HEADPIECE ASSEMBLY HAVING REMOVABLE BALLISTIC SHELL AND BUMP SHELL WITH SUSPENSION ASSEMBLY

FIELD OF THE INVENTION

The present application relates to an article of headwear and, more particularly, to a helmet for protecting a human head.

BACKGROUND

The United States military has a history of providing a variety of headgear for military personnel. During World War II, the military standard issue included the M1 helmet. The M1 helmet included a “steel pot” portion made of metal and a liner that nestled inside the steel pot. The M1 helmet was a “one-size-fits-all” type helmet, where the size was fitted by adjusting the liner. In the early 1980's, advances in material caused the M1 helmet to give way to the Personal Armor System for Ground Troops (PASGT), which included a Kevlar helmet and vest. The PASGT helmet was produced in five sizes and, while offering more protection than the M1 helmet, still weighed about the same. More recently, the PASGT helmet has given way to the Modular Integrated Communications Helmet (MICH), the Advanced Combat Helmet (ACH), and the Lightweight Helmet (LWH). The MICH is primarily used by Special Operations, the ACH is primarily used by the Army, and the LWH is primarily used by the Marines and the Navy. These later helmets, while an improvement over the steel pot type helmets of the World War II era, are still in need of improvements relating to weight and versatility.

SUMMARY

In one embodiment, a headpiece assembly for use with a night vision mounting arm on a head of a human may include a bump shell and an interior suspension assembly adapted for seating on the head of the human to permit the bump shell to be worn by the human. The bump shell may include a front and a mounting bracket secured to the front for removably attaching the night vision mounting arm to the bump shell. The assembly may also include a ballistic shell having a bottom forming an opening and a coupling mechanism for removably securing the ballistic shell to the bump shell when the ballistic shell is placed over the bump shell. The ballistic shell may include a front and a notch extending upwardly from the opening into the front for receiving the mounting bracket when the ballistic shell is placed over the bump shell so as to permit the night vision mounting arm to be attached to the bump shell during use of the ballistic shell.

In another embodiment, a ballistic headpiece for use by a human having a head may be provided. The headpiece may be used with a night vision mounting arm, a bump shell having a front, an interior suspension assembly for seating on the head of the human to permit the bump shell to be worn by the human, and a mounting bracket secured to the front of the bump shell for removably attaching the night vision mounting arm to the bump shell. The ballistic headpiece may include a ballistic shell having a bottom forming an opening and a coupling mechanism for removably securing the ballistic shell to the bump shell when the ballistic shell is placed over the bump shell. The ballistic shell may include a front and a notch extending upwardly from the opening into the front for receiving the mounting bracket when the ballistic shell is placed over the bump shell so as to permit the night vision mounting arm to be attached to the mounting bracket during use of the ballistic shell without removing the mounting bracket from the bump shell.

In yet another embodiment, a suspension assembly for use with a headpiece by a human having a head with frontal and parietal regions may include a unitary impact protection element adapted for seating on the head. The unitary impact protection element may have a front portion having a shape that closely contours at least the frontal region of the head and a top portion and rear portion together depending from the front portion and having a shape that closely contours the parietal region of the head. The suspension assembly may also include a mounting assembly for positioning the protection element on the head.

In still a further embodiment, a bump shell assembly for use with ancillary equipment adapters and a ballistic shell by a human to protect a head during combat may include an outer body having a bottom forming an opening adapted to receive the head of the human and a suspension assembly coupled to the body and at least partially disposed in the body for seating on the head so as to permit the body to be worn by the human during combat. The body may have an exterior convex surface and at least one recessed surface recessed below the convex surface for receiving the ancillary equipment adapters whereby the ballistic shell can be worn over the body when the ancillary equipment adapters are removed from the body.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an isometric view of the front and right side of a headpiece assembly according to an embodiment of the present invention.

FIG. 2 is an isometric view of the rear and left headpiece assembly of FIG. 1.

FIG. 3 is an exploded view of the headpiece assembly of FIG. 1.

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 1 of the headpiece assembly of FIG. 1 where the suspension assembly has been omitted for clarity.

FIG. 5 is an isometric view of the suspension assembly of the bump shell of the headpiece assembly of FIG. 1.

FIG. 6 is a front elevational view taken along the line 6-6 of FIG. 5 of the suspension assembly of FIG. 5.

FIG. 7 is a rear elevational view taken along the line 7-7 of FIG. 5 of the suspension assembly of FIG. 5.

FIG. 8 is a bottom plan view taken along the line 8-8 of FIG. 6 of the suspension assembly of FIG. 5.

FIG. 9 is an isometric view of the mounting assembly of the suspension assembly of FIG. 5.

FIG. 10 is an isometric view of the impact protection element of the suspension assembly of FIG. 5.

FIG. 11 is a side elevational view taken along line 11-11 of FIG. 10 of the impact protection element of FIG. 10.

FIG. 12 is an isometric view of the outer body of the bump shell of the headpiece assembly of FIG. 1.

FIG. 13 is a top plan view taken along the line 13-13 of FIG. 12 of the outer body of FIG. 12.

FIG. 14 is a front elevational view taken along the line 14-14 of FIG. 13 of the outer body of FIG. 12.

FIG. 15 is a rear elevational view taken along the line 15-15 of FIG. 13 of the outer body of FIG. 12.

FIG. 16 is a side elevational view taken along the line 16-16 of FIG. 13 of the outer body of FIG. 12.

FIG. 17 is a bottom plan view taken along the line 17-17 of FIG. 14 of the outer body of FIG. 12.

FIG. 18 is an isometric view of the outer body of FIG. 12 and a night vision arm for use therewith.

FIG. 19 is an isometric view of the outer body of FIG. 12 and an ancillary equipment adapter for use therewith.

FIG. 20 is an isometric view of the removable ballistic shell of the headpiece assembly of FIG. 1.

FIG. 21 is a front elevational view taken along the line 21-21 of FIG. 20 of the removable ballistic shell of FIG. 20.

FIG. 22 is a rear elevational view taken along the line 22-22 of FIG. 20 of the removable ballistic shell of FIG. 20.

FIG. 23 is a bottom plan view taken along the line 23-23 of FIG. 21 of the removable ballistic shell of FIG. 20.

