Abstract:
A protective helmet includes: a rigid shell including a generally domed-shaped section, a three attenuating liner within the dome-shaped section shell and operatively connected to the rigid shell; and a visor mount in operative connection with the force attenuating liner, the visor mount be adapted to have a visor mounted thereto.

Description:
RELATED U.S. APPLICATION DATA  
     Provisional application No. 60/844,562, filed on Sep. 14, 2006.  
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to protective head gear and, in several embodiments, to protective helmets including a force attenuation liner or impact cap to which a structural mount for a visor is operatively connected. 
     The following information is provided to assist the reader in understanding the invention disclosed below and the environment in which it will typically be used. The terms used herein are not intended to be limited to any particular narrow interpretation unless clearly stated otherwise in this document. References set forth herein may facilitate understanding of the present invention or the background of the present invention. The disclosure of all references cited herein are incorporated by reference. 
     Protective head gear is used or should be used in numerous activities in which the head can be impacted, including, but not limited to, sports activities, recreational activities, vehicular operation, work activities in hazardous industrial environments, military operations, aviation, and fire fighting. Such protective head gear typically includes a rigid outer shell of metal or plastic and a suspension system to support the shell on the wearer&#39;s head. The rigid outer shell prevents an impacting object from contacting the head and the suspension system operates to attenuate and distribute impact forces transferred to the head. 
     Impact attenuating suspensions can, for example, include a web of straps attached to the shell and arranged as a cradle over the top of the wearer&#39;s head or a compressible foam liner positioned between the wearer&#39;s head and the interior of the shell. 
     U.S. Pat. No. 4,286,339, assigned to the assignee of the present invention, the disclosure of which is incorporated herein by reference, discloses a protective helmet, such as firefighter helmet, which combines aspects of a web suspension with aspects of a foam liner suspension. A chinstrap for the helmet assembly of U.S. Pat. No. 4,286,339 is rigidly affixed to the outer shell to retain the protective helmet on the head. Fixing the chinstrap to the outer shell in an unyielding manner, however, can potentially place too much force on the wearer&#39;s neck under certain circumstances (for example, during a fall through a floor in the case where the helmet impacts an object or becomes stuck). 
     To reduce the likelihood of placing excessive force on the neck, a number of protective helmets have included a chinstrap assembly that is releasably attached to the protective helmet assembly. Typically, detachment of the entire protective helmet assembly from the user left the user&#39;s head completely unprotected against subsequent impacts with an object or against a stationary object. 
     U.S. Pat. No. 5,044,016, assigned to the assignee of the present invention, the disclosure of which is incorporated herein by reference, describes a helmet assembly including an outer shell and an inner impact attenuation liner assembly. A chinstrap assembly is mounted to the inner impact attenuation liner assembly and the inner impact attenuation liner assembly is mounted within the outer impact shell such that it detaches under predetermined load conditions from the outer impact shell. After separation of the inner liner assembly from the outer shell, the inner liner assembly remains on the user&#39;s head. The inner liner assembly thus continues to provide the user with some protection from subsequent impacts. 
     Although significant improvements have been made in protective helmets, it remains desirable to develop improved protective head gear. 
     SUMMARY OF THE INVENTION 
     In one aspect, the present invention provides a protective helmet including: a rigid shell including a generally domed-shaped section, a force attenuating liner within the dome-shaped section shell and operatively connected to the rigid shell; and a visor mount in operative connection with the force attenuating liner, the visor mount be adapted to have a visor mounted thereto. 
     The visor mount can include a section that extends at least partially around an outer surface of the force attenuating liner. The section of the visor mount can, for example, extend over a top of the force attenuating liner. 
