Strap for a safety helmet

Abstract

A safety helmet is disclosed. The safety helmet comprises a suspension strap assembly comprising a plurality of straps. Each strap comprises a first yarn comprising liquid crystal polymer (LCP) threads. Further, each LCP thread is wrapped with a dyeable thread and a second yarn woven with the first yarn. Further, the second yarn comprises synthetic threads.

Description

Atorney DockctNo.: 81205.433.WO01STRAP FOR A SAFETY HELMETCROSS-REFERENCE

[0001] This application claims the benefit of Chinese Patent Application No.202411099103.8 filed August 9. 2024, the entire contents of which are incorporated herein by reference.TECHNOLOGICAL FIELD

[0002] Example embodiments of the present disclosure relate generally to a protective helmet, and more particularly, to a strap for a safety helmet and method for protecting a user’s head from various hazards.BACKGROUND

[0003] In various industrial applications, a safety helmet is an important component of personal protective equipment (PPE). The safety helmet is provided to workers in various industrial arenas such as production facilities, utilities, and industrial settings. Additionally, the safety helmets are crucial in various activities and professions to protect the head from injuries caused by impacts, falls, and other hazards. The safely helmets are designed with materials and structures that absorb and dissipate the energy from impacts, thereby reducing the risk of serious injury. One critical component of a safety helmet is suspension strap assemblies, which often includes a cradle of straps that helps to distribute the force of an impact and secure the helmet on wearer's head. The straps are typically made from materials like polyester or nylon, having strength and durability. However, in different regions such as very low temperature (e.g. -20°C) or high temperature (e.g. 50°C) and specialized applications such as climbing, the safety helmets need straps with a stable elongation ratio to meet certification standards, ensuring that the helmet remains securely positioned during a fall or an impact. Standard suspension strap assemblies made from synthetic yams like polyester or nylon, usually exhibit higher elongation rates exceeding 15% in high temperature than low temperature because of polymer creeping property in high temperature, which can compromise the safety7helmet's stability7and effectiveness in critical situations.

[0004] The inventors identified numerous deficiencies and problems in in existing technologies and processes, which are the subjects of embodiments described herein. Through applied effort, ingenuity, and innovation, many of these deficiencies and problems have beenAtorney DockctNo.: 81205.433.WO01 solved by developing solutions that are included in embodiments of the present disclosure, many examples of which are described in detail herein.BRIEF SUMMARY

[0005] The following presents a summary of some example embodiments to provide a basic understanding of some aspects of the present disclosure. This summary’ is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such elements. It will also be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described in the detailed description that is presented later.

[0006] In an example embodiment, a safety helmet is disclosed. The safety helmet comprises a suspension strap assembly comprising a plurality' of straps. Each strap comprising a first yam comprising liquid crystal polymer (LCP) threads. Further, each LCP thread is wrapped with a dyeable thread and a second yam woven with the first yam. Further, the second yam comprises synthetic threads.

[0007] In some embodiments, the synthetic threads of the second yam comprise polyester, nylon, cotton, other natural or synthetic blended yams.

[0008] In some embodiments, the dyeable thread that is wrapped around the LCP thread has a green color. In some embodiments, the dyeable thread that is wrapped around the LCP thread has a helical shape or double helix structure. In some embodiments, the dyeable thread that is wra ped around the LCP thread comprises at least one of polyester, nylon, cotton, other natural or synthetic blended yams.

[0009] In some embodiments, each strap of the plurality' of straps is configured to elongate by three percent or less without breaking.

[0010] In some embodiments, each of the LCP threads extend in a warp direction, at least some of the synthetic threads extend in the warp direction, and at least some of the synthetic threads extend in a weft direction.

[0011] In some embodiments, each strap of the plurality of straps comprises at least 4 insert LCP threads or all LCP threads. In some embodiments, the LCP threads are arranged in pairs that are separated by a plurality of the synthetic threads.

[0012] In some embodiments, the suspension strap assembly defines a peak force of 4450 Newton within a temperature range of -30°C ± 2°C to 49°C ± 2°C.

[0013] In another example embodiment, a strap is disclosed. The strap comprising a first yam comprising liquid crystal polymer (LCP) threads. Further, each LCP thread is wrapped with aAtorney DockctNo.: 81205.433.WO01 dyeable thread, and a second yam woven with the first yam. Further, the second yam comprises synthetic threads.

