Detailed Description
Multilayer helmets may be easy in the manufacture of helmets, where the hard outer shell may be manufactured separately from the inner helmet liner, which may optimally be made of entirely different materials and subjected to different manufacturing processes. For example, the helmet inner liner may be manufactured using materials and features designed to provide a tight and comfortable fit on the inside, while having a shock absorbing material (e.g., polystyrene foam, bladder, vinyl nitroxyl foam, expanded polypropylene foam) applied to the outer surface of the helmet inner liner. The helmet shell may then be made of a rigid or penetration resistant material, such as Kevlar (Kevlar), carbon fiber, polycarbonate, molded plastic, composite material, or a combination thereof.
While the multi-layer embodiment provides certain advantages, ensuring proper fit of such helmets is often a difficult task. This is due in part to the different head sizes and shapes of the wearers as well as the comfort and other preferences of those wearers. The adaptation customization may be provided by one or more of an adjustable strap and belt. Importantly, such customization can be performed in a time-efficient manner. In addition, in some cases, it may be desirable that such customization be repeatable on different devices that a single wearer may use (e.g., a fire helmet for fire rescue exercises, a helmet for non-fire search and rescue tasks).
The systems and methods described herein provide a helmet with an adjustable headgear assembly. In an embodiment, a helmet includes a helmet liner having a plurality of headgear attachment points including a first opening for receiving and retaining a primary attachment structure and a second opening for receiving a locking pin of a headgear assembly. The attachment points provide a mechanism for quickly and efficiently adjusting the fit of the helmet, thereby promoting a firm, safe, comfortable fit.
Fig. 1 is a schematic diagram depicting a rear view of a helmet having a configurable headgear assembly. Helmet 100 includes a helmet liner 102, which may take the form of a hardened material, such as molded or 3D printed plastic or some other rigid material. The helmet liner 102 includes a plurality of headgear attachment points 104, 106, 108, 110, 112, 114, six of which are depicted in fig. 1. The helmet also includes a headgear assembly 116 configured to facilitate fitting the helmet 100 to a wearer's head (e.g., by increasing an internal shape of the headgear assembly 116 within the helmet). The headgear assembly 116 includes an adapter adjustment mechanism 118 configured to adjust the internal shape of the headgear assembly 116. In the example of fig. 1, the fit adjustment mechanism 118 includes a rotatable knob configured to ratchet certain plastic straps of the headgear assembly 116 to make the internal shape of the headgear assembly 116 larger or smaller. Headgear assembly 116 includes a soft pad portion, indicated at 120, configured to engage the nape of the neck of the wearer to ensure positioning of helmet 100 on the head of the wearer.
In an embodiment, the headgear attachment points are arranged in pairs, wherein the headgear assembly 116 is configured to attach to one (e.g., exactly one) of the pairs at a time. (in embodiments, the headgear attachment points may be arranged in triplets or other sized groupings.) the example of fig. 1 includes three pairs of headgear attachment points, a top pair 104, 110, a middle pair 106, 112, and a bottom pair 108, 114. By attaching the headgear assembly 116 to one of those three pairs of headgear attachment points, the relative position of the helmet liner 102 with respect to the nape of the wearer's neck can be raised or lowered. In the example of fig. 1, the headgear assembly is connected to the intermediate pair of headgear attachment points 106, 112.
Each headband attachment point of fig. 1 includes two openings. The first opening 122 of the first headgear attachment point 104 may be a larger opening (as shown in fig. 1) than the second opening 124, the first opening configured to retain the primary attachment structure of the headgear assembly 116. In the example of fig. 1, the first opening 122 takes the shape of two overlapping circles of different sizes, sometimes referred to as a snowman shape. One edge of the larger circle has a raised ridge for guiding the primary attachment structure. The first headgear attachment point 104 also includes a second opening 124 in the form of a slit or slot for receiving a locking pin of the headgear assembly 116.