     In one embodiment, the rigid shell includes a rib extending side to side over a top of the dome-shaped section, and at least a portion of the visor mount is located within an interior portion of the rib. In another embodiment, the dome-shaped section of the rigid shell includes a rib extending front to back, and at least a portion of the visor mount is located within the top center portion of the rib. In a further embodiment, the dome-shaped section of the rigid shell is generally rounded over the dome-shaped section, and at least a portion of the visor mount is located adjacent to an interior surface of the dome shaped section. 
     The section of the visor mount can also extend around a side of the force attenuating liner. The section of the visor mount can, for example, extend around a perimeter of the force attenuating liner. 
     The force attenuating liner can be adapted to disconnect from operative connection with the shell under a predetermined load. In several embodiments, the visor mount is adapted to remain in connection with the force attenuating liner upon disconnection of the force attenuating liner from operative connection with the shell. 
     The visor mount can be operatively connected to the shell. The visor mount can, for example, be adapted to disconnect from operative connection with the shell under a predetermined load. The visor mount can be adapted to remain in connection with the force attenuating liner upon disconnection of the visor mount and the force attenuating liner from operative connection with the shell. 
     In another aspect, the present invention provides a protective helmet including a shell and a connector system connected to the shell for attaching a visor to the helmet. The shell includes a dome-shaped section. The connector system includes a first connector attached to a first side of the shell and a second connector attached to a second side of the shell. Each of the first connector and the second connector include a seating for removable connection of a cooperating connector positioned on each side of the visor so that the visor is rotatably attachable to the helmet such that the visor can be rotated to a stowed position within the dome-shaped section of the shell and to a deployed position outside of the dome-shaped section of the shell. The seating can, for example, include abutment members that form a removable connection with flexing capture arms of the cooperating connector of the visor. A shield portion of the visor can be rotatably attached to the cooperating connectors of the visor. 
     In still another aspect, the present invention provides a force attenuating liner for use in a protective helmet including a visor mount operatively connected to the force attenuating liner, the visor mount be adapted to have a visor mounted thereto. 
     The present invention, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a top perspective view of a traditional style fire helmet of the present invention. 
         FIG. 2A  illustrates a bottom perspective view of an embodiment of a protective helmet of the present invention in a disassembled state including a force attenuation and/or distribution liner or impact cap assembly of the present invention, wherein a visor is attached to a structural mount or support in operative connection with the impact cap assembly. 
         FIG. 2B  illustrates a bottom perspective view of the helmet assembly of  FIG. 2A  in an assembled state. 
         FIG. 3A  illustrates a perspective view of the impact cap of  FIG. 2A  with the visor in a deployed state. 
         FIG. 3B  illustrates a perspective view of the impact cap of  FIG. 2A  with the visor in a stowed state. 
         FIG. 4  illustrates a perspective view of the impact cap of  FIG. 2A  in a disassembled state. 
         FIG. 5A  illustrates a perspective view of the visor assembly of  FIG. 2A  in an assembled state. 
         FIG. 5B  illustrates a perspective view of the visor assembly of  FIG. 2A  in a disassembled state. 
         FIG. 6  illustrates a perspective view of the mount for the visor assembly of  FIG. 2A  with a chin strap attached thereto. 
         FIG. 7A  illustrate a top view of the mount of  FIG. 6 . 
         FIG. 7B  illustrates a side view of the mount of  FIG. 6 . 
         FIG. 7C  illustrates another perspective view of the mount of  FIG. 6 . 
         FIG. 7D  illustrates a rear view of the mount of  FIG. 6 . 
         FIG. 8A  illustrates a bottom perspective view of an embodiment of a protective helmet of the present invention including a force attenuation/distribution liner or impact cap assembly including a structural mount for a visor wherein the structural mount extends around the lower side perimeter of the impact cap. 
         FIG. 8B  illustrates a perspective view of another embodiment of a visor for use in connection with the impact cap of  FIG. 8A . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Several representative embodiments of protective head gear of the present invention are discussed herein in connection with various firefighter helmets. One skilled in the art appreciates, however, that the devices, systems and methods of the present invention can be used in a wide variety of protective head gear. 
