Abstract:
In one aspect, a shroud assembly for headgear includes a frame formed of a polymer material having a shape that matches a contour of the headgear. An insert is formed of metal or metal alloy and is attached to a front side of the frame. The insert is configured for removable attachment to a mounting assembly. The frame includes first and second spaced flexible walls disposed on the front side of the frame on opposite sides of the insert. The first and second flexible walls are spaced a sufficient distance apart to provide an interference fit between the mounting assembly and the first and second flexible walls. In another embodiment, the shroud assembly further includes a friction pad disposed on a rear surface of the frame for increasing friction between the shroud assembly and the headgear. In another aspect, a method for attaching a mounting assembly to headgear is provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. provisional application No. 61/878,901 filed Sep. 17, 2014. The aforementioned application is incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to an improved shroud for mounting an accessory device to headgear. The shroud described herein may advantageously be used in connection with mounting assemblies for attaching night vision devices and will be described herein primarily by way of reference thereto. However, it will be recognized that the shroud herein may be used with all manner of helmet or other headgear mounted accessories devices. 
         [0003]    Night vision devices are used by military personnel, law enforcement personnel, and so forth when conducting military or tactical operations at night or under other low light conditions. Commonly, a mounting system is employed on the front of the user&#39;s headgear, such as a field helmet, to provide hands free support of the night vision device in front of the eyes of the user. Such mounting systems typically provide vertical, lateral, fore-and-aft, and tilt adjustment mechanisms for alignment of an attached night vision device with the eye or in the case of a binocular device eyes of the user. Mounting systems are known which allow the user to pivot the night vision device up to a stowed position out of the user&#39;s line of sight when not in use without removing the night vision device from the helmet. 
         [0004]    Although mounting assemblies are known that allow the user to pivot the night vision device out of the way when the night vision device is not in use, it is often desirable to completely remove the night vision system and the mounting system from the headgear, e.g., during the daytime, in order to reduce helmet weight and strain on the user&#39;s neck, when entanglement hazards exist, etc. Commonly, night vision mounting systems are made removably attachable to a helmet through the use of a mounting bracket or shroud, as described, for example, in commonly owned U.S. Pat. No. 7,219,370. Such shrouds attach to the headgear with threaded fasteners using one or more holes drilled through the helmet. Standardized hole patterns have been developed, such as the Army-compatible single hole pattern and the MARSOC/WARCOM three-hole pattern. The use of standard hole patterns allow helmets to be pre-drilled to accept any shroud compatible with that hole pattern. 
         [0005]    Typically, such helmet shrouds are machined using aluminum or other metal and include a receptacle for removable attachment of the mounting assembly. It has been found, however, that the manufacturing tolerances of the prior art shrouds are such that there is generally some clearance between the receptacle of the shroud and the interfacing portion of the mounting system, which results in a small amount of movement or play between the shroud and the mounting assembly. If has also been found that the process of repeated removal and attachment of the night vision mount creates wear, resulting in greater clearance and play between the shroud and the mounting assembly. 
         [0006]    The present disclosure contemplates a new and improved shroud assembly that overcomes the above-referenced problems and others. 
       SUMMARY 
       [0007]    In one aspect, a shroud assembly for headgear includes a frame formed of a polymer material and having a shape that matches a contour of the headgear. An insert is formed of a metal or metal alloy and is attached to a front side of the frame. The insert is configured for removable attachment to a mounting assembly. The frame includes first and second spaced flexible walls disposed on the front side of the frame on opposite sides of the insert. The first and second flexible walls are spaced a distance apart so as to provide an interference fit between the mounting assembly and the first and second flexible walls. 
         [0008]    In another embodiment, the shroud assembly further includes a friction pad disposed on a rear surface of the frame for increasing friction between the shroud assembly and the headgear. 