In the example of FIG. 1, the headgear assembly 116 includes two attachment structure sets 126, 128;130, 132. Two sets of attachment structures are connected to a second pair of headgear attachment points 106, 112 of the helmet liner 102. The first set of attachment structures 126, 128 are connected to the helmet liner 102 via the headgear attachment points 106. Specifically, the primary attachment structures 126 of the first set of attachment structures are shown as being retained within a first opening of the headgear attachment points 106 while the locking pins 128 are positioned within slots of a second opening of the headgear attachment points 106. In one example, the connection is achieved by first sliding the top of the primary attachment structure 126 into a larger circumferential portion of the first opening that is large enough for the primary attachment structure 126 to pass through. The primary attachment structure 126 is then displaced or slid (to the left in fig. 1) such that its top is over a smaller circumferential portion of the first opening that is smaller than the top of the primary attachment structure 126 and does not allow the top to pass therethrough. In that position, the thinner base of the primary attachment structure that bridges the top of the primary attachment structure to the remainder of the headgear assembly is retained within the smaller circumferential portion of the first opening of the headgear attachment points 106. When in this position, the locking pins 128 of the first set of attachment structures are positioned within the second openings 124. To remove the first set of attachment structures 126, 128 from the headgear attachment points 106, the pins 128 may first be removed from the second opening, which may then allow the primary attachment points 126 to be slid from the smaller circumferential portion of the first opening to the larger circumferential portion (e.g., strike the raised track on the right edge to prevent overshooting), where the primary attachment points 126 may then be pulled through the larger circumferential portion. Similarly, the second set of attachment structures 130, 132 are positioned within the headgear attachment points 112. There, the primary attachment structure 130 is positioned in the first opening while the pin 132 is positioned within the second opening slot. In the embodiment of fig. 1, the second opening of the headband attachment point is a slot, rather than a circular opening. The slot shape is configured to allow each locking pin to move within its slot, which allows some rotation of the primary attachment structure during movement of the locking pin within the slot (where the rotation is limited by the length of the slot). This arrangement provides some limited play of the liner 102 relative to the headgear assembly 116, which may aid in assembly and in some cases may provide enhanced safety (e.g., mitigate undesired helmet removal).
Fig. 1 also includes a ridge 134 at the top of the helmet liner 102 for supporting an external structure (e.g., a hard shell) that is attached to the helmet liner 102. As noted above, helmets having configurable headgear assemblies as described herein can take a variety of forms. Fig. 2 is a schematic diagram depicting an exploded view of a full-visor firefighting helmet and helmet liner. The helmet includes a helmet liner 102 having certain headgear attachment points 202 thereon. The helmet includes an outer shell 204 that is configured to attach to the helmet liner 102 once set in place, such as via a sliding locking mechanism 206. When attached, the housing 204 covers the plurality of headband attachment points 202. In the embodiment of fig. 2, the outer shell takes the form of a full-visor firefighting helmet. Other shells may include a visor, lip or visor (e.g., baseball cap) arrangement.
Fig. 3 is a schematic diagram depicting an interior view of an exemplary helmet liner. The helmet liner 102 includes a plurality of headgear attachment points 104, 106, 108, 110, 112, 114, each including a first opening for receiving and retaining a primary attachment structure and a second opening for receiving an attachment pin. The helmet liner 102 also includes receptacles 206 for receiving pins to form a slide lock for attaching the outer shell to the helmet liner 102.
Fig. 4 provides an enhanced view of three of the headgear attachment points 104, 106, 108. Each of the three headgear attachment points 104, 106, 108 includes a first larger opening for receiving and retaining the primary attachment structure, and a second opening for receiving a locking pin. With further reference to the intermediate attachment point 106, the first opening 402 includes a first portion 404 that is large enough to pass the top of the primary attachment structure of the headgear assembly and a second portion 406 that is smaller than the top of the primary attachment structure but larger than the base of the primary attachment structure (e.g., the primary attachment structure shaped like a stud). In the example of fig. 4, the first opening 404 and the second opening 406 include non-overlapping circular portions. In other examples, the first opening 404 and the second opening 406 are formed by overlapping circles. The first opening 404 is configured to allow the primary attachment structure to be displaced from the first portion to the second portion. The intermediate headgear attachment points 106 also include second openings 408 for receiving locking pins of the headgear assembly. In the example of fig. 4, the second opening 408 is formed as a slit or slot that allows some movement of the locking pin within the second opening. In other embodiments, the second opening has a circular shape that allows the locking pin to move more limitedly or not while remaining in the second opening.