[0014] The above summary is provided merely for purposes of summarizing some exemplary embodiments to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which are further explained within the following detailed description and its accompanying drawingsBRIEF DESCRIPTION OF THE DRAWINGS

[0015] Having thus described certain example embodiments of the present disclosure in general terms, reference will hereinafter be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0016] FIG. 1A illustrates a front view of a safety helmet in accordance with an example embodiment of the present disclosure;

[0017] FIG. IB illustrates a perspective view of the safety helmet in accordance with an example embodiment of the present disclosure;

[0018] FIGS. 1C-1D illustrate a bottom view of the safety helmet, in accordance with an example embodiment of the present disclosure;

[0019] FIG. 2 illustrates an exploded view of the safety helmet and atop view of a suspension strap assembly in accordance with an example embodiment of the present disclosure;

[0020] FIG. 3 illustrates a top view of the suspension strap assembly and an enlarged view- of the suspension strap assembly in accordance with an example embodiment of the present disclosure;

[0021] FIGS. 4A-4F illustrate enlarged views of portions of the suspension strap assembly in accordance with an example embodiment of the present disclosure;

[0022] FIG. 5 illustrates a table showing comparison of different types of yam based on one or more properties in accordance with an example embodiment of the present disclosure;

[0023] FIG. 6A illustrates a side view of a first yam comprising a liquid crystal polymer (LCP) thread wrapped with a dyeable thread in accordance with an example embodiment of the present disclosure;

[0024] FIG. 6B illustrates a side view of the dyeable thread in helical shape in accordance with an example embodiment of the present disclosure;Atorney DockctNo.: 81205.433.WO01

[0025] FIG. 6C illustrates a side view of a thread of the first yam of each strap of a plurality of straps in accordance with an example embodiment of the present disclosure; and

[0026] FIG. 7 illustrates a table showing a structure pattern of a strap of the plurality of straps in accordance with an example embodiment of the present disclosure.DETAILED DESCRIPTION

[0027] Some embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the present disclosure are shown. Indeed, various embodiments may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0028] The components illustrated in the figures represent components that may or may not be present in various embodiments of the present disclosure described herein such that embodiments may include few er or more components than those shown in the figures while not departing from the scope of the present disclosure. Some components may be omitted from one or more figures or shown in dashed line for visibility of the underlying components.

[0029] As used herein, the term “comprising” means including but not limited to and should be interpreted in the manner it is ty pically used in the patent context. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of.

[0030] The phrases “in various embodiments,” “in one embodiment,” “according to one embodiment,” “in some embodiments,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0031] The word “example” or "exemplary" is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0032] If the specification states a component or feature “may,” “can.” “could.” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that a specific component or feature is not required to be included or to have the characteristic. Such a component or feature may be optionally included in some embodiments or it may be excluded.Atorney DockctNo.: 81205.433.WO01

[0033] The present disclosure provides various embodiments of a safety helmet is disclosed. Embodiments may comprise a suspension strap assembly. The suspension strap assembly may comprise a plurality of straps, each strap may comprise a first yam. The first yam may further comprise liquid crystal polymer (LCP) threads. Further, each LCP thread may be wrapped with a dyeable thread. Embodiments may comprise a second yam woven with the first yam. Further, the second yam may comprise synthetic threads.

[0034] FIG. 1A illustrates a front view of a safety helmet 100, in accordance with an example embodiment of the present disclosure. FIG. IB illustrates a perspective view of the safety helmet 100, in accordance with an example embodiment of the present disclosure. FIGS. 1C- 1D illustrate a bottom view of the safety helmet 100, in accordance with an example embodiment of the present disclosure.

[0035] In some embodiments, the safety helmet 100 may comprise an outer shell 102, an eyewear 104, a chinstrap 106, and a ratchet 108. In some embodiments, the safety helmet 100 may be configured to be worn by a user over a head of the user. Further, the outer shell 102 of the safety helmet 100 may be configured to protect the user’s head from various hazards. Further, the hazards may include, but are not limited to, falling of objects and other external impacts. In some embodiments, the outer shell 102 may be composed of one or more materials. The one or more materials may comprise at least one of metals, plastic, alloys, and alike. In some embodiments, the outer shell 102 may be crafted with a shape that may comprise at least one of a hemi-spherical shape or any other shape known in the art. In some embodiments, the shape of the outer shell 102 may be selected such that the safety helmet 100 perfectly fits on the user’s head.

