GB2633558A - Helmet assembly - Google Patents

Abstract

A helmet assembly 100 for protecting against an electrical arc flash event, comprising a chin and neck protector 106 removably mounted to a helmet 102, and a visor 104 pivotally mounted to the helmet and movable between deployed, closed and retracted, open positions. The chin and neck protector may comprise a support member (114, fig.2) having a boss (134, fig.5) at each end region (130, 132, fig.5) for locating in an aperture (152, fig.6) of each ear portion 110, 112 of the helmet in a bayonet coupling. Each boss may comprise ribs (148, fig.5) for engagement in recesses (158, fig.6) of each aperture to retain the support member in first and second rotational positions. The support member may comprise projections (124, fig.4) extending from a beam portion (122, fig.4) for engagement with a curtain portion (116, fig.2), made of arc flash protective textile. The visor may comprise hinge portions (190, 192, fig.7) each with a first latch (198, fig.7) and a first stop surface (201, fig.7) engageable with, respectively, a second latch (168, fig.6) and a second stop surface (203, fig.6) of each ear portion in the open and closed positions.

Description

HELMET ASSEMBLY

The present invention relates to protective headgear and in particular, but not exclusively, to a helmet assembly for protecting a wearer's face, chin and neck from an electrical arc flash event.

Protective helmet assemblies, such as arc flash helmet assemblies, are designed to meet various safety standards and typically include a helmet, a transparent visor mounted to the helmet, and a chin/jaw protector which is often configured to also protect the neck. Some known arc flash helmet assemblies use a textile chin and neck protector which hangs from the lower edge of the visor and is mounted to the visor by press studs, clips, or the like. However, the textile protector moves with the visor when it is lifted to a retracted open position inside the helmet which undesirably requires the textile protector to be removed from the visor before it is retracted inside the helmet or to be stowed with the visor inside the helmet which undesirably requires the helmet to be relatively bulky and introduces the risk of the textile protector becoming stuck or snagged inside the helmet. Other known arc flash helmet assemblies provide chin/neck protection by rigid plastic extensions to the visor which are fixed or hinged to the visor. Similarly, these plastic extension sections move with the visor and require stowage on the outside of the helmet when the extension section is hinged to the visor or in front of the helmet when the extension section is fixed to the visor. When the visor is raised, these types of plastic extension sections increase the size of the helmet assembly making it bulky to use. They can also extend from the front the helmet when the visor is in the open position and present an obstruction which can easily knock into objects or cause limited movement of the user's head when working in a confined space. Furthermore, the helmet assembly's centre of gravity can be shifted forward which can cause the assembly to drop down when the visor is in the open position and/or make the assembly feel unbalanced and uncomfortable to wear.

The helmet of some conventional arc flash helmet assemblies includes inner and outer shells between which the visor is stowed when in the open position. The inner and outer shells are typically made from injection moulded acrylonitrile butadiene styrene (ABS) or blended ABS materials and often they are made of the same material. The outer shell must withstand potential high load impacts whilst the inner shell must support additional headgear components such as headbands, textile head cradles and chinstraps, etc. which are generally fixed to the inner shell via fixture bosses therein. However, shell systems with two layers of injection moulded plastic often makes the overall helmet assembly heavy and increases the burden on the wearer and detracts from the performance of the product.

It is also known for the chinstraps of conventional arc flash helmet assemblies to be mounted to the edge of the outer shell but this can restrict the location, coverage and path of motion of the visor since the front fixtures of the chinstrap are normally required to be in the front portion of the helmet. Chinstraps of known arc flash helmet assemblies are often fixed to an inner ring located inside the outer shell of the helmet, however this limits the capability of the helmet assembly to meet the requirements of certain safety standards.

Improvements to helmet assemblies, and particularly arc flash helmet assemblies, are required.

It is an aim of certain embodiments of the present invention to provide a helmet assembly, such as an arc flash helmet assembly, that is efficient and comfortable to wear and use, particularly when the visor is in an open position with respect to the helmet.

It is an aim of certain embodiments of the present invention to provide a helmet assembly, such as an arc flash helmet assembly, that can be efficiently used with or without a removeable chin and neck protector.

It is an aim of certain embodiments of the present invention to provide a helmet assembly, such as an arc flash helmet assembly, that is lightweight without 30 compromising the strength and/or performance of the helmet assembly.

According to a first aspect of the present invention there is provided a helmet assembly for protecting a wearer from an electrical arc flash event, comprising: a helmet; a chin and neck protector removably mounted to the helmet; and a visor pivotally mounted to the helmet and moveable with respect to the chin and neck protector between a deployed closed position and a retracted open position.

Optionally, the chin and neck protector comprises a curved support member mounted at opposed end regions thereof to a respective one of a pair of opposed ear portions of the helmet, and a protective curtain member extending downwardly from the support member.

Optionally, each end region of the support member comprises an outwardly extending boss configured to locate in a corresponding aperture of a respective one of the ear portions.

Optionally, the support member is substantially flexible yet resilient to urge each outwardly extending boss into the corresponding aperture of the respective ear portion.

Optionally, each outwardly extending boss comprises a first pair of diametrically opposed and outwardly extending flanges defining a first bayonet coupling part, and wherein each ear portion aperture comprises a first pair of diametrically opposed and inwardly extending flanges defining a second bayonet coupling part for engagement with the first bayonet coupling part to mount and laterally retain the support member with respect to the helmet.

