US20070261153A1 - Protective helmet with flush pivoting ear cups - Google Patents

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.

Description

BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• 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.
• 2. Description of the Related Art
• 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.
• 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.
• 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.
• Consequently, known safety helmets are not completely adequate for some applications due to certain unsolved problems.
SUMMARY OF THE INVENTION
• 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
• FIG. 1 is a right side plan view of a safety helmet.
• FIG. 2 is a left side plan view of the safety helmet.
• FIGS. 3A-3B are a rear views of the safety helmet.
• FIG. 4 is an exploded top perspective view of the safety helmet.
• FIG. 5A is a partial, top perspective view of the safety helmet.
• FIG. 5B is a partial, bottom oblique view of the safety helmet.
• FIG. 6 is a perspective view of a headband assembly.
• FIG. 7 is an exploded view of a headset assembly.
• FIGS. 8A-8B are perspective views of an eye shield guide and eye shield guide, respectively.
• FIG. 9 is a perspective view of a rear shell and lens.
• FIG. 10 is an underside perspective view of an electronics module.
DETAILED DESCRIPTION
• 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
• 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 ofhelmet100.
• Broadly, thehelmet100 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 thehelmet100, awearer150 is shown for reference and perspective.
• Thehelmet100 includes afront end102 and arear end104. One part of the helmet is a rigidupper shell105 to protect the wear's head from impact injury. Theupper shell150 is made of a suitable material for this purpose, such as polycarbonate or another suitable reinforced or non-reinforced material.
• Within theupper shell105 are defined a number ofvents124, which in the illustrated example comprise aerodynamic channels with apertures leading to the interior of thehelmet100. Thevents124 permit air exchange between the wearer's head and outside the helmet without taking rain in.
• Thehelmet100 is shaped to form avisor106, which protrudes well forward of the wearer's face. Thevisor106 affords some protection of the wearer's face from sun, rain, and falling debris. Integral with a lower side of thevisor106 is an arc-shapedfront lens108, which protects a multiple beam light (not shown in this view) such as an LED array.FIG. 1 reveals a portion of an eye shield107 (in retracted position). Theshield107 is illustrated and described in greater detail below.
• At the rear104 of thehelmet100, there is arear shell110 and a curvedrear lens114. Within therear shell110, there is an electrical connector (not visible inFIG. 1) for attaching electronic equipment of thehelmet100 to various off-helmet electrical equipment. Components at the rear104 of the helmet are described in greater detail below.
• Thehelmet100 also includes ear cups, one116bof which is visible in the view ofFIG. 1. The ear cups pivot about respective axes, such as theaxis120 of the ear cup116b. 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 cup116band anengaging feature118 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 shells105/110, and more particularly, they present a surface that is substantially continuous with the arc and shape of therear shell110 andupper shell105. By minimizing any protrusion from the helmet, the ear cups present a contiguous part of the helmet when retracted.
• FIG. 2 shows thehelmet100 from the wearer's left side. This view demonstrates some of thehelmet100's movable parts. Namely, theeye shield107 and an ear cup116aare shown in their respective, extended positions.
• FIGS. 3A-3B show thehelmet100 in rear view, in two different configurations. In one configuration (302,FIG. 3A), ear cups116a-116bare extended. In another configuration (304,FIG. 3B), the ear cups116a-116bare retracted. Both configurations302-304 illustrate the rear104 of the helmet, including features such as therear lens114 andrear shell110.
• FIG. 4 shows an exploded view of thehelmet100 to better illustrate the individual pieces' shapes and interconnections. Optionally, thehelmet100 includes vent plugs412. In one example, the vent plugs412 include apertures (not shown) that are pressed over studs (not shown) protruding from theshell105'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. Eachvent plug412 comprises an elastomeric member with protrusions shaped to fit inside corresponding holes of thevents124. While thehelmet100 is not being worn, the wearer can insert/remove the vent plugs412 into/from thevents124 by bendably manipulating theplugs412.
• Beneath theshell105 is aframe408. Theframe408 serves as a common attachment point for theupper shell105,rear shell110,rear lens114,front lens108, and other components described below.
• A number of additional components are coupled to theframe408. One such component is theconnector112. Theconnector112 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, theconnector112 is mounted to a printed circuit board (PCB), which is attached to theframe408.
• Theconnector112 is coupled to other electrical components aboard thehelmet100, as described in greater detail below. Some of these components include an electronics module and headset assembly, and these may be electrically coupled to theconnector112 by one or more wiring harnesses, electrical buses, PCB traces, wires, Bluetooth or other wireless links, etc. Theconnector112 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, theconnector112 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.
