Abstract:
There is provided a protective helmet assembly that includes a shell, a suspension band, and an adjustable headband and a crown pad. The shell is constructed from at least PARA-ARAMID to provide ballistic protection. The suspension band is attached to the shell. The adjustable headband and the crown pad collectively adjust to a shape of a head of a user while maintaining the head of the user in a non-direct-contact relationship with the shell. The adjustable headband and the crown pad each have a plurality of screw less connectors for directly securing the adjustable headband and the crown pad to the suspension band without screws.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to a protective helmet assembly having a lightweight suspension system for use in military, law enforcement, and other applications requiring protection of the head against ballistic and other impacts.  
         [0003]     2. Background of the Invention  
         [0004]     Various forms of military helmets and the like are known in the prior art. These helmets are constructed to protect the wearer&#39;s head against injury. In addition, modern combat requires military personnel to utilize certain helmet-mounted electronic systems, for example, night vision systems and helmet mounted displays.  
         [0005]     Various suspension systems for supporting a military helmet relative to the head of a wearer are also known in the art. Typical suspension systems of the prior art are disclosed in U.S. Pat. Nos. 3,897,596 and 3,994,023. In each of the suspensions shown in these patents, a rigid suspension frame is formed with an upwardly opening outer peripheral channel for receiving the lower edge of the shell of the helmet. Straps of a crown structure for receiving the top of the wearer&#39;s head are secured to the suspension frame at spaced locations there around, while pads cooperating with one another to form a peripheral headband are independently secured to the same suspension frame.  
         [0006]     Although such suspensions satisfactorily achieve the objects of their invention, certain areas remain for improvement. The need for improved suspensions arises particularly in the case of heavier, ballistic-impact-resistant helmets and also when adding ancillary equipment to a helmet. These heavier helmets create the need for a suspension system that permits adjustment of the helmet&#39;s center of gravity relative to the wearer, as well as providing increased stability and retention of the helmet on the head. Further, the suspension system should minimize pressure points on the head that might cause discomfort. Aside from these requirements arising from the use of heavier ballistic-type helmets, it is also desirable that a suspension system accommodate a range of head sizes and allow easy servicing or replacement of components.  
         [0007]     U.S. Pat. No. 5,584,073 discloses an integrated helmet system having an outer shell and an inner helmet subassembly. The inner helmet subassembly has a shell and a headband. The shell has a frame portion that extends around the head of a wearer. The headband supports the frame in an adjustable relationship to position an inner surface of a visor relative to the eyes of a wearer. Non-rear crown straps are secured at their lower ends to the frame and through and to the headband. Rear crown straps are secured at their lower ends to a shell of the inner helmet assembly. The upper ends of the non-rear and rear crown straps are stitched to form loops through which a cord is passed. The ends of the cord are tied to retain the crown strap loops over the crown pad. The adjustment of the cord length adjusts the vertical position of the headband and frame relative to the head of the wearer. However, an inner and outer helmet arrangement is neither necessary nor feasible in many circumstances.  
         [0008]     Accordingly, it would be desirable and highly advantageous to have a protective helmet assembly with a lightweight suspension system that is especially suitable for use with heavier, ballistic-impact-resistant materials, that permits adjustment of the helmet&#39;s center of gravity relative to the wearer, that provides increased stability and retention of the helmet on the head, that minimizes pressure points on the head, that accommodates a range of head sizes, and that allows easy servicing or replacement of components.  
       SUMMARY OF THE INVENTION  
       [0009]     The problems stated above, as well as other related problems of the prior art, are solved by the present invention, a protective helmet assembly having a lightweight suspension system.  
         [0010]     According to an aspect of invention, there is provided a protective helmet assembly that includes a shell, a suspension band, and an adjustable headband and a crown pad. The shell is constructed from at least PARA-ARAMID to provide ballistic protection. The suspension band is attached to the shell. The adjustable headband and the crown pad collectively adjust to a shape of a head of a user while maintaining the head of the user in a non-direct-contact relationship with the shell. The adjustable headband and the crown pad each have a plurality of screw less connectors for directly securing the adjustable headband and the crown pad to the suspension band without screws.  
