POWER AND DATA RETROFIT FOR HELMET SIDE RAIL SYSTEM

INCORPORATION BY REFERENCE

This application is related to U.S. provisional patent application Ser. No. 63/722,035 filed Nov. 18, 2024 [131017P], entitled Boltless Helmet Shroud System, and to U.S. patent application Ser. No. 18/755,052 filed Jun. 26, 2024 [126591R], entitled Power and Data Interface for Weapon Accessory Mounting Rail. The entire contents of each of the aforementioned applications including the specification and drawings are incorporated herein by reference in its entirety.

BACKGROUND

In one aspect, the present development relates to a weapon mounting system, and more particularly to a retrofit system and method for providing electrical power and data connections on a legacy weapon rail interface.

In another aspect, the present development relates to a helmet mounting system, and more particularly to system and method for providing electrical power and data connections on helmet side rail system.

Advantages and benefits of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.

SUMMARY

In one aspect, an apparatus is provided for providing electrical power to and communicating data and control signals among weapon accessory devices disposed on a handguard having a weapon rail interface and a plurality of slots. The apparatus includes a control module attachable to the handguard via at least one of the plurality of slots of the handguard. The control module includes a processor and a power supply operably coupled to the processor. A control module connector element is adapted to extend through the at least one of the plurality of slots via which the control module is attachable to the weapon rail interface. At least one insert includes an insert connector element, the at least one insert adapted for operative coupling with a weapons accessory device, wherein the processor of the control module includes a communications interface for data communication with the at least one insert. At least one cable includes connector ends on either end of the at least one cable, wherein the connector ends are adapted to couple to at least the control module connector element of the control module and the insert connector element of the at least one insert.

In a more limited aspect, the control module further includes a power interface for operably connecting the power supply of the control module.

In another more limited aspect, the at least one cable includes at least two cables and the connector ends are further adapted to couple to the weapons accessory device, wherein the operative coupling of the at least one insert with the weapons accessory device is via one of the at least two cables.

In another more limited aspect, the weapons accessory device with which the at least one insert is adapted for operative coupling is selected from the group consisting of a flashlight, a laser package, an optical sight, and a fire control system.

In another more limited aspect, the apparatus further includes at least one of the weapons accessory devices with which the at least one insert is adapted for operative coupling, wherein the at least one weapons accessory device is one or more selected from the group consisting of a flashlight, a laser package, an optical sight, and a fire control system.

In another more limited aspect, the control module connector element includes connector receptacles that engage with the connector ends of the at least one cable.

In another more limited aspect, the insert connector element includes connector receptacles that engage with the connector ends of the at least one cable.

In another more limited aspect, the at least one insert further includes a housing attached to the insert connector element with at least one electrical contact electrically coupled to connector receptacles for transmitting power and data signals.

In another more limited aspect, the at least one electrical contact is four electrical contacts, a first of which is electrically coupled to the ground/negative terminal of the power supply; a second of which is electrically coupled to a data line that carries positive signals for transmitting data between devices; a third of which is electrically coupled to a data line that carries negative signals for transmitting data between devices; and a fourth of which is electrically coupled to the voltage/positive terminal of the power supply.

In another more limited aspect, the housing has at least one upper peripheral flange.

In another more limited aspect, the at least one upper peripheral flange has a beveled edge.

In another more limited aspect, the at least one insert further includes at least one retention clip with an extending tab portion and a threaded fastener around which the at least one retention clip is rotatable. A channel is defined between the at least one upper peripheral flange and the extending tab portion of the at least one retention clip. Rotation of the retention clip around the threaded fastener allows for tightening and loosening of the at least one insert within a slot of the weapon rail interface.

In another more limited aspect, at least one corner of the at least one retention clip is rounded to permit retention clip to rotate when the threaded fastener is rotated.

In another more limited aspect, at least one corner of the at least one retention clip is squared to act as a stop to prevent the retention clip from rotating when the threaded fastener is rotated.

In another more limited aspect, the apparatus further includes at least one cable extender.

In another more limited aspect, the apparatus further includes an accessory controller device electrically coupled to the at least one insert and the control module. The accessory controller device includes a plurality of buttons for controlling operation of the weapons accessory device with which the at least one insert is adapted for operative coupling.

In another more limited aspect, the apparatus further includes an optics riser operatively coupled to the weapons accessory device with which the at least one insert is adapted for operative coupling and to the at least one cable.

In another more limited aspect, the apparatus further includes the handguard including the weapons rail interface and having a plurality of slots adapted to receive a weapons accessory device.

In another more limited aspect, the communications interface of the processor is a wireless interface.