Optionally, each outwardly extending boss comprises at least one projection on an outer surface thereof for engagement in at least one recess on an inner surface of a respective one of the ear portion apertures to rotationally retain the support member with respect to the helmet.

Optionally, the at least one projection comprises a pair of diametrically opposed ribs and the at least one recess comprises a first pair of diametrically opposed elongate recesses for engagement with the ribs when the support member is in a first rotational position with respect to the helmet and a second pair of diametrically opposed elongate recesses for engagement with the ribs when the support member is in a second rotational position with respect to the helmet.

Optionally, the support member comprises a laterally oriented beam portion extending between the ear portions when mounted thereto, and a plurality of spaced apart elongate projections downwardly extending from the beam portion and at least partially down an inner surface of the curtain member to add structure thereto.

Optionally, the curtain member comprises a downwardly extending curtain portion attached at an upper edge to the beam portion and a return curtain portion extending inwardly from a lower edge of the downwardly extending curtain portion.

Optionally, each downwardly extending projection comprises an elongate stem portion and an enlarged head portion defining a relatively flat end surface for engagement with an inner surface of the return curtain portion where it extends from the downwardly extending curtain portion.

Optionally, the curtain member comprises a plurality of flexible textile layers of arc flash protective material.

Optionally, each ear portion aperture is defined by an inwardly extending hollow boss and the visor comprises opposed hinge portions each including an aperture for pivotally mounting the visor on a respective one of the ear portion bosses.

Optionally, each ear portion boss comprises a second pair of diametrically opposed and outwardly extending flanges defining a third bayonet coupling part, and each visor aperture defines a second pair of diametrically opposed and inwardly extending flanges defining a fourth bayonet coupling part for engagement with the third bayonet coupling part to mount and laterally retain the visor with respect to the helmet.

Optionally, each hinge portion of the visor comprises a first latch part engageable with a second latch part of a respective one of the ear portions to hold the visor in the open position.

Optionally, each hinge portion of the visor comprises a first stop surface engageable with a second stop surface of a respective one of the ear portions to limit rotational movement of the visor and to define the closed position.

Optionally, a lower edge region of the visor is configured to extend over an upper edge of the chin and neck protector.

Optionally, the lower edge region of the visor extends forwardly to receive and overlap the upper edge of the chin and neck protector when the visor is in the closed 10 position.

Optionally, a central portion of the lower edge region of the visor defines a handle for opening or closing the visor.

Optionally, a central lower front region of the visor extends outwardly for accommodating a wearer's chin.

Optionally, the helmet comprises an inner shell, an outer shell and a void therebetween in a front region of the helmet for stowing the visor when in the open 20 position.

Description of the Drawings

Certain embodiments of the present invention will now be described with reference 25 to the accompanying drawings in which: Figure 1 illustrates a helmet assembly according to certain embodiments of the present invention including a helmet, a visor and a chin and neck protector, wherein the visor is in a deployed closed position; Figure 2 illustrates the helmet assembly of Figure 1 with the visor removed; Figure 3 illustrates a rear view of the helmet assembly of Figure 1; Figure 4 illustrates a front view of the helmet assembly with the visor and a curtain member of the chin and neck protector removed; Figure 5 illustrates an end region of a support member of the chin and neck protector 5 removed; Figure 6 illustrates the inner side of an ear portion of the helmet; Figure 7 illustrates an outer side of a hinge portion of the visor; Figure 8 illustrates an inner side of an inverted outer shell of the helmet; Figure 9 illustrates an outer rear side of an inner shell of the helmet; Figure 10 illustrates an inverted view of the inner shell of the helmet; Figure 11 illustrates a fixture plate fixed into a rear portion of the inner shell of the helmet for connecting the inner and outer shells together during assembly; Figure 12 illustrates a pair of opposed ear portions of the helmet attached to the fixture plate of Figure 11; Figure 13 illustrates a head band and chin strap assembly of the helmet assembly; and Figure 14 illustrates an exploded assembly of an anchor body for coupling the head band and chin strap assembly to the outer shell of the helmet.

Detailed Description

As illustrated in Figures 1 and 2, an arc flash helmet assembly 100 according to certain embodiments of the present invention includes a helmet 102, a visor 104 pivotally mounted to the helmet and moveable between a deployed closed position (as shown in Figure 1) and a retracted open position, and a chin and neck protector 106 removably coupled to the helmet.

The helmet 102 comprises an inner shell (not shown) and an outer shell 108 including downwardly extending opposed ear portions 110 to protect the ear regions of a wearer. The ear portions may be integral with or removably attached to the outer shell or aptly the inner shell. The visor 104 is stowed in a cavity between the inner and outer shells when in the retracted open position. Desirably, the visor 104 moves between the open and closed positions with respect to the chin and neck protector 106, i.e. the latter is not fixed to the visor to move therewith like in conventional arc flash helmet assemblies.

The lower edge region 105 of the visor 104 is configured to extend over the upper edge of the chin and neck protector 106. The lower edge region 105 of the visor extends forwardly to receive and overlap the upper edge of the chin and neck protector 106 when the visor is in the closed position to thereby provide an effective barrier to prevent arc flash effects (heat, blast energy, fire, projectiles, etc.) passing between the visor 104 and the chin and neck protector 106. A central lower front region 103 of the visor also extends outwardly to provide additional space in that region for accommodating the wearer's chin. A central lower edge region 107 of the visor extends forward in a substantially perpendicular direction to the front region 103 to provide a handle for the wearer to locate and grip when moving the visor up or down in use.