• Another component attached to theframe408 is theelectronics module406. Among other components, themodule406 includes a source of light that projects through thefront lens108 when themodule406 is mounted to theframe408. Thus, in thefinished helmet100, themodule406 andlens108 are built into thevisor106 ofFIG. 1. Themodule406 is mounted to the top side of theframe408, as viewed inFIG. 4.
• Another component, attached to theframe408, is aneye shield guide402. Theguide402 provides a base for slidable movement of theeye shield107, defines full up and down travel, and removably secures theshield107 in a user selected position. Theguide402 and its attachment to theframe408 are described in greater detail below.
• Another component, attached to theframe408 is aheadset assembly430. Primary components of the headset assembly are the ear cups116a-116band theband413, to which the ear cups116a-116bare mounted. Theassembly430 and its attachment to theupper shell105 are described below.
• Still another component of thehelmet100 is theheadband assembly414. Theassembly414 provides an adjustable harness to provide a snug fit to the wearer's head, which supports thehelmet100 during use. Theassembly414 mounts to theframe408 by four supports416-419. Theassembly414 and its attachment to theframe408 are discussed below.
• FIGS. 5A-5B illustrate some of the components ofFIG. 4 in assembled form. Namely,FIG. 5A shows a top perspective view of theframe408,headband assembly414, supports416-419, eye shield guide402 (witheye shield107 removed), andelectronics module406.FIG. 5B shows a bottom oblique view of thehelmet100, where the following components are visible: theframe408,headband assembly414,lens108, guide402,eye shield107,support416, ear cups116a-116b,rear shell110, vent plugs412,connector112, andupper shell105.
• Headband Assembly
• FIG. 6 shows theheadband assembly414 in greater detail. As mentioned above, theheadband assembly414 provides an adjustable harness so that the wearer's head can comfortable and securely support thehelmet100. In one example, theassembly414 includes aheadband base602 coupled to crisscrossingstraps610,612. Thestraps610,612, in one example, comprise nylon webbing. Thebase602 includesmechanism614 to adjust the base to fit different head sizes.
• In the illustrated example, theheadband assembly414 is attached to the base408 at the supports416-419. More particularly, the supports416-419 are attached by fasteners, clips, glue, press fit, screws, rivets, detent or other shape fit, etc. Theheadset assembly430 attaches to theshell105 as discussed above. Thebase408 attaches to theshell105 by fasteners, clips, ultrasonic bonding, glue, press fit, screws, rivets, detent or other shape fit, etc. Thus, in the final construction, theheadset assembly430 is positioned over theheadband assembly414, permitting theassembly414 to comfortably direct the weight of thehelmet100 upon the wearer's head.
• Headset Assembly
• FIG. 7 shows theheadset assembly430 in greater detail. Broadly, theassembly430 includes the ear cups116a-116b, which pivotably attach to theband413. Theband413 includesstuds704 about which the ear cups116a-116bare free to rotate, as discussed below. In one example, theband413 is made of spring steel, and thestuds704 include Press-in studs such as PEM part THFS-632-6. Theband413 also includesholes724 for use in attaching theband413 to theupper shell105. For example, theband413 may be screwed or riveted to theshell105 viaholes724. In a different example, theholes724 may receive barbed studs (not shown) projecting from theshell105, in order to secure theband413 to theshell105. Of course, other arrangements may be used such as fasteners, clips, glue, press fit, shape fit, etc.
• Each ear cup is comprised of anear pad710,inner shell712,acoustic foam714, andouter shell716. Theshells712,716 comprise plastic or another material providing suitable protective strength and light weight. In one example, theshells712,716 are bonded to each other using ultrasonic welding, solvent bond, epoxy, or other permanent seal. In one example, theear cushion710 comprises water impenetrable material such as GORE-TEX® material surrounding padding of neoprene foam. In another example, the ear cushions710 are gel or foam filled plastic or another durable yet soft material to provide cushioning between the wearer's head and theassembly430.
• Eachinner shell712 includes apivot housing723 to permit free rotation of the respective ear cup about anaxis722 through thepivot housing723. In one example, eachpivot housing723 is implemented by a drilled or tooled or vacuum molded hole theshell712. Astud704 protrudes through each such hole, enabling the ear cup can to pivot about this hole. The ear cups116a-116bare held in place byfasteners706, such as nuts with spring steel washers, and thefasteners706 are cosmetically disguised bycaps708. As an alternative, thepivot housings723 may be implemented by other arrangements such as bearings, bushings, axles, etc. Furthermore, instead of permitting free rotation of the ear cups116a-116babout theirrespective studs704, thepivot housings723 and/orstuds704 may be defined to provide rotation under friction, ratcheting movement, detent holding ear cups in position until forcibly overcome, etc.