In a further aspect, an apparatus for providing electrical power to and communicating data and control signals to a helmet accessory device mounted on a helmet includes a control module attachable to the helmet. The control module comprises a processor, power supply interface, and one or more control module connectors. One or more helmet side rail assemblies have a plurality of interface slots and are configured to be secured to a surface of the helmet. At least one insert includes an insert connector element and is adapted for operative coupling with the helmet accessory device, wherein the processor of the control module comprises a communication interface for exchanging data signals, control signals, or both data and control signals with the helmet accessory device via the insert connector element. At least one cable comprises a first connector end adapted to couple a control module connector and a second connector end configured to couple to the insert connector element, wherein each of the one or more helmet side rail assemblies has an internal space configured for routing at least a portion of the at least one cable.

In a more limited aspect, the apparatus is provided in combination with the one or more helmet side rail assemblies.

In another more limited aspect, the one or more helmet side rail assemblies comprises a left helmet side rail assembly configured to be secured to the helmet above the left ear of a user when the helmet is worn and a right helmet side rail assembly configured to be secured to the helmet above the right ear of the user when the helmet is worn.

In another more limited aspect, the second connector end is coupled to couple to the insert connector element via a connection selected from the group consisting of a hardwired connection and a selectively detachable connection.

In a more limited aspect, the apparatus is provided in combination with the one or more power supplies.

In another more limited aspect, the one or more control module connectors comprises left and right connector receptacles, each of the left and right connector receptacles configured to engage with a complementary plug connector.

In another more limited aspect, the at least one insert further comprises a plurality of electrical contacts for transmitting power and one or both of data signals and control signals.

In another more limited aspect, the plurality of electrical contacts comprises four electrical contacts, a first of which is electrically coupled to a ground/negative terminal of the power supply; a second of which is electrically coupled to a data line that carries positive signals for transmitting data between devices; a third of which is electrically coupled to a data line that carries negative signals for transmitting data between devices; and a fourth of which is electrically coupled to a voltage/positive terminal of the power supply.

In another more limited aspect, each insert of the at least one insert includes a peripheral flange which is larger in at least one dimension than a corresponding dimension of a corresponding one of the plurality of interface slots.

In another more limited aspect, each at least one insert further comprises at least one retention clip with an extending tab portion and a threaded fastener around which the at least one retention clip is rotatable and a channel is defined between the at least one upper peripheral flange and the extending tab portion of the at least one retention clip, wherein rotation of the retention clip around the threaded fastener allows for securing and detaching the at least one insert within a corresponding one of the plurality of interface slots.

In a more limited aspect, the apparatus is provided in combination with the helmet accessory device.

In another more limited aspect, the combination further comprises an input actuator module comprising a plurality of switches for controlling operation of the helmet accessory device.

In another more limited aspect, the helmet accessory device is selected from the group consisting of a headlamp, a video recorder module, and an input actuator module.

In another more limited aspect, the plurality of interface slots comprises at least first, second, and third interface slots located along a longitudinal axis and wherein the helmet accessory device comprises an electrical connector element which is configured to be aligned with and facing the insert connector element of an insert of the at least one insert received within the first interface slot. A first retention clip is rotatable between a secured position configured to secure the helmet accessory device to the second interface slot. A second retention clip is rotatable between a secured position configured to secure the helmet accessory device to the third interface slot, wherein the second and third interface slots are located on opposite sides of the first interface slot along the longitudinal axis.

In another more limited aspect, the control module comprises a communications interface configured to couple the control module to an external computer based information handling system.

In another more limited aspect, the external computer based information handling system comprises a computer network, the computer network configured to transmit, send, or both transmit and send one or more of data signals, control signals, or both data and control signals between the computer network and the control module.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.

FIG. 1 is an isometric view taken generally from the right side and front illustrating the receiver and barrel portions of a firearm having a data and power distribution system in accordance with an exemplary configuration applied to a weapon accessory interface thereof.

FIG. 2 is an isometric view taken generally from the left side and front illustrating the firearm components and retrofit assembly appearing in FIG. 1.

FIG. 3 is a view taken generally from above and the right side of the firearm components and retrofit assembly appearing in FIG. 1.

FIG. 4 is a partially exploded, generally right side view of the system appearing in FIG. 3, with the handguard removed for illustrative purposes.

FIG. 5 is a further exploded, generally right side view of the system appearing in FIG. 4.

FIG. 6 is an enlarged side view of an exemplary riser with embedded connector operatively coupled to an exemplary accessory device with partial cutaway illustrating an embedded connector.

FIG. 7 is an isometric view of a handguard having exemplary power and data inserts attached thereto.

FIG. 8 is an enlarged isometric view showing the manner of serially coupling multiple power and data ports or inserts.

FIG. 9 is an enlarged isometric view of the system appearing in FIG. 8 further including a cable extender.

