PROTECTIVE HEADGEAR

Abstract

A boltless retention system for a protective headgear includes a ballistic helmet portion having an inner surface. A first substrate is boltlessly secured to the inner surface of the ballistic helmet portion and the retention system is boltlessly secured to the first substrate. The retention system includes attachment members, straps, and a nape pad. The attachment members each include a second substrate and a loop. A portion of each strap of the retention system extends through a loop of an attachment member to an adjustable locking member disposed on the strap. The nape pad is secured to a portion of at least two of the straps between the adjustable locking member and the loop. The second substrate of the attachment members are boltlessly secured to the first substrate of the helmet.

Description

TECHNICAL FIELD

The present invention relates generally to a new and improved apparatus for boltlessly securing a retention system to protective headgear.

BACKGROUND OF THE INVENTION

The present invention relates to a retention system. It finds particular application in conjunction with a protective headgear retention system and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other applications.

Current protective headgear retention systems typically use standard metallic fasteners, particularly, e.g., bolts, to secure a retention system to a protective headgear, such as, e.g., a helmet. To use such standard fasteners, manufacturers create holes through the protective headgear by, for example, drilling. The fasteners are then secured in the respective holes. Respective straps are then secured to the fasteners. The straps are releasably secured together under a user's chin by, for example, a buckle.

Ballistic resistant protective headgear, such as ballistic helmets for law enforcement and military applications, are primarily comprised of high-performance fiber reinforced composite materials that are not amenable to fabrication processes that could provide an attachment point for the retention system. The helmets with these materials are substantially rigid. In addition, creating the holes in the protective helmet requires additional steps during the manufacturing process. Another consideration is the weight added to the protective helmet by the metallic fasteners.

Many law enforcement and military personnel attach accessories the exterior surfaces of the helmet, such as, for example, a flash light, a camera, a two-way radio, a night vision system, a battery to power the accessories, or the like. Imbalances in the distribution of the weight of the accessories can cause the helmet to shift or creep on the wearer's head. One of the many issues caused by creep is the obstruction of the field of view of the wearer.

Attempts to reduce shifting or creep of helmets have been made. Heavier components may be distributed around the helmet to reduce imbalances that cause creep, for example, by attaching a battery to the rear of the helmet to offset the weight of a vision system attached to the front of the helmet. Even if substantially perfect balance is achieved, however, the increased inertia of the accessorized helmet may cause creep because of slack in the retention system. In response, the wearer may tighten the chin strap of the retention system to reduce slack and increase friction between the helmet and the wearer's head. This, however, causes discomfort and also performs inconsistently because of the variety of conditions affecting the friction between the helmet and the wearer's head, such as, for example, hair cut style and length, sweat, and the shape of and materials used in the pads of the helmet.

The present invention provides a new and improved retention system for protective headgear.

SUMMARY

Exemplary embodiments of ballistic helmets and retention systems for the same are disclosed herein.

In one embodiment, a boltless retention system for a protective headgear includes a ballistic helmet portion having an inner surface. A helmet substrate is boltlessly secured to the inner surface of the ballistic helmet portion and the retention system is boltlessly secured to the helmet substrate. The retention system includes attachment members, straps, and a nape pad. The attachment members each include a substrate and a loop. A portion of each strap of the retention system extends through a loop of an attachment member to an adjustable locking member disposed on the strap. The nape pad is secured to a portion of at least two of the straps between the adjustable locking member and the loop. The substrates of the attachment members are boltlessly secured to the first substrate of the helmet.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will become better understood with regard to the following description and accompanying drawings in which:

FIG. 1 illustrates a perspective view of a protective headgear in accordance with one embodiment of an apparatus illustrating principles of the present invention;

FIG. 2 illustrates an inside view of the protective headgear helmet of FIG. 1 showing a schematic representation of a boltless retention system in accordance with one embodiment of an apparatus illustrating principles of the present invention;

FIG. 3 illustrates a schematic representation of a the boltless retention component of FIG. 2;

FIG. 4 illustrates a protective headgear helmet showing a schematic representation of a boltless retention system in accordance with a second embodiment of an apparatus illustrating principles of the present invention;