FIG. 24 is an isometric view of the rear attachment device of the headpiece assembly of FIG. 1.

FIG. 25 is a front elevational view taken along line 25-25 of FIG. 24 of the rear attachment device of FIG. 24.

FIG. 26 is a bottom plan view taken along line 26-26 of FIG. 25 of the rear attachment device of FIG. 24.

FIG. 27 is a rear elevational view taken along line 27-27 of FIG. 26 of the rear attachment device of FIG. 24.

FIG. 28 is a side elevational view taken along line 28-28 of FIG. 25 of the rear attachment device of FIG. 24.

DETAILED DESCRIPTION

The present application relates to a headpiece assembly 100, as shown in FIGS. 1-3, having a removable ballistic shell 102 and a bump shell 104 with a suspension assembly 106. The bump shell 104 together with the suspension assembly 106 may be worn alone or with the ballistic shell 102 in place atop the bump shell 104. When worn alone, the bump shell 104 may protect the human head in a hardhat-like fashion against contact with overlying material or equipment or falling or flying debris. The bump shell 104 may also be adapted for attachment of devices, tools, or other equipment, such as, for example, a night vision arm 105 or ancillary equipment adapters 107. The ballistic shell 102 may be worn to provide additional protection such as protection against bullets, shrapnel, or other impalements resulting from combat and as such, the headpiece assembly 100 may also be referred to as a ballistic headpiece 100. The ballistic shell 102 may fit over the bump shell 104 and may include a coupling mechanism 108 for attaching the ballistic shell 102 to the bump shell 104. The ballistic shell 102 may also be configured to accommodate one or more of the devices on the bump shell 104 to facilitate ease of placing and removing the ballistic shell 102 while also facilitating use of the devices while the ballistic shell 102 is in place. The headpiece assembly 100 may also include a rear attachment device 110 for connection to the bump shell 104 or the ballistic shell 102 and adapted for securing equipment to its surface.

The following detailed description describes each of the portions of the headpiece assembly 100, in detail, beginning with the suspension assembly 106, moving to the bump shell 104 and the ballistic shell 102, and ending with a discussion of the rear attachment device 110. While reference to the figures will be made to provide examples of what is being described, the detailed description is not limited to the embodiment shown in the figures.

The suspension assembly 106 may be described with general reference to FIGS. 5-11. The suspension assembly 106 may be adapted to support the headpiece 100 on a human head (not shown) by nesting within the bump shell 104. As such, the suspension assembly 106 may also be referred to as the interior suspension assembly 106 as it may be positioned or disposed at least partially within the bump shell 104. The suspension assembly 106 may include a unitary impact protection element 112 and a mounting assembly 114. The unitary impact protection element 112, or impact protection element 112, may be configured to suitably rest on a human head and hold the bump shell 104 in a spaced-apart relationship relative to the human head. The mounting assembly 114 may be configured to secure the impact protection element 112 to a human head and allow for adjustment to suitably fit a human head.

With regard to the impact protection element 112, also referred to as the liner, foam liner, or spacer, several of the following elements may be included and will be described in detail. The element 112 may include a generally concave inner or head side 116, a generally convex outer or shell side 118, and a bottom forming an opening. The head side 116 may be adapted for seating on the human head and the shell side 118 may be adapted for nesting within the bump shell 104. Additional elements may include vents 120 extending from the head side 116 to the shell side 118 and slots 122 and recessed areas 124 adapted for accommodating the mounting assembly 114. Further elements of the impact protection element may include depressions 126, 127 for accommodating fastening mechanisms to connect the impact protection element 112 to the bump shell 104 or to accommodate padding. Additionally, cavities 129 may be provided to accommodate a portion of the coupling mechanism 108.

Each of these elements will now each be described in detail. It is noted that several of the elements may be defined by their relation to the human head. By way of background, the human head includes several regions defined by the several bones that make up the human skull. One of these regions is a frontal region corresponding to the frontal bone of the skull in the forehead portion of the head. Another region is the parietal region corresponding to the parietal bone of the skull in the top and back portion of the head. Another region is the occipital region corresponding to the occipital bone of the skull in the lower back of the head. On opposing sides of the head, temporal regions are defined by a temporal bone of the skull.

The impact protection element 112, or liner, may include areas corresponding to these several anatomic regions of the human head. For example, the impact protection element 112 may include a frontal area 128 corresponding to the frontal region of a wearer's head and a parietal area 130 corresponding to the parietal region of a wearer's head. In addition, the impact protection element 112 may include portions dividing up the several areas. For example, the impact protection element 112 may include a front portion 135 making up the frontal area 128 and a top portion 137 and rear portion 139 making up the parietal area 130. Additional regions and portions within each region can be provided.

With particular regard to the head side 116 of the impact protection element 112, reference is made to FIG. 8. The head side may be adapted to substantially cover the frontal region and parietal region of the human head. The head side 116 may have a contour in the front portion 135 reflecting that of the frontal region of the human head and a contour in the top portion 137 and rear portion 139 reflecting that of the parietal region of the human head. Accordingly, the transition 131 between the front portion 135 and the top portion 137 may be positioned at or near the corresponding transition in the frontal and parietal regions of the skull. The transition 133 between the top portion 137 and the rear portion 139 may be positioned along a line extending from the mid-squamous region on one side of the head to the mid-squamous region on the opposing side of the head. The head side 116 may include a front edge 132 configured to encroach the eyebrow area of the head and a rear edge 140 following the contour of the back of the head and configured for positioning at or just below the occipital protuberance. As best shown in FIG. 11, the head side 116 may include substantially curvilinear side edges 136 extending from the front edge 132 around the side of the head. As the side edge 136 extends away from the front edge 132, a smooth upward curve may be provided in the temple region of the head causing the side edge 136 to extend a short distance upward before an additional smooth curve causes the side edge 136 to extend toward the rear again. The side edge 136 may further extend toward the rear of the head following a path similar to that of the seam between the parietal bone and the temporal bone and, as such, curve downward along the rear edge of the temporal bone. The side edge 136 may extend along the side of the head to the rear edge 140 of the head side 116.