[0036] In some embodiments, the safety helmet 100 may further comprise the eyewear 104. Further, the eyewear 104 may be pivotally mounted with the safety helmet 100. In some embodiments, the eyewear 104 may be mounted with the parallel sides of the safety helmet 100. Further, the eyewear 104 may be configured to protect the user’s eyes from the hazards. In some embodiments, the eyewear 104 may be attached with each of the parallel sides of the safety helmet 100 via an adaptor 114. In one example, the eyewear 104 may be configured to cover the user’s eyes while performing one or more tasks, such as machining operations, operations involving chemicals, etc. that may require protection to the user’s eyes. Further, the adaptor 114 may be configured to couple each of the parallel sides of the safety helmet 100 with the eyewear 104. In some embodiments, the adaptor 114 may be configured to enable movement of the eyewear 104 from a first position to a second position. Further, the firstAtorney DockctNo.: 81205.433.WO01 position may correspond to a stowed position and the second position may correspond to a deployed position.

[0037] In some embodiments, the eyewear 104 may be constructed with a material that is selected from a group of materials such as, but is not limited to, polycarbonate, acrylic, polystyrene, and any other material known in the art. It may be noted that the materials for making the eyewear 104 may be selected carefully as the eyewear 104 may demand durability and rigidity as the user may be exposed to various external factors that may physically damage the eyewear 104. Further, the various external factors may include scratches from sharp objects or dropping from a particular height, without departing from the scope of the disclosure.

[0038] In some embodiments, the safety helmet 100 may comprise the chinstrap 106. In some embodiments, the chinstrap 106 of the safety helmet 100 may be configured to provide support to the user’s jaw while wearing the safety helmet 100. In some embodiments, the chinstrap 106 may be attached with each parallel side of the safety helmet 100. Further, the chinstrap 106 may be manually pulled and placed by the user under the user’s jaw. In some embodiments, the chinstrap 106 may be composed of a stretchable material. In some embodiments, the material of the chinstrap 106 may facilitate the user to easily pull and place the chinstrap 106 under the user’s jaw. In some embodiments, the chinstrap 106 may comprise a lock 11 . Further, the lock 116 may facilitate the use to manually lock movement of the chinstrap 106. Further, the lock 116 may be configured to prevent loosening of the chinstrap 106 during movement of the user’s head while wearing the safety helmet 100.

[0039] In some embodiments, the chinstrap 106 may comprise a chin cup 110. In some embodiments, the chin cup 110 may be configured to accommodate chin of the user. In some embodiments, the chin cup 110 may be composed of one or more materials comprising at least one of a silicon, rubber, etc. Further, the material for the chin cup 110 may be selected such that the chin cup 110 may provide comfort to the chin of the user. In some embodiments, the chin cup 110 may be manually positioned by the user under the chin of the user upon pulling and placing the chinstrap 106. In one example, the chin cup 110 may be fabricated with a plurality of apertures 118. Further, the plurality of apertures 118 may be configured to provide air ventilation to the chin of the user to prevent any discomfort to the user while wearing the chin cup 110.

[0040] In some embodiments, the safety helmet 100 may further comprise the ratchet 108. In some embodiments, the ratchet 108 of the safety helmet 100 may be configured to provide support to a back portion to the user’s head by adjusting a ratchet wheel 108A of the ratchet 108 according to a circumference of the user’s head. In some embodiments, the ratchet 108Atorney DockctNo.: 81205.433.WO01 may be attached with the parallel sides of the safety helmet 100. Further, the ratchet 108 may be manually pulled and placed by the user at the back portion of the user's head. In some embodiments, the ratchet 108 may be composed of a stretchable material (e.g. a plastic material or a rubber material). In some embodiments, the material of the ratchet 108 may facilitate the user to easily pull and place the ratchet 108 at the back portion of the user’s head. In some embodiments, the ratchet 108 may further comprise a cushioned pad 112. Further, the cushioned pad 112 may be configured to provide comfort to the back portion of the user’s head while wearing the safety helmet 100. In some embodiments, the cushioned pad 112 may be constructed with a shape comprising at least one of a rectangular shape, an oval shape, etc.