FIG. 5 illustrates a cross-sectional view of the protective headgear helmet and boltless retention system of FIG. 4;

FIG. 6 illustrates various schematic representations of different boltless retention component designs;

FIG. 7 illustrates a graph of load vs. extension from preload for three (3) of the designs of FIG. 6;

FIG. 8 illustrates a perspective view of a protective headgear helmet showing a schematic representation of a boltless retention system in accordance with a third embodiment of an apparatus illustrating principles of the present invention;

FIG. 9 illustrates a top view of a pad of FIG. 8, which has been substantially flattened;

FIG. 10A illustrates a side view of a sectioned helmet showing the helmet in a desired position on the head of a wearer;

FIG. 10B illustrates a side view of a sectioned helmet showing the helmet in a crept-forward position on the head of a wearer;

FIG. 11 illustrates a perspective view of a protective headgear helmet and retention system in accordance with a fourth embodiment of an apparatus illustrating principles of the present invention;

FIG. 12 illustrates a perspective view of the retention system of FIG. 11 with the helmet portion removed; and

FIG. 13 illustrates a perspective view of the rear portion of the retention system of FIG. 12.

DETAILED DESCRIPTION

This Detailed Description merely describes exemplary embodiments of the invention and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than the exemplary embodiments, and the terms used in the claims have their full ordinary meaning, unless a limiting definition is expressly provided herein.

With reference to FIG. 1, a perspective view of a helmet portion 8 of a protective headgear 12 including an exemplary boltless retention system 10 is illustrated in accordance with a first embodiment of the present invention. With reference to FIG. 2, a view inside a cavity 11 of the helmet portion 8 is illustrated in accordance with the first embodiment of the present invention. In the illustrated first embodiment, the boltless retention system 10 includes the protective headgear 12, the helmet portion 8, and a retention component 14. The protective headgear 12 is of a known material (e.g., phenolic-polyvinyl butryl (PVB) coated woven aramid fabric), which provides ballistic and impact protection to a user wearing the headgear 12.

With reference to FIGS. 1-3, the retention component 14 includes a substrate (e.g., a platform) 16, a strap 20, and a buckle 22. In one embodiment, the substrate 16 is a piece of material including a first securing means 24 on a first face 26 (e.g., the back face) (see FIG. 3). The first securing means 24 in this embodiment is contemplated to be an adhesive such as polyurethane, epoxy, polyacrylate, styrene-butadiene-styrene, cyanoacrylate, glue, thermally activated glue, or other suitable adhesive. The substrate 16 also includes a second securing means 30 on a second face 32 (e.g., the front face) (see FIGS. 1-3). The second securing means 30 in this embodiment is contemplated to be one portion of a hook-and-loop fastener (e.g., either a hook portion or a loop portion of a hook-and-loop fastener such as a VELCRO® hook-and-loop fastener).

The strap 20 is secured to the substrate 16. In the illustrated embodiment, the strap 20 is secured to the second (front) face 32 of the substrate 16. A third securing means 34 secures the strap 20 to the substrate 16. The third securing means 34 includes a stitching (e.g., a box stitching) that passes through the strap 20 and the substrate 16. In one embodiment, the stitching includes 8-10 stitchings per inch using a T-45 bonded Anefil Nylon® twisted filament thread, or some other relatively strong thread that resists deterioration. Including less than 8-10 stitchings per inch may cause the strap 20 to “pucker” and may (or may not) reduce the strength of the connection of the strap 20 to the substrate 16 (depending on how many fewer stitchings than 8-10 stitchings per inch are used). On the other hand, including more than 8-10 stitchings per inch may cause the connection between the strap 20 and the substrate 16 to weaken by, for example, weakening the substrate 16 and/or the strap 20.

In order to provide adequate strength, the substrate 16 is greater than or equal to about 2 inches². In one embodiment, the substrate 16 is at least 3″×3″. The strap 20 is contemplated to be about ¾″ wide and 5¼″ long. As illustrated, the strap 20 is positioned across the substrate 16 with one of the shorter edges 36 of the strap 20 proximate to an edge 40 of the substrate 16. The strap 20 is also substantially centered on the substrate 16 so that approximately equal portions of the substrate 16 are on either side along the length of the strap 20.

