Abstract:
An improved helmet construction and method having a circuit carried within an edge trim member received over the unfinished edge of the helmet shell. A plurality of electrical connectors are provided at different locations on the helmet for providing power, data transmission, and/or signal transmission to one or more accessory devices on the helmet.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 61/672,908 filed Jul. 18, 2012. The aforementioned application is incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates generally to protective helmets such as ballistic helmets or other helmets having a similar construction, such as a ballistic tactical helmet for use by law enforcement personnel, military field or combat helmets, or the like. More particularly, the present disclosure relates to a helmet edge trim and a helmet employing same with integral wiring for routing electrical power or signals to one or more electrical or electronic accessory devices or components attached or mounted to the helmet. 
     Commonly, a military ballistic helmet or the like is configured with mounts, brackets, or the like to carry one or more accessories or attachments, such as a flashlights, viewing optics and devices, such as a monocular, binoculars, monocular or binocular night vision (NVG) devices (including passive night vision devices and enhanced night vision (eNVG) devices), thermal imaging devices, cameras, friend or foe identification (IFF) systems, communications devices, and so forth. 
     To connect accessories to an electrical source, a wiring harness may be routed along the interior of the helmet. However, an internally routed wire harnesses may be subject to chemical attack due to perspiration, damaged through impact with the wearer&#39;s head, and so forth. In addition, an internally routed wiring harness may require one or more holes or vias through the ballistic material of the helmet, thus compromising the antiballistic properties of the helmet in these regions. Alternatively, a wire harness may be routed externally over the exterior surface of the helmet. However, external wiring harnesses may be cumbersome and susceptible to failure. 
     In addition, the number and complexity of helmet mounted components is increasing, with such components often including computer or microcontroller-based devices controlled through the use of electronic signals and sensors. This results in the need for larger and more complex wiring assemblies and poses difficulties in installing such devices while maintaining the ballistic integrity of the helmet. 
     Therefore, there exists a need for an improved helmet construction and method having an integrated accessory mounting and electrical interconnection device which could replace the wiring typically used for electrical power, data, and/or signal transmission and which would reduce wiring complexity, simplify helmet assembly and device attachment. 
     SUMMARY 
     A helmet system and method are provided that allow an electrical connection between one or more electrical or electronic components on the helmet by integrating a wiring harness or other flexible circuit between the edge trim and the brim of a helmet shell. 
     In preferred aspects, the helmet system and method allow a secure connection of helmet mounted accessories to the helmet without the need to run an exposed wiring harness over the exterior surface of the helmet shell and without the need to penetrate the ballistic shell with wiring vias. One advantage of the present development is that the edge trim with circuit components as described herein may be retrofit to any existing helmet by replacing existing edge trim with the edge trim as described herein, and may be adapted for use with any existing helmet design. It is to be understood that both the following detailed description is exemplary and explanatory only and are not restrictive of the invention. 
     In one aspect, a protective helmet includes an outer shell bounded by a peripheral edge and an edge trim attached to and extending around the peripheral edge. A wiring harness is disposed within the edge trim. 
     In a more limited aspect, the wiring harness is integral with the edge trim. 
     In another more limited aspect, the wiring harness is received between the peripheral edge and the edge trim. 
     In still another more limited aspect, the wiring harness comprises a plurality of conductive elements. 
     In another more limited aspect, the wiring harness is selected from a ribbon cable and a flexible circuit substrate carrying one or more printed circuit elements. 
     In yet another more limited aspect, the wiring harness comprises a flexible circuit substrate formed of a flexible polymer film having one or more conductive elements printed thereon. 
     In another more limited aspect the edge trim defines a channel receiving the peripheral edge. 
     In still another more limited aspect, the protective helmet includes one or more power connectors on the outer shell configured to attach to an electrical power source and one or more device connectors on the outer shell configured to connect to an electrically powered device. The wiring harness is electrically coupled to the one or more power connectors and the one or more device connectors. 
     In another more limited aspect, each of the one or more the power connectors includes a mechanical fastener for removably attaching a power source and further includes a first set of electrical contacts which is aligned with a second set of electrical contacts on the power source when the power source is attached. 
     In yet another more limited aspect, the power supply is selected from a battery and a battery pack. 
     In another more limited aspect, each of the one or more the device connectors includes a mechanical fastener for removably attaching a powered device and further including a first set of electrical contacts which is aligned with a second set of electrical contacts on the powered device when the powered device is attached. 
     In still another more limited aspect, the protective helmet further includes one or more powered devices selected from the group consisting of flashlights, illumination devices, passive night vision devices, enhanced night vision devices, thermal imaging devices, cameras, video recorders, and friend or foe identification (IFF) devices. 