FIG. 10 is a side view of an alternate configuration attached to a weapon accessory interface.

FIG. 11 illustrates another alternate configuration, with the weapon handguard portion removed for illustration purposes.

FIG. 12 is schematic block diagram of an exemplary configuration of the power and data distribution system in accordance with the present disclosure.

FIG. 13 is a front view of a helmet having an exemplary helmet mounting system supported thereon.

FIG. 14 is a left side view of the helmet and helmet mounting system appearing in FIG. 13.

FIG. 15 is a rear view of the helmet and helmet mounting system helmet appearing in FIG. 13.

FIG. 16 is an isometric view, taken generally from the left side and above, of the helmet mounting system appearing in FIGS. 13-15 with the helmet removed.

FIG. 17 is a left side view of the helmet mounting system appearing in FIG. 16.

FIG. 18 is an isometric view, taken generally from the left side and below, of the helmet mounting system appearing in FIG. 16.

FIG. 19 is an isometric view, taken generally from the left side and above, of the helmet mounting system appearing in FIG. 16 with the mounting hardware removed to expose the arrangement and routing of electrical power and data connections from the rear battery to a slot rail power and data insert configured to be detachably coupled to the helmet side rails.

FIG. 20 is a side view of the interior-facing, i.e., helmet-facing, surface of the right helmet side mount having a slot rail power and data insert secured to one of the mounting interface slots, the left helmet side mount being a mirror image thereof.

FIG. 21 is a rear view of the left helmet side mount with exemplary accessory device the right helmet side mount being a mirror image thereof.

FIG. 22 is a rear cross-sectional view of the right helmet side mount, sectioned along the interface slot receiving the slot rail power and data insert.

FIG. 23 is an isometric view of the helmet and helmet mounting system appearing in FIG. 13, taken generally from the right side and above, illustrating a first exemplary accessory device disposed on the right helmet side mount.

FIG. 24 is an isometric view of the helmet and helmet mounting system appearing in FIG. 13, taken generally from the right side and above, illustrating a second exemplary accessory device disposed on the right helmet side mount.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present inventive concept in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the present development. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The terms “a” or “an,” as used herein, are defined as one or more than one. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having” as used herein, are defined as comprising (i.e., open transition). The term “coupled” or “operatively coupled,” as used herein, is defined as indirectly or directly connected.

As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” “left,” “right,” and other orientation descriptors are intended to facilitate the description of the exemplary embodiment(s) of the present invention and are not intended to limit the structure thereof to any particular position or orientation.

All numbers herein are assumed to be modified by the term “about,” unless stated otherwise. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

Referring now to the drawing FIGS. 1-6, there is shown an exemplary firearm receiver portion 10 having a handguard 12 attached thereto. The receiver 10 includes a Picatinny rail interface section 14r (e.g., MIL-STD-1913 or STANAG 4694). An exemplary handguard 12 appears in FIG. 7. The handguard 12 includes an upper Picatinny rail interface portion 14h and one or more slot rail portions 16a-16g for mounting one or more accessories to the weapon for increased functionality of the weapon, such as scopes, sights, lasers, rangefinders, and others. The slot rail interface portions 16a-16g may comprise an M-LOK™ (Magpul Industries Corp., Austin, TX) compatible mounting interface or similar system.

Each slot rail portion 16a-16g includes a series of apertures or slots 18 which are configured to receive an M-LOK or similar accessory or fastener. In the illustrated embodiment, a computer or control module 20 is attached to the slot rail section 16d via the slots 18 thereon. The control module 20 includes a battery interface 22 for operably connecting a power supply 24. In the illustrated embodiment, the battery interface 22 is a bayonet style interface configured to attach a Small Tactical Universal Battery (STUB) type rechargeable battery pack 24. The control module 20 includes a processor and wireless interface for management of data communications with one or more power and data ports or inserts 30 as will be described in greater detail below. The position of the arrangement of the control module 20 and the power and data ports can be selected by the user to form a custom configuration of data and power ports, e.g., in accordance with the functionality desired by the user.

The control module 20 is secured via a slot 18 and includes a control module connector element 32 which extends through the slot 18 into the interior of the handguard 12. The control module connector element 32 is coupled to a cable 34a. The cable 34a in turn is coupled to an insert connector element 36 on an insert 30. The insert connector element 36, in turn, is coupled to another cable 34b. The cables 34a, 34b include connector ends 35 which engage connector receptacles, such as receptacles 50 on the inserts 30, and like receptacles on the controller 20, and the accessory device 64, flashlight 38, laser package 40, keypad controller 45, and so forth. The cable 34b, in turn, is coupled to an accessory device, such as a flashlight 38 or laser package 40. In embodiments, the laser package 40 is a weapon laser accessory for targeting which integrates a plurality of laser emitters, such as visible and infrared aiming lasers, an IR illumination laser, etc., which are coaligned within a single housing. It will be recognized that the illustrated configuration is exemplary only and that any number of additional or alternative devices may be employed and any number of additional inserts 30 can be serially connected as shown in FIGS. 8 and 9.