In the illustrated embodiment, the stitching 34 is about 1¾″ long and about ⅝″ wide. One edge 42 of the stitching 34 is between about ⅞″ and about 1″ from an edge 44 of the substrate 16 beyond which the strap 20 extends (i.e., an edge of the substrate 16 that is proximate to the edge of the strap 20). The about ⅞″ or about 1″ between the edge 44 of the substrate 16 and the edge 42 of the stitching 34 provides flexibility to the strap (for added comfort to the user) while maintaining a secure connection between the strap 20 and the substrate 16.

Although the strap 20 is illustrated as secured to the second (front) face 32 of the substrate 16, it is also contemplated that the strap 20 may be secured to the first (back) face 26 of the substrate 16.

The substrate 16 and the strap 20 are of a fabric material. In one embodiment, the strap 20 is a “webbing” material.

The buckle 22 is illustrated as a locking bar (e.g., a ladder lock) securing mechanism to secure the straps 20 beneath a user's chin (e.g., at least one of the straps runs under the user's chin). However, other types of buckles are contemplated.

As discussed above, the second securing means 30 on the front face 32 of the substrate 16 is contemplated to be one portion of a hook-and-loop fastener (e.g., either a hook portion or a loop portion of a hook-and-loop fastener such as a VELCRO® hook-and-loop fastener). The portion of a hook-and-loop fastener on the front face 32 of the substrate 16 provides a means for securing optional one or more pads 46, which are used for providing comfort and achieving a better fit. The pad(s) 46 may be removably secured at various locations on the substrate 16.

One example of the substrate 16 is a VELCRO® Part #151931, which provides a static pull strength of between about 200 pounds and 300 pounds.

FIG. 4 illustrates a simplified component diagram of a second embodiment of an exemplary boltless retention system 10′. In the second illustrated embodiment, the boltless retention system 10′ includes pass-through openings 60 in the protective headgear 12′. FIG. 5 illustrates a cross-sectional view of the protective headgear 12′ with the straps 20′ passing through the opening 60.

With reference to FIG. 6, various schematic representations of different boltless retention component designs are illustrated. A first design 70 includes a small Kevlar fabric backing, a 3″×3″ hook tape, and a 1″ overlap of lanyard onto substrate. A second design 72 includes no Kevlar fabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard onto substrate, and an X-stitch. A third design 74 includes no Kevlar fabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard onto substrate, and three (3) parallel stitches. A fourth design 76 includes no Kevlar fabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard onto substrate, and a large rectangular stitch to edge of substrate. A fifth design 80 includes no Kevlar fabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard onto substrate, and a stitch ⅞″ to 1″ from the edge of the substrate (see FIG. 3).

FIG. 7 illustrates a graph of load (pounds) vs. extension from preload (millimeters) for three (3) of the designs (i.e., the second, third, and fifth designs 72, 74, 80, respectively) of FIG. 6. In the illustrated graph, each of the second, third, and fifth designs 72, 74, 80, respectively, failed between 150 lbs. and 300 lbs. The extension from preload axis represents how far the retention component stretched before failing.

It is typically desirable for the chinstrap assembly to fail at a load greater than the requirement, but below 300 lbs of force (e.g., to withstand a static pull strength of less than 300 lbs.) to ensure the helmet portion 8 can release under extreme duress to reduce/minimize neck and head trauma. From FIGS. 6 and 7, it can be seen that all three of the second, third, and fifth designs 72, 74, 80, respectively, meet the performance requirement of >150 lbs. of force at failure. The second and third designs 72, 74, respectively, (Graphs 82, 84, respectively) meet the minimum load requirement (static pull strength) of >150 lbs, and approach the upper desired (static pull strength) limit of 300 lbs., with failure loads (static pull strengths) of about 245 lbs. and about 265 lbs, respectively. In addition, the fifth design 80 (Graph 86) is relatively easier to manufacture, has relatively improved material interaction (e.g., the), and is relatively more readily removable (because, for example, the X-Stitch assembly in second design 72 and the parallel stitch assembly in third design 74 includes stitching closer to all of the edges relative to the fifth design 80) in the case that the helmet portion's chinstrap assembly requires replacement. The third design 74 typically requires a lifting of the stitch during processing which adds time to the process.

