor 70 to mounting locations 16 or auxiliary ridges 26 of hard hat 10.

In a specific embodiment, hard hat system 8 includes hard hat 10 including a shell 11 formed from a rigid material and visor 70 reversibly coupled to hard hat 10. The shell 11 includes an accessory mounting location 16 located along an outer surface 7 of shell 11.

In various embodiments, visor 70 includes a first portion 130 and a second portion 132. The first portion 130 extends circumferentially around at least a portion of the shell 11 and extends radially outward from the shell 11 forming a sun-blocking flange. The second portion 132 is coupled to the first portion 130 and positioned adjacent to the accessory mounting location 16. The second portion 132 is deformable relative to the first portion 130 such that the second portion 132 deforms to accommodate and cover a portion of an accessory 18 (e.g., an ear muff) coupled to an accessory mounting location, shown as one of front port 80, middle port 82, or rear port 84. The deformation of second portion 132 allows accessory 18 to extend from the accessory mounting location (e.g., front port 80, middle port 82, or rear port 84) to below the second portion 132.

In various embodiments, second portion 132 is formed from a material that is more elastic than a material of the first portion 130. In various embodiments, second portion 132 includes a first zone 134 on a first side 136 of shell 11, and a second zone 138 on a second side 140 of shell 11 opposite the first side 136. In a specific embodiment, the first side 136 is a left side of the shell 11 and the second side 140 is a right side of the shell 11. In various embodiments, a fastener, shown as joint 72, couples the visor 70 to the left side of the shell 11 and a second fastener, shown as joint 72, couples the visor 70 to the right side of the shell 11. In various embodiments, second portion 132 includes a third zone 142 and a fourth zone 144 separated by a bridge 78, and the third zone 142 and the fourth zone 144 are both positioned on a first side of the shell 11 (e.g., a left side of the shell 11, a right side of the shell 11). The bridge 78 is formed from a material that is less elastic than a material forming the second portion 132.

As described in detail below, visor 70 enables a user to fold a brim 12, e.g., front over the back or back over the front, and retain the fold. Visor 70 couples to mounting locations 16 and/or ports 34 of auxiliary ridge 26 on different styles and sizes of brim 12 and/or bill 42 hard hats 10 (e.g., climbing styled helmets and traditional hard hats 10). FIG. 10 shows a rear view of hard hat 10 with visor 70 coupled to the rear mounting ridge via bracket 24, as illustrated in FIG. 9.

With reference to FIGS. 9 and 10, visor 70 includes a front portion, shown as front brim segment 74, and a rear portion, shown as rear brim segment 76, that are interconnected by opposite stretch zones 77. Front brim segment 74 and rear brim segment 76 are similar to front and rear portions 50 and 52 of visor 48. A fastener, shown as joint 72, couples two parallel stretch zones 77 to a port 34 on the auxiliary ridge 26 to secure visor 70. In one embodiment, the front brim segment 74 and/or rear brim segment 76 includes bracket 24 that couples visor 70 to mounting locations 16 (or auxiliary ridges 26) on hard hat 10. A non-elastic material or bridge 78 between stretch zones 77 forms integrally with joint 72 (FIG. 9) or is a separate component that couples to and supports joint 72 (FIG. 10).

Front brim segment 74 is moveable between a covering configuration in which the front brim segment 74 extends in a forward direction 71 away from a front 14 of hard hat 10, and a stowed configuration in which the front brim segment 74 extends in a rearward direction 73 away from a rear 15 of the hard hat 10. Front brim segment 74 interfaces with the rear brim segment 76 when the front brim segment 74 is in the stowed configuration.

In various embodiments, clip 24 is coupled to rear brim segment 76 and clip 24 couples visor 70 to hard hat 10 (FIG. 9). In various embodiments, clip 24 is coupled to front brim segment 74, and clip 24 couples to rear 15 of hard hat 10 when the front brim segment 74 of visor 70 is in the stowed configuration. In various embodiments, clip 24 couples front brim segment 74 to front 14 of hard hat 10 when front brim segment 74 of visor 70 is in the covering configuration. In various embodiments, clip 24 is coupled to the front brim segment 74 of visor 70, the clip 24 couples to a front 14 of the hard hat 10 when the visor 70 is in the covering configuration.