The head side 116 may be a generally continuous surface defined by the front portion 135 in the frontal area 128 and the top portion 137 and rear portion 139 in the parietal area 130. However, as shown in FIG. 8, the head side 116 may be interrupted by openings to form vents 120 extending through the impact protection element 112. The perimeter edge of the openings may include a radiused edge falling away from the surface of the head side 116 and intersecting with walls defining the vent 120 extending through the impact protection element 112. One or more vents 120 may be provided. As shown, in one embodiment, four vents 120 may be provided and positioned in a radial array where the vents 120 are substantially equally spaced about the crown of the impact protection element 112. As also shown, the array may be oriented such that one vent 120 is positioned in each of four quadrants defined by a longitudinal axis extending in a forward and rear direction and a transverse axis extending in a side to side direction. In other embodiments, other orientations can be provided. For example, a five vent arrangement may be provided similar to the four vent arrangement, but with an additional vent 120 positioned on a longitudinal axis of the assembly between the vents 120 in the rear portion 139 of the impact protection element 112.

The head side 116 may also include depressions 126 defining padding locations where comfort and/or absorbent pads may be adhered or otherwise secured to the impact protection element 112. Other surface indentations and recesses may be provided. As shown best in FIG. 8, one or more depressions 126 may be provided around the inner surface of the impact protection element 112. In one embodiment, four depressions may be provided where two are positioned in the frontal portion 135 of the head side 116 and two are positioned along the lateral sides of the top portion 137 of the impact protection element 112. Accordingly, when the mounting assembly 114 is tightened, the pads positioned in the depressions 126 may be drawn against the front and sides of the wearer's head. Other depression positions may also be provided including positions in the rear portion 139 of the impact protection element 112. The depressions 126 may be relatively broad square, rectangular, trapezoidal or other shapes so as to accommodate relatively broad pads to suitably distribute loads and suitably absorb perspiration, while also allowing air flow between the impact protection element 112 and the wearer's head.

The shell side 118 of the impact protection element 112 may be generally convex and may share the front, rear, and side edges 132, 140, 136 with the head side 116 described. The surface of the shell side 118 of the impact protection element 112 may have a similar contour to the head side 116 or another contour can be provided. As best shown in FIG. 11, the longitudinal contour of the shell side 118 may be a substantially continuous contour extending from the front edge 132 to the rear edge 140 of the impact protection element 112 where the curvature of the shell side 118 in the front portion 135 is relatively sharp, the curvature through the top portion 137 is relatively mild and the curvature through the rear portion 139 is relatively sharp again. As best shown in FIG. 6, the transverse contour of the shell side 118 from one side edge 136 to the opposing side edge 136 may have a relatively sharp curvature as the surface extends from one side edge 136 up to the top of the parietal area 130 where the curvature may be relatively mild and, again, a relatively sharp curvature as the surface extends to the opposing side edge 136. As best shown in FIG. 3, the surface contour of the shell side 118 of the impact protection element 112 may be configured for nesting within the bump shell 104 and, accordingly, may take on any surface contour similar to the bump shell 104.

The shell side 118 of the impact protection element 112 may be a generally continuous surface. However, like the head side 116, the shell side 118 may be interrupted by openings to form vents 120 extending through the impact protection element 112. The perimeter edge of the openings may include a radiused edge falling away from the surface of the shell side 118 and intersecting with walls defining the vent 120 extending through the impact protection element 112. The shelf side 118 may also include depressions 127 defining securing locations where hook and loop securing elements (e.g., Velcro) can be placed, allowing the impact protection element 112 to be secured to the bump shell 104. As shown in FIG. 7, the shell side 118 surface may also include ballistic shell clip cavities 129 along rear edge 140. The cavities 129 may be generally rectangular in shape and may be positioned generally symmetrically about a centerline of the impact protection element 112 and in a position corresponding to the clips 146 on an inner surface of the ballistic shell 102.

In addition, and as shown in FIGS. 5, 10, and 11, the shell side 118 of the impact protection element 112 may also include recessed areas 124 to accommodate straps 150 of the mounting assembly 114 described below. The areas 124 may extend across the shell side 118 surface of the impact protection element 112 and may have a width and depth the same as or slightly larger than the strap 150 allowing the strap 150 to lie in the channel without projecting above the shell side surface. As shown in FIG. 10, the shell side surface may include a slot 122 positioned at or near the end of a recessed area 124 that extends longitudinally along the shell side surface. The slot 122 may have a width and thickness slightly larger than a corresponding strap 150 allowing the strap 150 to be positioned through the impact protection element 112.

The impact protection element 112 can be made from an impact attenuating material. In one embodiment, the material is a foam material. More particularly, the foam may be an expanded polypropylene. Other foams, pads, insulations, or other attenuating material may be used. In one embodiment, the impact protection element 112 may be made from a single material. In other embodiments, the impact protection element 112 may include several materials in several layers or located in several locations.

In one embodiment, as shown in FIGS. 10 and 11, the impact protection element 112 may be made from a material with different densities. As such, the impact protection element 112 may include one or more density regions. As shown, the impact protection element may include a first density region 143, a second density region 145, and a third density region 147. As shown, the density regions may correspond to the front, top, and rear portions 135, 137, 139 of the impact protection element 112.

Other arrangements of the density regions may be provided and the several densities may or may not correspond to the several portions of the impact protection element 112. However, in some embodiments, the several densities may be particularly adapted to protect particular areas of the head and as such, the transitions between them may correspond to the seams between the regions of a wearer's head. That is, in the example shown in FIGS. 10 and 11, the density in the second density region 145 may be higher than that of the first and third density regions 143, 147 in an effort to more thoroughly protect the top portion of the parietal region of the head, while also minimizing the weight by providing lesser densities in the first and third density regions 143, 147. The density of the material can be selected based on the type of material being used together with the level of protection desired. For example, the material may be an expanded polypropylene foam and the density of the density regions may range from approximately 1 pound per cubic foot to 5 pounds per cubic foot. In one embodiment, as shown in FIGS. 10 and 11, the first and third density regions 143, 147 may have a density ranging from approximately 2.0 pounds per cubic foot to approximately 2.4 pounds per cubic foot. In this embodiment, the density of the second density region 145 may range from approximately 3.0 pounds per cubic foot to approximately 3.2 pounds per cubic foot. Other combinations of densities in the density regions can be used, such as the first and second density region having a higher density and the third density region having a lower density. Additionally, other combinations may include each density region having a different density or all three density regions having the same density. In still other embodiments, alternative numbers of density regions may be provided such as, for example, two density regions or more than three density regions.