FIG. 8 illustrates a simplified component diagram of a third embodiment of an exemplary boltless retention system 10″. In the third illustrated embodiment, the boltless retention system 10″ includes a pad 100 (e.g., a unitary pad) secured within the cavity 11″ of the protective headgear 12″. The pad 100 is boltlessly secured within the cavity 11″. For example, the pad 100 is sized to frictionally fit within the cavity 11″. Alternatively, it is also contemplated that the pad 100 is secured to an inner surface of the helmet portion 8″ via, for example, a hook-and-loop fastener.

It is contemplated that the straps 20″ are secured between the pad 100 and the inner surface of the helmet portion 8″. Two embodiments for securing the straps are illustrated in FIG. 8. In one embodiment, the strap 20a″ is secured directly to the pad 100 (and, also, possibly to the inner surface of the helmet portion 8″) via, for example, a hook-and-loop fastener. It is also contemplated that the strap 20a″ is secured directly to the inner surface of the helmet portion 8″ via, for example, a hook-and-loop fastener or an adhesive. In another embodiment, the strap 20b″ is boltlessly secured to the pad 100 via, for example, a substrate 16″ and a hook-and-loop fastener (as discussed above). Alternatively, the substrate 16″ may be secured to the inner surface of the helmet portion 8″ using an adhesive. Although both embodiments for securing the strap between the pad 100 and the inner surface of the helmet portion 8″ are illustrated in FIG. 8, typically only one or the other embodiment would be used with a particular headgear 12″.

FIG. 9 illustrates one embodiment of a design for the unitary pad 100. In the illustrated embodiment, the pad 100 is flattened and includes various “cut-outs.” When the flattened pad 100 is fit into the cavity 11, various edges of the cut-outs come into contact with one another to form a single, continuous pad covering most of the inner surface of the helmet portion 8″. FIG. 9 illustrates an embodiment in which the straps 20a″ are secured to a surface of the pad 100 contacting the inner surface of the helmet portion 8″. As discussed above, in this embodiment, the straps are secured to the pad 100 via a hook-and-loop fastener. A similar pad may be used if the straps and/or substrates are secured to the inner surface of the helmet portion 8″ instead.

It is to be understood that the various sizes, lengths, and designs of the straps 20″ and/or substrates 16″ in FIGS. 8 and 9 are discussed above with reference to the other embodiments. For example, if a substrate is used, a strap may be boltlessly secured to the substrate using a stitching pattern as discussed above.

FIGS. 10A and 10B illustrate a simplified diagram of a helmet 150 positioned on the head of a wearer to show how accessories assembled to the helmet 150 may cause it to creep forward and obscure the wearer's field of view, indicated by a line of sight arrow 164. As can be seen in FIG. 10B, the helmet 150 has crept forward on the wearer's head such that the wearer's line of sight 164 is obscured. The helmet 150 includes an outer shell 152 supported on the wearer's head by pads 154. A rear accessory 156 and a front accessory 158 are attached to the exterior of the shell 152. A retention system (not shown) secures the helmet 150 to the wearers head and includes a nape pad 160. The nape pad 160 is positioned below the helmet shell 152 a distance 162 so that it is located at the nape of the wearer's neck.

Existing helmet retention systems include nape pads 160 that slide or float along the straps of the retention system. These retention systems allow the nape pad to float so that the wearer can adjust the position of the nape pad for comfort and fit. Some nape pads are significantly larger than the nape pad 160 to attempt to reduce creep of the helmet. Some nape pads are “dog-bone” shaped to conform to the nape of the wearer's neck. These larger or shaped nape pads increase the weight and/or material cost of the retention system, and may be less comfortable than smaller pads.