     In another more limited aspect, the protective helmet further includes a mount attached to a front portion of the outer shell for positioning a viewing device in front of an eye of a user wearing the helmet. 
     In yet another more limited aspect, the protective helmet is a ballistic helmet. 
     In another more limited aspect, the outer shell comprises a ballistic shell formed of multiple plies of reinforcing fibers within a polymer matrix material. 
     In yet another more limited aspect, the edge trim is formed of a material selected from a molded polymer material and an extruded polymer material. 
     In another more limited aspect, the wiring harness includes a plurality of conductors for transmitting one or more of power, data signals, sensor signals, and communication signals. 
     In still another more limited aspect, the peripheral edge is unfinished. 
     In another more limited aspect, the edge trim is secured to the peripheral edge with a mechanical fastener. 
     In yet another more limited aspect, the edge trim is permanently secured to the peripheral edge with an adhesive. 
     In another more limited aspect, the adhesive is an epoxy adhesive. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and together with the general description, serve to explain the principles of the invention, and are not to be construed as limiting the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be better understood by those skilled in the art by reference to the accompanying drawing figures, in which: 
         FIG. 1  is an isometric view, taken generally from the front and side, of an exemplary helmet in accordance with the present disclosure; 
         FIG. 2  is a front elevational view of the embodiment appearing in  FIG. 1 ; 
         FIG. 3  is an exploded, isometric view of the embodiment appearing in  FIG. 1 ; 
         FIGS. 4 and 5  are generally front and rear isometric views of the helmet embodiment appearing in  FIG. 3 , with the electrical connectors removed; 
         FIG. 6  is front elevational view of the embodiment appearing in  FIGS. 4 and 5 ; 
         FIG. 7  is an enlarged view of the region A appearing in  FIG. 6 ; 
         FIG. 8  is an isometric view taken generally from the rear and side, illustrating the manner of attachment of accessories and a power supply; 
         FIG. 9  is an enlarged view of the front of the helmet, illustrating the manner of attachment of a bracket or shroud for attaching a night vision device, such as an NVG or eNVG, or other optical or viewing device; 
         FIG. 10  is a side cross-sectional view of the helmet embodiment appearing in  FIGS. 4 and 5 ; 
         FIG. 11  is an enlarged view of the region C appearing in  FIG. 10 ; and 
         FIG. 12  is a generally rear isometric view illustrating an exemplary electrical connector for electrically coupling the edge trim circuit to a power supply remotely located from the helmet. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings wherein like reference numerals designate like parts throughout the several views,  FIGS. 1-12  illustrate a helmet  100 , which may advantageously be a ballistic helmet although other helmet types are contemplated as well. The helmet  100  includes a shell  110 , which may be formed, e.g., by laying up multiple plies of a fiber reinforced composite material on a generally helmet-shaped pre-form. Such composite material may include fibers, e.g., polymer fibers such as aramid fibers (e.g., KEVLAR®) or other ballistic fiber impregnated with a polymer resin. Other ballistic and non-ballistic helmet types, including metal helmets, molded plastic helmets, etc., are also contemplated. 
     An edge trim member  120  is shaped to correspond to the peripheral edge  112  of the shell  110  and defines a groove or channel  122  sized to receive the unfinished edge  112  of the shell  110 . The edge trim member may be a molded construction or, alternatively, may be formed as an elongate strip by extrusion and cut to the appropriate length. 
     A wiring harness or circuit member  130  is received within the groove  122 . The circuit  130  may comprise a ribbon cable comprising a plurality of conductors  132  (5 conductors in the exemplary embodiment illustrated although other numbers of conductors are contemplated). Alternatively, the circuit member may comprise a flexible circuit substrate such as a flexible polymer film having conductive tracings formed thereon. In still further embodiments, the conductive elements may be formed directly in the edge trim member  120 , e.g., by molding the circuit elements within the edge trim or printing circuit elements directly on the edge trim member. 
     As best seen in  FIG. 11 , the circuit member  130  is seated between the unfinished helmet brim  112  and the base of the groove  122 . The edge trim member  122  is secured to helmet shell  110  via an adhesive, e.g., an epoxy adhesive or the like, although other fasteners such as mechanical fasteners are also contemplated. 
     In the depicted embodiment, there appear four device connectors coupled to the edge trim member, including a front connector  140 , a rear connector  160 , and left and right side connectors  180 . It will be recognized, however, that other numbers of connectors, spacings, and electrical connector configurations are also contemplated. 
     The front mounting member  140  includes a bracket or shroud  142  adapted to attach a night vision goggle, enhanced night vision goggle, or other optical device (not shown) to be positioned in in front of one or both eyes of a user. In preferred embodiments, the bracket  142  is adapted to attach a pivoting mount which allows the user to selectively move the optical or viewing device between a lowered, operable position in front of the user&#39;s eyes and to a raised, stowed position on the helmet out of the line of sight of the viewer. 