[0041] As illustrated in FIGS. 1C-1D, the safety helmet 100 may comprise a suspension strap assembly 120. In some embodiments, the suspension strap assembly 120 may be positioned within an inner portion of the safety helmet 100. Further, the suspension strap assembly 120 may be configured to enhance impact distribution and reduce force transmitted to the user’s head during an impact event. In some embodiments, the suspension strap assembly 120 maybe composed of one or more high strength and flexible materials. Further, the suspension strap assembly 120 may be configured to suspend the safety helmet 100 slightly above the user’s head. Further, in an instance of impact occurrence, the suspension strap assembly 120 disperses energy generated during the impact across the suspension strap assembly 120 rather than being concentrated on any one part of the user's head. Further, the distribution of the energy may minimize pressure on any one portion of the user’s head, reducing a risk of fractures and other severe injuries. In some embodiments, the suspension strap assembly 120 may comprise a strap hub 122 and a plurality- of straps 124.

[0042] In some embodiments, the plurality- of straps 124 of the suspension strap assembly 120 may be attached with the safety helmet 100 at a plurality of points within the inner portion of the outer shell 102. In some embodiments, the plurality of straps 124 of the suspension strap assembly- 120 may be attached with the plurality of points to ensure a stability of the safety helmet 100 and an even distribution of forces, in the event of impact. In some embodiments, one end of each of the plurality of straps 124 may be attached with the inner portion of the outer shell 102 and other end of the each of the plurality of straps 124 may be attached to the strap hub 122. In one example, the suspension strap assembly 120 may be coupled with the inner portion of the outer shell 102 through six specific points to reduce impact force to the safety helmet 100 and the user’s head.

[0043] In some embodiments, the safety helmet 100 may comprise a cushioning pad 126. Further, the cushioning pad 126 of the safety helmet 100 may be configured to provide comfortAtorney DockctNo.: 81205.433.WO01 to the user's head while wearing the safety helmet 100. In some embodiments, the cushioning pad 126 of the safety’ helmet 100 may be engineered to fit in accordance to size of the user's head. In some embodiments, the cushioning pad 126 of the safety7helmet 100 may be adhered or coupled to an inner surface of the outer shell 102 of the safety helmet 100.

[0044] FIG. 2 illustrates an exploded view of the safety helmet 100 and a top view of the suspension strap assembly 120, in accordance with an example embodiment of the present disclosure. FIG. 3 illustrates a top view of the suspension strap assembly 120 and an enlarged view of the suspension strap assembly 120, in accordance with an example embodiment of the present disclosure. FIGS. 4A-4F illustrate one or more dimensions of each strap of the suspension strap assembly 120, in accordance with an example embodiment of the present disclosure.

[0045] In some embodiments, the safety helmet 100 may further comprise a sweatband 200. In some embodiments, the syveatband 200 may be positioned within the inner surface of the outer shell 102 of the safety helmet 100. In some embodiments, the sweatband 200 may be configured to provide comfort to a front portion of the user’s head. In one example, the sweatband 200 may define dimensions that facilitate a maximum comfort to the front portion of the user’s head while wearing the safety helmet 100. In some embodiments, the outer shell 102 of the safety helmet 100 may further comprise an inner shell 202. Further, the inner shell 202 may be configured to provide a layer of protection that may suppress the impact forces during the instance of impact occurrence. In some embodiments, the inner shell 202 of the safety helmet 100 may be composed of materials that absorb forces while experiencing the impact forces. In some embodiments, the inner shell 202 of the safety helmet 100 may comprise a plurality of cavities 204. In some embodiments, the plurality of cavities 204 may be configured to provide air ventilation to the user’s head through the cushioning pad 126 while wearing the safety helmet 100. In one example, the plurality’ of cavities 204 may define one or more dimensions that may facilitate a maximum circulation of air through the cushioning pad 126.

[0046] In some embodiments, the suspension strap assembly 120 may be coupled with a center portion of the inner surface of the outer shell 102. In some embodiments, the suspension strap assembly 120 may be suspended vertically downyvard from the inner surface of the outer shell 102. In some embodiments, the suspension strap assembly 120 may be configured to couple with the inner surface of the outer shell 102 of the safety helmet 100. In some embodiments, the suspension strap assembly 120 may comprise the strap hub 122 and the plurality of straps 124. In some embodiments, the strap hub 122 may be configured to serve as a central anchorAtorney DockctNo.: 81205.433.WO01 of the suspension strap assembly 120 of the safety helmet 100. In some embodiments, the strap hub 122 may be configured to enable convergence of the plurality of straps 124 of the suspension strap assembly 120. In some embodiments, the strap hub 122 may be positioned at the center portion of the inner surface of the outer shell 102.