FIGS. 11-13 illustrate a fourth embodiment of an exemplary boltless retention system 210 for a ballistic helmet 200. The exterior shell 202 of the illustrated helmet 200 includes side attachment rails 204, a front mount 206, a rear mount (not shown), and boltless attachment pads 208 for receiving accessories. The helmet 200 is made from high-performance composite materials that form a substantially rigid structure. The exterior shell 202 of the helmet is formed of a single piece, does not have any seams, and is not penetrated or perforated by any holes, such as those used with metal fasteners. The boltless retention system 210 is boltlessly secured within the helmet 200 as described in the embodiments above. For example, a substrate is attached to the interior surface of the helmet 200 using an adhesive. Attachment members 230 attach the retention system 210 to the exposed side the substrate using, for example, hook-and-loop fastener material. That is, one half of the hook-and-loop material is disposed on the substrate and the other half is disposed on the attachment member 230.

The retention system 210 is formed by interconnected straps that may be glued or stitched together, for example, according to the stitching patterns discussed above. The straps used in the retention system 210 are narrower than those described above and may be about ⅝″ wide. The stitchings joining the straps may include about 12-15 stitchings per inch. As is shown in FIGS. 12 and 13, the straps of the retention system 210 form a chin strap 240, a left assembly 242, and a right assembly 244. The chin strap 240 is shown as an integral part of the right assembly 244, but may be permanently connected to either of the left or right assemblies 242,244. The other end of the chin strap 240 includes a first component 241 if a two-part connector. A second component 243 of the two-part connector is included in the left assembly 244, so that when the components of the connector 241, 243 are joined, the chin strap 240 attaches the right assembly 242 to the left assembly 244.

The attachment members 230 each include a substrate 232, a strap 234, and a loop 249. The strap 234 is secured to the substrate 232 with a stitching 236 after being threaded through the loop 249 to secure the loop 249 to the substrate. The stitching 236 includes about 12-15 stitchings per inch. A first side 238 of the substrate 232 includes one half of a hook-and-loop material (i.e. the “hook” portion) and a second side 239 of the substrate 232 includes the opposite half of a hook-and-loop fastener material (i.e. the “loop” portion). When attached to the helmet 200, the first side 238 of the substrate is boltlessly secured to the inner surface of the helmet 200. The second side 239 of the substrate 232 is then exposed to the interior of the helmet 200 to receive pads or other liner components.

Both the left and right assemblies 242, 244 include front straps 246 and rear straps 247 that connect the chin strap 240 to the attachment members 230. The front and rear straps 246, 247 extend from the chin strap 240, through sliding locks 248, through the loops 249 of the attachment members 230, and are then secured to the sliding locks 248. The straps 246, 247 are adjusted by sliding the sliding locks 248 along the straps 246, 247.

The nape pad 220 of the retention system 210 is attached to both of the rear straps 247 between the sliding locks 248 and the loops 249. As can be seen in FIG. 13, an attachment member 222 of the nape pad 220 extends from the rear of the nape pad 220 and is secured on the rear straps 247 of the retention assembly. In the illustrated embodiment, the attachment member 222 is formed from hook-and-loop material that is wrapped around a portion of the rear strap 247, folded back on itself, and secured to the nape pad 220. During use, this configuration restricts the movement of the nape pad 220 relative to the helmet 200, reducing forward creep of the helmet 200. The nape pad 220 is not fixed to the straps, but is tightly secured so that smaller forces will not disturb its position. Thus, the pad 220 can shift slightly for comfort, but is sufficiently fixed that creep is reduced.

During use, the retention system 210 resists forward creep of the helmet. When a load is placed on the exterior of the helmet 200 (e.g. from attached accessories that are out of balance), the helmet 200 begins to creep forward. As the rear of the helmet 200 lifts slightly because of the forward creep, the nape pad 220 remains in position on the wearer's head, exerting a downward force on the portion of the rear straps 247 to which it is attached. This downward force is redirected by the loops 249 to pull upward on the rear straps 247. This tightening force exerted on the rear straps 247 is transferred to the chin strap 240 as a tightening force, resulting in the helmet 200 being pulled downward in the rear to oppose the forward creep.