As illustrated in Figure 2, the chin and neck protector 106 comprises a support member 114 mounted at opposed end regions thereof to a respective one of the ear portions 110,112, and a protective curtain member 116 that hangs from the support member 114. Aptly, the support member 114 is formed from a plastics material, such as NylonTM or the like, and is relatively elongate and strip-like to be flexible allowing the two opposed end regions thereof to be urged towards each other and form a curved U-shape when mounted to the helmet 102. The support member 114 is substantially resilient such that when it is detached from the helmet 102, and no forces are acting on its ends, it elastically returns to a substantially flat state. Similarly, when the support member 114 is mounted to the ear portions 110,112 its resilience urges its opposed end regions outwardly to securely retain it on the ear portions as described further below. When the visor 104 is in the closed position, its lower edge region 105 abuts the upper edge of the curved support member 114, as described further below. The curtain member 116 aptly comprises a plurality of flexible textile layers of arc flash protective material and is attached to the support member 114 by stitching, adhering, hook and loop, mechanical fasteners, or the like.

As illustrated in Figure 3, the curtain member 116 includes a downwardly extending portion 118 for protecting the chin and neck from direct arc flashes or blasts, and an optional return portion 120 which extends inwardly towards the wearer's neck and below their chin to provide additional protection from below. Aptly, the return portion 120 is oriented substantially perpendicularly with respect to the downwardly extending portion 118 and may be a separate portion stitched to the downwardly extending portion 118. Aptly, at least the return portion 120 of the curtain member 116 is substantially elastic to closely fit under the chin and around a portion of the neck to protect the chin and at least some of the neck. The curtain portion may extend down towards the lower neck region if required.

As illustrated in Figure 4, the support member 114 includes a plurality of spaced apart elongate projections 124 downwardly extending from the main beam portion 122 of the support member 114. Each projection 124 extends down the inner surface of the downwardly extending portion 118 of the curtain member 116 and at least partially towards the return portion 120. Aptly, the support member 114 is located between opposed layers of the downwardly extending curtain portion 118, e.g. the downwardly extending curtain portion defines a sleeve or pocket in which the support member is located. Preferably each projection 124 extends to the return portion 120 of the curtain member 116 to support the downwardly extending portion 118 across its width and entire height. Each projection 124 includes an elongate stem portion 126 and an enlarged head portion 128 defining a relatively flat end surface for engaging the inner surface of the return portion 120 of the curtain member 116 where it extends from the downwardly extending portion 118. This arrangement ensures the downwardly extending portion 118 is fully supported along its height and is also kept relatively taut and does not ride up in use which could otherwise undesirably expose the neck of the wearer. Aptly, the stem portion 126 of each projection 124 tapers inwardly towards the head portion 128 to provide sufficient bending stiffness along its length and particularly at its root, whilst also minimising material and weight. The enlarged head portion 128 defines a relatively wide end region for contacting the curtain member 116 without compromising its integrity. Desirably, the support member 114 provides the chin and neck protector 106 with a skeletal structure whilst ensuring the same remains lightweight. The main beam portion 122 of the support member 114 supports the textile curtain portion 116 and also acts as a guard to protect the wearer's chin from impacts or the like, and the downwardly extending projections 124 provide structure against lateral impacts, such as arc flash blasts or the like, to protect the neck of the wearer.

As illustrated in Figure 5, each end region 130,132 of the support member 114 includes a slot 113 for stitching the opposed layers of the curtain member 116 together through the slot to anchor the same on the support member 114.

Alternatively, the slot may be a circular hole or other shaped aperture and/or may be a plurality of spaced apart apertures.

As illustrated in Figure 5, each end region 130,132 of the support member 114 includes an outwardly extending projection in the form of a boss 134 or the like.

Each boss 134 is substantially hollow and cylindrical and includes a pair of opposed recessed and arcuate wall regions 136,138 and a pair of opposed and projecting arcuate wall regions 140,142. Each recessed wall region 136,138 comprises opposed flanges 144,146 extending radially outwardly from the end of the boss wall, but extending only partially along the respective recessed arcuate wall region, to define a bayonet-type coupling part. Each projecting wall region 140,142 comprises a rib 148 extending substantially centrally up the outer surface of the wall region and oriented substantially perpendicular to an outer surface of the respective end region 130,132 of the support member 114. Each end region 130,132 of the support member 114 includes an arcuate slot 150 located below each respective arcuate projecting wall region 140,142 such that the base edge of each projecting wall region is not connected to the respective end region 130,132. This provides each projecting wall region 140,142 with a degree of flexibility and resilience to act like a leaf spring, as described further below.

As illustrated in Figure 6, each ear portion 110,112 includes an inwardly extending projection in the form of a boss 152 or the like. Each boss 152 is substantially hollow and cylindrical to define a substantially circular wall region comprising an inner wall surface 154. The circular aperture defined by each boss 152 is configured in size and shape to receive a respective one of the support member bosses 134 illustrated in Figure 5. Alternatively, each end region of the support member may comprise an aperture or recess for receiving an inwardly extending projection, such as a boss, of a corresponding one of the ear portions.