[0047] In some embodiments, the plurality' of straps 124 may be configured to ensure a proper fitting of the safety helmet 100 on the user’s head. In some embodiments, the plurality of straps 124 of the suspension strap assembly 120 may be configured to distribute impact forces evenly within the safety helmet 100. Further, the plurality of straps 124 may be arranged in a cradle like structure that may support the user’s head. In some embodiments, the plurality of straps 124 may be anchored with different anchor points around the inner surface of the outer shell 102 of the safety helmet 100. In one example, the different anchor points may comprise at least one of front, sides, and back of the safety helmet 100.

[0048] In some embodiments, the plurality of straps 124 may be configured to enable the user to customize the fitting of the suspension strap assembly 120 over the user’s head. In some embodiments, the plurality of straps 124 may be coupled with at least one mechanism that may facilitate customization of the fitting of the suspension strap assembly 120. Further, the at least one mechanism may comprise buckles, sliders, or ratchets. As illustrated in FIG. 2, each of the plurality of straps 124 may comprise at least one buckle 206. Further, the at least one buckle 206 may facilitate tightening or loosening of the plurality of straps 124 to provide a proper fit to the suspension strap assembly 120 around the user’s head. In some embodiments, the plurality of straps 124 of the suspension strap assembly 120 may be configured to enable distribution of load and impact forces evenly across the user’s head. In one instance, when an impact occurs, the plurality of straps 124 may absorb and dissipate energy around the user’s head, and thus reducing the risk of injury to the user’s head.

[0049] As illustrated in FIG. 3, each strap of the plurality- of straps 124 may be configured to elongate three percent or less without breaking. In some embodiments, each strap of the plurality of straps 124 may comprise a first yam 300 and a second yam 302. In some embodiments, the first yam 300 may be woven with the second yam 302 to provide each strap of the plurality of straps 124 of the suspension strap assembly 120. In some embodiments, the first yam 300 may comprise liquid crystal polymer (LCP) threads 600 (FIGS. 6A-6C). In some embodiments, the first yam 300 may comprise a dyeable thread 602 (FIGS. 6A-6C). For example, each LCP thread 600 of the LCP threads 600 may be wrapped with the dyeable thread 602. In some embodiments, the dyeable thread 602 that is wrapped around the LCP thread 600 may have a green color. In one example, the dyeable thread 602 may be fabricated with colorsAtorney DockctNo.: 81205.433.WO01 comprising orange, yellow, etc. As will be appreciated in light of the present disclosure, LCP thread has poor dyeability. As such, it may be difficult, or impossible, to dye the LCP thread 600 to a desired color. As such, wrapping each LCP thread 600 with a dyeable thread 602 may result in the first yam 300 having the benefits of both the LCP thread 600 and the dyeable thread 602. For example, the first yam 300 may benefit from the low elongation rate of the LCP thread 600 while also benefiting from the good or excellent dyeability of the dyeable thread 602.

[0050] In some embodiments, the dyeable thread 602 that is wrapped around the LCP thread 600 may comprise one or more materials. The materials of the dyeable thread may be configured to have good or excellent dyeability. For example, the one or more materials of the dyeable thread 602 may comprise polyester, nylon, or cotton. In some embodiments, the synthetic threads of the second yam 302 may comprise at least one of a polyester, nylon, cotton, other natural or synthetic blended yams. In some embodiments, the first yam 300 and the second yam 302 may be weaved in one or more directions. Further, the one or more directions may correspond to a warp direction and a weft direction.

[0051] In some embodiments, during weaving of the first yam 300 and the second yam 302. each of the LCP threads 600 of the first yam 300 may extend in the warp direction (i.e., in the longitudinal direction). At least some of the synthetic threads of the second yam 302 may extend in the warp direction. At least some of the synthetic threads of the second yam 302 may extend in the weft direction (i.e., in the transverse direction). In some embodiments, each strap of the plurality of straps 124 may comprise at least 4 insert LCP threads or all LCP threads 600. In some embodiments, the LCP threads 600 of the first yam 300 may be arranged in pairs that are separated by a plurality' of synthetic threads (as illustrated in FIG. 3). In some embodiments, due to weaving of the first yam 300 comprising the LCP threads 600 with the second yam 302, each strap 124 of the suspension strap assembly 120 may be configured to elongate by three percent or less without breaking. As illustrated in FIGS. 4A-4F, upon weaving of the first yam 300 and the second yam 302, each strap 124 of the plurality of straps 124 defines one or more dimensions. Further, the one or more dimensions may comprise a width W of 23 millimeter (mm) and a thickness T of 0.85 mm.