         [0011]     These and other aspects, features and advantages of the present invention will become apparent from the following detailed description of preferred embodiments, which is to be read in connection with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a diagram illustrating a protective helmet assembly, according to an illustrative embodiment of the present invention;  
         [0013]      FIG. 2  is a diagram illustrating a cross-sectional view of the shell of the protective helmet assembly of  FIG. 1 , according to an illustrative embodiment of the present invention;  
         [0014]      FIG. 3  is a diagram illustrating a right side view of the lightweight suspension system of  FIG. 1 , according to an illustrative embodiment of the present invention;  
         [0015]      FIG. 4  is a diagram illustrating a front view of the lightweight suspension system of  FIG. 1 , according to an illustrative embodiment of the present invention;  
         [0016]      FIG. 5  is a diagram illustrating a rear view of the lightweight suspension system of  FIG. 1 , according to an illustrative embodiment of the present invention;  
         [0017]      FIG. 6  is a diagram illustrating top view of the lightweight suspension system of  FIG. 1 , according to an illustrative embodiment of the present invention; and  
         [0018]      FIG. 7  is a diagram illustrating a fastener for connecting the suspension band, the nape pad, and the chinstrap subassembly of the lightweight suspension system to the helmet shell, according to an illustrative embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     The present invention is directed to a protective helmet assembly having a lightweight suspension system. The protective helmet assembly provides ballistic and other impact protection to a wearer. The suspension system permits adjustment of the helmet&#39;s center of gravity relative to the wearer, provides increased stability and retention of the helmet on the head, minimizes pressure points on the head, accommodates a range of head sizes, and allows easy servicing or replacement of components.  
         [0020]      FIG. 1  is a diagram illustrating a protective helmet assembly  100 , according to an illustrative embodiment of the present invention. The protective helmet assembly  100  includes a shell  110 . The protective helmet assembly  100  further includes a lightweight suspension system  150 . The suspension system  150  has a suspension band  160  attached to shell  110 . The suspension system  150  further includes a headband  170  and a crown pad  180  directly secured to suspension band  160  without screws.  
         [0021]      FIG. 2  is a diagram illustrating a cross-sectional view of the shell  110  of the protective helmet assembly  100  of  FIG. 1 , according to an illustrative embodiment of the present invention. The shell  110  is fabricated from at least PARA-ARAMID  210  to provide ballistic protection.  
         [0022]      FIG. 3  is a diagram illustrating a right side view of lightweight suspension system  150  of  FIG. 1 , according to an illustrative embodiment of the present invention. As noted above, suspension system  150  has suspension band  160  attached to shell  110  (not shown in  FIG. 3 ) and further has headband  170  and crown pad  180  directly secured to suspension band  160 .  
         [0023]     The headband  170  is directly secured to suspension band  160  via loops  305 . Each of loops  305  may be formed from a strap that is folded into a loop. Each of loops  305  may be formed of nylon and include a hook-and-loop fastener  320 . However, it is to be appreciated that loops  305  may be formed of any suitable material and may include any suitable type of fastener.  
         [0024]     For each of the loops  305  that attaches headband  170  to suspension band  160 , another hook and loop fastener  322  is employed “underneath” loop  305  in between and as part of both headband  170  and suspension band  160 . Thus, for each of the loops  305 , there is hook and loop fastener  320  on the headband  170  for wrapping around suspension band  160  and another hook and loop fastener  322  having portions on both the contact areas of headband  170  and suspension band  160  that are under a given one of the loops  305  when that loop is fastened.  
         [0025]     The crown pad  180  is directly secured to suspension band  160  via loops  310  and straps  315 . The loops  310  and straps  315  that attach crown pad  180  to suspension band  160  may be formed from nylon or any other suitable material. The crown pad  180  includes a mesh portion  198  and a re-enforced edge portion  197 . The mesh portion  198  provides load distribution.  
         [0026]     The loops  310  that attach crown pad  180  to suspension band  160  include first rear loops  310   a  and second rear loops  310   b . The first rear loops  310   a  are attached to suspension band  160 , and the second rear loops  310   b  are attached to first rear loops  310   a  and crown pad  180 . The first rear loops  310   a  may be formed of straps and the second rear loops  310   b  may be formed of cord. However, it is to be appreciated that the loops  310   a  and  310   b  may be formed of any suitable configurations including but not limited to straps and cord.  
         [0027]     The suspension band  160  is attached to shell  110  via fasteners  180 . Referring now to  FIG. 7 , a diagram is provided illustrating one of the fasteners  180   a  of  FIG. 1 , according to an illustrative embodiment of the present invention. The fastener  180   a  connects, at the least, suspension band  160  of suspension system  150  to shell  110 . The metal fastener  180   a  may include a screw  791  and a clip  792 . The screw  791  may have a head portion  793  and a threaded portion  794 . The clip  792  is for receiving threaded portion  794  of screw  791  and for providing a surface of adjustable tension between at least suspension band  160  and shell  110 .  