         [0009]    In another aspect, a method for attaching a mounting assembly to headgear includes providing a shroud assembly by attaching an insert formed of a metal or metal alloy attached to a front side of a frame. The insert is configured for removable attachment to the mounting assembly. The frame is formed of a polymer material and has a shape that matches a contour of the headgear. The insert is attached to the frame between first and second spaced flexible walls disposed on the front side of the frame on opposite sides of the insert. The first and second flexible walls are spaced a distance apart to provide an interference fit between the mounting assembly and the first and second flexible walls. The mounting assembly is removably attached to the insert. 
         [0010]    One advantage of the present development resides in its ability to prevent relative movement or play between the mounting assembly and the shroud. 
         [0011]    Another advantage of the present development is found in the weight reduction that is capable of being achieved by making a portion of the shroud assembly from a polymer material. 
         [0012]    Still further 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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    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. 
           [0014]      FIG. 1  illustrates a shroud according to a first exemplary embodiment, attached to a helmet. 
           [0015]      FIG. 2  is an enlarged isometric view of the shroud appearing in  FIG. 1 . 
           [0016]      FIG. 3  is an exploded view of the shroud appearing in  FIG. 1 . 
           [0017]      FIG. 4  illustrates the shroud embodiment of  FIG. 1  with a night vision mount removably attached. 
           [0018]      FIG. 5  illustrates the shroud embodiment of  FIG. 1  with the night vision mount removed. 
           [0019]      FIG. 6  is a front elevational view of the shroud embodiment of  FIG. 1 . 
           [0020]      FIG. 7  is a left side elevational view of the shroud embodiment of  FIG. 1 , the right side view being a mirror image thereof. 
           [0021]      FIG. 8  is a rear elevational view of the shroud embodiment of  FIG. 1 . 
           [0022]      FIG. 9  illustrates a shroud according to a second exemplary embodiment, attached to a helmet. 
           [0023]      FIG. 10  is an enlarged isometric view of the shroud appearing in  FIG. 9 . 
           [0024]      FIG. 11  is an exploded view of the shroud appearing in  FIG. 9 . 
           [0025]      FIG. 12  is a front elevational view of the shroud embodiment of  FIG. 9 . 
           [0026]      FIG. 13  is a left side elevational view of the shroud embodiment of  FIG. 9 , the right side view being a mirror image thereof. 
           [0027]      FIG. 14  is a rear elevational view of the shroud embodiment of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    Referring now to the drawings,  FIGS. 1-8  illustrate a first embodiment shroud assembly  110  for attachment to the front of a helmet  112 . For the sake of brevity, the present shroud assembly will be described herein primarily by way of reference to use with night vision systems. However, it will be recognized that the present shroud assembly is also amenable for use with all manner of monocular and binocular devices, including optical viewing devices, thermal cameras, head up displays, virtual reality goggles, or other electronic or optoelectronic imaging devices. 
         [0029]    The shroud assembly  110  includes a polymer frame  114 , a metal or metal alloy insert  116 , and a natural or synthetic elastomeric pad  118 . The shroud assembly  110  is primarily intended for use in connection with a helmet  112  having a single mounting hole, such as the standard U.S. Army one-hole mounting pattern, and will be described primarily by way of reference thereto. It will be recognized, however, that the shroud assembly  110  could likewise be used with or without the elastomeric backing pad  118  with a helmet having holes drilled in a three hole mounting pattern, such as the standard MARSOC/WARCOM three-hole pattern, in the same manner as detailed below in connection with the shroud assembly  210 . 
         [0030]    The shroud assembly  110  provides an interface for the removable attachment of a night vision mounting system  120 . The mounting system may be, for example, a night vision mounting system in the L4 product line available from Wilcox Industries Corp. of Newington, N.H. It will be recognized that the present shroud assembly can be adapted for use with all manner of night vision mounting systems by providing an insert  116  which has retention features complimentary with a desired night vision mounting system. In certain embodiments, the polymer frame may be provided with a plurality of interchangeable metal inserts to provide a modular system capable of being used with multiple mounting systems. 
         [0031]    The frame  114  and the friction pad  118  have a generally concave rearward surface which is shaped to generally conform to the shape of the helmet  112 . The elastomeric pad  118  may be formed of natural or synthetic rubber or other elastomer. The pad  118  increases the friction between the shroud assembly  110  and the helmet  112  and is particularly advantageous for use with a helmet  112  having a one hole pattern to prevent rotation about fasteners  124 ,  130  which secure the shroud assembly  110  to the helmet  112 . 