[0052] FIG. 5 illustrates a table 500 showing comparison of different types of yam based on one or more properties, in accordance with an example embodiment of the present disclosure.

[0053] In some embodiments, the table 500 provides a dataset associated with comparison of the different types of yam. Further, the table 500 may comprise a plurality of columns such as different types of yam 502, tensile strength (cN / dtex) 504, heat resistance (°C) 506,Atorney DockctNo.: 81205.433.WO01 flammability 508, density (g / cm3) 510, dyeability 512, elongation (%) 514, and moisture absorption 516. Herein, the types of yam 502 may comprise PET (Polyethylene Telephthalate), Nylon-66, filament 29, para-aramid filament, staple 450, Meta-aramid staple, polyimide PI-I staple, LCP (Liquid Crystal Polymer), and UHWMPE (ultrahigh weight polyethylene). In some embodiments, the table 500 defines the tensile strength (cN / dtex) 504 for each of the different types of yam 502 such as PET - 7.8. Nylon-66 - 6, filament 29 - 20.3, para-aramid filament - 20.5. staple 450 - 4, Meta-aramid staple - 3.86. PI-I staple - >4. LCP - 21, and UHWMPE - 31. In some embodiments, the table 500 defines the heat resistance (°C) 506 for each of the different types of yam 502 such as PET - 160, Nylon-66 - 130, filament 29 - 427, para-aramid filament - 427. staple 450 - 400, Meta-aramid staple - 400, PI-I staple - >500, LCP - 280, and UHWMPE - <100. In some embodiments, the table 500 defines the flammability 508 for each of the different types of yam 502 such as PET - HB (Horizontal Burning), Nylon-66 - HB, filament 29 - V0 (Vertical Burning), intrinsic fire retardant, para-aramid filament - V0, intrinsic fire retardant, staple 450 - V0, intrinsic fire retardant, Meta-aramid staple - V0, intrinsic fire retardant, PI-I staple - V0, intrinsic fire retardant, LCP - V0, intrinsic fire retardant, and UHWMPE - HB.

[0054] In some embodiments, the table 500 defines the density (g / cm3) 510 for each of the different types of yam 502 such as PET - 1.38, Nylon-66 - 1.14, filament 29 - 1.44, paraaramid filament - 1.44, staple 450 - 1.38. Meta-aramid staple - 1.38, PI-I staple - 1.41. LCP - 1.4, and UHWMPE - 0.98. In some embodiments, the table 500 defines the dyeability 512 for each of the different types of yam 502 such as PET - excellent, Nylon-66 - excellent, filament 29 - poor, para-aramid filament - poor, staple 450 - poor, Meta-aramid staple - poor, PI-I staple - poor, LCP - poor, and UHWMPE - poor. In some embodiments, the table 500 defines the elongation (%) 514 for each of the different types of yam 502 such as PET - 14%, Nylon-66 - 25%, filament 29 - 3.6%, para-aramid filament - 3.3%, staple 450 - 30.5%, Metaaramid staple - 31.4%, PI-I staple - 15%, LCP - 3%, and UHWMPE - 4%. In some embodiments, the dataset provided by the table 500 defines the moisture absorption 516 for each of the different types of yam 502 such as PET - 0.4%, Nylon-66 - 2.5%, filament 29 - 4.5%, para-aramid filament - 4%~6%, staple 450 - 4.5%, Meta-aramid staple - 6.2%, PI-I staple - 2%, LCP - 0.04%, and UHWMPE - 0.01%. It may be noted that the dataset provided by the table 500 may conclude that the LCP threads 600 of the first yam 300 of each of the plurality of straps 124 may define a lowest elongation rate (i.e. 3%). Further, due to the lowest elongation rate of the LCP threads 600, each strap of the plurality of straps 124 may elongate by three percent or less without breaking.Atorney DockctNo.: 81205.433.WO01

[0055] FIG. 6 A illustrates a side view of the first yam 300 comprising a liquid cry stal polymer (LCP) thread 600 wrapped with a dyeable thread 602, in accordance with an example embodiment of the present disclosure. FIG. 6B illustrates a side view of the dyeable thread 602 in helical shape, in accordance with an example embodiment of the present disclosure. FIG. 6C illustrates a side view of the LCP thread 600 of the first yam 300 of each strap of the plurality of straps 124, in accordance yvith an example embodiment of the present disclosure.