A pair of opposed flanges 156 extend inwardly from the inner wall surface 154 of each boss 152 and are configured such that the opposed outwardly extending flanges 144,146 of a corresponding one of the support member bosses 134 locate under a respective one of the inwardly extending flanges 156 when the support member 114, and in turn its bosses 134, is in a coupled rotational position with respect to the helmet 102 to thereby axially/laterally retain and couple the support member 114 to the helmet 102, i.e. the inwardly extending opposed flanges 156 define a second bayonet coupling part for engagement with the first bayonet coupling part defined by the outwardly extending flanges 144,146 of the support member bosses 134. Aptly, each inwardly extending and opposed flange 156 may comprise a pair of axially spaced apart flanges (as illustrated) to define a channel therebetween for guiding and axially constraining the opposed outwardly extending flanges 144,146 of a corresponding one of the support member bosses 134. This bayonet coupling arrangement allows the support member 114 to be decoupled from the helmet when it is rotated from the coupled rotational position to a decoupled rotational position with respect to the helmet and the end portions 130,132 of the support member 114 are urged towards each other to move each boss 134 thereof axially out of and away from the respective ear portion boss 152. Decoupling the support member 114 and in turn the curtain member 116 from the helmet 102 desirably allows the helmet assembly 100 to be used without the chin and neck protector 106 if the assembly is, for example, to be used for an application other than arc flash protection and for ease of replacing, cleaning or generally maintaining the chin and neck protector 106 which in turn prolongs the service life of the helmet assembly 100 and further increases its performance value to the user.

The inner wall surface 154 of each ear portion boss 152 comprises a plurality of axially oriented and circumferentially spaced apart recesses 158 on each opposed side of the boss and between the flanges 156. Aptly, at least two recesses 158 are provided on each side of the inner wall surface 154. Each recess 158 is configured to receive a respective one of the ribs 148 on the support member bosses 134 when the support member 114 is in a corresponding rotational orientation with respect to the helmet 102. When the support member 114 is in a first rotational position with respect to the helmet 102, the diametrically opposed ribs 148 of the support member 114 engage into corresponding opposed first pairs of the recesses 158 to hold the support member 114 in the first rotational position. The rib and recess arrangement provides tactile feedback to the wearer to indicate the support member is secured in the desired rotational position with respect to the helmet. The second pair of opposed recesses allows the support member 114 to be rotated to and held in a second rotational position with respect to the helmet which allows a degree of adjustment for accommodating different anatomies of wearer. The rotational position of the support member may define the closed position of the visor in view of the lower edge of the visor abutting the top edge of the support member when in the closed position. Providing each projecting wall region 140,142 of each support member boss 134 with a degree of flexibility and resilience to act like a leaf spring, as described above, allows the opposed ribs 148 thereof to move into and out of the recesses 158 for selective adjustment of the support member 114 and also to securely retain the support member 114 in the desired rotational position. Alternatively, the support member 114 may not be rotationally adjustable with respect to the helmet 102. Aptly, each ear portion boss 152 may include at least one recess 158 for engagement with a corresponding projection, such as a rib 148, to rotationally retain the support member 114 in a single rotational position with respect to the helmet 102.

Each ear portion boss 152 further includes a pair of outwardly extending and diametrically opposed flanges 160,161 each extending about an arc of around 70-90 degrees and aptly around 78 degrees. Each ear portion 110,112 also includes on its inner surface a plurality of spaced apart teeth 162 partially surrounding the base of the respective boss 152. These teeth aptly help strengthen this region of the ear portion by adding material thereto and also reduce the chance of surface defects such as 'sinking' during the moulding process.

Each ear portion 110,112 of the helmet 102 also includes an elongate projection 168 extending upwardly and forwardly from a wall 170 formed on the inner surface of the ear portion. The wall 170 forms part of a moulded formation 171 to add stiffness and strength to the ear portion. The elongate projection 168 is substantially flexible yet resilient and includes an angled/hooked end region defining a leading upslope ramp surface 172, a trailing downslope ramp surface 174 and an apex 176 in between.

The angled ramp surfaces 172,174 could alternatively be provided by other means, such as a strengthening wall or stiffer formation, instead of a resilient projection.

Ear portion 110,112 also includes a stop surface 178 extending inwardly from a lower edge region 180 of the ear portion and proximal to a front edge 182 of the ear portion.

As illustrated in Figure 7, the visor 104 comprises a pair of opposed hinge portions 190,192 for pivotally coupling to the bosses 152 of the helmet ear portions 110,112 illustrated in Figure 6. Aptly, the ear portions are substantially flexible yet resilient to be flexed outwardly during assembly to allow each hinge portion of the visor to be located on the inner surface of a respective one of the ear portions as described below. Each visor hinge portion 190,192 includes a through hole 194 defining diametrically opposed notches 196,197 which are configured in size and shape to allow the opposed outwardly extending flanges 160,161 of the boss 152 of a corresponding one of the ear portions 110,112 to pass therethrough when the visor is in a decoupled rotational position with respect to the helmet. The notches define a pair of inwardly extending and diametrically opposed flanges 193,195 for engagement with the outwardly extending flanges 160,161 of the ear portion bosses 152 when the visor is rotated to a coupled rotational position with respect to the helmet. When the visor 104 is rotated with respect to the ear portions 110,112 about an axis defined by the ear portion bosses 152, the notches 196,197 are rotated out of alignment with the flanges 160,161 to axially retain the visor with respect to the ear portions 110,112 and couple the same to the helmet 102 itself. The flange and notch arrangement of the ear portion bosses and the visor hinge portions act as a bayonet coupling. Desirably, the visor 104 is pivotally mounted on the same bosses 152 as the support member 114 of the chin and neck protector 106 is mounted on in a coaxial manner which helps to provide a compact and efficient helmet assembly.