The attached Appendix shows individual components of an exemplary boltless retention system. The Appendix is incorporated herein by reference in its entirety.

While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. A boltless retention system for a protective headgear, the boltless retention system comprising: a ballistic helmet portion having an inner surface;a helmet substrate boltlessly secured to the inner surface of the ballistic helmet portion;a retention system boltlessly secured to the helmet substrate, the retention system comprising: a plurality of attachment members having a substrate, an attachment strap, and a loop;a plurality of retention straps; anda nape pad;wherein each retention strap extends through a loop of an attachment member and is secured to itself with an adjustable locking member; andwherein the nape pad is secured to a portion of at least two of the retention straps between the adjustable locking member and the loops;wherein the attachment substrate is boltlessly secured the helmet substrate.

2. The boltless retention system of claim 1, wherein the adhesive is an epoxy.

3. The boltless retention system of claim 1, wherein the attachment strap is secured to the attachment substrate by a stitching.

4. The boltless retention system of claim 3, wherein the stitching includes about 12 stitches to about 15 stitches per inch.

5. The boltless retention system of claim 4, wherein the attachment substrate is about 3 inches by about 2.5 inches.

6. The boltless retention system of claim 4, wherein the attachment strap is substantially centered on the attachment substrate.

7. The boltless retention system of claim 4, wherein the stitching is about 1 inch long and about ½ inch wide.

8. The boltless retention system of claim 1, wherein the retention strap extends around a wearer's chin to secure the wearer's head in the ballistic helmet portion.

9. A boltless retention system for a protective headgear, the boltless retention system comprising: a ballistic helmet portion having an inner surface;a helmet substrate boltlessly secured to the inner surface of the ballistic helmet portion;a pad boltlessly secured to the helmet substrate;a retention system boltlessly secured to the helmet substrate, the retention system comprising: a plurality of attachment members having a substrate, an attachment strap, and a loop;a plurality of retention straps; anda nape pad;wherein each retention strap extends through a loop of an attachment member and is secured to itself with an adjustable locking member; andwherein the nape pad is secured to a portion of at least two of the retention straps between the adjustable locking member and the loops;wherein the attachment substrate is boltlessly secured the helmet substrate; andwherein the pad is at least partially secured to at least one attachment substrate.

10. The boltless retention system of claim 9, wherein the attachment substrate is secured to the helmet substrate and the pad with a hook-and-loop fastener.

11. The boltless retention system of claim 9, wherein the helmet substrate is secured to the inner surface of the ballistic helmet portion with an adhesive.

12. The boltless retention system of claim 11, wherein the adhesive is an epoxy.

13. The boltless retention system of claim 9, wherein the attachment strap is secured to the attachment substrate by a stitching.

14. The boltless retention system of claim 13, wherein the stitching includes about 12 stitches to about 15 stitches per inch.

15. The boltless retention system of claim 44, wherein the attachment substrate is about 3 inches by about 2.5 inches.

16. The boltless retention system of claim 44, wherein the attachment strap is substantially centered on the attachment substrate.

17. The boltless retention system of claim 44, wherein the stitching is about 1 inch long and about ½ inch wide.

18. The boltless retention system of claim 9, wherein the retention strap extends around a wearer's chin to secure the wearer's head in the ballistic helmet portion.

19. A boltless retention system for a protective headgear, the boltless retention system comprising: a ballistic helmet portion having an inner surface;a helmet substrate boltlessly secured to the inner surface of the ballistic helmet portion with an adhesive;a retention system boltlessly secured to the helmet substrate, the retention system comprising: at least one attachment member having a substrate, an attachment strap, and a loop;at least one retention strap; anda nape pad;wherein the at least one retention strap extends through the loop of the at least one attachment member and is secured to itself with an adjustable locking member; andwherein the nape pad is secured to a portion of the at least one retention strap between the adjustable locking member and the loop;wherein the attachment substrate is boltlessly secured to the helmet substrate; andwherein a separation force of greater than 150 pounds is required to separate the retention strap from the ballistic helmet portion.

20. The boltless retention system of claim 19, wherein the attachment strap is secured to the attachment substrate with a stitching.