[0056] In some embodiments, each strap of the plurality of straps 124 of the suspension strap assembly 120 may comprise the first yam 300 and the second yam 302. Further, the first yam 300 may comprise the LCP threads 600 that may be known for their exception mechanical and thermal properties. Further, each of the LCP threads 600 within the first yam 300 may be engineered to provide high tensile strength, excellent heat resistance, and intrinsic fire retardance. In some embodiments, to enhance the aesthetic and functional properties of the LCP threads 600, each of the LCP threads 600 may be wrapped with the dyeable thread 602. In one example, the dyeable thread 602 that is wrapped around the LCP thread 600 may have the green color. Further, wrapping of the dyeable thread 602 around the LCP threads 600 may provide not only visual distinction but also a potential for use in color-coded applications. In some embodiments, the dyeable thread 602 that is wrapped around the LCP thread may have the helical shape (as illustrated in FIGS. 6A-6B) or double helix structure (not shown) to add a unique structural characteristic to the first yam 300. As will be appreciated in light of the present disclosure. LCP threads 600 have poor dyeability- and have a yellow color. As such, wrapping the dyeable thread 602 around each LCP thread 600 allows the first yam 300 to be configured to be in any color, yvhich may be beneficial. In some embodiments, the dyeable thread 602 is more tightly wound around the LCP thread 600 than what is depicted in FIG. 6A. For example, the dyeable thread 602 may have a helical shape. The helix shape may define an inner radius and a thread angle. The inner radius may be approximately equal to an outer radius of the LCP thread 600. The thread angle may be configured to result in sides of portions of the dyeable thread 602 touching with other portions of the dyeable thread 602. As such, the dyeable thread 602 may substantially cover a surface of the LCP thread 600. For example, at least 90 percent, such as at least 95 percent, such as at least 98 percent of the LCP thread 600 may be covered with the dyeable thread 602. In some embodiments, the suspension strap assembly 120 may define a peak force of 4450 Newton in a specific certificate test yvithin a temperature range of -30°C ± 2°C to 49°C ± 2°C. In one example, the specific certificate test may correspond to, but is not limited to, American National Standards Institute (ANSI) Z89.1 certificate test.Atorney DockctNo.: 81205.433.WO01Further, the certificate test may comprise a set of criteria developed for design, performance, testing, and use of industrial head protection.

[0057] FIG. 7 illustrates a table 700 showing a structure pattern of a strap of the plurality of straps 124, in accordance with an example embodiment of the present disclosure.

[0058] In some embodiments, the table 700 may depict a plurality of bars (e.g. 1-19 bars). In some embodiments, the bars 1-6 of the table 700 may represent the second yam 302, the bars 7-8 of the table 700 may represent the first yam 300 comprising the LCP threads 600 wrapped with the dyeable thread 602. Further, the bars 9-14 of the table 700 may represent the second yam 302, the bars 15-16 of the table 700 may represent the first yam 300. Further, the bars 17- 20 of the table 700 may represent the second yam 302. In some embodiments, the table 700 of the strap of the plurality of straps 124 may illustrates a weaving pattern of the strap. Further, each of the LCP threads 600 (i.e. 7, 8, 15, and 16) may extend in the warp direction. Further, the at least some of the synthetic threads (i.e. 1-6, 9-14, and 17-20) may extend in the warp direction. In some embodiments, the LCP threads 600 may be arranged in pairs that may be separated by the plurality of the synthetic threads.

[0059] In some embodiments, a method for the safety helmet 100 is disclosed. Further, the method may comprise one or more operations. Firstly, each of the LCP threads 600 of the first yam 300 of each strap of the plurality of straps 124 of the suspension strap assembly 120 may be wrapped with the dyeable thread 602. In some embodiments, the dyeable thread 602 that is wrapped around the LCP thread may have the green color. Further, the dyeable thread 602 that is wrapped around the LCP thread may have the helical shape or double helix structure. In some embodiments, the dyeable thread 602 that is wrapped around the LCP thread may comprises polyester, nylon, or cotton. Successively, the second yam 302 may be weaved with the first yam 300. Further, the second yam 302 may comprise the synthetic threads. Further, the synthetic threads of the second yam 302 may comprise polyester, nylon, cotton, other natural or synthetic blended yams . In some embodiments, each strap of the plurality of straps 124 may be configured to elongate by three percent or less without breaking.