         [0032]    The insert  116  is preferably formed by machining although cast or molded inserts  116  are also contemplated. The insert  116  is preferably formed of aluminum or aluminum alloy. In the illustrated preferred embodiment, the insert  116  includes an opening  122  for receiving a threaded fastener  124 . The opening  122  may be elongated in the vertical direction to provide vertical adjustability when mounting the assembly  110 , e.g., to accommodate differences between the drilled hole placement on the helmet, accommodate edge trim on the brim of the helmet, and so forth. 
         [0033]    The threaded fastener passes through the hole  122 , a large central opening  126  in the polymer frame  114 , a large central opening  128  in the elastomeric pad  118 , and a hole (not shown) in the helmet  112 . The fastener  124  is secured to a complementary threaded fastener  130  on the inside of the helmet  112 . 
         [0034]    The insert  116  includes features, such as upper and lower recesses  132 ,  134 , respectively, for removably engaging latch members  133  formed on the mounting system  120 . The insert  116  is received within a like sized cavity  136  on the composite member  114 . One or more fasteners, such as threaded fasteners  138  secure the insert  116  within the cavity  136  via openings  140  in the insert  116  and openings  142  in the frame  114 . Other fasteners, such as other types of mechanical fasteners or adhesives are also contemplated. 
         [0035]    The polymer frame  114  may be formed of an injection moldable plastic, such as a thermoplastic resin, although thermosetting polymers are also contemplated. In preferred embodiments, the frame  114  is formed of a fiber reinforced polymer matrix composite material. Reinforcing fibers for polymer matrix composite materials are generally known. Exemplary fibers include carbonaceous fibers (e.g., carbon or graphite fibers), glass fibers, and other filamentary materials. In an especially preferred embodiment, the frame  114  is formed of a 30% glass filled polyimide composite material. 
         [0036]    A pair of flexible walls or blades  115  extends from the face of the polymer frame  114  immediately adjacent the cavity  136  on opposite lateral sides thereof. Because the blades  115  are formed of a polymer material, they can flex and can therefore be spaced apart a distance that provides a snug, interference fit between the blades  115  and the sides of an attached mounting system  120 . In this manner, side-to-side movement between the mounting system  120  and the shroud assembly  110  can be eliminated. This is in contrast to prior art metal shrouds which must be toleranced to provide a clearance fit between the shroud and the mounting system, allowing undesirable side-to-side movement between the shroud and the helmet mount. In addition, the use of a polymer frame  114  provides a reduction of the weight of the shroud assembly  110  as compared to prior art metal shrouds. 
         [0037]    In the depicted preferred embodiment, the blades  115  include a tapered or angled surface  117  on the interior facing side thereof to facilitate insertion of the mounting system  120  and outward flexing of the blades  115 . 
         [0038]    The depicted preferred embodiment illustrates an exemplary shroud assembly adapted for use with a mounting assembly that has latches that move or provide tension in the vertical direction, such that the blades  115  are disposed on opposite lateral sides of an attached mounting assembly. Other orientations of the blades, however, are also contemplated. For example, in the case of a mounting assembly having latch members that move and provide tensioning in a horizontal direction, the flexible blades could be oriented horizontally above and below the mounting assembly interfacing portion to eliminate up and down movement. 
         [0039]    The frame  114  is of a generally triangular construction and includes three openings  144  at the corners. The friction pad  118  is shaped to receive the frame  114  on the outward facing surface of the friction pad  118  in a stacked or nested arrangement. The pad  118  includes three openings  146  at the corners aligned with the openings  144  at the corners of the frame  114 . The pad  118  further includes three bosses or protrusions  148 , which are disposed intermediate the central opening  128  and the openings  146 . When the frame  118  and the friction pad  118  are stacked in the assembled, nested configuration, the bosses  148  extend through aligned openings  150  in the frame  114 , to interlock the frame  114  and the pad  118  together. The frame  114  and pad  118  are further secured via three plugs  152  at the corners of the unit  110 . Each plug  152  includes a base  154  which is received in one of the openings  146  in the pad  118 . Each plug  152  further includes a protrusion  156  that extends through a corresponding one of the openings  144  in the frame  114 . 