In various embodiments, joint 72 couples to a port 34 in auxiliary ridge 26. For example, as shown in FIG. 9, joint 72 couples to a front port 80. FIG. 10 shows joint 72 coupling visor 70 to a middle port 82. Similarly, joint 72 can couple to any port 34 (e.g., rear port 84) of auxiliary ridge 26 and/or a front or rear mounting location 16 on hard hat 10. Joint 72 location in a front port 80, middle port 82, or rear port 84 determines a fold location 86 of visor 70. Also, the use of a particular port 34 (e.g., front port 80, middle port 82, or rear port 84) facilitates the attachment of other accessories 18 to either the mounting location 16 and/or other ports 34 in auxiliary ridge 26. For example, using a front port 80 to attach a face shield 22 and/or visor 70 facilitates earmuff 38 attachment at a middle or rear port 82 or 84 of auxiliary ridge 26.

In various embodiments, bracket 24 is coupled directly to visor 70 (FIG. 9) or over visor 70 (FIG. 10) at the mounting location 16. FIG. 9 shows bracket 24 coupled to visor 70 and securely coupled to a rear mounting location 16 on hard hat 10. In contrast, FIG. 10 shows visor 70 wrapped around an outer perimeter 88 of hard hat 10. Outer perimeter 88 includes the transition perimeter of the front and rear mounting locations 16 and the side auxiliary ridges 26 towards/adjacent the brim 12 of hard hat 10. Visor 70 has a hollowed elliptical shape (elongated donut) that extends radially from an inner diameter 90 (e.g., adjacent outer perimeter 88 of hard hat 10) to an outer diameter 92. Bracket 24 couples to a rear mounting location 16 and captures visor 70 around the outer perimeter 88, between the hard hat 10 brim 12 and bracket 24 (e.g., under notch 69 but over brim 12 of hard hat 10). Bracket 24 includes exterior mounting locations 16 and/or a notch 69 to further support and/or couple an additional accessory 18. An elastic or strap 94 extends under front brim 12 to fold the brims 12 and hold the folded configuration.

FIGS. 11A and 11B compares an axial or parallel stretch visor 70 (FIG. 11A) with two stretch zones 77 on opposite sides of visor 70 to a radial stretch visor 70 (FIG. 11B) with only one stretch zone 77. As shown in FIGS. 11A and 11B, the radial stretch visor 70 expands an inner diameter 90 of visor 70 to open a radial circumference of inner diameter 90 and fit visor 70 on different sizes, shapes, and configurations of hard hats 10 and/or accessories 18. The parallel stretch visor 70 includes stretch zones 77 on opposite sides of visor 70, e.g., adjacent to auxiliary ridge 26. The parallel stretch visor 70 enables folding and may include folding locations 86, such that a user can fold visor 70. For example, folded visor 70 extends the brim 12 on a front or rear half, while providing unobstructed access to the mounting system (mounting locations 16 and ports 34 on auxiliary ridge 26) on the other half of hard hat 10. Parallel stretch visor 70 also enables users to access ports 34 of auxiliary ridges 26 on opposite sides of hard hat 10.

FIGS. 12-14 show different views of visor 70 of FIG. 9 in a folded configuration. Fold locations 86 on opposite sides of visor 70 provide pivots to allow the user to flip the front (or rear) brim 12 of visor 70 and attach an accessory to the mounting location 16 on the front of hard hat 10. Bracket 24 slides over the flipped brim 12 to capture and hold the rotated brim 12 in the folded configuration. Strap 94 is rotated around both brims 12 (e.g., front and rear brim 12) to hold the brims 12 together in the folded configuration shown. This configuration provides the user access to mounting locations 16 and/or auxiliary ridges 26 without interference from visor 70 and permits the user to modify visor 70 according to the user's preferences and circumstances.

In various embodiments, visor 70 includes a first folding location 86 on a first side 81 of visor 70, and a second folding location 87 on a second side 79 of visor 70 opposite the first side 81. In various embodiments, first folding location 86 includes a stretch zone 77 that is more clastic than neighboring portions of visor 70 (e.g., portions of visor 70 adjacent to stretch zone 77).

FIG. 15 shows another embodiment of a modular visor 100. Modular visor 100 is the same as or similar to visor 48, 64, and 70, except for the differences described. Modular visor 100 includes individual modules or brim segments (e.g., front brim segment 74 and rear brim segment 76) that couple together around the outer perimeter 88 of hard hat 10. In this way, modular visor 100 can include different materials, shapes, and/or accessories 18 based on user preference to provide different functionalities. As shown, front brim segment 74 includes a semi-transparent plastic that, for example, blocks UV rays to the user's eyes but permits some visible light through. Joint 72 couples front brim segment 74 to interconnect rear brim segment 76. Rear brim segment 76 includes two stretch zones 77 and an opaque plastic material brim 12.