• Eachinner shell712 further includes atab720 designed to interact with a correspondingengaging feature118 of theframe408, which is most clearly shown inFIGS. 1, 2, and4A. In this example, the point of rotation of the ear cups116a-116bis defined relative theframe408 so that increasing movement of the ear cups116a-116binto their stowed position places thetabs720 into increasingly firm contact with their respective engaging features118. This holds the ear cups116a-116bfirmly in place by friction between thetabs720 and engagingfeatures118. Further force applied to the ear cups116a-116bin this direction more firmly engages the ear cups with the frame. Alternatively, thehelmet100 may employ other means to hold the ear cups116a-116bin place, such as springs, snaps, hooks, clips, magnets, etc.
• Thefoam714 comprises acoustically absorbent material such as that typically used in conventional and industrial headsets. Theouter shell716 includes aspeaker assembly718 electrically coupled to theconnector112. One example of the speakers is a circumaural type speaker.
• Eve Shield and Guide
• FIG. 8A-8B highlight theguide402 andeye shield107, respectively. In one embodiment, theshield107 is made of a clear or intentionally tinted material that meets or exceeds OSHA, UL, and/or CSA requirements for safety glasses. For example, theshield107 may be made of polycarbonate, acrylic, or another suitable material. Theguide402 is made of a material suitable to provide self-lubrication e.g. nylons and others.
• Although theshield107 and guide402 are shown separately, the shield rides in a path defined and limited by theguide402. When coupled to theguide402, theshield107 is slidable in generally upward and downward movements, allowing the wearer to retract and extend the shield (respectively).
• Theshield107 includes a number of features that help establish and limit its position with respect to the rest of thehelmet100. In this respect, theshield107 includes down catches810. Eachcatch810 includes a protrusion that engages a corresponding feature of theguide402 to stop extension of theshield107. Positioningnotches812 are defined in theshield812 to engage a corresponding pawl of theguide402 and thereby hold theshield107 one of these positions under adjustment by the wearer.Channels814 defined in theshield107 engage corresponding features of theguide402 to help stop retraction of theshield107.
• Theguide402 includesfoldover flaps808 definingslide slots809 that receive and accommodate theshield107. Up-stops802 stop retraction of theshield107 by engaging thechannels814. Thestops802 include protrusions that are biased toward theshield107 by their size, position, and the natural springiness of theguide402 material.Pedestals804 are provided for mounting of theguide402 to theframe408 by barbed studs, fasteners, clips, glue, press fit, screws, rivets, detent or other shape fit, etc. Apawl806 engages with thepositioning notches812 to hold theshield107 in place, or releasably permit the extension or retraction of theshield107 when the wearer applies sufficient force to slide theshield107 and thereby disengage and reengage thepawl806 from thenotches812 one at a time.Notches807 are engaged by the down catches810 to stop extension of theshield107. Alternatively, thenotches807 may be omitted, with the upper edge of theguide402 serving to engage the down catches810, albeit at an earlier point than thenotches807 would, and thereby not permitting as much down travel.
• Rear Panel & Lens
• FIG. 9 shows therear shell110 andlens114 in greater detail. In the rear shell, anotch902 is defined to accommodate theconnector112, which is attached to theframe408 as shown above.Aligners910 permit theshell110 to be accurately positioned with respect to theframe408. As shown, each of thealigners910 is a base with a hole defined therein. Mounting to theframe408 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.
• Theshell110 bears attachment pegs904 shaped to engage corresponding holes906 in therear lens114 and thereby secure the lens relative to theshell110. Theshell110 andlens114 may be attached by a press fit between thepegs904 and holes906 and/or additional means such as ultrasonic welding, solvent bond, epoxy, etc. Along these lines, thelens114 includesknobs908 to affix thelens114 with respect to theframe408.
• A number of rear-facing light sources (not shown) may be attached to theframe408 at a suitable position to be aligned with thelens114. 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 theelectronics module406 via one or more wiring harnesses, electrical buses, PCB traces, wires, Bluetooth or other wireless links, etc.
• As an alternative to therear shell110 andlens114 that are separate from theupper shell105 as illustrated, these features may be integral with theupper shell105, thereby forming a larger, contiguous combined upper/rear shell.
• Electronics Module
• FIG. 10 shows theelectronics module406 in greater detail. As mentioned above, theelectronics module406 includes a source of light that projects through thefront lens108 when themodule406 is mounted to theframe408. In one example, themodule406 may be mounted to theframe408 by fasteners, clips, glue, press fit, screws, rivets, detent or other shape fit, etc. In thefinished helmet100, themodule406 andlens108 are built into thevisor106 ofFIG. 1.
• One example of themodule406 includes an array ofLEDs1002 mounted to a printedcircuit board1003. In the illustrated example, six white LEDs of type T1-3/4 may be used. TheLEDs1002 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, theLEDs1002 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.