The thickness of the impact protection element 112 can also be adjusted to provide suitable protection to the wearer's head. In some embodiments, the impact protection element may have a thickness between the outer and inner sides 118, 116 ranging from approximately ¼ inch to approximately 3 inches. In another embodiment, the thickness may range from approximately ¼ inch to approximately 2 inches. In still another embodiment, the thickness may be approximately ¼ inch.

In one embodiment, the several materials can be adhered to one another to form the impact protection element 112 or the materials can be fused to form a monolithic element. It may be advantageous for purposes of better protection to construct the impact protection element 112 free of seams and joints. Accordingly, in one embodiment, the impact protection element 112 may be constructed by injecting beads into a mold from multiple ports, where the ports are positioned to place beads injected therethrough in a particular density region of the protection element 112. For example, a port may be positioned in the second density region 145 and beads with a higher density may be injected through the port. In the first and third density regions 143, 147, additional ports may be provided through which lower density beads may be injected. Upon placement of the beads, the mold may be heated, steamed, or otherwise treated to fuse the beads in the several density regions of the impact protection element 112 together. In other embodiments, the several regions may be co-injected. Other processes can be provided to create a unitary impact protection element 112 between one or more of the materials used.

Turning now to the mounting assembly 114 of the suspension assembly 106 and referring to FIG. 9, the mounting assembly 114 may include a headband portion 154 and a strap portion 150. The head band portion 154 may be configured for adjustably seating around the periphery of the human head and the strap portion 150 may be configured for engagement with the headband portion 154 and the impact protection element 112 to removably secure the impact protection element 112 to the headband 154. As such, the mounting assembly 114 may removably secure the impact protection element 112 to the human head.

The headband portion 154 may include a frontal band 156 and a rear band 158. The frontal band 156 may be configured for seating against the forehead of a human user and extending along the sides of the head. The frontal band 156 may include a relatively thin band type element with a width and having a plurality of perforations extending therethrough. The frontal band 156 may have a length similar to that of the distance from the mid-squamous region on one side of the human head extending along the side of the head across the brow line and returning to the opposing mid-squamous region. The rear band 158 may extend downward and rearward from the mid-squamous region and further be configured to extend around the rear of the human head below the occipital protuberance. The rear band 158 may include a non-linear discontinuity 160 positioned on either side of the band 158 as it extends around the rear sides of the back of the head allowing the rear band 158 to drop below the occipital protuberance and then extend across the rear side of the head. The rear band 158 may include two portions, one on each side of the mounting assembly 114 and being connected at the rear of the mounting assembly 114 by an adjustment mechanism 162. The adjustment mechanism 162 may be configured to draw the two portions of the rear band 158 toward one another to tighten the headband 154 or allow the two portions to move away from one another to loosen the headband 154.

The strap portion 150 of the mounting assembly 114 may include one or more straps 150 extending from the headband 154 and extending upward and across the head to an opposing or other side of the headband 154. The straps 150 can be adapted to nest in the recessed areas 124 described in the shell side 118 of the impact protection element 112. The straps 150 can be relatively thin yet relatively wide so as to apply a relatively uniform pressure to the surface of the impact protection element 112 The straps 150 may intersect with the headband 154 in an overlapping condition and may be connected to the headband 154 with protruding tabs 164 that engage corresponding slots in the headband 154. As shown in FIG. 9, the mounting assembly may include three straps 150 extending from the headband 154 and meeting at a joint 166 positioned near the crown of the impact protection element 112. As shown, side straps 150 may each extend from the opposing locations on the headband 154 where the frontal band 156 and the rear band 158 intersect. A front strap 150 may extend from a location at or near the middle of the frontal band 156. All of the side and front straps 150 may extend to the crown area of the mounting assembly 114 and be connected to one another with a joiner 166. In other embodiments, the three straps 150 may be integral with one another and, for example, be cut from an extruded membrane and a joiner 166 may not be provided.

The mounting assembly 114 may be secured to the impact protection element 112 as best shown in FIG. 5 to form the suspension assembly 106. The front strap 150 may be threaded through the slot 122 in the impact protection element 112 and the side straps 150 may be positioned to extend along the shell side surface of the top portion 137 of the impact protection element 112. As best shown in FIG. 5, the straps may have a length configured to position a bottom edge of the frontal portion 156 of the headband 154 substantially flush with the front edge 132 of the impact protection element 112. In this position, the frontal portion 156 of the headband 154 may extend around to the sides of the suspension assembly 106 and extend just below the side edge 136 of the impact protection element 112.

The suspension assembly 106 described may be used to support and secure the bump shell 104 to a human head. As such, it is noted that the bump shell 104 and the suspension assembly 106, together, may be referred to as a bump shell assembly. Accordingly, the bump shell 104 may now be described with general reference to FIGS. 12-19. The bump shell 104 may be configured for protection against bumps, falling objects, or other encounters and may provide protection similar to that of a hardhat. As such, the bump shell 104 may be configured for use with the suspension assembly 106 for positioning on a human head and may be constructed of a relatively hard material. In addition, the bump shell 104 may be configured to receive a ballistic shell 102 for added protection of the wearer.

The bump shell 104, also known as the shell, helmet shell, or helmet 104, may include a body 168 with an outer surface having a generally convex shape. The body 168 may have a bottom forming an opening adapted for receiving the suspension assembly 106. The body 168 may have a mounting assembly surface, or inner surface, opposite the outer surface defining a thickness therebetween. The outer surface of the body 168 may have a generally spherical contour with a relatively sharp curvature near the outer periphery of the body 168 and relatively minimal curvature near the center of the body, the center of the body corresponding to the top portion 137 of the impact protection element 112. The body 168 of the bump shell 104 may include a front edge 170, side edges 172, and a rear edge 174 configured for general alignment with corresponding edges of the suspension assembly 106. The body 168 may include a side surface extending from the side edge 172 up to the top of the body 168 and an additional side surface extending down from the top of the body 168 to the other side edge 172. The body 168 of the bump shell 104 may include a mounting bracket 176 for attachment of a night vision mounting arm 105 or other device, a first portion of a coupling mechanism 108 for attachment of a ballistic shell 102, openings in the form of vents 178, and ancillary equipment features 180 for attachment of ancillary equipment adapters 107. In addition, the bump shell 104 may include securing elements 182 for the attachment of chin straps for securing the headpiece assembly 100 to the wearer. The body 168 of the bump shell 104 may be constructed from a plastic material, a hard plastic material, or a composite material. Other materials may also be used to construct the body 168 of the bump shell 104.