     In the illustrated embodiment, the front connector  140  is secured to the edge trim member via threaded fasteners  144  which engage aligned openings  145  in the bracket  142  and openings  124  in the edge trim member. The openings  124  may be reinforced, e.g., via tapped metal inserts. In the illustrated embodiment, a bolt  146  passes through an opening  147  on the bracket  142  and an opening  114  in the shell  110  and receives a complimentary nut  148  to further secure the front connector  140  to the helmet  110 . 
     An electrical connector  150  is provided on the exterior surface of the front connector  140 . The electrical connector is positioned to align with a mating connector on a helmet mount (not shown) for attaching an optical/viewing device. The electrical connector  150  is adapted to connect to an electrical connector on a helmet mount, which in turn is electrically coupled to electrical contacts on a mounting shoe for the optical/viewing device. It will be recognized, however, that other arrangements are possible. 
     The electrical connector  150  includes contacts  151 , which are electrically coupled to protruding contacts  152  (see  FIG. 9 ) on the inward facing surface of the front connector  140 . Each of the contacts  152  makes contact with a corresponding aligned contact  126 , e.g., flush or recessed contact pads, on the edge trim member  120 . The contacts  152  are preferably spring contacts, i.e., resiliently biased toward the contacts  126  to ensure a sold electrical connection therebetween. 
     The electrical connector  160  is adapted to receive a power supply, e.g., a battery or battery pack,  162 . The connector  160  is secured to the edge trim  120  via threaded fasteners  144 , which pass through openings  161  in the connector  160  and engage complimentary openings  124  in the edge trim  120 . The rear connector  160  includes a mounting shoe  164 , e.g., a dovetail type mounting shoe for receiving a complimentary female dovetail connector  166  on the power supply  162 . The power supply may also include a latch  168  to release the power supply  162  and replacing the power supply  162  with a new of newly charged power supply. It will be recognized that other connectors, such as a bayonet or other quick connect/disconnect type connectors on the battery pack and the rear connector are also contemplated. Electrical contacts  170  on the mounting shoe  164  align with corresponding contacts (not shown) on the power supply connector  166 . 
     The contacts  170 , in turn, are electrically coupled to corresponding spring contacts  152 . The spring contacts  152 , in turn, are coupled to aligned contacts  126  on the edge trim  120  (see  FIG. 5 ). In alternative embodiments, as shown in  FIG. 12 , the power supply  162  may be replaced with a connector  172  having a first end  174  mating with the connector  160  and a second end  176  mating with an electrical connector of a power supply, such as a power supply adapted to be worn by the user or incorporated into a garment worn by the user. 
     Left side and right side connectors  180  are secured to the edge trim member at the respective left and right sides of the helmet  110  via threaded fasteners  144  which pass through aligned openings  185  in the connectors and engage openings  124  in the edge trim member. The side connectors  180  as illustrated include a rail section  182  configured to allow clamping via a rail grabber  181  of an accessory device  183  to be attached. 
     In the illustrated embodiment, the side mounted accessory  183  is a flashlight, however, it will be recognized that all manner of accessories may be provided, including without limitation, friend/foe (IFF) transponders, cameras including video recording (e.g., DVR) devices, communication devices, and so forth. In the illustrated embodiment, the rail section conforms to the so-called Picatinny interface standard (e.g., MIL-STD-1938) although other mounting rails, brackets, etc., are contemplated as well. 
     The rail interface  182  includes contacts  184  which are electrically coupled to protruding contacts  152  (see  FIG. 3 ) on the inward facing surface of the side connectors  180 . Each of the contacts  152  makes contact with a corresponding aligned contact  126 , e.g., flush or recessed contacts, on the edge trim member  120 . Again, the contacts  152  are preferably spring or otherwise resiliently biased contacts. The contacts  184  are adapted to provide an electrical coupling through the rail interface  182  and to the connectors  152 . 
     In addition to powering externally mounted devices, the edge trim circuit herein may also optionally be adapted to power in-helmet devices, such as devices embedded within the helmet or devices mounted within the interior of the helmet, i.e., between the used head and the interior surface of the shell. For example, the power supply attached via the connector  160  may supply power to a helmet recording system such as a monitor for recording and/or transmitting the shock profile or forces experienced by the helmet. 
     In the illustrated embodiment, the circuit is shown with five conductors, which may be used to provide power from the power supply to the attached devices, as well as data or control signals to record data or to allow one attached accessory device to operate or control another without the need for an external wired connection between the multiple devices. 
     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.