     In the 19 th  century, firefighters in the United States commonly used leather helmets which included a long rear brim and curled up side brims to prevent water from running down the firefighter&#39;s neck and into his coat. Leather helmets, which are still popular among firefighters today, are strong enough to provide protection from failing objects, and the large brim of the traditional leather helmets sheds water effectively and prevents objects from dropping down the back of the fire fighter&#39;s neck. 
     In addition to leather, modern firefighter helmets, including those of a traditional design (that is, similar in appearance to traditional leather helmets), are often fabricated from high-tech plastic and composite materials. To satisfy the NFPA standard, firefighter helmets are usually fabricated from highly impact resistant and thermally stable materials such as thermosets (for example, fiberglass composites including vinylester/polyester thermoset resins). For example, the CAIRNS® 1010 helmet, available from Mine Safety Appliances Company (“MSA”), is an NFPA approved helmet fabricated from fiberglass composites, which can be reinforced with ballistic-grade KEVLAR® material (poly(ρ-phenyleneterephtalamide), available from Dupont of Wilmington, Del.). 
     Firefighter&#39;s helmets can take a variety of forms as, for example, disclosed in U.S. Pat. Nos. 4,286,339, 5,044,016 and 6,260,212, assigned to the assignee of the present invention, the disclosures of which are incorporated herein by reference.  FIG. 1  illustrates one embodiment of the present invention that has the “traditional” shape. However, as is clear to one skilled in the art of protective helmets, the protective helmets of the present invention can have generally any shape suitable for protective headgear. 
     Firefighter protective helmet  10  includes an outer shell  20 . Outer shell  20  is formed with a generally dome-shaped section  30  and a radially outward extending brim  40  which can be wider at the back than at the front and on the sides to shield the back of the wearer&#39;s neck. An inner impact attenuation liner assembly or impact cap assembly  100  (not shown in  FIG. 1 ; see, for example,  FIGS. 2 through 4 ) can be positioned within domed-shaped section  30  of outer shell  20 . “Traditional” style helmet  10  further includes several ribs extending over dome-shaped section  30 . In the illustrated embodiment, a major or larger ridge or rib  32  extends from one side to another over dome-shaped section  30 . Another major or larger ridge or rib  34  extends front to back over dome-shaped section  30 . 
     As discussed above, the protective helmets of the present invention can have generally any shape suitable for protective headgear. For example, “modern” style or shaped firefighter helmets and other helmets suitable for use in the present invention can have a narrower brim than brim  40  illustrated for helmet  10  or have no brim at all. Moreover, such protective helmets can be smooth/rounded (that is, without ridges or ribs) over a dome-shaped section thereof or can have different ridging or ribbing than appears in the traditional style firefighter helmet. For example, a number of protective helmets include a single, relatively large ridge or rib extending front to back over a dome-shaped section of the protective helmet. 
     As used herein terms such as “side”, “front”, “back”, “up”, “down”, “inward”, “outward” and similar terms when used to refer to helmet  10  or any portion thereof refer to a direction relative to the orientation of helmet  10  (or a portion thereof) when helmet  10  is worn by a user. 
     In several embodiments of the present invention, an eye protection shield, face shield or visor  200  (see, for example,  FIGS. 2A through 7D ), including a shield section  204 , is in operative connection with impact attenuation liner assembly or impact cap  100 . In that regard, a structural mount  300  (see, for example,  FIGS. 2A through 4 , and  6  through  7 D) for visor  200  can be placed in operative connection with impact cap  100 . A connector  340  can, for example, be provided for a relatively ready or quick connection of visor  200  thereto. In several embodiments of the present invention as used in connection with protective firefighter helmets of the traditional style, a hoop section  310  of mount  300  which extends over the top of impact cap  100  is positioned and dimensioned so that it is located or seated within an internal recess of dome-shaped section  30  created by the formation by rib or ridge  32 . In another style of a helmet of the present invention wherein a generally dome-shaped section includes only a ridge or rib extending front to back, at a least a portion of a visor mount similar to visor mount  300  can, for example, be located within the top center portion of the ridge or rib. In other protective helmets of the present invention in which the dome-shaped section is generally smoothly curved or rounded (without ridges or ribs), the visor mount can, for example, simply be located adjacent to the interior surface of the dome-shaped section. 