Each hinge portion 190,192 of the visor 104 includes a rearwardly extending latch arm 198 located above each through hole 194. This elongate and substantially flexible yet resilient arm 198 includes an enlarged end region 200 defining a latch surface 199 for slidably engaging the leading and trailing ramp surfaces 172,174 of the resilient projection 168 of the corresponding ear portion 110,112 when the visor is rotated about the pivot axis towards the open/retracted position to be stowed between the inner and outer shells of the helmet. As the visor approaches the open position, the latch surface 199 at the end of the visor latch arm 198 engages with and slides over the leading ramp surface 172 of the resilient projection 168. The latch arm 198 has a higher bending stiffness than the resilient projection 168 and the same is caused to bend downwardly as the latch arm 198 slides over the leading ramp surface 172 towards the apex 176. Further rotation of the visor towards the open position causes the latch surface 199 of the visor latch arm 198 to slide over the apex and at least partially down the trailing ramp surface 174 of the resilient projection 168. The apex 176 of the resilient projection 168 is now located behind the end region 200 of the latch arm 198 to securely hold the visor in the open position. When the wearer wishes to close the visor 104, it is pulled downwardly by gripping a tab/handle 107 (as shown in Figure 1) forwardly extending from the lower edge of the visor to rotate the same about the pivot axis from the latched open position towards the desired closed position. This rotational movement urges the latch surface 199 of the visor latch arm 198 over the apex 176 of the resilient projection 168 whilst flexing the same downwardly to thereby unlatch the visor from the ear portions to allow the visor to be freely rotated by the wearer to the closed position. The closed position is defined by the stop surface 178 on each ear portion 110,112 which an outwardly extending projection 204 on each hinge portion 190,192 of the visor 104 abuts with to thereby limit the rotational movement of the visor about the pivot axis. Additionally, or alternatively, a projecting stop surface 201 of each hinge portion engages with a recessed stop surface 203 of the respective ear portion 110,112 when the visor is in the closed position. This stop arrangement/s may be desirable when the chin and neck protector 106 is not attached to the helmet or to prevent the visor falling on to and/or impacting the support member 114 when the visor is moved to the closed position with the chin and neck protector 106 attached to the helmet.

As illustrated in Figures 8 and 9 respectively, the helmet comprises an outer shell 108 and an inner shell 208. The outer shell 108 is aptly formed from injection moulded ABS or blended ABS or the like, whereas the inner shell 208 is aptly formed from expanded polystyrene (EPS) foam or the like. This desirably reduces the overall weight of the helmet and also reduces the centre of gravity of the helmet which in turn reduces the physical burden on the wearer, increasing the helmet's performance and comfort. The foam inner shell 208 requires secure fixture within the helmet assembly, however in view of the visor being moveable between the inner and outer shells, and being stowed therebetween when in the open position, the front section of the helmet must be free of fixtures to allow the visor to move within a void provided between the inner and outer shells and to provide a sufficiently sized visor to adequately cover and protect the wearer's face in use. Therefore, the fixtures need to be in the rear section of the helmet.

As illustrated in Figure 10, a fixture plate 210 is moulded into the rear lower edge of the inner foam shell 208 when the inner shell is being formed, e.g. by over-moulding the inner shell on to the fixture plate 210 in a single moulding operation during manufacture. Aptly, the fixture plate 210 is injection moulded plastics material, e.g. a polyamide plastics material such as glass-filled NylonTM or the like, which is relatively rigid and stiff with respect to the EPS foam of the inner shell.

As illustrated in Figures 10 and 11, the fixture plate 210 comprises a curved plate portion 212 defining a substantially flat and planar lower surface 214. An upstanding curved wall 215 extends along an inner edge of the curved plate portion 212 and between opposed end walls 216,218 extending upwardly from each end of the curved plate portion 212. The end walls 216,218 extend partially up an exposed shoulder surface of the foam inner shell 208 proximal to an upper region of each ear portion 110,112 of the outer shell 108 where the inner shell 208 has a reduced region 220 to form the void between the inner and outer shells for stowage of the visor 104 therebetween. The end walls 216,218 protect the foam inner shell 208 in that region and also secure the fixture plate 210 to the inner shell 208 in the aft direction. The inner shell 208 is aptly moulded over the curved wall 215 such that it acts as an anchor for securing the fixture plate 210 to the inner shell and adds strength in that area of the inner shell.

As illustrated in Figure 11, the fixture plate 210 includes further anchor features in the form of a plurality of spaced apart fins 222 extending upwardly from a central region of the upper surface 224 of the fixture plate 210, and a plurality of spaced apart bridge elements 226 extending between the upper surface 224 and the curved wall 215. The fins 222 secure the fixture plate 210 to the inner shell 208 at least in the lateral (side to side) direction, and the bridge elements 226 allow foam to cure thereunder and around to fully anchor and constrain the fixture plate 210 to the inner shell 208 in all directions.

As illustrated in Figures 11 and 12, an aperture 228 is disposed proximal to each end of the fixture plate for receiving a projection 230, such as a barbed snap lock element, extending from an upper edge region of a respective one of the ear portions 110,112 to securely attach the ear portions to the fixture plate 210 and in turn to the inner shell 208. Each ear portion 110,112 includes a plurality of shorter projections 232,234,236 in the form of elongate tabs extending upwardly from the upper edge region for locating in a corresponding slot 238,240,242 provided on the inner surface of the outer shell 108 proximal to its lower edge as illustrated in Figure 8. Each resilient tab 232,234,236 includes a rib/barb 237 which engages with a lower surface surrounding the corresponding slot 238,240,242 when the tab is inserted in the respective slot and the rib/barb has passed through the slot to provide a snap lock connection and securely attach each ear portion 110,112 to the outer shell 108. This arrangement efficiently uses the ear portions 110,112 to couple the inner and outer shells 208,108 together via the fixture plate 210 which optimises the structural integrity and performance of the helmet assembly and provides a non-complex assembly that is efficient to assemble and minimises weight and material.

