Patent Abstract:
A ballistic armored component attaches to the existing retention straps of common combat helmets and provides protection to the otherwise exposed lower skull and upper neck region. A fabric covering contains a soft armor or hard armor insert, and is mounted by straps or other fasteners to existing straps found in conventional helmets. The armored component adds additional protection from ground-level or subterranean munitions, by placing a ballistic shape on the lower skull region (occipital region), providing significant additional ballistic coverage with minimal weight and bulk. The fabric shell may also be connected directly to the helmet shell, to allow the component to withdraw within the helmet when the wearer&#39;s neck is flexed rearwardly.

Full Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
       [0001]    This applications claims benefit from U.S. provisional app. 60/778,552, filed Mar. 2, 2006, the disclosure of which is incorporated by reference herein. 
     
    
     STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention relates to body armor systems worn for protection against projectile threats such as rifle and handgun bullets, and shrapnel. 
         [0004]    Persons exposed to projectile threats, such as police officers and soldiers, may seek a certain level of protection by wearing armored clothing. Low velocity projectiles such as handgun rounds, fragmentation rounds from a grenade or mortar, and miscellaneous shrapnel may be countered by so-called “soft armor.” Soft armor is worn in the form of jackets, vests, etc. which are composed of assemblies of ballistic fabric such as those formed from DuPont Kevlar® fibers or of Spectra® ultra high molecular weight polyethylene fibers from Honeywell. The soft armor is often fabricated as flexible panels which are received within pockets or pouches formed in fabric vests or jackets. In more serious threat situations, where higher velocity rifle rounds and fragments must be countered, soft armor has typically been supplemented with hard armor fabricated of rigid plates of ceramic, polymer, or metal. 
         [0005]    Most Ballistic helmets in use today are flared at the lower edge. This shape makes the helmets easier to produce by allowing single direction molds and also aids in airflow under the helmet, and may in some circumstances allow greater range of motion. Although this flared shape may be helpful in defending against air-bursting munitions traveling downward toward the wearer from a point above, this shape leaves the serviceman&#39;s head exposed to projectiles coming from ground-level or subterranean munitions—a significant threat in certain modern conflict situations. A projectile from such a munition typically travels towards the wearer with an upward angle of incidence. A helmet with a flared lower edge exposes significant portions of the head and upper neck to this upwardly traveling threat. 
         [0006]    What is needed is a ballistic helmet assembly which protects the lower skull and upper neck region of a wearer while preserving necessary range of motion, and which can be retrofitted to existing helmet systems. 
       SUMMARY OF THE INVENTION 
       [0007]    The ballistic helmet assembly of this invention has a ballistic armored component that attaches to the existing retention straps of common combat helmets and provides protection to the otherwise exposed lower skull and upper neck region. The component may comprise a fabric coverings which contains a soft armor or hard armor insert. The component has straps or other fasteners which allow for removable attachment to existing straps found in conventional helmets. The invention adds additional protection from ground-level or subterranean munitions, by placing a ballistic shape on the lower skull region (occipital region). In doing so, a significant amount of ballistic coverage can be achieved with minimal weight and bulk. Moreover, replacement or new retention assemblies can be provided with the nape protecting component integrated therewith. 
         [0008]    In some current combat situations, the primary threats being encountered are high speed fragments from ground-based explosions. While certain fragments cannot be stopped, even by thick steel plate, many fragments that would otherwise kill or severely injure a human can be stopped by an attached ballistic component, for example small fragments traveling at high speeds. Protecting the base of the skull protects large portions of the brain stem, cerebellum, occipital lobe, and temporal lobe. These regions control highly important functions. Breathing, sight, locomotion, and language are all functions that reside in this area. 
         [0009]    It is an object of the present invention to provide a lightweight protective element which can assist in protecting soldiers from ground based or subterranean munitions. 
         [0010]    It is an additional object of the present invention to provide a protective element for the base of the skull which can be rapidly attached to and removed from an existing helmet. 
         [0011]    Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a rear perspective view, looking upwardly at the ballistic assembly of this invention installed in a U.S. Army Advanced Combat Helmet. 
           [0013]      FIG. 2  is an exploded rear perspective view, looking downwardly at the nape protecting component of the assembly of  FIG. 1 , with the ballistic element shown exploded from its fabric covering. 
           [0014]      FIG. 3  is a rear elevational view of the nape protecting component of  FIG. 2 . 