[0060] The present disclosure streamlines suspension of impact forces w hile w earing the safety helmet 100. Embodiments of the present invention may reduce a risk of injury to the user's head through the suspension strap assembly 120 of the safety helmet 100. Embodiments of the present invention may reduce elongation of each strap of the suspension strap assembly 120 using the LCP threads 600 in each of the plurality of straps 124 of the suspension strap assembly 120. Embodiments of the present invention may enhance comfort and fitting of the safety helmet 100 by using the suspension strap assembly 120. The first yam 300 having theAtorney DockctNo.: 81205.433.WO01LCP threads 600 and the second yam 302 of the plurality of straps 124 may ensure optimal protective performance of the safety helmet 100 during various activities. Additionally, the use of LCP threads 600 in the suspension strap assembly 120 contributes to cost-effectiveness of the safety helmet 100 by providing a durable and reliable material that reduces need for frequent replacements.

[0061] Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the present disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and / or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

Atorney DockctNo.: 81205.433.WO01CLAIMS:

1. A safety helmet comprising: a suspension strap assembly comprising a plurality of straps, each strap comprising: a first yam comprising liquid crystal polymer (LCP) threads, wherein each LCP thread is wrapped with a dyeable thread; and a second yam woven with the first yam. wherein the second yam comprises synthetic threads.

2. The safety helmet of claim 1. wherein the synthetic threads of the second yam comprise at least one of polyester or nylon.

3. The safety helmet of either of claims 1 or 2, wherein the dyeable thread that is wrapped around the LCP thread has a green color.

4. The safety helmet of any one of claims 1 to 3, wherein the dyeable thread that is wrapped around the LCP thread has a helical shape or double helix structure.

5. The safety helmet of any one of claims 1 to 4, wherein the dyeable thread that is wrapped around the LCP thread comprises at least one of polyester, nylon, cotton, other natural or synthetic blended threads.

6. The safety helmet of any one of claims 1 to 5, wherein each strap of the plurality of straps is configured to elongate by three percent or less without breaking.

7. The safety helmet of any one of claims 1 to 6, wherein: each of the LCP threads extend in a warp direction, at least some of the synthetic threads extend in the warp direction, and at least some of the synthetic threads extend in a weft direction.

8. The safety helmet of any one of claims 1 to 7, wherein each strap of the plurality of straps comprises at least 4 insert LCP threads or all LCP threads.Atorney DockctNo.: 81205.433.WO019. The safety helmet of any one of claims 1 to 8, wherein the LCP threads are arranged in pairs that are separated by a plurality of the synthetic threads.

10. The safety helmet of any one of claims 1 to 9, wherein the suspension strap assembly defines a peak force of 4450 Newton within a temperature range of -30°C ± 2°C to 49°C ± 2°C.

11. A strap comprising: a first yam comprising liquid crystal polymer (LCP) threads, wherein each LCP thread is wrapped with a dyeable thread; and a second yam woven with the first yam, wherein the second yam comprises synthetic threads.

12. The strap of claim 11, wherein the synthetic threads of the second yam comprise at least one of polyester or nylon.

13. The strap of either of claims 11 or 12. wherein the dyeable thread that is wrapped around the LCP thread has a green color.

14. The strap of any one of claims 11 to 13, wherein the dyeable thread that is wrapped around the LCP thread has a helical shape or double helix structure.

15. The strap of any one of claims 11 to 14, wherein the dyeable thread that is wrapped around the LCP thread comprises at least one of polyester, nylon, cotton, other natural or synthetic blended yams.

16. The strap of any one of claims 11 to 15, wherein the strap is configured to elongate by three percent or less without breaking.

17. The strap of any one of claims 11 to 16. wherein the strap comprises at least 4 insert LCP threads or all LCP threads.

18. The strap of any one of claims 11 to 17, wherein: each of the LCP threads extend in a warp direction, at least some of the synthetic threads extend in the warp direction, andAtorney DockctNo.: 81205.433.WO01 at least some of the synthetic threads extend in a weft direction.

19. The strap of any one of claims 11 to 18, wherein the LCP threads are arranged in pairs that are separated by a plurality of the synthetic threads.

20. The strap of any one of claims 11 to 19, wherein the first yam and the second yam define a peak force of 4450 Newton within a temperature range of -30° C ± 2°C to 49°C ± 2 C.

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