As illustrated in Figure 8, the outer shell 108 includes a plurality of substantially horizontally oriented locking projections 244,246 extending inwardly from its inner surface 250. The plurality of locking projections includes a centrally located rear projection 244 and opposed rear side projections 246 (left hand side projection not shown). With reference to the rear projection 244, each locking projection defines a horizontally oriented and upwardly (in normal use) facing abutment surface 252 supported by one or more angled ribs 254.

During assembly, the inner shell assembly 208,210 is inserted into the outer shell 108. With reference to Figures 8 and 9, a plurality of locating projections 256,258,260,262 extend downwardly from the inner surface 250 of the outer shell 108 around the crown region thereof. A central locating projection 256 in the form of a circular dome locates in a correspondingly shaped and sized recess 264 in the inner shell 208. Forward and aft locating projections 258,260 located rearward of the central projection 256 and on the central axis or sagittal plane of the outer shell 108 locate in a correspondingly sized and shaped recess or aperture 266 in the inner shell 208 and respectively engage forward and aft and side surfaces of the recess or aperture 266 to constrain the inner shell 208 in forward and aft and lateral directions with respect to the outer shell 108 and vice versa. A further locating projection 262 is provided on each side of the sagittal plane to locate in and engage with a correspondingly shaped and sized recess or aperture 267 in the inner shell 208 to further constrain the inner shell with respect to the outer shell when connected. A further set of locating projections 265 extend laterally across the crown region of the outer shell 108 and are configured to engage a forward-facing surface 269 of the inner shell 208 which defines a rear limit to the void in which the visor moves in use and is stowed. These laterally extending projections 265 also constrain the inner shell 208 in the forward direction with respect to the outer shell 108. The locating projections 256,258,260,262,265 also desirably help to correctly locate and orient the inner shell 208 with respect to the outer shell 108 during assembly.

As the inner shell assembly 208,210 is inserted into the outer shell 108, the edge region of the fixture plate 210 moulded into the inner shell 208 engages with the angled/ramped ribs 254 formed on the inside of the outer shell 108 which urges the respective regions of the outer shell 108 to flex outwardly. Desirably, the fixture plate 210 provides a relatively stiff edge region for the angled ribs 254 of the outer shell 108 to slidably engage on. Further insertion of the inner shell assembly 208,210 into the outer shell 108 urges the fixture plate 210 edge region over the angled ribs 254 until the respective regions of the outer shell resiliently return to their original shape/position and the lower surface 214 of the fixture plate 210 engages on the upwardly facing abutment surface 252 of each locking projection 244,246,248. The inner shell assembly 208,210 is now securely connected to the outer shell 108.

For additional security/support, one or more downwardly facing abutment surfaces 268,270 provided by at least one projection 272,274 extending inwardly from the inner surface 250 of the outer shell 108 engage with at least one upwardly facing surface 276,278 formed in the rear of the inner shell 208 to thereby clamp the rear portion of the inner shell 208 between the upwardly facing abutment surface 252 and the downwardly facing abutment surface/s 268,270 provided by the outer shell 108. The at least one upwardly facing surface 276,278 formed in the rear portion of the inner shell 208 is defined by a recessed region 280 extending forwardly into the rear portion of the inner shell 208.

As illustrated in Figure 13, the helmet assembly 100 includes a head band and chin strap assembly 300 for securing the helmet assembly to the wearer's head. The head band sub-assembly 301 includes four elongate head straps 302 extending upwardly from a brow strap 304. The flexible head straps 302 are located to engage the four approximate corner regions of the wearer's head for balanced support and security. A free end region of each head strap 302 is attached to an anchor body 306 fixed in the inner shell 208. The brow strap 304 locates around the brow/forehead of the wearer and extends along the side of the wearer's head above the wearer's ears. The elongate brow strap 304 includes a plurality of spaced apart tri-star apertures 305. Each aperture is defined by three elongate slots angled with respect to each other, wherein a first slot is oriented at 0 degrees (12 o'clock), a second slot is oriented at 120 degrees and a third slot is oriented at 240 degrees. Where a width of the brow strap allows, a plurality of vertically aligned apertures is provided such that the first slots of each aperture in an aligned array are vertically aligned. The second and third slots of each aperture are directed towards the centre of an adjacent aperture. Each tri-star aperture 305 is configured to allow a degree of flex in at least three directions corresponding to an opening or closing of the slots across their width. The apertures 305 also allow the brow strap to 'breathe' and prevent the same sticking to the wearer's brow and/or sweat build up. The apertures 305 also provide grip to prevent the helmet slipping or sliding on the wearer's brow.

Opposed free end regions 307 of the brow strap are angled downwardly to terminate behind the wearer's ears. Each free end region 307 includes a pivot aperture 308 for a respective end region 309,311 of a ratchet mechanism 310 to attach and couple the free end regions together. The ratchet mechanism 310 allows the wearer's to selectively draw the free end regions 307 towards each other or urge them apart to respectively tighten or loosen the brow strap 304. Operation of the ratchet mechanism is relatively conventional so will not be described herein. The pivot aperture 308 allows the ratchet mechanism 310 to rotate with respect to the brow strap 304 for additional adjustment if required. A plurality of retaining apertures 312 in each end region 307 of the brow strap 304 are configured to receive a projection of the respective end region 309,311 of the ratchet mechanism 310 to allow the same to be retained in a desired rotational orientation with respect to the brow strap 304.