The mounting bracket 176 may be positioned on the front of the bump shell 104 and may be configured to receive and retain a mounting plate of a night vision mounting arm 105. The bracket 176 may include a generally flat mounting surface 184 at least partially surrounded on three sides by retaining elements 186 and on a fourth side by an insertion and release lever 188. Other arrangements and attachment mechanisms are known in the art for securing night vision equipment to a helmet and these are within the scope of the present disclosure.

As shown in FIG. 12, the mounting bracket 176 may be positioned on a reinforcing element 190 on the front of the bump shell 104. The reinforcing element 190 may include a plurality of tiers of reinforcing material arranged in stepped fashion as shown. The reinforcing element 190 may be constructed of a unassailable or bulletproof material such as steel, titanium, aluminum alloy, and an aramid material like Kevlar. The several tiers of reinforcing material may be monolithic with one another or constructed from separate pieces of the same or differing materials.

A first tier 192 of reinforcing material may be positioned against the outer surface of the bump shell 104 in the front of the bump shell 104. The first tier 192 of reinforcing material may include one or more layers or sheets of material each with a thickness where the total thickness of the tier is equal to the sum of each of the layer thicknesses. The first tier 192 may be positioned adjacent to the front edge 170 of the bump shell 104 and may have a width measured along the front edge 170 of the bump shell 104 and a height measured orthogonally to the front edge 170.

A second tier 194 of reinforcing material may be positioned on the first tier 192 and may also include one or more layers or sheets of material, each with a thickness, the total thickness of the tier 194 being equal to the sum of the layer thicknesses. The second tier 194 may also be positioned adjacent to the front edge 170 of the bump shell 104 such that the front edge 170 of the bump shell 104, the first tier 192, and the second tier 194 are all in substantial alignment with one another. The second tier 194 may include a width measured along the front edge 170 and a height measured orthogonally to the front edge 170 where the width and height of the second tier 194 are each shorter than the width and height of the first tier 192 defining a ledge 196. The ledge 196 may have a width equal to the difference between the height of the first tier 192 and the height of the second tier 194 and the width of the ledge 196 may be substantially constant around the perimeter of the reinforcing element 190. As shown best in FIG. 14, the width of the first and second tiers 192, 194 may decrease slightly as the tiers 192, 194 extend away from the front edge 170 creating a slightly tapered shape of the tiers 192, 194.

The width and height of the first and second tiers 192, 194 may be selected to be greater than the width and height of the mounting bracket 176 to provide a surface for which to attach the bracket 176. In one embodiment, the first tier may have a width ranging from approximately 1¾ inches to approximately 5 inches and a height ranging from approximately 1⅝ inches to approximately 4 inches. In this embodiment, the second tier 194 may have a width ranging from approximately 1½ inches to approximately 3 inches and a height ranging from approximately 1½ inches to approximately 3 inches. In this embodiment, the ledge 196 may have a width ranging from approximately ⅛ inch to approximately 1 inch. In another embodiment, the first tier 192 may have a width of approximately 3 inches and a height of approximately 3 inches, the second tier 194 may have a width of approximately 2½ inches and a height of approximately 2¾ inches, and the ledge 196 may thus have a width of approximately ¼ inch. Other dimensions may be provided to adjust the width of the ledge 196. Each tier may have a thickness depending on the type of material used and the level of protection desired. In one embodiment, the first tier 192 may have a thickness ranging from approximately ⅛ inch to approximately ⅜ inch and the second tier 194 may have a thickness ranging from approximately ¾ inch to approximately ½ inch.

As mentioned, the bump shell 104 may also include a first portion of a coupling mechanism 108. The first portion of the coupling mechanism 108 of the bump shell 104 may be configured for engagement with a second portion on the ballistic shell for removable attachment of the ballistic shell 102 to the bump shell 104. As shown in FIG. 16, the first portion of the coupling mechanism 108 may include one or more receiving slots 198 near the rear edge 174 of the body 168 and one or more ratchet surfaces 200 extending along side the reinforcing element 190 on the front of the body 168. The receiving slots 198 may be rectangular and may be oriented generally horizontally and positioned on opposing sides of a centerline of the body 168. The ratchet surfaces 200 may include a plurality of ratchet teeth 202 positioned along a periphery of the body 168. The ratchet teeth 202 may include a riding surface 204 extending along and slightly away from the periphery of the body 168 defining a generally gradual slope, the direction up the slope defining a ratchet direction. The riding surface 204 may extend to a point 206 from which a latching surface 208 abruptly returns to the periphery of the body 168 at an acute angle relative to the riding surface 204. The ratchet teeth 202 may be consecutively arranged to form an elongate strip and the strip may be vertically oriented with the ratchet direction extending downward along the front of the body 168. As shown in FIG. 14, two ratchet surfaces may be provided and may be equally spaced from a centerline of the body 168 and positioned on opposing sides of the reinforcing element 190 on which the mounting bracket 176 is positioned.

The ancillary equipment features 180 in the body 168 may be configured for attachment of adapters, such as adapters 107 illustrated in FIG. 19, that may, in turn, be used for securing ancillary equipment (not shown) to the helmet. The ancillary equipment features 180 may include recessed channels 210 having a bottom 212 or recessed surface 212, two side walls 214, and an open top 215. The recessed channels 210 may have a plurality of perforations or depressions 216 penetrating the recessed surface or bottom 212 of the channel 210 and a plurality of perforations or depressions 218 may also be positioned adjacent the channels 210. The recessed channels 210 may extend along the outer surface of the body 168 of the bump shell 104 and may be positioned offset from and generally parallel to the side edges 172 of the bump shell 104. The recessed channels 210 may have a generally trapezoidal cross-section that is substantially constant along the length of the channel 210 where the bottom or recessed surface width is at least slightly larger than the top width. The side walls 214 of the channel 210 may be straight or slightly flared. In one embodiment, the channel 210 may be generally rectangular and the side walls may be flared. The perforations or depressions 216 in the bottom of the channel 210 may be of any suitable shape such as for example rectangular with a length extending generally perpendicular to the length of the channel 210. The perforations or depressions 216 may be substantially equally spaced throughout the length of the channel 210 as shown, for example, in FIG. 16. The perforations or depressions 218 positioned adjacent the channel 210 may be generally square and be positioned on each side of the channel 210. Other arrangements and shapes of perforations or depressions 216, 218 may also be provided.