Strap 94 can be coupled to front brim segment 74 and/or rear brim segment 76. Joint 72 can be biased or unbiased to provide folding locations 86 for rotation of either modular section. Joints 72 couple front brim segment 74 to rear brim segment 76. Joints 72 also couple modular visor 100 to auxiliary ridge 26. In other embodiments, a compressive force generated by stretch zones 77 expanded about outer perimeter 88 retains visor 100. Various shims 104 are located around outer perimeter 88 to adjust modular visor 100 to the size, shape, and/or style.

In some embodiments, joint 72 includes mating protrusions 106 and slots 108 between front brim segment 74 and rear brim segment 76. For example, protrusions 106 couple or snap into slots 108 to couple the front and rear segments 74 and 76 of modular visor 100. In various embodiments, joint 72 includes other mechanisms for temporarily and securely joining segments of modular visors 100, such as hook and loop joints, pressure/friction generating joints, metal and/or plastic quick-release joints, fasteners, buckles, and/or adhesives.

FIG. 16 is a perspective view of modular visor 100 of FIG. 15 coupled to a front 14 and folded visor 70 of FIG. 9 and coupled to a rear 15 of hard hat 10. Bridge 78 and/or joint 72 couple/form folding locations 86 in opposite parallel stretch zones 77. For example, joint 72 couples stretch zone 77 to front port 80, leaving the middle port 82 and rear port 84 available to couple additional accessories 18. Stated differently, modular visor 100 independently couples to front 14 of hard hat 10, such as with a clamping frictional force created by a frictional fit or a bracket 24 or inserted fastener. In some embodiments, a single segment (e.g., front brim segment 74) includes multiple materials, e.g., a first semi-transparent material 110 and a second opaque material 112. Since the modules or segments of modular visor 100 are independent, front segment 74 and rear segment 76 can also be fabricated from different materials to exhibit different properties and functionality. Alternatively, one segment, e.g., either segment 74 or 76, can be used in combination with another accessory 18, such as face shield 22.

As illustrated, no physical connection exists between modular visor 100 and folded visor 70. This configuration enables the functional coupling or pairing of a modular visor 100 and a folded visor 70. Modular visor 100 is used in combination with other accessories 18 and/or sun-visors (e.g., visors 48, 67, and/or visor 70, or another visor described herein). For example, two or more modular visors 100 (e.g., a front brim segment 74 and a rear brim segment 76) are combined to extend around the outer perimeter 88 of hard hat 10 entirely. Front brim segment 74 and rear brim segment 76 of modular visor 100 can be different materials and/or have different transparencies (e.g., transparent, semi-transparent, or opaque). In addition, front brim segment 74 and/or rear brim segment 76 are interchangeably removed and replaced with one or more accessories 18 to fit the operator's preferences, safety, and/or use at the specific job site.

FIG. 17 is a top perspective view of modular visor 100 coupled to face shield 22 accessory 18. Face shield 22 includes bracket 24 that couples to front 14 mounting locations 16 on hard hat 10. Face shield 22 extends around the user's face. In various embodiments, face shield 22 can create a seal between the face (e.g., eyes, nose, and/or mouth) of a user, An optional guard 114 (e.g., a visor sized for face shield 22) extends outward to form a scam 115 along a joint between face shield 22 and guard 114. In various embodiments, seam 115 is hermetic, watertight, or another secured seal to prevent debris (e.g., hot/melted metal in a welder helmet) from entering around the user's face. Bracket 24 on face shield 22 includes outer mounting locations 116 with side ridges 125 and a notch 169 that is the same as or similar to the geometry of the mounting locations 16. Thus, the mounting system enables the use of additional mounting location 116 to attach another accessories 18 (e.g., a lamp and/or eyeglass holder).