• Themodule406 may include further electronics. In one example, themodule406 includesbrow microphones1004 enabling the wearer of thehelmet100 to conduct hands free communications utilizing an off-helmet audio module coupled to theconnector112. 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. Themicrophones1004 may include a moisture barrier, such as GORE-TEX® or a similar material.
• As shown, themodule406 also includes aphoto sensor1008, such as a Perkin Elmer part A9060. Optionally, circuitry of theboard1003 may automatically activate theLEDs1002 and/or the rear light when thesensor1008 finds that ambient light is less than a given threshold.
• In order to provide more intelligent functionality to thehelmet100, themodule406 may also accommodate various circuitry in the form of discrete circuit elements, integrated circuits, ASICs, and the like. For example, themodule406 may include Fortemedia brand FM1072LP chips in order to aid processing of audio signals received at themicrophones1004, prevent feedback between the microphone and speakers, etc. As a further example, themodule406 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 thespeakers718.
• Themodule406 further includes hand-operateddual switches1006, such as E-Switch part EG2305A. Thedual switches1006 may be attached to permit the wearer to selectively deactivate theLEDs1002, rear light,microphones1004, and/or other electronic equipment.
• Optionally, through theswitches1006 or on-board circuitry, themodule406 may automatically or manually adjust the volume of the ear cup speakers. For instance, themodule406 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 cups116a-116bmay actuate a switch mounted to theframe408 or other structure, where this switch is activated by a raised feature of one or both ear cups116a-116bclose 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 tabs730-731 (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 theelectronics module406, which regulates volume accordingly.
• Helmet Features
• As described above, thehelmet100 offers a variety of useful features in one package. Thehelmet100 provides MP3, CD player, radio, cell phone, two-way radio, or other audio to the wearer by virtue of thespeaker assemblies718 in ear cups116a-116b. And, with thedirectional brow microphones1004, thehelmet100 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 theconnector112 and appropriate cabling (not shown). Moreover, the wearer's eyes are protected by theretractable eye shield107. To fully illuminate the wearer's workspace with minimal intrusion, the front-facinglight assembly1002 is provided internal to thevisor106 and protected by abrow lens108 that is flush with thevisor106. For added safety, the rear-facing light makes sure that the helmet is visible from behind. Furthermore, the ear cups116a-116bare 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 cups116a-116bwhen retracted are flush with helmet's exterior surface, namely, theupper shell105 and therear shell110. Despite the collective benefit of these features, the helmet still provides significant utility if one or more of these are omitted.
• Helmet Operation
• In preparation for use of thehelmet100, the wearer uses themechanism614 to adjust theheadband base602. The wearer also couples theconnector112 to the desired electrical equipment, such as one-way or two-way audio equipment, battery pack, etc. When the wearer dons thehelmet100, theaxis722/120 is generally just above the wearer's ears. Thus, the ear cups116a-116bwhen retracted rest above and generally behind the wearer's ears, flush with the outer surface of theshells105,110. The ear cups116a-116bare secured in the stowed position by friction between thetab720 of theheadset assembly430 and theengaging feature118 of theframe408. In this position, recognizing that the ear cups are stowed, thehelmet100 may automatically provide an increased “speaker phone” volume to the ear cup speakers.
• When thehelmet100 is being worn, the wearer operates theswitches1006 to configure electrical features such as the front lights, rear lights, audio on/off, microphone mute, and the like. To extend the ear cups116a-116b, the wearer applies downward force to the ear cups116a-116b, which disengages thetabs720 from the engaging features118. The ear cups116a-116bthen 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, thehelmet100 may automatically select a decreased volume for ear cup speakers.
• To retract the ear cups116a-116bagain, the wearer pivots the ear cups rearward, ultimately engaging thetabs720 with thefeatures118. Greater force applied to the ear cups in this way more snugly engages them with theframe408 in tighter fit.
Other Embodiments
• 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.
• 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 35USC 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.”
• 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.
• 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.

Claims (17)

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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 1, further comprising:

means for securing the ear cups in the retracted position.

12. The helmet ofclaim 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 ofclaim 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 ofclaim 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 ofclaim 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.

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