         [0040]    In alternative embodiments, the plugs  152  can be omitted, as well as the central helmet fasteners  124 ,  130  and the unit  110  can be secured to a helmet having a three-hole pattern. The helmet drill/hole pattern may advantageously be the standard MARSOC/WARCOM three-hole pattern. It will be recognized that the unit  110  could also be attached to a helmet using both the central hole via the fasteners  124 ,  130  as well as three threaded fasteners (see e.g., fasteners  245 ,  247  appearing in  FIG. 11 ) using the openings  144 ; however, in general, it is preferable to use only the one hole pattern or the three hole pattern, since unnecessary holes drilled into the helmet can compromise the ballistic integrity of the helmet. 
         [0041]    Referring now to  FIGS. 9-14 , a second embodiment shroud assembly  210  for attachment to the front of a helmet  212  is illustrated. The shroud assembly  210  is similar to the embodiment  110  described above, however, the friction pad is omitted. 
         [0042]    The shroud assembly  210  includes a polymer frame  214  and a metal or metal alloy insert  216 . Because the should assembly  210  is intended for use with a three hole pattern, the insert  216  need not include the central fastening hole  122 . The insert  216  may be formed by machining aluminum or an aluminum alloy. In the illustrated preferred embodiment, an enlarged central opening  223  is provided in the insert  216  to reduce the weight of the assembly, thereby reducing overall weight on the user&#39;s neck. However, the insert  216  otherwise interfaces with the mounting assembly in the manner as described above. 
         [0043]    The mounting features of the insert  216  may be modified depending on the particular helmet mounting system to be employed. A modular system may also be provided wherein multiple metal inserts  216  are interchangeable to provide a system capable of being used with multiple mounting systems. 
         [0044]    The insert  216  includes features, such as upper and lower recesses  232 ,  234 , respectively, for removably engaging complementary latch members  133  (see  FIG. 5 ) on the mounting system. The insert  216  is received within a like sized cavity  236  formed on the composite member  214 . One or more fasteners, such as threaded fasteners  238  secure the insert  216  within the cavity  236  via openings  240  in the insert  216  and openings  242  in the frame  214 . Other fasteners such other mechanical fasteners or adhesives are also contemplated. 
         [0045]    The polymer frame  214  may be formed of an injection moldable plastic, and may be formed of the same materials as described above by way of reference to the frame  114  (see  FIGS. 1-8 ) 
         [0046]    A pair of flexible walls or blades  215  extends from the face of the polymer frame  214  immediately adjacent the cavity  236  on opposite lateral sides thereof. Because the blades  215  can flex, the blades can be spaced apart a distance that provides a snug, interference fit between the blades  215  and the sides of the mounting system  120  (see  FIGS. 4 and 5 ). In this manner, side-to-side movement between the mounting system and the shroud assembly  210  can be eliminated. In the depicted preferred embodiment, the blades  215  include an angled or tapered surface  217  on the interior facing side thereof to facilitate insertion of the mounting system  120  and outward flexing of the blades  215 . In reducing the present development to practice, it has been found that the present shroud continues to provide an interference fit between the shroud assembly and the mounting system even after insertion and removal of the mounting system more than 5,000 times. Again, vertically oriented blades are illustrated in the depicted embodiment, although other blade orientations are also contemplated. 
         [0047]    The frame  214  is of a generally triangular construction and includes three openings  244  at the corners. Threaded fasteners  245  pass through the openings  244  and engage complementary threaded fasteners  247  passing through the helmet  212  to secure the shroud assembly to the helmet. The helmet drill/hole pattern may advantageously be the standard MARSOC/WARCOM three-hole pattern. 
         [0048]    The invention has been described with reference to the preferred embodiment. 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.