FIG. 18 is a top perspective view of a front modular visor 100 made from a semi-transparent material coupled to a rear modular visor 100 made from an opaque material. Front and rear segments 74 and 76 are coupled to form a modular visor 100 that is coupled to hard hat 10 with a joint 72. Joint 72 includes protrusions 106 coupled to slots 108 to adjust the side of inner diameter 90 of the combined modular visor 100 (e.g., the visor resulting from the joining of front and rear modular visors 100). This feature enables a user to modify the size of inner diameter 90 to accommodate the size, style, and/or dimensions of mounting locations 16 and/or auxiliary ridges 26. As shown in FIG. 18, outer diameter 92 can increase from the solid line to the dotted outer diameter 92 based on changes to the inner diameter 90. Front brim segment 74 is made from a different material than rear brim segment 76 to form a multi-material modular visor 100. For example, front brim segment 74 includes a semi-transparent tinted plastic material. Rear brim segment 76 includes an opaque fabric material coupled to a polymer center. Modular visor 100 has front and rear brim segments 74 and 76 and includes different material features.

In some embodiments, modular visor 100 includes one or more materials and/or stretch zones 77 to adjust the frictional clamping force of inner diameter 90 of visor 100 on outer diameter 92 of hard hat 10. In various embodiments, the frictional clamping force and/or bracket 24 couple visor 100 to hard hat 10. Bracket 24 either forms a part of brim segment 74 or 76 (e.g., is affixed to) or fits over and captures brim segment 74 and/or 76 against hard hat 10 (e.g., is not joined but proximate to segments 74 and 76).

FIG. 19 shows another embodiment visor 150 with an enclosed clastic area 152 in the brim 12. Visor 150 is the same as or similar to other visors described herein (e.g., visors 48, 64, 70, and/or modular visor 100, but combines different features and modifications from these visors. For example, enclosed elastic area 152 of visor 150 extends from inner diameter 90 of brim 12 but does not extend across brim 12 to outer diameter 92. Unlike stretch zones 77 of visor 70 the clastic area 152 is enclosed within brim 12 and adjacent to auxiliary ridge 26. Enclosed elastic area 152 is surrounded by a non-elastic region 154 of brim 12 on visor 150. Thus, the outer diameter 192 is firm (e.g., not extendible or flexible), but deflections near the sides of hard hat 10 (e.g., near auxiliary ridges 26) provide access to ports 34 in auxiliary ridge 26.

Visor 150 also couples rear brim segment 76 to both front ports 80 and rear mounting location 16. This configuration creates a stable visor 150 connection and also enables the operator to insert and attach earmuffs 38 to auxiliary ridge 26 through elastic area 152. Specifically, the operator passes a four-bar support arm 156 linkage for either face shield 22 or earmuffs 38. Support arm 156 passes into or through elastic area 152 and couples inserts 158 (at the terminus of support arm 156) into the remaining middle or rear port 82 or 84 of each opposite auxiliary ridge 26 (FIG. 20). Coupling rear brim segment 76 to front port 80 and rear mounting location 16 improves the ergonomic attachment of earmuffs 38 to either a middle port 82 or rear port 84 that aligns most comfortably over the individual user's ear.

FIG. 20 shows different views of the enclosed elastic area visor 150 and support arm 156 to insert 158 and couple earmuff 38 within the rear port 84. As described above, some users may opt to use the middle port 82 to fit earmuff 38 directly over their ear ergonomically. In contrast, the rear port 84 may be a better fit for other users. The modular configuration of visor 150 coupled to front port 80 enables the user to optionally choose the configuration that is most ergonomic and comfortable. This configuration also keeps another port 34 available on each side of auxiliary ridge 26 for another accessory 18 (e.g., reflector, eyeglass holder, or tool carrier).

FIG. 21 shows another embodiment of visor 160 with mixed materials. Visor 160 includes different materials with a rigid outer perimeter or outer diameter 92 and a soft fabric inner diameter 90 to accommodate differences in the sizes, styles, and/or dimensions of various hard hats 10 or helmets with different sized mounting locations 16 or auxiliary ridges 26. For example, visor 160 includes two stretch zones 77 interconnecting front and rear brims 12. Brim 12 include a pad 162 and bracket 24 to couple visor 160 to different sizes and shapes of hard hats 10 and/or attached accessories 18 (e.g., face shield 22).

In various embodiments, face shield 22 can be a convertible face shield 22 that attaches to hard hat 10 when visor 100 is folded towards the rear 15 of hard hat 10 (FIG. 17). Alternatively, face shield 22 couples to a rear segment 74 of modular visor 150. Visor 160 combines various features of visors previously described herein (e.g., visors 48, 64, 70, 100, and/or 150) to further customize attachment of different accessories 18 (e.g., face shield 22) to mounting locations 16 and/or auxiliary ridges 26.