     As known in the art, impact cap  100  can, for example, be fabricated from a foamed material such as a foamed urethane or other foamed polymeric material that is suitable to attenuate impact forces. In the illustrated embodiment, impact cap  100  includes a force attenuating and/or distributing upper section  110  formed from a foamed urethane material and a lower section  160  formed from a molded (for example, vacuum molded) thermoplastic polymeric material such as ABS (acrylonitrile-butadiene-styrene). As illustrated, for example, in  FIG. 4 , lower section  160  is formed with a seating  164  around the lower perimeter thereof in which the lower perimeter of upper section  110  is seated when the two sections are assembled. The outer surface of dome-shaped section  170  of the lower section  160  is shaped and dimensioned to generally conform to the inner surface of upper section  110 . Lower section  160  can, for example, facilitate cleaning of impact cap  100  as a relatively smooth, molded thermoplastic material is, for example, more readily wiped clean than a foamed material. Further, lower section  160  can prevent damage to friable upper section  110 . 
     As also illustrated, for example, in  FIG. 4 , a web suspension  400  can be in operative connection with impact cap  100 . Web suspension  400  is connected to impact cap  100  via an extending member such as a tie strap  420 . Tie strap  420  is seated or positioned within a groove or seating  120  formed in upper section  110  of impact cap  100 . When assembled, tie strap  420  retains web suspension  400  in operative connection with impact cap  100 . Web straps  410  pass over and around the lower perimeter of lower section  160  of impact cap  100  and assist in maintaining upper section  110  and lower section  160  in operative connection. 
     Mount  300  can, for example, be formed from a material of greater structural integrity than the friable foamed material of upper section  110  of impact cap  100  and provides structural support for the mounting of visor  200 . Mount  300  can, for example, be formed by injection molding of a thermoplastic material such as nylon. In the illustrated embodiment, mount  300  can assist in maintaining proper alignment of impact cap  100  with helmet shell  20  (for example, via seating of hoop section  310  within the interior of rib or ridge  32 ) and proper alignment of visor  200  with impact cap  100  and helmet shell  20 . As illustrated, for example, in  FIG. 3B , visor  200  can be rotated to a recessed or stowed position in which it is positioned between impact cap  100  and shell  20  of helmet  10 , within dome-shaped section  30 . Upper section  110  can, for example, include a recess  112  formed therein for positioning of visor  200  in the stowed position. For use in shielding the eyes and upper face of the wearer of helmet  10 , visor  200  can be rotated downward to be positioned in a deployed position in front of the face of the user as, for example, illustrated in  FIG. 3A . 
     In addition to facilitating, alignment of impact cap  100  within helmet shell  20 , placing hoop section  310  of mount  300  within the internal recess of rib or ridge  32  as described above reduces or eliminates internal projections into helmet shell  20 . Mount  300  also interconnects outer shell  20  and impact cap assembly  100  by acting as an intermediate structure member upon complete assembly, assisting in preventing motion of impact cap  100  relative to helmet shell  20  during normal use. 
     In the embodiment illustrated in  FIGS. 1 through 7D , hoop section  310  of mount  300  seats or is positioned within a groove or seating  130  formed in upper section  110  of impact cap  100 . Upper section  110  and lower section  160  also include openings or seatings  140  and  190 , respectively, with which connectors  340  align upon assembly, Connectors  340  can also include a tab or flange  341  that seats or is positioned within a seating  164  of lower section  160  to, for example, assist in proper alignment of mount  300  on impact cap  100 . 