A chin strap sub-assembly 314 of the head band and chin strap assembly 300 includes four substantially flexible straps 316 each extending downwardly from a respective one of the anchor bodies 306. The upper end of each strap is coupled to a respective one of the anchor bodies and a lower end of each strap is coupled to a chin strap 318 locatable under the chin of the wearer and selectively separable by way of a clasp or clip 320. The chin strap 318 is also adjustable in length to accommodate different anatomies.

As illustrated in Figure 14, each anchor body 306 comprises a body portion 322 and a base portion 324. The body portion 322 includes a peripheral wall region 326 defining inner and outer surfaces 328,330 and a through aperture 332. A peripheral flange 334 extends outwardly from the upper edge of the body portion 322 to define an undercut surface. The body portion 322 of each anchor body 306 is fixed into the foam inner shell 208 during manufacture by for example over-moulding the inner shell on each body portion 322 during the moulding process. The undercut surface provided by the flange 334 helps to anchor the body portion 322 in the foam inner shell 208 particularly in the downward direction when a tension is applied in use to the head and chin straps. A handle or hoop element 336 extends outwardly from each opposed side of the flange 334 of each body portion 322 which allows the foam to fully surround the handle/loop element 336 during the moulding process and to securely anchor each body portion in the foam when cured.

Each body portion 322 includes at least one concave cam/bearing surface 338 extending inwardly from a first end region of the inner surface 328 of the wall region 326 and towards a second end region of the body portion opposed to the first end region. Aptly, the at least one cam/bearing surface 338 comprises a pair of laterally spaced apart cam/bearing surfaces.

The base portion 324 of each anchor body 306 includes a pair of laterally spaced apart upstands 342,344 extending forwardly from the upper surface of the base portion and the front end region thereof. The free end region 345 of each upstand 342,344 is substantially curved for rolling engagement with a corresponding one of the cam/bearing surfaces 338,340 during assembly as described below. A bar portion 346 extends between the free end regions of the upstands 342,344. The base portion 324 further includes at least one aperture 348 configured to receive and retain a projection provided on the free end region of a corresponding one of the head straps 302 to thereby attach each head strap to its corresponding anchor body 306. This projection and aperture arrangement may provide a snap-fit connection and/or allow each head strap to be decoupled from its anchor body if required. Aptly, at least two longitudinally arranged and spaced apart apertures 348 are provided in the base portion 324 for cooperation with a pair of projections on a corresponding head strap 302 for added security and/or adjustability. The second end region of the base portion 324 opposed to the first end region includes an upwardly extending curved projection 350 for locating in and slidably engaging with a curved inner surface 352 of the wall region 326 of the body portion 322 when the base portion 324 is assembled therewith.

To assemble each anchor body 306, the prong-like upstands 342,344 and bar portion 346 are inserted from below through the aperture 332 of the body portion 322. Opposed notches 354 on each side of the inner surface 352 of the wall region 326 provide space for the upstands and bar portion to be inserted up into the body portion from below and forwardly at an angle such that the curved ends 345 of the upstands 342,344 correspondingly engage with the cam/bearing surfaces 338 of the body portion 322. Rotation of the base portion 324 about an axis of the cam/bearing surfaces brings the second end region of the base portion 324 up towards the second end region of the body portion 322 and the curved projection 350 enters the aperture 332 of the body portion and slidably engages with the correspondingly curved end surface 352 of the aperture 350 to properly locate the base portion 324 in and with respect to the body portion 322. The base portion 324 can be pressed into the body portion 322 and is retained therein by a friction fit between the curved projection 350 and the inner surface of the aperture 332 and also in view of the curved projection 350 urging the curved surfaces of the upstands 342,344 against the respective cam/bearing surfaces 338,340 to clamp the base portion 324 in the body portion 322 at least in the longitudinal direction. In view of the location of each head strap 302 being attached proximal to the first end region of the body portion 322, i.e. proximal to the hinge axis defined by the curved upstands and cam/bearing surfaces, there is no or at least minimal moment acting on the second end region of the base portion 324 when a tension is applied to the head straps in use which thereby prevents the base portion 324 being rotated away from the body portion. The second end region of the base portion 324 is configured to extend beyond the corresponding end of the body portion 322 and is tapered to allow a thumb nail or tool to be inserted between the end of the base portion and the body portion to lever the second end region of the base portion away from the body portion and allow a user to remove the base portion from the body portion if, for example, removal and/or adjustment of the head straps and/or chin straps is required, such as for cleaning or replacement. Aptly, the upper end of a respective one of the flexible chin straps 318 extends up into the anchor body 306 via an opening 356 provided under the bar portion 346 of the base portion 324. The upper end region of the chin strap 318 is aptly stitched around the bar portion 324 to secure it to its respective anchor body 306. Alternatively, the end region of each chin strap 318 may comprise an enlarged portion, such as being stitched or adhered around a barrel element, which is sized to prevent it passing back through the opening 356 in the base portion 324, particularly when the chin strap is under tension in use. Further alternatively, a pin may be located in a looped end of each chin strap and the ends of the pin may engage/lock in corresponding recesses in the inner surface of the wall region of the body portion 322 to securely couple them to the respective anchor body whilst allowing rotation of the end region in the anchor body about an axis of the pin. The ends of the pin may be free to move along a channel formed in each side of the body portion 322 to allow for up and down movement of the upper end of the chin strap for additional adjustability.