           [0015]      FIG. 4  is an exploded rear perspective view of a combat vehicle crewman helmet, showing the position of an alternative embodiment nape protective component of this invention. 
           [0016]      FIG. 5  is a rear perspective view of the assembly of  FIG. 4 , with the helmet shell partially broken away in section, shown the attachment of the nape protective component to the cap. 
           [0017]      FIG. 6  is a front perspective view of a U.S. Marine Corps helmet. 
           [0018]      FIG. 7  is a fragmentary side cross-sectional view of the helmet of  FIG. 6  with an alternative embodiment nape protecting component attached to the nape pad of the helmet retention assembly. 
           [0019]      FIG. 8  is a rear elevational view of an alternative embodiment nape protecting component, adding side straps to the nape protecting component of  FIG. 7 , partially broken away in section to show the ballistic element therein. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    Referring more particularly to  FIGS. 1-8 , wherein like numbers refer to similar parts, a nape protecting component  20  of this invention is mounted to a ballistic combat helmet  22  and is worn by a soldier  24 . The nape protecting component  20  shown in  FIGS. 1-3  is configured for use with a conventional US Army Advanced Combat Helmet (ACH) such as those manufactured by Mine Safety Appliances Company, of Pittsburgh, and shown in U.S. Pat. No. D449,411, the disclosure of which is incorporated by reference herein. 
         [0021]    The ACH helmet has a stiff ballistic shell  26  provided with a pad suspension system, not shown, and a chinstrap retention system  28  with hardware  30  which fastens the retention system to the shell. The chinstrap retention system  28  has two downwardly extending rear retention straps  32  or rear legs which are connected to the helmet ballistic shell  26  by the hardware  30 , and which are provided with various buckles which permit the overall length of the retention straps to be adjusted. The rear retention straps  32  extend forwardly to be connected to two front retention straps  34  and a chin strap  36 . The two rear retention straps  32  are connected by a nape strap  38 , as shown in  FIG. 1 . The nape strap  38  is a sidewardly extending strap with a loop  42  on one end through which one of the rear retention straps  32  extend, the other end  44  of the nape strap extends behind the other rear retention strap, and is then folded back on itself and secured in place by a two-part hook and loop fastener such as such as VELCRO® fastener manufactured by Velcro Industries B.V. 
         [0022]    The conventional pad suspension system is comprised of a number of resilient pads which have one part of hook and loop fastener on the surface which faces the interior of the helmet shell. The interior of the shell is provided with an array of patches of the other part of the hook and loop fastener, such that the pads may be inserted and attached at the desired locations. 
         [0023]    The nape protecting component  20  is readily connected to the conventional helmet assembly to form a ballistic helmet assembly  46  with added protection to the lower skull and nape of the neck. As best shown in  FIG. 2 , the nape protecting component  20  has a fabric covering  48  in an oblong shape, the covering has a front sheet  50  which is sewn to a rear sheet  52  to define a pocket  54  which receives a ballistic element  56  therein. By “ballistic element” is meant an element or soft or hard armor, configured to resist ballistic projectiles or fragments. The ballistic element  56  may be conventional soft armor, i.e., assemblies of ballistic fabric such as those formed from DuPont Kevlar® fibers, fibers of Spectra® ultra high molecular weight polyethylene fibers from Honeywell, or other ballistic material, or hard armor, for example elements fabricated of rigid plates of ceramic, polymer, or metal. Moreover, because the ballistic inserts are replaceable elements, the nape protecting component  20  may be readily updated with more advanced materials as they become available. A rifle-level protection is envisioned with enhanced materials, for example with ceramic or metal. The fabric covering  48  may be sewn with an upwardly extending slot  58 , as shown in  FIG. 3 , to permit the insertion and removal of the ballistic element  56 . The front sheet  50  of the fabric covering may be a different material than the rear sheet  52 , for example the front sheet may be a brushed perforated fabric such as spacer mesh to promote wicking and avoid abrasion to the back of the wearer&#39;s neck, while the rear sheet may be a more durable material such as nylon, cotton/nylon, or DuPont&#39;s NOMEX® resistant meta-aramid material, or other fabric, and may have a camouflage design placed thereon. 