Visor 160 mounts around hard hat 10 perimeter 88 with a coupled accessory 18 (face shield 22) at a front mounting location 16 of hard hat 10. This configuration demonstrates how the features and/or materials of visor 160 interact with various attached accessories 18 (e.g., four-bar linkages, support arms, and/or inserts) at mounting locations 16 and/or auxiliary ridges 26. FIG. 22 is an isolated perspective view of visor 160 of FIG. 21.

As illustrated in FIGS. 21-22, bracket 24 includes an external mounting location 116 that is the same as or similar to the mounting location 16 on hard hat 10. In some embodiments, bracket 24 includes external mounting locations 116 with ridges 125. In this way, bracket 24 serves as a bridge that couples a first accessory 18 (e.g., face shield 22) to front mounting location 16 of hard hat 10 and provides a second outer mounting location 116 to attach a second accessory 18. Stated differently, bracket 24 forms a bridge of connections that enables stacking multiple accessories 18 onto a single mounting location 16 of hard hat 10.

A front pad 162 along the inner diameter 90 of a front transparent brim segment 74 provides a tolerance 165 to fit visor 160 on different sizes and shapes of various accessories, hard hats 10, and helmets. Two opposite and parallel stretch zones 77 are located adjacent auxiliary ridge 26 and extend from inner diameter 90 to outer diameter 92 of brim 12. A spring-loaded or biased fastener creates a biased pivot 164 (e.g., similar to joint 72) that couples stretch zones 77 of visor 160 to a port 34 on auxiliary ridge 26 (e.g., front port 80, middle port 82, or rear port 84). Biased pivot 164 creates the bias or spring force against visor 160, such that the operator applies a downward force on visor 160 to create a clamping frictional force at the inner diameter 92 on brim 12. Stretch zones 77 include a stretched flexible material that extends from inner diameter 90 to outer diameter 92 to create a compressive force on outer perimeter 88 and enable pad 162 and visor 160 to deflect for different sizes, shapes, and styles of hard hat 10. A wire 166 extends along outer diameter 92 of visor 160 to create a rigid outer diameter 92.

An optional bracket 24 couples to a rear segment 76 of visor 160. Bracket 24 couples or captures visor 160. Pad 162 slides under a notch 69 at mounting location 16 of hard hat 10. As illustrated, mounting location 16 is coupled to face shield 22, and pad 162 fits under notch 169 to couple to the outer perimeter 88 of hard hat 10 with the attached accessory 18. Stretch zones 77 are elastic/flexible adjacent auxiliary rides 26, but wire 166 forms a rigid/firm outer diameter 92 of visor 160. This configuration enables multiple materials in semi-transparent or tinted front and rear segments 74 and 76, stretch zones 77, and pad 162 to form expandable features at the joint between outer perimeter 88 of hard hat 10 and inner diameter 90 of visor 160. In contrast, outer diameter 92 is relatively rigid and firm through the various materials due to wire 166. In one embodiment, stretch zones 77 extend over and/or deflect around both support arms 156 and inserts 158 that attach face shield 22 and/or earmuffs 38.

Referring to FIGS. 23-27, various aspects of a visor 220 are shown. Visor 220 is substantially the same as visor 48, visor 60, visor 64, visor 67, visor 70, visor 100, or visor 150, except for the differences discussed herein. Visor 220 includes a rear portion 224 coupled to hard hat 210 via frame 240. Side portions 222 extend from rear portion 224 circumferentially extend around hard hat 210. Folding portion 232 is coupled to rear portion 224 via folding location 230 at connecting portion 236. In a specific embodiment, rear portion 224 and folding portion 232 are formed from a fabric or fabric-like material.

Frame 240 is coupled to safety headwear, shown as hard hat 210, at one of a plurality of mounting slots along the side of hard hat 210. In the specific embodiment shown, frame 240 is coupled to a middle port 214 of hard hat 210. In a specific embodiment, frame 240 is formed in an arch, U or horseshoe-shape and is formed from a plastic material.

Folding portion 232 includes a frontal relief portion, shown as front flap 226, configured to receive various accessories, such as the arms of ear muffs. Similarly, side portion 222 includes a rear relief portion, shown as rear flap 228, configured to receive various accessories, such as the arms of ear muffs. In use, front portion 234 and folding portion 232 can be folded up and over the dome of hard hat 210 and backwards towards rear portion 224 (see FIG. 27). In this position, front portion 234 and/or folding portion 232 can be coupled to a coupling element, shown as clip 242 (FIG. 24), to hold these portions of visor 220 in the folded position.