Power Distribution System and Helmet and Method Employing the Same

• US 20130086722A1
• Filed: 10/09/2012
• Published: 04/11/2013
• Est. Priority Date: 10/07/2011
• Status: Active Grant

• Current Assignee: Wilcox Industries Corp.
• Original Assignee: Wilcox Industries Corp.
• Inventors: Teetzel, James W., Harris, Justin D.
• Granted Patent: US 8,908,389 B2
• Time in Patent Office: Days
• US Class Current: 2/2.5
• CPC Class Codes: A42B 3/04 Parts, details or accessories of helmets
• CPC Class Codes: F41H 1/04 Protection helmets crash helmets A42B3/00
• CPC Class Codes: H02J 1/00 Circuit arrangements for dc mains or dc distribution networks

Abstract

An integrated accessory mounting and electrical interconnection device are provided which can be embedded or attached to the surface of a ballistic or non-ballistic helmet. The helmet system herein includes a flexible circuit substrate that may be embedded between a ballistic shell and an outer skin or shell. The helmet system and method allow a secure connection of helmet mounted accessories to the helmet without the need to penetrate any one or more layers of the ballistic shell with mounting hardware, fasteners, wiring vias, and so forth.

Claims

1. A helmet accessory power distribution system for providing a supply of electrical power to one or more electrical power-consuming devices attached to a helmet, the system comprising:

a circuit layer extending across a portion of the helmet, said circuit layer defining a circuit and including a plurality of terminal pads, each of said terminal pads including two or more electrical contacts, and electrical conductors interconnecting the terminal pads;

a cover attached to the circuit layer over each terminal pad, said cover having an aperture aligned with and exposing the electrical contacts; and

one or more mechanical fasteners configured to removably and securely hold a helmet accessory in mechanical contact with the cover and in electrical contact with the exposed electrical contacts.

2. The helmet accessory power distribution system of claim 1, wherein the circuit layer includes a circuit board substrate having a circuit formed thereon.

3. The helmet accessory power distribution system of claim 2, wherein the circuit board substrate is formed of a flexible, electrically insulating material.

4. The helmet accessory power distribution system of claim 3, further comprising a rigid housing covering a portion of the circuit board substrate and receiving the terminal pads and having at least one aperture exposing the electrical contacts.

5. The helmet accessory power distribution system of claim 1, further comprising an externally threaded grommet extending through aligned openings in said cover and said circuit layer and an internally threaded nut engaged with said externally threaded grommet to attach said cover to said circuit layer.

6. The helmet accessory power distribution system of claim 5, wherein said circuit layer is wherein said cover is attached to said circuit layer using a pair of said externally threaded grommets disposed on opposite transverse sides of the circuit layer.

7. The helmet accessory power distribution system of claim 5, wherein said externally threaded grommet further includes an internally threaded portion adapted to removably engage complimentary externally threaded connectors on a helmet accessory.

8. The helmet accessory power distribution system of claim 1, wherein the circuit comprises one or both of:

a power bus for providing electrical power from a battery device to an accessory device; and

a signal bus for transmitting an electronic signal to or from an accessory device.

9. The helmet accessory power distribution system of claim 8, wherein the electronic signal is selected from one or more of an analog video signal, digital video signal, analog audio signal, digital audio signal, analog control signal, digital control signal, analog data signal, and digital data signal.

10. The helmet accessory power distribution system of claim 1, wherein the helmet accessory is selected from one or more of a power supply, friend-or-foe transponder, audio and/or video communications system, optical and/or electro-optical viewing device, audio, video and/or image recording device, and electronic data storage medium.

11. The helmet accessory power distribution system of claim 1, wherein the circuit is a printed circuit.

12. The helmet accessory power distribution system of claim 1, wherein the circuit is a printed circuit printed with a conductive ink.

13. The helmet accessory power distribution system of claim 1, further comprising a power connector electrically coupled to the circuit for electrically coupling an electrical power-consuming device on the helmet to a remotely located power supply.

14. The helmet accessory power distribution system of claim 1, further comprising a mounting adapter removably secured to the cover, the mounting adapter for both mechanically attaching an electrical power-consuming device and for providing a pass through electrical connection between the circuit and the electrical power-consuming device.

15. A helmet construction comprising the helmet accessory power distribution system of claim 1 and a helmet attached to the circuit layer.

16. The helmet construction of claim 15, wherein the helmet is a multilayer ballistic helmet comprising one or more layers of ballistic resistant material, and further wherein the one or more mechanical fasteners do not penetrate any of the one or more layers of ballistic resistant material.

17. The helmet construction of claim 16, further comprising an outer layer disposed over the helmet and the circuit layer.

18. The helmet construction of claim 17, wherein the outer layer is selected from a shell formed of a non-ballistic resistant material and one or more plies of a ballistic resistant material.

19. The helmet construction of claim 18, wherein the outer layer is selected from an outer layer separately applied over the circuit layer and the covers and an outer layer that is integrally formed with the covers.

20. A method of providing a supply of electrical power to one or more electrical power-consuming devices attached to a helmet, the method comprising:

providing a circuit layer extending across a portion of the helmet, said circuit layer defining a circuit and including a plurality of terminal pads, each of said terminal pads including two or more electrical contacts and electrical conductors interconnecting the terminal pads;

attaching covers to the circuit layer over each terminal pad, the covers having an aperture aligned with and exposing the electrical contacts;

securing a power supply to one of the covers and an electrical power-consuming device to another one of the covers one or more mechanical fasteners, the one or more mechanical fasteners configured to removably and securely hold the power supply and the electrical power-consuming device in mechanical contact with the cover and in electrical contact with the exposed electrical contacts; and

providing power delivery from the power supply to the electrical power-consuming device through the circuit layer.