Desirably, the head band and chin strap assembly 300 is securely anchored to the relatively soft foam inner shell 208 via the anchor bodies 306 fixed therein and located around the crown of the wearer, including the front section of the helmet, which ensures the helmet assembly can be fully secured and adjusted on and around the wearer's head without compromising the space envelope stowing the visor between the inner and outer shells when in the fully open position.

Certain embodiments of the present invention therefore provide an arc flash helmet assembly that is efficient and comfortable to wear and use, particularly when the visor is in an open position with respect to the helmet. The arc flash helmet Zs assembly can be efficiently used with or without a removeable chin and neck protector in view of the same being removably mounted to the helmet and separate to the visor. The arc flash helmet assembly is desirably compact and lightweight without compromising its strength and/or performance, and is also efficient to manufacture and assemble in terms of the process, parts and materials.

Claims (13)

1. Claims 1. A helmet assembly for protecting a wearer from an electrical arc flash event, comprising: a helmet; a chin and neck protector removably mounted to the helmet; and a visor pivotally mounted to the helmet and moveable with respect to the chin and neck protector between a deployed closed position and a retracted open position.
2. 2. The helmet assembly according to claim 1, wherein the chin and neck protector comprises a curved support member mounted at opposed end regions thereof to a respective one of a pair of opposed ear portions of the helmet, and a protective curtain member extending downwardly from the support member.
3. 3. The helmet assembly according to claim 2, wherein each end region of the support member comprises an outwardly extending boss configured to locate in a corresponding aperture of a respective one of the ear portions.
4. 4. The helmet assembly according to claim 3, wherein the support member is substantially flexible yet resilient to urge each outwardly extending boss into the corresponding aperture of the respective ear portion.
5. 5. The helmet assembly according to claim 3 or 4, wherein each outwardly extending boss comprises a first pair of diametrically opposed and outwardly extending flanges defining a first bayonet coupling part, and wherein each ear portion aperture comprises a first pair of diametrically opposed and inwardly extending flanges defining a second bayonet coupling part for engagement with the first bayonet coupling part to mount and laterally retain the support member with respect to the helmet.
6. 6. The helmet assembly according to claim 4 or 5, wherein each outwardly extending boss comprises at least one projection on an outer surface thereof for engagement in at least one recess on an inner surface of a respective one of the ear portion apertures to rotationally retain the support member with respect to the helmet.
7. 7. The helmet assembly according to claim 6, wherein the at least one projection comprises a pair of diametrically opposed ribs and the at least one recess comprises a first pair of diametrically opposed elongate recesses for engagement with the ribs when the support member is in a first rotational position with respect to the helmet and a second pair of diametrically opposed elongate recesses for engagement with the ribs when the support member is in so a second rotational position with respect to the helmet.
8. 8. The helmet assembly according to claim 2, wherein the support member comprises a laterally oriented beam portion extending between the ear portions when mounted thereto, and a plurality of spaced apart elongate projections is downwardly extending from the beam portion and at least partially down an inner surface of the curtain member to add structure thereto.
9. 9. The helmet assembly according to claim 8, wherein the curtain member comprises a downwardly extending curtain portion attached at an upper edge to the beam portion and a return curtain portion extending inwardly from a lower edge of the downwardly extending curtain portion.
10. 10. The helmet assembly according to claim 9, wherein each downwardly extending projection comprises an elongate stem portion and an enlarged head portion defining a relatively flat end surface for engagement with an inner surface of the return curtain portion where it extends from the downwardly extending curtain portion.
11. 11. The helmet assembly according to claim 2, wherein the curtain member comprises a plurality of flexible textile layers of arc flash protective material.
12. 12. The helmet assembly according to claim 3, wherein each ear portion aperture is defined by an inwardly extending hollow boss and the visor comprises opposed hinge portions each including an aperture for pivotally mounting the visor on a respective one of the ear portion bosses.
13. 13. The helmet assembly according to claim 12, wherein each ear portion boss comprises a second pair of diametrically opposed and outwardly extending flanges defining a third bayonet coupling part, and each visor aperture defines a second pair of diametrically opposed and inwardly extending flanges defining a fourth bayonet coupling part for engagement with the third bayonet coupling part to mount and laterally retain the visor with respect to the helmet.The helmet assembly according to claim 12 or 13, wherein each hinge portion of the visor comprises a first latch part engageable with a second latch part of a respective one of the ear portions to hold the visor in the open position.The helmet assembly according to claim 14, wherein each hinge portion of the visor comprises a first stop surface engageable with a second stop surface of a respective one of the ear portions to limit rotational movement of the visor and to define the closed position.The helmet assembly according to any preceding claim, wherein a lower edge region of the visor is configured to extend over an upper edge of the chin and neck protector.The helmet assembly according to claim 16, wherein the lower edge region of the visor extends forwardly to receive and overlap the upper edge of the chin and neck protector when the visor is in the closed position.The helmet assembly according to claim 16 or 17, wherein a central portion of the lower edge region of the visor defines a handle for opening or closing the visor.The helmet assembly according to any preceding claim, wherein a central lower front region of the visor extends outwardly for accommodating a wearer's chin.The helmet assembly according to claim 19, wherein the helmet comprises an inner shell, an outer shell and a void therebetween in a front region of the helmet for stowing the visor when in the open position. 14. 15. 16. 17. 18. 19. 20.