Fig. 5 is a schematic diagram depicting a headgear assembly installed inside a helmet liner. The headgear assembly 116 in the example of fig. 5 includes a plurality of semi-rigid plastic (e.g., molded, 3-D printed) members that are connected to one another. The headgear assembly 116 includes an adaptation adjustment mechanism 118 configured to adjust the internal shape of the lower loop 502 of the headgear assembly. In fig. 5, the fit adjustment mechanism 118 includes a rotatable knob configured to ratchet the sub-portions 504, 506 closer or farther from each other to adjust the lower loop 502 of the headgear assembly 116 to have a larger or smaller size, wherein the soft-pad portion 120 is configured to engage the nape of the wearer's neck at the intersection of the portions 504, 506. In addition to forming a sub-portion of the headgear assembly of the lower loop 502, the headgear assembly 116 also includes one or more (e.g., 2 or more) branches 508, 510 extending from the lower loop 502 for engaging the headgear assembly 116 with the helmet liner 102. The branches 508, 510 each include a separate set of attachment structures (e.g., a primary attachment structure and a locking pin) for engaging with the headgear attachment points of the helmet liner 102. In fig. 5, the set of attachment structures are not visible because they are on opposite sides of the branches 508, 510. In the example of fig. 5, the branches 508, 510 are connected to respective left and right intermediate headband attachment points of three sets of headband attachment points provided on the helmet liner. Fig. 5 also depicts a hanging web 512. The hanging web 512 of fig. 5 includes a plurality of straps for supporting the helmet liner 102 partially on the wearer's head. The hanging web 512 may be configured to provide for the fitting of the helmet liner 102 on top of the wearer's head, wherein in combination with the lower loop 502 of the headgear assembly provides for a secure fitting of the helmet to the wearer's head. In the embodiment of fig. 5, the hanging web 512 is secured to the helmet liner 102 via six hanging attachment points 514, with clips connected to six straps (e.g., three longer straps stitched together at a center point) inserted into the hanging attachment points 514.
Fig. 6 is a schematic diagram depicting an exemplary set of attachment structures for a headgear assembly. Each branch (e.g., 508, 510) of the headgear assembly includes a primary attachment structure 126 and a locking pin 128. The primary attachment structure may take various forms, including the form of a nail head depicted in fig. 6. The primary attachment structure 126 includes a top portion 602 and a base portion 604. The top portion 602 is wider than the base portion 604. As described above, the first opening of the headgear attachment points may include a first portion that is larger than the top 602 of the primary attachment structure, while a second portion is smaller than the top 602 but larger than the base 604, such that in combination with inserting the locking pin 128 into the second opening of the headgear attachment points, the first opening is configured to allow the primary attachment structure 126 to be displaced from the first portion to the second portion for retention. The branches may include tabs 606 configured to assist a user in sliding the main attachment portion 126 into the correct portion of the first opening and for inserting the locking pin 128 into the second opening.
Fig. 7 is a schematic diagram depicting the opposite side of the attachment structure. One or more of the branches (e.g., 508, 510) of the headgear assembly may include a structure 702. The structure 702 may be configured to provide finger traction to facilitate mounting of the attachment structure. The tabs 606 provide a gripping point for facilitating installation and removal of the branches from the inner liner. In one embodiment, the structure 702 may be configured to retain a helmet accessory. The example of fig. 7 provides structure 702 as one side of a clasp. The structure 702 can be configured to be positioned toward the interior of the helmet liner and can be configured to retain the helmet fit, alone or in combination with other structures. The helmet accessory may take a variety of forms including a radio, a face shield, an ear protection, a badge, a light, a sensor, a pad, or a locating beacon.
Fig. 8 and 9 are schematic diagrams depicting left and right branches 508 and 510, respectively, of a headgear assembly connected to intermediate headgear attachment points of the helmet liner 102. Fig. 10 is a schematic diagram depicting two branches 508, 510 mounted into a middle pair of headband attachment points of the helmet liner 102.
Figure 11 is a schematic diagram depicting a single opening headband attachment point. The above exemplary headgear attachment points primarily depict headgear attachment points having two openings. In some embodiments, the headgear attachment points for attaching the headgear assembly or other structure from the underside or outside of the helmet liner 102 may include only a single opening. Fig. 11 depicts a set of three single-opening headband attachment points (i.e., without a second opening) for adjustably receiving a primary attachment structure. The single opening 1102 of each adjustment point includes a first portion that is large enough to pass the top of an attachment structure (e.g., a spike attachment structure) and a second portion that is smaller than the top of the attachment structure and larger than the base, wherein the single opening 1102 is configured to allow the attachment structure to be displaced from the first portion to the second portion. In embodiments, the attachment structure may be connected to one or more of the three headband attachment points shown from the inside to the outside of the helmet liner 102 (as shown in fig. 11) or from the outside to the inside of the helmet liner 102.