The vents 178 of the bump shell 104 may include perforations penetrating through the thickness of the body 168. The vents 178 may be oval, rectangular, or other shapes and may be positioned at or around the crown of the bump shell 104 so as to most effectively release heat given off by the head of a wearer. A plurality of vents 178 may be provided and, in one embodiment, may correspond to the vent locations of the impact protection element 112 to facilitate uninterrupted air flow through the bump shell 104 and the impact protection element 112. Each vent 178 may be placed flush with the shell surface as shown or in an aerodynamic shaped recess.

The securing elements 182 of the bump shell 104 may include perforations for receiving bolts, knobs, or other hook-like features for attachment of a chin strap to the bump shell 104. The securing elements 182 may include two perforations positioned along the rear edge 174 of the bump shell 104 and two additional perforations may be positioned along the side edge 172 of the bump shell 104 near the temple region of the wearer. The perforations may be threaded perforations for receiving threaded fasteners such as bolts or screws. As such, bolts, knobs, or other features can be fastened to the bump shell by inserting and securing a fastener in the perforations.

Turning now to the ballistic shell 102, reference can be made generally to FIGS. 20-23. The ballistic shell 102 can be configured for nested positioning over the bump shell 104. Accordingly, the ballistic shell 102, also referred to as reinforcing shell, or protective shell, or outer shell, may have an outer surface having a generally convex shape similar to that of the outer body 168 of the bump shell 104. The ballistic shell 102 may have a bottom forming an opening adapted for receiving the bump shell 104 and may have an inner surface opposite the outer surface defining a thickness therebetween. The outer surface of the ballistic shell 102 may have a contour substantially matching that of the bump shell 104 and may include a front edge 224 and a rear edge 228 configured for general alignment with corresponding edges of the suspension assembly 106 and bump shell 104. The ballistic shell may also include side edges 226 that differ from the side edges 172 of the bump shell 104. That is, the side edges 226 of the ballistic shell 102 may extend more directly from the front edge 224 along the sides of the shell 102 and then curve downward and around the rear of the shell. More particularly, a curved portion similar to the curved portion of the side edges 172 of the bump shell 104 near the temple region of the wearer may not be provided on the ballistic shell 102. Rather, the side edges 226 may flare outward away from the bump shell 104 to provide overhanging regions configured for sheltering the ear area of a wearer. As shown, the ballistic shell may have a low cut ear portion. Other known ear portions such as medium cut and high cut ear portions can be provided.

The ballistic shell 102 may be constructed of a protective material and more particularly, an unassailable or bulletproof material. The material may include steel or an aramid material, particularly a para-aramid such as Kevlar. Other materials may also be used. The ballistic shell 102 may include a notch 230 for accommodating the mounting bracket 176 on the bump shell 104 and a plurality of perforations 232 for attachment of ancillary equipment rails. In addition, the ballistic shell 102 or outer shell may include a second portion of the coupling mechanism 108 for coupling the ballistic shell 102 to the bump shell 104 and the ballistic shell 102 may also include a reinforced rim 234.

The notch 230 on the ballistic shell 102 may be configured for relatively tight positioning around the mounting bracket 176 of the bump shell 104 and may be further adapted for overlapping engagement with the ledge 196 of the reinforcing element 190 of the bump shell 104. The notch 230 may be positioned to extend into the ballistic shell 102 from the front edge 224 and may have a geometry substantially the same as and slightly larger than the second tier 194 of the reinforcing element 190 on the bump shell 104. With reference to FIG. 4, the ballistic shell 102 is positioned on the bump shell 104 and a cross-sectional view of the relationship of the notch 230 to the mounting bracket 176 and reinforcing element 190 is shown. As shown, the periphery 236 of the notch may have a cross-sectional shape adapted to overlap the ledge 196 provided by the first and second tiers 192, 194 of the reinforcing element 190. Along the periphery 236 of the notch 230, the position of the outer surface of the ballistic shell 102 may be maintained, while the thickness of the ballistic shell 102 is reduced creating a lip-type edge 238 along the periphery 236 of the notch 230. The lip 238 may have a width adapted to accommodate the first tier 192 extending beyond the second tier 194. In some embodiments, the width of the lip 238 may be substantially the same as the width of the ledge 196 on the reinforcing element 190 allowing the ballistic shell 102 to overlap the reinforcing element 190 when the ballistic shell 102 is placed on the bump shell 104.

As shown in FIGS. 20-23, the ballistic shell 102 may include a plurality of perforations 232 for attachment of conventional ancillary equipment rails (not shown). Two perforations 232 may be positioned along the rear edge 228 of the ballistic shell 102 and two additional perforations 232 may be positioned along the side edge 226 of the ballistic shell 102 in the temple region. The perforations 232 may be threaded perforations and may be adapted to receive bolts or screws for attachment of rails configured to receive ancillary equipment adapters 107. For example, a rail such as that currently sold by OPS CORE may be secured to the ballistic shell 102 via the perforations 232 shown. As such, the perforations 232 may be positioned to align with the fastening elements on the rail or another rail provided by a different manufacturer.

The second portion of the coupling mechanism 108 of the ballistic shell 102 may be configured to couple the ballistic shell 102 to the bump shell 104 by engaging the first portion of the coupling mechanism 108 positioned on the bump shell 104. Accordingly, the second portion of the coupling mechanism 108 of the ballistic shell 102 may include clips 146 for engaging the slots 198 near the rear edge 228 of the bump shell 104 and ratchet surfaces 236 positioned to engage the corresponding ratchet surfaces 200 on the bump shell 104.