As best seen in FIGS. 8 and 9, each insert 30 includes a housing 42 having an upper peripheral flange 44. In embodiments, the peripheral flange 44 has a beveled edge 46 which provides smoother profile, thereby reducing snagging potential and improving ergonomics and comfort when handling and manipulating the weapon. The housing 42 is attached to the connector element 48 which includes cable connectors 50 for cable connection to the controller 20 and/or an adjacent insert 30 in the chain. Electrical contacts 52a-52d are potted within an electrical insulator block 54 and electrically coupled to the connectors 50 for transmitting power and data signals.

In embodiments, the contact 52a is a ground (GND) pad used as a reference point for electrical potential and common return path for the circuit. In operation, the contact 52a is electrically coupled to the ground (e.g., negative) terminal of the power supply 24. In embodiments, the contact pads 52b and 52c are coupled to data plus (D+) and data minus (D−) data lines, respectively, which carry the positive and negative signals respectively, for transmitting data between devices in accordance with a digital communication protocol. The digital communication protocol and corresponding connectors may be adapted to accommodate any communication protocol that is suitable for low speed data communication. This includes, without limitation, various protocols such as Universal Serial Bus (USB), Controller Area Network (CAN), General Purpose Input/Output (GPIO), Serial Peripheral Interface (SPI), Inter-Integrated Circuit (12C), Universal Asynchronous Receiver-Transmitter (UART), Modbus, and Apple Lightning. In embodiments, the contact 52d is a voltage common collector (VCC) contact which is electrically coupled to the power supply voltage (e.g., positive) terminal of the power supply 24.

Threaded fasteners 56 engage rotatable retention clips 58 which are rotatable in the direction of the arrows appearing in FIG. 8. The retention clips 58 include an extending tab portion 60 which cooperate with the peripheral flange 44 to define a channel 62 at each end. Rotation of the fastener 56 allows for selectively tightening/clamping and loosening/unclamping the insert within a slot 18. Certain corners of the retention clips 58 can be selectively radiused or rounded to permit the clips 58 to rotate when the threaded fasteners 56 are rotated and other corners may be squared to act as stops to prevent rotation of the clips 58 when the threaded fasteners 56 are rotated, i.e., depending on the direction of rotation and current position of the clips 58. Accessory devices can be electrically coupled to the connector elements on the insert and mechanically secured to the slot rail interface using one or more adjacent slots on the slot rail interface.

In FIG. 8, there appears an embodiment where a relatively short cable 34 is provided to provide a serial connection between inserts 30 to be utilized between adjacent devices in the serial chain where the inserts are placed in relatively close proximity on the firearm. Referring now to FIG. 9, there is shown a further embodiment wherein a cable extender 70 (e.g., a male-female cable extender) includes a socket connector end 72 configured to receive a connector end 35 of the cable 34 and a plug connector end 74 configured to be received within a socket connector 50 the connector element 36 of an adjacent rail insert 30. The cable extender 70 allows the positioning of serially adjacent components relatively apart on the weapon, providing flexibility in configuring the user's setup. In alternative embodiments, the cable extender 70 could be replaced with a barrel connector (socket to socket) for coupling two like connection cables 34.

In the embodiments of FIGS. 1-5, an accessory controller device such as a keypad controller 45 is electrically coupled to an insert 30 which, in turn, couples the keypad controller 45 to the controller system 20. In the illustrated embodiment, the keypad controller 45 comprises a plurality of buttons or keys 47a, 47b, 47c for controlling operation of an attached accessory device such as the flashlight 38 and laser package 40.

In certain embodiments, as illustrated, an optics riser 66 may be provided between the rail section 14h, 14r, as necessary, to raise the height of the device 64 to a suitable height. In the embodiment illustrated in FIGS. 1-4, a cable 34c has a proximal end electrically coupled to a connector the optics riser 66. The optics riser 66, in turn is operatively coupled to the accessory device 64 via an embedded connector. The accessory device 64 may be a sight, fire control system, or the like. As best seen in FIG. 6, which illustrates an exemplary embodiment, the proximal end of the cable 34c includes a connector element 37 embedded within the riser 66 which detachably engages a complementary connector element 39 on the accessory device 64. In embodiments, the proximal end of the cable 34c is nondetachable or hardwired to the connector element 37 and the riser 66. Alternatively, the proximal end of the cable 34c includes a plug which is detachable from the connector element 37.