         [0024]    The fabric covering with interior ballistic element  56  is longer than it is tall, for example about eight inches wide, and from two-and-a-half to three inches tall, however, it may be produced in a number of sizes to suit the range of servicemen who will use the device. Preferably, in order to preserve hearing, the component  20  will extend from behind one ear to just behind the other ear in the side to side direction, and will extend vertically from a position about one inch above the lower rim of the helmet shell to a position about one inch above the wearer&#39;s collar. The lower edge  60  of the fabric covering  48  may have a downwardly opening concave contour, to better conform to the wearer&#39;s neck. The entire component  20  may be somewhat flexible, depending on the composition of the ballistic element  56 , but is generally concave toward&#39;s the wearer, so that the sides of the component wrap around the head of the wearer. 
         [0025]    As shown in  FIGS. 2 and 3 , two short upwardly extending strips of webbing are sewn to the rear sheet  52  of the fabric covering  48  to define two sidewardly spaced loops  62  which are large enough to permit free end  44  of the nape strap  38  to be threaded therethrough. The loops  62  may be spaced about one-and-a-half inches apart. Between the two loops  62 , a helmet mounting strap  64  is sewn to the rear sheet  52  of the fabric covering  48 . The helmet mounting strap  64 , as shown in  FIG. 1 , extends upwardly and has one part of a two-part hook and loop fastener, for example the loop part, on a rearwardly facing surface  66  for attachment to the interior of the helmet shell  26 . The helmet mounting strap  64  may be, for example, about four inches long, extending about three, inches upward from the fabric covering  48 . 
         [0026]    The nape protecting component  20  readily attaches to the existing helmet straps and is very unobtrusive to the wearer, while providing significant additional ballistic protection. To mount the component  20 , the free end  44  of the conventional nape strap  38  is released from its hook-and-loop fastener attachment to itself. Typically, a conventional pad will be mounted on the nape strap  38 , if so this pad may be removed and will not be needed when the nape protecting component  20  is in use. In addition, one of the helmet suspension pads, not shown, is temporarily removed from the rear interior surface of the helmet shell  26 . The nape strap  38 , which is connected at one end to a first rear retention strap  32 , is threaded through the two loops  62 , around the second rear retention strap  32 , and then secured to itself with the hook-and-loop closure adjacent the first rear retention strap. The helmet mounting strap  64  is extended upwardly within the helmet shell  26 , and is attached by pressing together the hook-and-loop fastener to a patch, not shown, on the interior of the helmet. The removed helmet suspension pad is then reattached, but at least one inch above the termination of the helmet mounting strap  64 , thereby leaving a space for the nape protecting component  20  to slide upwardly into the helmet when the wearer arches back his neck. 
         [0027]    The illustrated nape protecting component is sized to allow the wearer to use earphone-based communications equipment. It may extend downwardly a greater distance, although with some interference with neck mobility. An enlarged nape protecting component may be employed where additional protection is required, and the loss in mobility and versatility is acceptable. 
         [0028]    An alternative embodiment ballistic helmet assembly  68  is shown in  FIGS. 4 and 5 . The nape protecting component  70 , like the component  20  discussed above, has a fabric covering  72  with a ballistic element contained therein, not shown. The fabric covering  72  also has an upwardly extending slot, not shown, which is positioned on the front surface of the fabric covering to permit the insertion and removal of the ballistic element. The nape protecting component  70  is configured to work with a conventional two-part helmet system  74  such as the combat vehicle crewman (CVC) helmet, such as is available from Sonetronics, West Belmar, N.J., which has a ballistic shell  76  to which is mounted a flexible liner or cap  78  having an integral headset  80  with attached microphone. The cap  78  is connected to the shell  76  by two front retention straps  82 , which are fixed at one end to the shell; a single rear retention strap  84  which is fixed at one end to the cap; and a two-part hook and loop fastener having a patch on the top of the cap, not shown, and a patch  86  on the underside of the helmet shell  76 . Each retention strap  82 ,  84  has one element of a two-part snap fastener  88  on its free end. 
         [0029]    The cap  78  has a rear nape strap  90  which is comprised of two separate nape strap segments  92  which are sewn to the cap at one end, and which have overlapping hook and loop fastener to permit the length of the nape strap  90  to be adjusted. Adjacent the fixed ends of the nape strap segments  92  are loops  94  of the nape strap segments which open upwardly and downwardly, near each headset  80  speaker  95 . 
         [0030]    The nape protecting component  70  has an upwardly extending helmet mounting strap  96  with the male part  98  of a two-part snap fastener mounted at the base of the strap where it is fixed to the fabric covering  72  of the nape protecting component. The free end of the helmet mounting strap  92  has the female part  100  of a two-part snap fastener mounted thereto. As shown in  FIG. 5 , the cap rear retention strap  84  extends from the cap and is snapped into engagement with the snap  98  on the mounting strap, and is thus not connected directly to the helmet shell. The helmet mounting strap  96  free end is snapped into engagement with the snap fastener  101  on the helmet shell intended for the cap rear retention strap  84 . 