As shown in FIGS. 21 and 23, the clips 146 may include flexible tabs 238 positioned along the rear edge 228 of the ballistic shell 102. The tabs 238 may be adhered or otherwise fastened to the inside surface of the ballistic shell 102 and may extend downward toward and/or beyond the rear edge 228 of the ballistic shell 102. The tabs 238 may be fastened to the inside surface of the ballistic shell 102 with fasteners extending through the perforations 232 previously described and, as such, a single fastener can be used to retain the tabs 238 as well as an ancillary equipment rail, for example. The rear edge 228 of the ballistic shell may be flared outward causing the inside surface of the ballistic shell to diverge from the outside surface of the tab 238 and creating a gap therebetween. An engagement feature 240 may be positioned on the flexible tab 238 at a position corresponding to the position of the slots 198 on the bump shell 104. The engagement feature 240 may include an additional tab or ledge directed inwardly from the flexible tab 238. The engagement feature 240 may also be a hook or other feature for engaging the slot 198 on the rear side of the bump shell 104.

The ratchet surfaces 236 on the ballistic shell 102 may be the same or similar to those on the bump shell 104, but may be oriented with a ratchet direction extending away from the front edge 224. As such, the ratchet surfaces 236 may be in the form of ratchet strips positioned on the inside surface of the ballistic shell 102 in a position corresponding to the ratchet surfaces 200 on the bump shell 104.

The rear attachment device 110 can be described with reference to FIGS. 24-28. The rear attachment device 110 may be configured for attachment to the back of the bump shell 104 or the ballistic shell 102. The rear attachment device 110 may include a securing surface 242 for attachment of equipment. The rear attachment device 110 may also include a securing mechanism 244 connected to the securing surface 242 for securing the device 110 to a shell 102, 104.

The securing surface 242 of the rear attachment device 110 may be a substantially flat surface adapted for adjacent placement of equipment such as a battery pack, radio, or other equipment mountable to a flat surface. The securing surface 242 may have a size slightly smaller than an area defined by the rear projection of the bump shell 104. The securing surface 242 may be generally rectangular in shape and one or more slots 246 may pass through the surface 242. As shown in FIG. 24, four slots are shown, two positioned adjacent each end of the securing surface 242. The slots 246 may extend through the securing surface 242 and a strap cavity 246 may be provided behind each slot 246 to accommodate straps being passed through the slots 246 and around the end of the securing surface 242.

The securing mechanism 244 of the rear attachment device may include one or more hooks 250 for engaging a bottom edge of the shell and a concave surface 252 substantially conforming to the outer surface of the bump shell 104 and the ballistic shell 102. The one or more hooks 250 may extend downward from the securing surface 242 and have a hook configured to engage the rear edge of the shell. As shown, two hooks 250 may be provided and the hooks 250 may be spaced apart from one another and have a width suitable for engaging the rear edge of the shell. The hooks 250 may be arranged to follow the curvature of the rear edge of the shell and as such may be oriented at an angle relative to the securing surface 242 as best shown in FIG. 26. The concave surface 252 may be positioned opposite to the securing surface 242 as best shown in FIG. 28. The concave surface 252 may have a contoured surface similar to the rear parietal area of the bump shell 104 and the ballistic shell 102. The concave surface 252 may be positioned substantially flush with the top edge of the securing surface 242 and extend downwardly for a portion of the height of the securing surface 242. The concave surface 252 may include an adhering feature such as hook and loop, adhesive, or other feature configured to removably secure the concave surface 252 to the convex surface of the shell.

In operation and use, a wearer can use the headpiece assembly 100 in at least two general ways at different times. That is, the wearer can wear the bump shell 104 alone or the wearer can wear the bump shell 104 together with the ballistic shell 102. This flexibility of allowing the bump shell 104 to be worn alone provides the advantage of offering protection against relatively minor injuries such as bumps, bruises, or even concussions, without the need to wear the heavier ballistic protection 102, which may be more suitable for preventing more serious or even deadly injuries to the head.

When wearing the bump shell 104 alone, the bump shell 104 may be placed upon the wearers head and chin straps extending from the securing elements 182 on the bump shell 104 may be fastened around a wearer's chin. The bump shell 104 may be worn, for example, by a soldier during exercises, drills, or other activities when otherwise not in combat or even simulated combat. The suspension assembly 106 of the bump shell 104 may be attached to the interior surface of the bump shell 104 by a hook and loop, or other adhering system. As such, the suspension assembly 106 may be removed from the bump shell for maintenance or replacement.

As shown best in FIGS. 18 and 19, the bump shell 104 can be used with a night vision system and other ancillary equipment. As depicted in FIG. 18, a night vision arm 105 can be attached to the mounting bracket 176 positioned on the front of the bump shell 104. The night vision mounting arm 105 may be positioned on the mounting bracket by actuating the lever 188 and sliding the mounting plate under the retaining elements 186 of the mounting bracket 176. Once the mounting plate clears the lever 188, the lever 188 can be released thereby securing the mounting arm 105 to the mounting bracket 176. The wearer can then rely on the night vision as desired by rotating the night vision arm 105 down in front of the wearer's face to allow sight through night vision goggles.

In addition, as shown in FIG. 19, ancillary equipment adapters 107 can be attached to the recessed channels 210 on the sides of the bump shell 104. These adapters 107, such as, for example, ACH-ARC Adapters provided by OPS CORE, may be slid into the front or rear of the channels 210 and secured with the OPS CORE catches (not shown), which may engage the perforations or recesses 216, 218. For example, a Picatinny adapter, which may engage the perforations 216, or a Wing-loc adapter, which may engage the perforations 218, may be used. In other embodiments, other adapters 107 can be slid into the channels 210 and secured with set screws, spring pins, or any other restraining type mechanism. The adapters 107 can then be used to secure flash lights, strobes, or other equipment to the headpiece 100 for use by the wearer.

Adding still further versatility, the rear attachment device 110 may be attached to the bump shell 104 by hooking the hooks 250 of the device 110 under the rear edge 174 of the bump shell 104 and pressing the concave surface 252 of the device 110 against the back of the bump shell 104. Hook and loop materials, such as Velcro, can be used to secure the concave surface 252 to the bump shell 104. Once in place, batteries, radios, or other equipment requiring a flat surface for attachment may be secured to the securing surface 252 of the rear attachment device 110. The rear attachment device 110 may be magnetized to secure equipment or hook and loop material or even tape can be provided on the securing surface 242. In addition, or alternatively, straps and/or tape can be inserted through the slots 246 on each end of the securing surface 242 and equipment can be strapped to the securing surface 242 of the rear attachment device 110.