         [0028]     The clip  792  may include a raised portion  795  for receiving threaded portion  794  of screw  791  and for allowing one or more grommets  796  to pass there through. The grommets  796  may be located on any straps corresponding to a chinstrap or nape pad (i.e., first sets of nylon straps  350   a  and  350   b ) as described below. The suspension band  160  includes apertures  477  for allowing raised portion  795  of clip  792  and threaded portion  794  of screw  791  to at least partially pass there through. That is, the apertures  477  allow for the raised portion  795  of clip  792  inserted from one side of the suspension band  160  (and through a corresponding grommet  796 ) to mate with the threaded portion  794  of screw  791  inserted from the other side of the suspension band  160 .  
         [0029]     Referring again to  FIG. 3 , as well as to  FIGS. 1-2  and  4 - 6 , the suspension system  150  further includes a nap pad and chinstrap subassembly  324 .  FIGS. 4-6  are diagrams illustrating a front, a rear, and a top view of the lightweight suspension system  150  of  FIG. 1 , respectively, according to an illustrative embodiment of the present invention.  
         [0030]     The nap pad and chinstrap subassembly  324  includes a nape pad subassembly  330  and a chinstrap subassembly  340 . The nape pad subassembly  330  is for providing fore and aft positioning of the protective helmet assembly  100  relative to a nape of a neck of a wearer. The nape pad subassembly  330  may be attached to shell  110  via at least some of the metal fasteners  180   a,b . The metal fasteners  180  maintain suspension band  160  in a fixed position with respect to shell  110  while at least some of the metal fasteners  180   a,b  provide adjustment of the fore and aft positioning of protective helmet assembly  100  relative to the nape of the neck of the wearer.  
         [0031]     The chinstrap subassembly  340  is for securing a position of protective helmet assembly  100  relative to a chin of a wearer. The chinstrap subassembly  340  is attached to shell  110  via at least some of the metal fasteners  180   c,d . The metal fasteners  180  maintain suspension band  160  in a fixed position with respect to shell  110  while at least some of the metal fasteners  180   c,d  provide adjustment of the position of protective helmet assembly  100  relative to the chin of the wearer.  
         [0032]     The nape pad subassembly  330  and chinstrap subassembly  340  respectively include a nap pad portion  360  and a chinstrap portion  370  joined together using a coupling  355 . The nape pad portion  360  may be constructed of at least leather.  
         [0033]     The chinstrap portion  370  includes a first nylon strap  372  for securing under the chin and a second nylon strap  374  connected to first nylon strap  372  for securing in front of the chin.  
         [0034]     The coupling  355  includes a first set of straps  376 , a first set of strap joiners  378 , and a first set of strap clips  380 . Each of strap joiners  378  has a first connection point  381 , a second connection point  382 , and a third connection point  383 . Each of straps  376  is respectively connected to one of the strap clips  380  and to the first connection point  381  of one of the strap joiners  378 , with adjustment provided the strap clip  380 .  
         [0035]     The second connection point  382  of each strap joiner  378  is respectively connected to the chinstrap portion  370  via a quick release latch  386  (on the right side of nap pad and chinstrap subassembly  324 ) and a strap clip (on the left side, see  420  of  FIG. 4 ). The quick release latch  386  provides a quick release of the chinstrap portion  370  from the chin of the wearer.  
         [0036]     The third connection point  383  of each of strap joiners  378  is respectively connected to shell  110  via straps  350   b , adjustment clips  455 , and at least some of the metal fasteners  180   c,d.    
         [0037]     The nape pad subassembly  330  includes nylon straps  350   a  that are attached to shell  110  via at least some of the metal fasteners  180   a,b.    
         [0038]     The headband  170  includes a nylon band  390  and a hook-and-loop fastener  392  for adjusting a circumference of the nylon band  390 . The headband  170  further includes a leather band  394  for overlaying over a portion of the nylon band  390  that is in contact with the head of a wearer.  
         [0039]     The suspension band  160  includes a nylon band  396  as a layer thereof. The suspension band  160  is disposed around an inner surface of shell  110  so as to allow air to pass between suspension band  160  and the inner surface of shell  110 .  
         [0040]     The crown pad  180  is disposed away from the inner surface of shell  110  to allow air circulation between crown pad  180  and the inner surface of shell  110 .  
         [0041]     The crown pad  180  includes an outer leather ring  397  and an inner nylon mesh portion  398 . The inner nylon mesh portion  398  is for allowing air to contact the crown portion of the head of a wearer. Moreover, the crown pad  180  includes a hook and loop fastener  396  and a leather re-enforcement portion  399  having grommets  796  thereon for allowing nylon cord  310   b  to pass there through to adjust the position of the crown pad  180 . Additional re-enforcement straps  610  are disposed on the top rear portion of crown pad  180 .  
         [0042]     Although the illustrative embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one of ordinary skill in the related art without departing from the scope or spirit of the invention. All such changes and modifications are intended to be included within the scope of the invention as defined by the appended claims.