In other embodiments, one or more additional headgear attachment points may be arranged with multiple (e.g., two or more) openings. Fig. 12 is a schematic diagram depicting five additional headgear attachment points for connecting a headgear assembly or other structure to a helmet liner. The helmet liner 102 includes a set of three headgear attachment points 1202 that can be configured to provide a structure for adjustably connecting the set of attachment structures to a helmet shell (e.g., a set of attachment structures including a primary attachment structure and a locking pin). Fig. 12 also includes additional headgear attachment points 1204, 1206 for further attaching a headgear assembly or other structure to the helmet liner 102.
Fig. 13 is a schematic diagram depicting a method of adjusting a helmet. The method includes receiving a helmet at 1302 that includes a helmet liner having a plurality of headgear attachment points, each headgear attachment point including a first opening for receiving and retaining a primary attachment structure and a second opening for receiving a locking pin, and a headgear assembly including an attachment structure set that includes a primary attachment structure and a locking pin. The position of the helmet liner relative to the headgear assembly is adjusted at 1304 by moving the set of attachment structures from a first headgear attachment point to a second headgear attachment point of the plurality of headgear attachment points.
The systems and methods as described herein may take various forms. For example, in some instances the helmet liner has been described as a single component. In embodiments, the helmet liner may be provided in multiple pieces.
Fig. 14 is a schematic diagram depicting a multi-component helmet liner and an outer shell for mounting on the multi-component helmet liner. The helmet liner includes an inner liner 102 having certain headgear and other headgear attachment points 202 thereon. The inner liner 102 has an open top with a hanging web 512 supporting the inner liner 102 on top of the wearer's head. The helmet liner also includes an intermediate liner 1404. The intermediate liner 1404 may be made of plastic, leather, metal, or other materials and may provide cushioning, penetration relief, helmet form, and other safety benefits. The helmet also includes an outer shell 204 configured to attach to the helmet liner 102 once set in place, such as via a sliding locking mechanism 206. When attached, the outer shell 204 covers the plurality of headband attachment points 202 alone or in combination with the intermediate liner 1404. In the embodiment of fig. 14, the outer shell takes the form of a full-cap visor fire helmet. As shown in fig. 14, the helmet liner may include one or more layers covered by the outer shell. In certain embodiments, the helmet liner to which the headgear assembly may be attached may be an entire helmet (e.g., the entire helmet is made of a single layer, such as a continuous sheet of material, such as molded or 3D printed plastic).
Figures 15 and 16 provide alternative configurations of branches of a headgear assembly having a primary attachment structure and locking pins. Fig. 15 depicts a primary attachment structure 1502 formed in two portions 1504, 1506. Each of the two portions includes a top subsection 1508 that together form the top of the primary attachment structure. These top sub-portions 1508 are supported by the base sub-portions that together form the base of the main attachment structure. The overall size of the two-part top can be manually adjusted by pressing the two top sub-parts 1508 together so that the two top sub-parts 1508 can pass through a smaller opening when pressed together. The base subsection may have a resiliency that applies a force to return the top subsection 1508 to its illustrated state when the top subsection is not squeezed or otherwise held. The two-part primary attachment structure of fig. 15 may enable the primary attachment structure to be inserted and retained within the first opening of the smaller size headband attachment point. In an embodiment, the first opening of the headgear assembly point may have only one portion (e.g., a single, circular, oval, square, or rectangular portion) instead of two portions as depicted in other examples herein. The example of fig. 15 also discloses a locking pin 1512 for insertion and retention in a second opening of the headgear attachment points. The branches may include tabs 1514 configured to assist a user in sliding the main attachment portion 1502 into the correct portion of the first opening and for inserting the locking pins 1512 into the second opening.
Fig. 16 shows the opposite side of the head tape assembly branch. The opposite side includes an indicator 1602 that shows the user the correct direction to slide the branch and the primary attachment structure thereon to achieve the locked state. This may be beneficial to installation users who can only see the underside of the branch during installation (e.g., during installation onto a helmet liner having an outer shell already attached thereto). The tab 1514 provides a gripping point for facilitating installation and removal of the branch from the liner. The opposite side 1604 also includes an opening in which other structures (e.g., a fitting attachment mechanism) may be inserted and retained.
Although the present disclosure has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the embodiments. Accordingly, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.