When the wearer desires or requires more protection than that provided by the bump shell 104, the wearer may place the ballistic shell 102 over the bump shell 104. If ancillary equipment adapters 107 are in place on the bump shell 104 or the rear attachment device 110 is in place on the bump shell 104, these items may be removed to provide a clean surface over which to place the ballistic shell 102. It is noted that the night vision arm 105 may remain attached to the bump shell 104 for placement of the ballistic shell 102.

To place the ballistic shell 102, the wearer may place the engagement features 240 of the clips 146 on the ballistic shell 102 into the slots 198 near the rear edge of the bump shell 104. The wearer may then rotate the ballistic shell 102 forward over the bump shell 104 causing the ratchet surfaces 236 on the inside surface of the ballistic shell 102 to engage the ratchet surfaces 200 on the front portion of the bump shell 104. The wearer can pull down on the ballistic shell 102 to secure the ballistic shell 102 by passing the ratchet surfaces 200, 236 along one another to engage the ratchet teeth 202. It is noted that the tapered shape of the side edges of the notch 230 in the ballistic shell 102 allow for the notch to pass down around the mounting bracket 176 without undue friction. That is, were the side edges oriented in a more vertical fashion, the edges may need to slide along the mounting bracket 176 and the reinforcing element for proper positioning and the sliding motion may cause the sides of the notch 230 to catch as the notch passes down around the mounting bracket 176. When the ballistic shell 102 is placed upon the bump shell 104, it is further noted that the lip 238 along the periphery 236 of the notch 230 of the ballistic shell 102 may overlap with the ledge 196 on the reinforcing element 190 of the bump shell 104. As such, impalements directed toward the seam between the mounting bracket 176 for the night vision arm 105 and the edge of the ballistic shell 102 may be arrested by the first tier 192 of the reinforcing element 190 passing behind this seam.

Upon placing the ballistic shell 102, the wearer may replace the rear attachment device 110 upon the headpiece assembly 100 by engaging the hooks 250 of the device 110 along the rear edge of the assembly 100 and pressing the concave surface 252 of the device 110 against the rear parietal region of the surface of the ballistic shell 102. As with the attachment to the bump shell 104, hook and loop or other systems can be used to adhere or attach the concave surface 252 to the surface of the ballistic shell 102. In addition, ancillary equipment rails such as, for example, OPS CORE ACH-ARC rails, may be attached to the ballistic shell 102 by bolting the rails to the perforations 232 positioned on the ballistic shell 102. Where the clips 146 on the ballistic shell are bolted in place, as opposed to adhered or otherwise secured to the inner surface of the ballistic shell 102, a single bolt can be used to secure the rear portion of the rail and the clips 146. Ancillary equipment adapters 107 such as, for example, ACH-ARC adapters as described with respect to the bump shell 104 may be positioned on and attached to the rails. Ancillary equipment may then be supported on or mounted to the adapters 107 or directly to the rails. As for the night vision arm 105, the notch 230 in the ballistic shell 102 allows the placement of the ballistic shell 102 without affecting the position or use of the night vision arm 105 and it thus, may be used in the same fashion as when the bump shell 104 is worn alone.

When a wearer desires to remove the ballistic shell 102, the wearer may reach upward underneath the assembly and grasp the clips 146 extending downward from the rear edge 228 of the ballistic shell 102. The divergence of the flared rear edge 228 of the ballistic shell 102 from the outside surface of the clips 146 may allow the user to squeeze the clips 146 toward the inner surface of the ballistic shell 102 thereby releasing the engagement features 240 on the clips 146 from the slots 198 in the bump shell 104. Upon releasing the engagement features 240, the rear portion of the ballistic shell 102 may be lifted causing the ballistic shell 102 to rotate forward on the wearer's head and release the ratchet surfaces 236 near the front of the assembly 100. The wearer may then replace any ancillary equipment adapters 107 and/or rear attachment devices 110 on the bump shell 104 as desired.

While the headpiece assembly has been described in detail above, several alternatives will be apparent to those of skill in the art and these alternatives are within the scope of the invention. For example, the securing surface 252 on the rear attachment device 110 may be round, triangular, or other shapes. It may also have a concave, convex, or other contour adapted to engage particular types of equipment. Still further, the slots 246 in the securing surface 252 of the rear attachment device 110 could be loops, clips, or other devices for securing straps.

In still other embodiments, the bump shell 104 and the ballistic shell 102 may be configured for use with varying sizes of one or the other. That is, the bump shell 104 may be provided in a variety of sizes and the ballistic shell 102 may be provided in a single size where the ratchet connection of the ballistic shell 102 to the bump shell 104 allows for a tight fit of several sizes. In other embodiments, the bump shell 104 may be a one-size-fits-all assembly where adjustment is made through adjustment of the chin straps and several ballistic shell 102 sizes may be provided. Still further, the bump shell 104 and ballistic shell 102 may be a single size and the suspension assembly 106 may be adjusted for suitable fit, where the head side 116 of the impact protection element 112 is provided in several sizes and the shell side 118 of the impact protection element 112 is provided to fit in a single size bump shell 104. Other combinations can be provided.

One having ordinary skill in the art will appreciate that there are numerous types and sizes of heads for which there can be a need or desire to provide a headpiece assembly 100. Additionally, one having ordinary skill in the art will appreciate that although the preferred embodiments illustrated herein reflect a generally spherical type assembly, the headpiece 100 can be constructed of different materials with differing cross-sections, e.g., rectangular, triangular, oval, round, or another cross-section.

As used herein, the terms “top,” “bottom,” and/or other terms indicative of direction are used herein for convenience and to depict relational positions and/or directions between the parts of the embodiments. It will be appreciated that certain embodiments, or portions thereof, can also be oriented in other positions.

In addition, the term “approximately” should generally be understood to refer to both the corresponding number and a range of numbers. In addition, all numerical ranges herein should be understood to include each whole integer within the range. While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.

	Number	Date	Country
Parent	12838395	Jul 2010	US
Child	13615297		US

HEADPIECE ASSEMBLY HAVING REMOVABLE BALLISTIC SHELL AND BUMP SHELL WITH SUSPENSION ASSEMBLY

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CPC

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