The opposite end of the cable 34c includes a plug 35 engaging a complementary first connector socket 50 on the connector element 32 on the control system 20. A cable 34a includes a plug 35 engaging a second electrical connector socket 50 on the connector element 32. The opposite end of the cable 34a includes a plug 35 engaging a first connector socket 50 on a connector element 36 on an insert 30a. A control keypad 45, in turn, is operatively coupled to the insert 30a. Another cable 34b includes a plug 35 engaging a second electrical connector socket 50 on the connector element 36 of the insert 30a. The opposite end of the cable 34b includes a plug 35 engaging a first connector socket 50 on a connector element 36 on an insert 30b. A laser module 40, in turn, is operatively coupled to the insert 30b. A cable 34d includes a plug 35 engaging a second electrical connector socket 50 on the connector element 36 of the insert 30b. The opposite end of the cable 34d includes a plug 35 engaging a first connector socket 50 on a connector element 36 on an insert 30c. A flashlight module 38, in turn, is operatively coupled to the insert 30c. A second connector socket 50 on the connector element 36 of the insert 30c is available to connect further devices in serial fashion.

Referring now to FIG. 10, there appears a system which includes an optics riser 66 having an accessory device 64 disposed on a Picatinny accessory rail portion 14r of a firearm receiver 10 and a controller 20 with battery 24, keypad controller 45, and flashlight accessory 38 attached to a slot rail handguard portion 12. The controller 20 includes a slot rail interface connector for connection to the handguard 12. The keypad controller 45 and flashlight 38 are coupled to the slot rail handguard 12 via rail inserts 30 as described above.

Referring now to FIG. 11, there appears a configuration that is similar to the configuration appearing in FIG. 10, but with the slot rail handguard removed for ease of exposition. The configuration in FIG. 11 is as described above by way of reference to FIG. 10, except that in FIG. 11, the riser 66 is removed and the accessory device 64 has been replaced with an alternative optical accessory 65 which is not coupled to the controller system 20. In addition, the flashlight module 38 appearing in FIG. 10 has been removed and the laser module 40 has been added to the configuration shown in FIG. 11.

Referring now to FIG. 12, there is shown a block diagram on an exemplary modular power and data distribution system herein. The system combines power and data on a weapon system that is scalable. The weapon system can be powered by battery 24 or wired connection. In embodiments, voltage and available current can be scaled up or down based on requests over a data bus 80. In embodiments, the data bus comprises a full duplex, copper-based interface that allows subsystems to communicate over the weapon-based network system.

Accessories connect to the weapon interface with a common power bus 82 and data bus 80. In embodiments, the power bus 82 is a bidirectional power bus that can sink and source current for the weapon platform. The power bus 82 interfaces with the power control module 20 as well as additional nodes on the power bus.

Accessories can include, without limitation, laser packages 40, optical detection systems, visual augmentation systems, fire control modules 84, as well as human-machine interfaces. In embodiments, attached devices can use bridges to convert power and data to acceptable common protocols for interface with other networked connections on the power and data buses 82, 80. In embodiments, the modular power and data distribution system herein is configured to use wireless bridges between a personal area network (PAN) and other soldier interface systems such as body worn appliances, head borne appliances, and so forth.

In embodiments, the power control module 20 comprises a modular sub-component that allows bidirectional source and sink capabilities with scalable voltage and current. In certain embodiments, the power control module 20 is configured to interface with batteries 24, hardwired power sources, and wireless power transmission to ensure a stable weapon power bus. In embodiments where multiple power sources are available, the power sources are switchable via the integrated power bus 82. In embodiments where multiple power sources are available, the battery 24 may be charged via the integrated power bus 82.

In embodiments, a soldier PAN gateway 86 provides an interface to wired and wireless inter soldier networks. In embodiments, the soldier PAN gateway 86 is configured to operably interface with head borne data links, body worn data links, vehicle data links, and others.

In embodiments, a fire control module 84 includes processing electronics configured to calculate laser drive parameters, provide signaling and sensor suite information to drive data for reticle or aim point display, ballistic solutions, laser communications, human-machine interfaces, power control, and data processing from external sources.

The laser package 40 provides real time laser drive capabilities as well as monitoring sensors. In embodiments, laser outputs can be mixed wavelength and specific to usage.

A rail accessory bridge 90 provides data and power bridge at rail junction points to support varying accessory end nodes. In embodiments, the rail accessory bridge 90 uses protocol conversion to enable dissimilar end nodes to communicate on the same network data bus 80.

Accessory end nodes 92a-92c, which may include up to any number N of accessories, comprise human-machine interfaces such as keypads, buttons, joysticks, sensors, displays, flashlights, and camera-based systems.