         [0031]    The nape protecting component  70  has two flexible straps  102  that extend from the front of the fabric covering  72  at about a 45 degree angle from the vertical. Each strap  102  is about five and one-half inches long and extends downwardly through one of the nape strap segment  92  loops  94  on the cap  78 . Each strap  102  passes through a loop  94 , and is then reversed to extend upwardly and overlie the rear surface of the fabric covering. Each strap  102  free end  104  has a patch  106  of one part of a hook and loop fastener, and is secured in place by engaging with a patch  108  of the other part of the hook and loop fastener which is fixed to the rear surface of the fabric covering, extending upwardly at about a 45 degree angle, and about three and one-half inches long. The nape protecting component  70  is thus readily attached to the helmet system  74  in such a way that it can be displaced upwardly on the interior of the helmet shell, but yet is still prevented from descending too low, or moving undesirably to the side. 
         [0032]    Another alternative embodiment nape protecting component  110  is shown in  FIG. 7  for use with a prior art helmet such as the USMC LW helmet  112 , shown in FIG.  6 . Such a helmet  112  is manufactured by Gentex Corporation of Simpson, Pa., for the United States Marine Corps, and has a four-point retention harness  113  with two downwardly extending retention straps  114  with a standard nape pad  116  attached thereto. The nape pad  116  also constitutes a strap, although in this case it has a cushioning padding. A variation  122  of the component for the helmet  112 , which is identical to the component  110  but a larger size with side straps  124 , is shown in  FIG. 8 . The nape protecting component  110 , as shown in  FIG. 7  has a fabric covering  118  similar in shape to the nape protecting components discussed above, with a similar ballistic element  119  retained therein. The nape protecting component  110  is secured to the retention harness  113  by two attachment straps  120 ,  121  which are sewn to the fabric covering  118  in the center of the component  110 . The first attachment strap  120  is attached along an upper seam, and the second attachment strap  121  is attached along a lower seam, and each of the attachment straps has one half of a hook and loop fastener, such that when the fabric covering and ballistic element  119  are positioned frontwardly of the helmet&#39;s nape pad  116 , the two attachment straps encircle the nape pad and are secured to one another to position the nape protecting component as desired. 
         [0033]    For use with larger size USMC LW helmets, a nape protecting component  122 , similar to the component  110  is used, but which is larger and provided with two side attachment straps  124 , as shown in  FIG. 8 . Each side attachment strap  124  extends upwardly and outwardly from the fabric covering, and has a first patch  126  and a second patch  128  of mating hook and loop material. Alternatively, the second patch may be sewn to the rearwardly facing surface  130  of the fabric covering  118 . As shown in phantom view in  FIG. 7 , the side attachment straps  124  extend upwardly and loop around existing straps or bands  132  which extend rearwardly from the front retention harness attachment points to the rear attachment points. The side attachment straps  124  are then looped back on themselves to form closed loops. 
         [0034]    It should be noted that various alternative closures and fastening assemblies may be used in place of the hook and loop fasteners shown, for example where appropriate snaps, ties, buttons, quick-release plastic buckles or clips, metal or plastic buckles, and lacing. 
         [0035]    It should be noted that the ballistic element may be formed as a stack of multiple layers of ballistic material, for example material of Kevlar® fibers. Or, for example, layers of Spectra® fiber material may be stitched around the periphery to form a stiffer ballistic element. If additional stiffness is desired, a stiffening formed plastic element may be employed with the ballistic element, or may be adhered or stitched to the ballistic element as disclosed in U.S. Pat. No. 6,892,392, the disclosure of which is incorporated by reference herein. The stitching may be around the perimeter, or in a quilted or other pattern. The greater stiffness of the nape protecting component can help in stabilizing the entire helmet assembly, simply by providing a greater stable surface area against the head. This can be particularly advantageous when equipment is mounted to the front of the helmet, such as night vision goggles, etc. 
         [0036]    It should be further noted that the ballistic element may be enclosed in a sewn lightweight fabric bag, to protect it from abrasion and soiling. 
         [0037]    It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces all such modified forms thereof as come within the scope of the following claims.

Technology Classification (CPC): 5