     In the illustrated embodiment, mount  300  includes extending members  320 , which extend from hoop section  310  of mount  300 . Extending members  320  are shaped to conform generally to groove or seating  120  of impact cap  100  (see, for example,  FIGS. 3A and 3B ). Hoop section  310  can include a notch or channel  312  formed therein where hoop section  310  passes over groove  120  to allow tie strap  420  to pass thereunder without contacting hoop section  310 . Tie strap  420  passes over a groove or seating  322  formed in extending members  320  and assists in maintaining mount  300  in operative connection with impact section  100 . 
     As illustrated in, for example,  FIG. 2A , each of connectors  340  includes a flange  342  that extends radially outward. Flange  342  includes two slots  344 . Screws  346  pass though slots and through holes  42  in brim  40 . A stabilizing member  348  can be provided to assist in aligning and stabilizing nuts  350  which cooperate with screws  346  to connect connectors  340  (and thereby impact cap  100 ) to helmet shell  20 . 
     Upon application of a predetermined force or predetermined load to helmet shell  20  that could result in undue stress on the wearer&#39;s neck (for example, in a case that the helmet impacts an object or becomes stuck during a fall), flange  342  will deform and slide out from under screws  346  to enable disconnection of connectors  340 , and thereby impact cap  100 , from helmet shell  20 . The NFPA 1971 standard, for example, indicates that separation should occur upon application of a downward load of no less than 80 pounds applied to the impact cap. Each of connectors  340  can also include a member  352  (see, for example,  FIG. 2A ) in operative connection therewith via screws  346  which includes a radially inward extending flange  354 . Members  352  remain in connection with helmet shell  20  when impact cap  100  disconnects from helmet shell  20  via screws  346  which pass through holes (not shown) in members  352 . Flanges  354  are deformable to allow disconnection of impact assembly  100  from connection with helmet shell  20 . In the case of, for example, certain side impacts (which can cause deformation of helmet shell  20 ) in which it is undesirable for impact cap  100  to disconnect from helmet  10 , flanges  354  can assist stabilizing the assembly and preventing undesirable disconnection. However, in the case of application of force to helmet  10  which would otherwise cause excessive force on the neck of the wearer as described above, both flange  342  and flange  354  deflect to allow impact cap  100 , including connected visor  200  to disconnect from helmet shell  20 . 
     In the illustrated embodiment, mount  300  including hoop section  310 , extending member  320  and connectors  340  was molded monolithically from a thermoplastic material. The thermoplastic material is preferably suitably compliant to allow disconnection of connectors  340  from connection with helmet shell  20  as described above. Extending members  320  act in the manner of leaf springs in connecting mount to upper section  110  of impact cap  100 . Extending members  320  have flexibility and absorb energy, preventing breakage (and retaining the assembled nature of impact cap assembly  100 ) upon application of a force thereto or to impact cap  100 . The thermoplastic material of mount  300  is also preferably has suitable rigidity to provide secure connection of cooperating visor connectors  210  to connectors  340  as described above. 
     As mount  300  and visor  200  remain in operative connection with impact cap  100  after impact cap assembly  100  breaks away from helmet shell  20 , visor  200  can continue to provide eye protection after break away of helmet shell  20  from impact cap  100 . 
     As described above, connectors  340  of mount  300  also provide for connection of visor  200  to connector  340  and thereby to impact cap  100 . In the illustrated embodiment, visor  200  includes a cooperating connector  210  that includes two flexing capture legs  214 . As cooperating connectors  210  are moved upward (represented by arrows C set forth in  FIG. 2A ) into contact with connector  340 , an upper end  218  of cooperating connector  210  enters an opening  360  formed on an inner side or connector  340 . Flexing capture legs  214  are force toward each other by contact with abutment members  364  on the sides of opening  360  until abutment members  364  are aligned with notches or seatings  224  formed in capture legs  214 . At that point, capture legs  214  flex away from each other so that notches  224  form an engagement with abutment members  364  to retain cooperating connectors  210  (and thereby visor  200 ) in removable connection with connectors  340 . 