Referring now to FIGS. 13-24, there is shown a helmet system comprising a 100 and an associated helmet mounting system. The illustrated helmet mounting system is a modular system configured to attach and support accessories on the helmet 100. In embodiments, the helmet mounting system is a boltless, cinching helmet mounting system as shown and described in the aforementioned commonly-owned U.S. provisional patent application No. 63/722,035 filed Nov. 18, 2024.

Components of the helmet mounting system include a front shroud assembly 102 and a helmet side rail system comprising left and right helmet side rail assemblies 104. The front shroud assembly 102 is located at the front of the helmet 100 and serves as an attachment point for a helmet mount assembly (not shown), such as for night vision goggles (NVGs), cameras, or other front-mounted accessories. The front shroud assembly 102 is secured to the helmet 100 via a front hook member 106 which engages the brim of the helmet 100.

Components of the helmet mounting system include the front shroud assembly, helmet side rail system, rear battery mount, and helmet mount assembly, along with any related adapters or mounting brackets. In the illustrated boltless/cinching helmet mounting system, a ratcheting cinch mechanism 108 is coupled to the front shroud assembly 102 and includes a pulley mechanism 110 to tension a fastening cable 112 for securing the front shroud assembly 102 and the left and right helmet side rail assemblies 104 to the helmet 100.

The cable 112 creates a first looped path 112a from the pulley mechanism 110 to pulley assembly 116 disposed at a forward end of the left helmet side rail assembly 104, a second first looped path 112b from the pulley mechanism 110 to a pulley assembly 116 disposed at a rearward end of the left helmet side rail assembly 104, a third looped path 112c from the pulley mechanism 110 to a pulley assembly 116 disposed at a forward end of the right helmet side rail assembly 104, and a fourth first looped path 112d from the pulley mechanism 110 to a pulley assembly 116 disposed at a rearward end of the right helmet side rail assembly 104. Each of the pulley assemblies 116 is coupled to a respective hook member 118a-118d which engages the brim of the helmet 100 and each of which, along with the front hook member 106, defines an attachment point of the helmet mounting system.

The cinch mechanism 108 mechanism includes a rotatable dial 120 connected to a spool, which winds the cable 112 when rotated. The cable 112 is routed through the pulley mechanism 110 comprising a series of pulleys to create the looped paths 112a-112d to create uniform tension across the attachment points 106 and 118a-118d. Incremental ratcheting teeth within the mechanism engage with a locking pawl, to maintain a desired tension. A release feature allows for controlled relaxation or complete disengagement of helmet mounting system from the helmet 100 when needed.

Each helmet side rail assembly 104 includes a housing 124 which may be formed of a polymer, metal, or composite material, and which may be formed by a molding, machining, or additive manufacturing. Each housing 124 includes a recess or

Each housing 104 features a plurality of mounting slots 126 spaced along its length to provide a modular and customizable system for attaching one or more helmet-mounted accessory components. In embodiments, the slots 126 are configured to detachably couple with an M-LOK™ fastener element.

A battery pack assembly 130 includes a center module 132 and left and right detachable battery packs 134. In embodiments, the battery packs 134 are hot swappable. The center module 132 includes processing electronics, such as a processor, microcontroller, or similar components. In embodiments, an associated electronically readable memory is operably coupled to the processing electronic and stores program instructions executable by the processing electronics. The program instructions can be implemented in hardware, software, firmware, or a combination thereof. In embodiments, the battery pack assembly 130 is secured to the helmet via a detachable fastener, such as a hot shoe receiver or receptacle (not shown) on the helmet 104 which receives a hot shoe (not shown) on the center module 132 or alternatively, a hot shoe receiver or receptacle (not shown) on the center module 132 which receives a hot shoe (not shown) on the center module 132.

The center module 132 is configured to provide power as well as data and/or control signals to one or more accessory devices coupled to the helmet side rail assemblies 104. In certain embodiments, the center module 132 includes an external communication interface, such as a wired interface port (e.g., a USB-C port) or radio frequency (RF) wireless interface link, to facilitates connection to an external computer-based information handling system such as a central network controller. In embodiments, the external computer-based information handling system is a portable device, such as a body worn device or a weapon mounted device. In such embodiments, the external communication interface is configured to extend the functionality of the helmet mounting system and/or to integrate the helmet mounting system into a larger system or network.

Cables 140 include a plurality of conductors and are configured to transmit power from the battery packs 134 to a powered accessory device mounted to the helmet side rail assemblies 104. The cables 140 are also configured to transmit data and/or control signals between the center module 132 and an accessory device mounted to the helmet side rail assemblies.

Each cable 140 includes an electrical connector 142 at one end configured to detachably engage with a complementary left and right electrical connector 144, respectively, on the center module 132. Each cable includes a slot rail insert 150 configured to communicate power as well as data and/or control signals to an accessory device when the accessory device is secured to the helmet side rail assembly 104.

The cable 140 passes into the interior of the housing 124 through a desired one of the slots 148 and passes out of the housing 124 through a notch or channel 146 formed near the rear of the housing 124 and to the corresponding left or right connector 144. In embodiments, a front notch or channel 145 is provided near the forward end of the housing 124 to provide a passage for a cable to pass into the interior of the housing from the front. The insert 150 includes a connector element 152 which is received through the slot 148 and engages the end of the cable 140. The insert 150 includes pivoting retention clips 154 which have an extending tab portion 156 which cooperate with a peripheral flange 158 on the insert 150 to define a channel 160 at each end. In this manner, the insert 150 is configured to engage the edge of the slot 148 in the housing 124, wherein the edge of the slot 148 is gripped between the peripheral flange 158 and extending tab portion 156 to secure the insert 150 in place. A plurality of electrical contacts 162 are potted within an electrical insulator block 164 and electrically coupled to the connector element 152 for transmitting power and data/control signals. By running the cable 140 within the housing 124, the potential snag hazards and clutter associated with externally run cables is reduced.

In the illustrated embodiment appearing in FIGS. 13-18, 21, 23, and 24, the left helmet side rail assembly 104 is depicted with a head lamp module 170 coupled thereto. In the illustrated embodiment appearing in FIGS. 13, 15, 16, 18, and 23, the right helmet side rail assembly 104 is depicted with a head worn video recording device 180 coupled thereto. In the illustrated embodiment appearing in FIG. 24, the video capture device coupled 180 has been replaced with a manual control or actuation device 190. It will be recognized that the development herein may be used with a variety of helmet-mounted accessory devices, and particularly advantageously, with those requiring power and/or an interface for transmission of data or control signals. The accessories illustrated in the drawings represent some of the presently preferred embodiments and are provided by way of example only, and not by way of limitation.

The headlamp assembly 170 includes a lamp head 172 coupled to a lamp body 174. The lamp head 172 includes one or more light elements such one or more light emitting diodes (LEDs) or incandescent bulbs. The lamp head 172 may further include a lens, reflector, or focusing mechanism as would be understood by persons skilled in the art. The headlamp assembly 170 further includes a plurality of electrical contacts (not shown), such as spring-biased pin connectors, which are configured to align with the contacts 162 on the insert 150 when the headlamp assembly 170 is coupled to the helmet side rail assembly 104 as described below to thereby provide power to operate the headlamp and optionally control and/or data signals. In certain embodiments, power is supplied to the headlamp assembly 170 via the insert 150 and headlamp controls are actuated directly via the headlamp assembly 170. In certain embodiments, power is supplied to the headlamp assembly 150 via the insert 150 and headlamp controls are actuated remotely via control signals transmitted via the insert 150. Exemplary headlamp controls include on/off, brightness level, wavelength (in the case of multi-wavelength headlamps), and mode (e.g., strobe, turbo, firefly, etc.)

The lamp body 174 includes slot rail connector elements, including a mounting base plate 175 and one or more slot-engaging connector elements. In embodiments, the slot-engaging connector elements comprise two spaced apart, elongated rotatable slot retention clips 155 with which are rotatably coupled to the base plate 175 via a threaded fastener 176. The elongated rotatable slot retention clips 155 are rotatable with a tool such as a driver engaging the fastener 176 and are rotatable between an engaged position and a disengaged position. The two rotatable slot retention clips 155 are spaced apart a distance such that when the headlamp assembly 170 is operably positioned over an insert 150 received within one of the slots 148 on the helmet side rail assembly 104, a first one of the retention clips 155 is aligned with a first neighboring slot 148 on one side of the slot receiving the insert 150 and a second one of the retention clips 155 is aligned with a second neighboring slot 148 disposed on the other side of the slot receiving the insert 150.

To attach the headlamp assembly 170 to the helmet side rail housing 124, the slot retention clips 155 are positioned so that the long axis of the slot retention clips 155 extend parallel to the axis of the slot 148. The slot retention clips 155 are then passed through the respective neighboring slots 148 positioned on opposing ends of the central slot 148 receiving the insert 150. Using a tool such as a screwdriver or similar implement, the fasteners 176 securing the locking tabs 155 are rotated to the slot engaging position wherein the long axis of the tabs 155 are oriented transverse with respect to the respective slot 148. In this transverse orientation, the locking tabs 155 engage the underside of the edge of the slot 148 to secure the slot edge between the tabs 155 and the mounting base plate 175.

The video recorder module 180 includes a camera assembly 182 comprising a lens assembly 184 and a housing 186 enclosing an image sensor, such as a charge-coupled device (CCD) or complementary metal-oxide-semiconductor (CMOS) image sensor and an associated processor or signal processing unit configured to process the raw image data from the image sensor into video output. The camera assembly 182 may be a visible light camera, thermal camera, low light camera, and others. The video recorder module 180 further includes a plurality of electrical contacts (not shown), such as spring-biased pin connectors, which are configured to align with the contacts 162 on the insert 150 when the video recorder module 180 is coupled to the helmet side rail assembly 104 as described below to thereby provide power to operate the video recorder module 180 and optionally control and/or data signals.

In certain embodiments, power is supplied to the video recorder module 180 via the insert 150 and operation of the video recorder module 180 is controlled remotely via control signals transmitted from a control interface in communication with the center module 132 and transmitted to video recorder module the via the insert 150. In certain embodiments, data representative of video output from the video recorder module 180 is transmitted to the center module 132 via the insert 150 where is stored on an electronic medium associated with the center module 132. Alternatively, or additionally, data representative of the video output is transmitted to a remote location via a wireless communication interface for remote storage and/or remote viewing.

The video recorder module 180 includes slot rail connector elements, including a mounting base plate 185 and one or more slot-engaging connector elements. In embodiments, the slot-engaging connector elements comprise two spaced apart, elongated rotatable slot retention clips 155 with which are rotatably coupled to the base plate 185 via a threaded fastener 176. The elongated rotatable slot retention clips 155 are rotatable with a tool such as a driver engaging the fastener 176 and are rotatable between an engaged position and a disengaged position. The two rotatable slot retention clips 155 are spaced apart a distance such that when the video recorder module 180 is operably positioned over an insert 150 received within one of the slots 148 on the helmet side rail assembly 104, a first one of the retention clips 155 is aligned with a first neighboring slot 148 on one side of the slot receiving the insert 150 and a second one of the retention clips 155 is aligned with a second neighboring slot 148 disposed on the other side of the slot receiving the insert 150.

To attach the video recorder module 180 to the helmet side rail housing 124, the slot retention clips 155 are positioned so that the long axis of the slot retention clips 155 extend parallel to the axis of the slot 148. The slot retention clips 155 are then passed through the respective neighboring slots 148 positioned on opposing ends of the central slot 148 receiving the insert 150. Using a tool such as a screwdriver or similar implement, the fasteners 176 securing the locking tabs 155 are rotated to the slot engaging position wherein the long axis of the tabs 155 are oriented transverse with respect to the respective slot 148. In this transverse orientation, the locking tabs 155 engage the underside of the edge of the slot 148 to secure the slot edge between the tabs 155 and the mounting base plate 175.

Referring now to FIG. 24, the helmet 104 and helmet mounting system as shown and described above is illustrated wherein the video recorder module 180 has been replaced with the modular manual actuator or input device 190. The input device 190 includes a housing 192 and plurality of switches 193, 194. The switches 193, 194 may be implemented as keys, buttons, momentary contact switches, rocker switches, slider switches, and so forth. In embodiments, the function of the switches 193, 194 is programmable through communication with the center module 132 wherein the programmed functions are stored in a memory associated with the center module 132. Exemplary functions of the switches 193, 194 include controlling flashlight on/off functions, mode selection, and other flashlight functions as described above, controlling functions associated with a helmet communications system (not shown), such as incrementing and decrementing volume, actuating a microphone, and so forth, switching between power sources such as selecting between the left and right battery packs 134, activating or deactivating battery-saving modes, monitoring charging status of the battery packs 134, among others.

The elements described and depicted herein, including in flow charts and block diagrams in the drawing figures, imply logical boundaries between the elements. However, according to software or hardware engineering practices, the depicted elements and the functions thereof may be implemented in a computer-based information handling system having one or more processors capable of executing program instructions stored thereon or in a memory operably associated therewith. Furthermore, the elements depicted in the flow chart and block diagrams or any other logical component may be implemented on a machine capable of executing program instructions. Thus, while the foregoing drawings and descriptions set forth functional aspects of the disclosed system, no particular arrangement of software for implementing these functional aspects should be inferred from these descriptions unless explicitly stated or otherwise clear from the context. Program instructions may be realized in hardware, software, firmware, or any combination of hardware, software, and/or firmware suitable for a particular application. The hardware may include a general-purpose computer, dedicated or specific computing device, or a particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable devices, along with internal and/or external memory. The processes may also, or instead, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine-readable medium.

The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

	Number	Date	Country
Parent	18830125	Sep 2024	US
Child	19032397		US

POWER AND DATA RETROFIT FOR HELMET SIDE RAIL SYSTEM

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