     To remove visor  200  from connection with connectors  340 , a user can force flexing capture legs  214  toward each other to remove notches  214  from cooperating contact with abutment members  364  by application of force to ends  228  of capture legs  214 . The cooperation of connectors  340  and  210  to removably connect visor  200  to the helmet assembly provides, for example, for simple removal of visor  200  for periodic cleaning or for replacement by another visor. 
     The cooperating connection between connector  340  and connector  210  of visor  200  also provides advantage even when used directly on helmet shell  20  and not as part of breakaway impact cap assembly  100 . In that regard, unlike a number of other connection mechanism for attaching visors and other accessories to helmets the connection formed in the present invention is very simple and does not require tools for either connection or disconnection. Further the, connection is formed on the inside perimeter of dome-shaped section  30  and provides for a stowed position of visor  200  between helmet shell  20  and impact cap  100 . In that interior position, visor  200  is protected from dirt, damage caused by contact with various object and damage caused by exposure to elevated temperatures. 
     To further protect visor  200  from dirt and exposure to heated air, a shield  500  can be provided to prevent dirt and air from entering between helmet shell  20  and impact cap  200 . Shield  500  can extend around the gap between helmet shell  20  and impact cap  100  only in the vicinity of visor  200  or can extend further around the gap. Shield  500  can even extend around the entire circumference of the gap. In several embodiments, shield  500  extends around a front section of the gap as illustrated in  FIGS. 2A and 2B . In several such embodiments, an ear/neck flap or shield (as known in the art) is removably attachable to several hook-and-loop type fasteners  60  positioned around the interior of the back of dome-shaped section  30  and further prevents dirt and heated air from entering the gap between helmet shell  20  and impact cap  100 . 
     As illustrated, for example, in  FIGS. 5A and 5B , visor  200  can be pivotably or rotatably attached to connectors  210  about a shaft such as provided by a tension screw  250  which can, for example, be adjustable to set the amount of force required to rotate visor between the stowed position (illustrated, for example, in  FIG. 3B ) and the deployed position (illustrated, for example, in  FIG. 3A ). Handles or flanges  260  can be provided for grasping by the wearer of helmet  10  to facilitate stowing and deployment of visor  200 . 
       FIG. 8A  illustrates another embodiment of an impact cap assembly  100 a of the present invention in which a structural mount  300  encompasses the lower perimeter of an upper force absorbing or attenuating section  110  of impact cap  100 a, rather than extending from one side to another over the top of impact cap  100  as described in the above embodiments. Visor  200 a is connected to mount  300  via a pivot connection  360 a. In the illustrated embodiment, passages  210 a formed on the sides of visor  200 a are captured by flexing capture arms  364 a of connectors  360 a. Breakaway attachments (for example, similar to those described above but not shown in  FIG. 8A ) can be provided around the circumference of mount  300  for breakaway attachment of mount  300  to shell  20  of helmet  10 a. 
       FIG. 8B  illustrates another embodiment of a visor  200 b for use in connection with pivot connection  360  of mount  300 . In the embodiment of  FIG. 8B , visor  200 b includes openings  212 b that can be used to form a connection with pivot connection  360 . In that regard, openings  212 b can be aligned with pivot connection  360  and force applied to visor  200 b causing openings  212 b to spread so that pivot connection  360  can be seated within passages  210 b. 
     In either of visors  200 a or  200 b, passages  210 a and  210 b, respectively, can be dimensioned so that some resistance is maintained to pivoting motion of visor  200 a or  200 b, thereby providing a mechanism to hold visor  200 a or  200 b in a desired position. 
     The foregoing description and accompanying drawings set forth the preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope.