EP1945051A1

EP1945051A1 - Protective helmets

Info

Publication number: EP1945051A1
Application number: EP06824374A
Authority: EP
Inventors: Glen Ernest Spink; David Bennett
Original assignee: PACIFIC HELMETS NZ Ltd
Current assignee: PACIFIC HELMETS NZ Ltd
Priority date: 2005-11-07
Filing date: 2006-11-06
Publication date: 2008-07-23
Also published as: WO2007053043A1; AU2006309377B2; EP1945051A4; AU2006309377A1

Abstract

In another aspect the present invention consists in a protective helmet assembly having a protective shell (1) with a head cradle system as wearable head support therefor (2,7), the assembly being characterised in that said protective shell (1) as a Level 1 shell is enhanced by at least one additional shell (8,9) carried directly or indirectly thereby, and being further characterised in that each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is next on the other thereby to hold the nested condition until the top most shell is uplifted from the low shell. Preferably there is such an interengagement over or near or over each ear of a user.

Description

PROTECTIVE HELMETS

FIELD OF THE INVENTION

This invention relates to protective helmets (such as those used by firemen) and engagement assemblies and components thereof. The nature of fire fighting and rescue operations is such that risks of injury and death to emergency service crews can vary from incident to incident. Currently helmets need to be interexchanged.

BACKGROUND

This invention relates to a safety helmet system (in a preferred instance but not limited to a fire fighting/rescue helmet design) which incorporates multiple layers of key components and structures into one helmet in such a manner that from a basic level of head protection, other higher levels of protection can be added without first removing the basic level.

BRIEF DESCRIPTION OF THE INVENTION The present invention is directed to an interengagement feature and the resultant components or subassemblies of a helmet assembly system. It provides for an engagement suitable for a system of our PCT/NZ2005/000108 (unpublished) and variations of the helmet system of PCT/GB2004/004290 (published as WO 2005/034667) of Helmets Integrated Systems Ltd. A modular head protection system has been designed in such a way that layers of protection can be added in single or multiple configurations to provide levels of protection appropriate to changing environments.

By proper wearing of this helmet system, injuries likely to result from impacts

(either from falling objects or falling over), sharp objects (penetration), flame and heat exposure, liquid or chemical splash, molten metals and other hot fluids, electrical discharges, electrocution, or radiation and UV are eliminated or at least substantially reduced. In particular, a major cause of head injury to emergency services crews arises from road accidents when the vehicles they are travelling in are involved in accidents.

These are comparatively common events as fire appliances and ambulances are large heavy vehicles and when travelling at speed to attend a call out, are vulnerable to over- turning and collisions. All the evidence is that personnel in these vehicles should be wearing a light protective safety helmet.

Until now, but with exception of said WO 2005/034667 and some component systems (such as those disclosed in the ISR of each of PCT/NZ2005/000108 and WO 2005/034667), many of the individual and separate items of safety equipment used by fire and rescue workers for different levels of risk have been developed as individual products, designed and manufactured to different Standards and performing to different physical tests. In some instances these individual and unrelated international safety Standards are increasingly becoming more closely related, but until now have required separate safety helmets to comply with the technical requirements of each Standard.

This invention in preferred forms provides a level of head protection, which not only integrates what previously was a multitude of helmets designed for different types of threats, but also widens the range of risks for which protection is provided.

The development of fire and rescue crew safety equipment has frequently been both uncoordinated and subject to the specialties and product whims of individual manufacturers. The result has been that as new technology tools arrive in the market place, these have simply been added to the list of equipment physically worn by the crews, adding weight and complexity to the fire or rescue environment. Furthermore, many of these devices were never designed to be fully compatible with each other, resulting in interface problems, duplication of function and unnecessary weight.

One intention of this design is to provide for the incorporation of a range of safety equipment used by fire and rescue workers into one integrated design, which avoids duplication while ensuring a complete lightweight safety helmet and which enables nesting/denesting by simple uplift unlike for a system of WO 2005/004290 where some retaining system require a direct user movement between positions to allow denesting.

In addition, this invention adds new features, technologies and designs for some sub-components, and, by using a series of laminated semi-rigid materials, a lower specification safety helmets can be metamorphosised into a higher-level helmet with obsolescing any the basic components. In another aspect the present invention consists in a protective helmet assembly having a protective shell (1) with a head cradle system as wearable head support therefor (2, 7), the assembly being characterised in that said protective shell (1) as a Level 1 shell is enhanced by at least one additional shell (8, 9) carried directly or indirectly thereby, and being further characterised in that each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is nest on the other thereby to hold the nested condition until the top most shell is uplifted from the low shell.

In another aspect the present invention consists in a protective helmet assembly having a protective shell (1) with a head cradle system as wearable head support therefor (2, 7), the assembly being characterised in that said protective shell (1) as a Level 1 shell is enhanced by at least one additional shell (8, 9) (i.e. Level 2 and so forth) carried directly or indirectly thereby, and being further characterised in that the or each shell has at least one formation interengageable with a complementary at least one formation of the underlying shell, the interengagement being a friction and/or interference fit formation to formation.

Preferably said formation comprises an (a) male flange and (b) female U-clip and are able to be interconnected.

In another aspect the present invention consists in a protective helmet assembly having a protective shell with a head cradle system as wearable head support therefor, the assembly being characterised in that said protective shell as a Level 1 shell is enhanced by at least one additional shell (i.e. Level 2 and so forth) carried directly or indirectly thereby, and being further characterised in that each shell has at least one formation interengageable with a complementary at least one formation of said underlying shell, said interengageable formations being a friction and/or interference fit formation of a female U-clip and complementary male flange, and wherein removable accessories or components are attachable, directly or indirectly, to a said formation member not otherwise in association, said interengagement such to allow rotation of said removable accessories or components relative to said helmet.

Preferably there is such an interengagement over or near or over each ear of a user. Preferably one or each formation is moulded. Preferably a Level 2 shell (8) as a said additional shell, is at least in nests or detachably nests the Level 1 shell.

Preferably said Level 2 shell (8) is more expansive than that of the Level 1 shell

(1). Preferably the Level 2 shell is more expansive in skirting (11) down alongside and/or behind the head of a wearer.

Optionally the Level 2 shall (8) at least in part nests or detachably nests a Level 3 shell (9).

A similar or dissimilar engagement form can be used between Level 2 and 3 shells as for between Level 1 and 2 shells.

Preferably there is a visor/face shield (10) carried by the Level 2 shell (8) or between the Level 1 and Level 2 shells (1, 8) or between Level 2 and 3 shells.

There may also be other removable accessories or components fitted. Examples of these are figures 24, 24b, 25 and 25b. Optionally the shells have a fireman's comb or central ridge as a design feature.

In another aspect the present invention consists in a nested shell interengagement system of a protective helmet kit, the kit having one shell nestable over another and at least one formation on the outside of the underlying, or to be underlying shell, friction or interference fitting to a complementary formation on the inside of the other. In one embodiment of the present invention said nested shell includes a chord facetted flange or disc receivable in an opposed chord engaging socket provides a said friction or interference fitting.

Preferably the first formulation is a flanged male member, the flanges of which are to be received in a grooved female member. Preferably the flange or flanges of the male member lie in a general plane and the female member receives such flange or flanges by relative movement in the general plane.

In another aspect the present invention consists in a multi-purpose fire/rescue/or other protective helmet incorporating a single shell to which can be added at least one additional shell or additional shells for higher level or higher levels of protection, characterised in that the single shell includes at least one formation interengageable with one or more complementary formation of another in a friction and/or interference.

This first shell is referred to hereafter as the basic Level 1 shell.

In another aspect the present invention consists in, in combination or as a kit, (a) a helmet ("Level 1 helmet") securable to the head of an intended user thereby to provide with its shell or equivalent at least some measure of impact protection to such user, and at least:

(b) a helmet component ("Level 2 component") to be associated with the Level 1 helmet thereby to provide (i) enhanced impact protection to said intended user beyond that of the

Level 1 helmet alone, by the addition of both additional shell and/or impact energy absorption materials fitted between the Level One helmet and the Level 2 shell, and/o

(ii) a more downwardly depending skirt than any of the Level 1 helmet, and/or

(iii) a visor for said intended user, and wherein each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is nest on the other thereby to hold the nested condition until the top most shell is uplifted from the low shell.

Preferably there is such an interengagement over or near or over each ear of a user. Preferably one or each formation is moulded, and be described as (a) Male Flange (refer Fig 23A) and (b) Female U-Clip (Refer Fig 23B) and interconnected (refer Fig 23c). The interegagment of the male flange with the female "U" clip effects the securing of the Level 1 helmet to the Level 2 shell. The male flange slide into the female "U" clip locks the two major helmet components together, such that they are retained together for operational use.

The female "U" clip consists of a single moulded component designed to be attached to the side of a helmet wall in such a way that the "U" section can intersect the male flange and lock the male flange in a secure position. The "U" section is circular shaped apart from the opening entrance. At one point on the circular shape, these is an eccentric dimple which protrudes in such a position and way as to both allow the male flange to enter the "U" section, but also to hold the male flange in place. The outer ring of male flange is circular but has a number of flat surfaces over approximately 80° (more or less) of its circumference that provide the index positions when used to retain a torch bracket or other accessory. The male flange clips past the dimple protrusion in the female "U" clip so that the male side is retained more securely within the female. A face shield/visor/eye protector that attach to the Level 1 shell rather than to the

Level 2 helmet, being affixed to the Level 1 shell either internally (between the Level 2 and 1 shells) or externally on the outside of the Level 1 shell (e.g. see Refer Fig. 24 and 24b).

Alternatively, a torch or flashlight might be attached to the Level 1 shell, but removable so that before the Level 2 shell is affixed to the Level one helmet, the torch is transferred to the Level 2 shell and affixed in the same manner. Refer to Fig 25 and 25b. In another aspect the present invention consists in, in combination or as a kit,

(a) a helmet ("Level 1 helmet") securable to the head of an intended user thereby to provide with its shell or equivalent at least some measure of impact protection to such user, and at least:

(b) a helmet component ("Level 2 component") to be associated with the Level 1 helmet thereby to provide

(i) enhanced impact protection to said intended user beyond that of the

Level 1 helmet alone, and/or (ii) a more downwardly depending skirt than any of the Level 1 helmet, and/or (iii) the said skirt will extend downwards at least on both sides of the helmet, or perhaps cover the entire Level 1 shell, and/or (iv) a skirt or skirts that extend down both sides of the Level 1 shell, connected from one side to the other by a section of the Level 2 shell (e.g. just extending around the lower extremities and below if necessary - Refer Fig.9), and/or

(v) a face shield/visor/eye protector for said intended user, and/or (vi) a face shield/visor/eye protector that attach to the Level 2 shell rather than to the Level 1 helmet, being affixed to the Level 2 shell either internally (between the Level 1 and 2 shells) or externally on the outside of the Level 2 shell (e.g. see Refer Fig. 10), and wherein each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is nest on the other thereby to hold the nested condition until the top most shell is uplifted from the lower shell.

Preferably there is such an interengagement over or near or over each ear of a user or in such other position(s) that will ensure security of the interconnection of both levels.

Preferably one or each formation is moulded. In a preferred form of the invention skirt or skirts of the Level 2 helmet will normally extend downwards at least on both sides of the helmet, or perhaps cover the entire Level 1 shell. Alternatively, the said skirt or skirts may extend down both sides of the Level 1 shell, and be connected from one side to the other by a section of the Level 2 shell just extending around the lower extremities (and below if necessary). Refer Fig.9. In a preferred form the Level 2 helmet has a face shield/visor/eye protector for said intended user that attach to the Level 2 shell rather than to a Level 1 helmet. These items of face and eye protection may be affixed to the Level 2 shell either internally (between the Level 1 and 2 shells) or externally on the outside of the Level 2 shell (Refer Fig. 10). Preferably there is a Level 3 component to be associated with the Level 1 helmet and the Level 2 component. Alternatively, there could be several of different Level 2 component versions each with features providing different or different mixes of capabilities.

In still another aspect the invention is a helmet comprising or including an inner protective shell configured to be worn on its own as a helmet an outer protective shell configured to be fitted or nested over the inner shell, and complementary formations on the outside of the inner protective shell and the inside of the outer protective shell which provide a friction and/or interface fit as an interengagement feature when the shells are fitted together or nested together thereby to allow the donning or doffing of the outer shell by the user by (i) a simple placement and pressing or pulling down of the outer shell or to remove the outer protective (ii) uplifting respectively.

The traditional design shapes and wearing position (on the head) of fire and other helmets for emergency services have, over the last century, exhibited great changes, but two primary distinctive characteristics have remained. These are the traditional comb line across and down the centre of the upper shell, and the fact that helmets have generally only covered the area of the wearers head above the reference plane line (i.e. approximately the ear opening) but also excluding the face.

This new design need not be limited to one particular shape of helmet or its styling or the area of head protected. Incorporated in the basic Level 1 shell is that component or are those components that permit the basic helmet to be retained on the wearer's head (i.e. chin strap, cradle system, headband, size adjustment system, etc.). These features can be all considered as "wearable head support" for the Level 1 shell or helmet. In addition, fitted to this shell is or can be a special energy absorbing liner and cradle system that provides impact, penetration, thermal and radiation protection greater and over a wider area than impact cradles or ribbon systems. This impact protection is especially valuable in vehicle accidents and falling from heights.

The Level 1 helmet is preferably designed to provide protection for those types of rescue and fire fighting commonly known as bushfire, RTA (road transport accident), USAR (urban search and rescue/ civilian rescue operations) MEDIVAC (medical rescue and evacuations) etc, where the risk of serious impacts or high risk fire and/or thermal threats are relatively low. To these common low level fire and rescue threats, the helmet preferably specifically adds protection from head injuries in the event of accidents involving emergency services vehicles.

Because this Level 1 helmet is designed to fit with at least one other and preferably a multiplicity of additional protective levels, it is possible that some of the optional components that might normally be attached to this type of helmet, will become absorbed within the higher levels or impediments to the attachment of higher levels of protection. These optional components could include helmet mounted hands- free torches, face shields, reflective markings and other accessories.

Where necessary, provision needs to be made to attach some of these optional components either internally in the Level 1 helmets, or to replicate their function on the Level 2 or higher Level components, by transferring these optional components from the Level 1 helmet to the Level 2 shell.

Because the Level 1 helmet provides only a basic level protection, the addition of a second shell with further energy and penetration resistance is necessary for most types of structural fire fighting, military fire and rescue and other high risk rescue operations.

Normally safety helmets designed for these operations are separate helmets. The specific feature of this design is the fact that the Level 1 helmet can be upgraded momentarily by the addition of the Level 2 shell. The Level 2 shell and impact system is specifically designed to be used and fitted to the Level 1 helmet, and cannot normally provide designed levels of protection to the wearer without combination with the Level 1 helmet.

Previously, a structural fire helmet or similar helmets used by other emergency services have required that the design of the helmet be specifically intended for this purpose. This claim specifically relates to a design of helmet with a plurality of both shell and impact/thermal protection system, designed in a modular fashion where the addition of levels of protection are built upon each other with the need to discard or remove the first level of helmets before wearing the second or subsequent levels. Such additional items of protection may be described as additional Levels or clipped-on components that supplement the original base helmet. Dependent upon the requirements of the Standard, and the operational requirements of the Service itself, attachments and other components can be provided including the Level 2 shell to provide face protection (face shields etc.) lighting, (hands- free torch or flash-light), rank markings, reflective trims etc.

The addition of further levels of protection is dependant on the circumstances of the emergency call-out. Once again, the principle is that additional protection can be added to the basic helmet without the requirement to discard earlier protective components. Not only is the wearer able to retain the lower levels of helmet on their head at all times, but the additional levels of protection can be selected or even discarded as the scene changes or evolves.

These third and subsequent levels of protection principally come about by the need for extremely high temperature fire fighting, or chemical or biological threats. Not infrequently, these risks are associated with training for these types of events, and the third and subsequent materials are destroyed, but the Level 1 and Level 2 components are protected from unnecessary damage.

In a further aspect the present invention therefore consists in a Level 1 shell helmet suitable for use in a combination or a kit of the present invention.

In still a further aspect the invention is a Level 2 component for association with a Level 1 shell helmet, said Level 2 component and/or Level 1 shell helmet being substantially as herein described with or without reference to any one or more of the accompanying drawings. Yet a further aspect of the Level 2 shell is the addition of a further component to improve the impact and thermal protection of the Level 2 combination.

An addition to the internal surface of the Level 2 shell is an inner middle shell manufactured from polyurethane or other energy absorbing and thermal resistant materials, moulded and shaped with reference to both the external surface and shape of the Level one shell and the internal shape of the Level two shell.

An addition function of the inner middle shell is to locate and position the Level 1 helmet in relationship to the Level 2 shell in conjunction with the engagement friction devices hereinafter described.

In yet a further aspect the present invention consists in a Level 3 component for association with both a Level 1 shell helmet and Level 2 component of the present invention, any aspect being substantially as herein described with reference to any one or more of the accompanying drawings.

In yet a further aspect the present invention consists in a helmet system enabling tuning, by choice of component association (directly or indirectly) with a base helmet, the level of protection to be afforded. Preferably at least one component is a Level 1 shell helmet in accordance with the present invention.

Preferably a further component is a Level 2 component in accordance with the present invention. Preferably a further component is a Level 3 component in accordance with the present invention.

In yet a further aspect the present invention consists in the use of a helmet assembly, a helmet system or helmet components or a combination or kit of the present invention so as to provide for different levels of protection. As used herein "friction" fit or "interference" fit, or both, means in the donning and doffmg directions.

Preferably a lapping arrangement restricts movement in some other directions.

As used herein the term "and/or" means "and" or "or", or both.

As used herein the term "(s)" following a noun includes, as might be appropriate, the singular or plural forms of that noun.

As used herein the "female" or "U" shape can include varieties and skeletal forms, and it need not have parallel sides (preferably it doesn't) nor need it have the base.

As used herein the term "shield/visor/eye protector" includes any form of protection preferably still allowing vision. This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Preferred forms of the present invention will now be described with reference to the accompanying drawings in which

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows as an exploded view a user wearing a Level 1 shell component helmet of an USA type in accordance with the present invention and having (in exploded view) sequentially thereover a Level 2 shell component and thereover a Level 3 shell component, the Level 2 component being shown with a visor whilst the Level 3 component is shown with expansive shroud,

Figure 2 shows the Level 1 shell helmet in use,

Figure 3 shows the combination of the assembly of the Level 1 shell helmet of Figure 2 in use with the Level 2 component,

Figure 4 shows the use of all of the components as an assembly as shown in Figure 1, Level 3 component nesting on the Level 2 component in turn which nests on the Level 1 shell helmet,

Figures 5 through 8 correspond to those of Figures 1 through 4 but in respect of European style helmet assembly as opposed to that depicted in Figures 1 through 4 more appropriate for use in USA, and other countries,

Figure 9 shows the design of a Level 2 shell whereby the said skirts extend downwards at the sides of the Level 1 helmets, may be joined and connected by the lower ring of the Level 2 shell extending around the brim of the Level 1 shell, in this instance rearwards, (but not exclusively) wherein the ring could extend either forward or backwards, or both,

Figure 10 shows the affixing of a face shield/eye protector/visor accessories in such a way that the means of securing and hinging/rotating these components is by way of attachment to the Level 2 shell, Figure 11 shows Level 2 shell of Figures 9 and 10 from below showing the visor engaged thereto so as to guidably be pivoted therefrom and able to assume a number of pull down positions,

Figure 12 to 21 show two components each engageable to a shell and of being mutually interengaged in an interference type fit arrangement (preferably but not necessarily as two pairs with preferably each pair near or over a user's ear),

Figures 12 shows the external view of the female "U" clip plan view,

Figure 13 shows the external view of the female "U" clip plan view with cut away showing position of indexing dimple,

Figure 14 shows the female "U" clip reversed plan view, shown from the inside, Figure 15 shows the female "U" clip reversed plan view, showing the indexing dimple cutaway, Figure 16 shows the external view of the male flange, showing the nominal 180 deg indexing, but may extend around the external circle more or less,

Figure 17 shows the male flange internal view in the context of inside the shell for appropriate use for the NZ/Australia/North America/USA shell style, Figure 18 shows the male flange external view in the context of the external shell for appropriate use for the NZ/Australia/North America/USA shell style,

Figure 19 shows external view of male flange on Level 2 shell,

Figure 20 shows external view of male flange on Level 2 shell,

Figure 21 shows the plan view of the inter-relationship of the female "U" clip and the male flange interengaging the Level 1 helmet with the Level 2 shell with exploded illustration,

Figure 22 shows plan view of the male flange on Level 2 shell being able to be provided on an inner or lesser Level shell with the U shape upright so as to receive therein the component of, Figure 23 (a) (b) and (c) show plan views of (a) male flange (b) female "U" clip and (c) male and female combined and engaged,

Figure 24a shows the plan view of face shield hinge carrier,

Figure 24b shows the plan view of face shield hinge carrier fitted to the Level 1 helmet shell. Figure 25 shows the plan view of torch clip and assembly with the clip adapted to carry the male flange showing fitted inside the female "U" clip,

Figure 25b shows the plan view of torch clip and assembly fitted to the side of a Level 1 helmet (alternatively transferable to the Level 2 of Level 3 shells), and

Figure 26 and 26b shows the Level 2 impact liner inner shell and its preferred location inside the Level 2 shell.

DETAILED DESCRIPTION OF THE INVENTION

In a preferred form of the present invention the design considerations taken into account have been those previously discussed.

Turning specifically to Figure 2 it can be seen that a first shell 1 (e.g. of a composite reinforced with fibreglass or Aramid materials or alternatively plastic injected external materials) is supported on a head cradle system (as a wearable support for the shell 1) which includes a size adjustment and impact protection materials. This is held to the wearer's face by appropriate harness and chin strap arrangements 2, etc. The shell 1 carries a unitary or fabricated skirt extension 11.

Figure 3 shows a Level 2 shell 8 with visor 10 preferably detachably nesting over part of the Level 1 shell 1. Figure 4 shows a Level 3 shell 9 with still more expansive skirts 12 nesting over the Level 2 shell 8.

Figures 9 to 11 show a level 2 shell 3 with a visor 4 pivoted at 5 and guided by the friction slide arrangement 6. The arrangement is as previously described.

In the preferred form the components of Figures 12 through 15 and 16 through 21 are used, each riveted on different shells but in a complementary way.

If, for example, the U 13 of the component 14 is upright on say a Level one shell and is fitted thereto reliant on fixing apertures 15, a male member 17 (e.g. of metal and/or plastic) carried by another Level internally with a disc form but with alignment flats 18 can be received beyond the dimple 19 under the flanges 20. Such a member 17 can be fixed by central screw thread 21.

Larger or smaller or same size U shapes can be mounted upright or be inverted.

Upright U shapes better allows the engagement to that inner Level shell of appliances such as a torch, communication device component, or the like with a complementary fitting such as 17. See, for example, use of such interengagements as disclosed in our unpublished New Zealand Patent Specification No. 539588.

Preferably two pairs of interengaging components are used, preferably near the ears but not necessarily so. Asymmetry of the fitting of the pairs or hybridisation of the "U" condition can ensure a single fit nested condition. The preference is for members 14 externally and members 17 internally but the reverse also works. Provided an interengagement of the present invention is used for one Level to

Level interengagement, any appropriate engagement (preferably not requiring tools) (and indeed another interengagement of the present invention) can be used to hold other Level to Level components in a nested arrangement (e.g. spring loaded clipping) so as not to allow dislodging without real effort. Whilst the different levels preferably serially nest, appropriate other retention interengagements include one or more of toggle, VELCRO, clip fit and other interengagements (e.g. even as in WO 2005/034667). The preference however is a simple pull on/push off mechanism as depicted.

Claims

WE CLAIM:

1. A protective helmet assembly having a protective shell with a head cradle system as wearable head support therefor, the assembly being characterised in that said protective shell (1) as a Level 1 shell is enhanced by at least one additional shell (i.e. Level 2 and so forth) carried directly or indirectly thereby, and being further characterised in that the or each shell has at least one formation interengageable with a complementary at least one formation of the underlying shell, the interengagement being a friction and/or interference fit formation to formation.

2. A protective helmet of claim 1 wherein said formation comprises an (a) male flange and (b) female U-clip and are able to be interconnected.

3. A protective helmet assembly having a protective shell with a head cradle system as wearable head support therefor, the assembly being characterised in that said protective shell as a Level 1 shell is enhanced by at least one additional shell (i.e. Level 2 and so forth) carried directly or indirectly thereby, and being further characterised in that each shell has at least one formation interengageable with a complementary at least one formation of said underlying shell, said interengageable formations being a friction and/or interference fit formation of a female U-clip and complementary male flange, and wherein removable accessories or components are attachable, directly or indirectly, to a said formation member not otherwise in association, said interengagement such to allow rotation of said removable accessories or components relative to said helmet.

4. A protective helmet of any one of claims 1 to 3 wherein one or each formation is moulded.

5. A protective helmet of any one of claims 1 to 4 wherein there is such an interengagement over or near each ear of a user.

6. A protective helmet of any one of claims 1 to 5 wherein a Level 2 shell has additional shell nests and formation to formation engageable the Level 1 shell and is detachable with respect thereto.

7. A protective helmet of claim 6 wherein the Level 2 shall at least in part nests or detachably nests a Level 3 shell.

8. A protective helmet of claim 7 wherein a similar or dissimilar engagement form can be used between Level 2 and 3 shells as for between Level 1 and 2 shells.

9. A protective helmet of any one of claims 1 to 8 wherein said Level 2 shell is more expansive than that of the Level 1 shell.

5 10. A protective helmet of claim 9 wherein the Level 2 shell is more expansive in skirting down alongside and/or behind the head of a wearer.

11. A protective helmet of any one of claims 1 to 10 wherein there is a visor/face shield carried by the Level 2 shell or between the Level 1 and Level 2 shells or between Level 2 and 3 shells.

10 12. A protective helmet of any one of claims 1 to 11 wherein the shells have a fireman's comb or central ridge as a design feature.

13. A nested shell interengagement system of a protective helmet kit, the kit having one shell nestable over another and at least one formation on the outside of the underlying, or to be underlying shell, friction or interference fitting to a complementary

15 formation on the inside of the other.

14. A nested shell interengagement system of claim 13 wherein a chord facetted flange or disc receivable in an opposed chord engaging socket provides a said friction or interference fitting.

15. A nested shell interengagement system of either claim 13 or 14 wherein the first 20 formulation is a flanged male member, the flanges of which are to be received in a grooved female member.

16. A nested shell interengagement system of any one of claims 13 to 15 wherein the flange or flanges of the male member lie in a general plane and the female member receives such flange or flanges by relative movement in the general plane.

25 17. The present invention consists in, in combination or as a kit,

(a) a helmet ("Level 1 helmet") securable to the head of an intended user thereby to provide with its shell or equivalent at least some measure of impact protection to such user, and at least: (b) a helmet component ("Level 2 component") to be associated with the Level 1 helmet thereby to provide

(i) enhanced impact protection to said intended user beyond that of the

Level 1 helmet alone, by the addition of both additional shell and/or

5 impact energy absorption materials fitted between the Level One helmet and the Level 2 shell, and/or

(ii) a more downwardly depending skirt than any of the Level 1 helmet, and/or

(iii) a visor for said intended user,

10 and wherein each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is nest on the other thereby to hold the nested condition until the top most shell is uplifted from the low shell.

18. A kit as claimed in claim 17 wherein one or each formation is moulded, and be 15 described as (a) Male Flange and (b) Female U-Clip and interconnected.

19. A kit as claimed in claim 18 wherein interegagment of the male flange with the female "U" clip effects the securing of the Level 1 helmet to the Level 2 shell.

20. A kit as claimed in either claim 18 or 19 wherein the sliding of said male flange into the female "U" clip locks the two major helmet components together, such that they

20 are retained together for operational use.

21. A kit as claimed in any one of claims 18 to 20 wherein the female "U" clip consists of a single moulded component designed to be attached to the side of a helmet wall in such a way that the "U" section can intersect the male flange and lock the male flange in a secure position.

25 22. A kit as claimed in any one of claims 18 to 21 wherein said female "U" clip is circular shaped apart from the opening entrance.

23. A kit as claimed in any one of claims 18 to 22 wherein said female "U" clip includes a dimple protrusion.

24. A kit as claimed in any one of claims 18 to 23 wherein the outer ring of said male flange is circular but has a number of flat surfaces over approximately 80° (more or less) of its circumference that provide the index positions when used to retain a torch bracket or other accessory.

5 25. A kit as claimed in either claim 23 or 24 wherein said male flange clips past said dimple protrusion in the female "U" clip such that said male side is retained more securely within the female.

26. A kit as claimed in any one of claims 18 to 25 wherein there is such an interengagement over or near or over each ear of a user.

10 27. A kit as claimed in any one of claims 18 to 26 having a face shield/visor/eye protector that attach to the Level 1 shell rather than to the Level 2 helmet, being affixed to the Level 1 shell either internally (between the Level 2 and 1 shells) or externally on the outside of the Level 1 shell.

28. A kit as claimed in claims any one of 18 to 27 wherein a torch or flashlight is 15 attached to the Level 1 shell, but removable so that before the Level 2 shell is affixed to the Level one helmet, the torch is transferred to the Level 2 shell and affixed in the same manner.

29. A combination or as a kit,

(a) a helmet ("Level 1 helmet") securable to the head of an intended user 20 thereby to provide with its shell or equivalent at least some measure of impact protection to such user, and at least:

(i) enhanced impact protection to said intended user beyond that of the 25 Level 1 helmet alone, and/or

(ii) a more downwardly depending skirt than any of the Level 1 helmet, and/or

(iii) the said skirt will extend downwards at least on both sides of the helmet, or perhaps cover the entire Level 1 shell, and/or (iv) a skirt or skirts that extend down both sides of the Level 1 shell, connected from one side to the other by a section of the Level 2 shell, and/or

(v) a face shield/visor/eye protector for said intended user, and/or (vi) a face shield/visor/eye protector that attach to the Level 2 shell rather than to the Level 1 helmet, being affixed to the Level 2 shell either internally (between the Level 1 and 2 shells) or externally on the outside of the Level 2 shell, and wherein each shell has at least one formation interchangeable with a complementary at least one formation of the other, the interengagement being a friction and/or interference fit formation to formation as one shell is nest on the other thereby to hold the nested condition until the top most shell is uplifted from the lower shell.

30. A kit as claimed in claim 29 wherein there is such an interengagement over or near or over each ear of a user or in such other position(s) that will ensure security of the interconnection of both levels.

31. A kit as claimed in either claim 29 or 30 wherein one or each formation is moulded.

32. A kit as claimed in any one of claims 29 to 32 wherein said Level 2 helmet extends downwards at least on both sides of the helmet, or perhaps cover the entire Level 1 shell.

33. A kit as claimed in claim 32 wherein said skirt or skirts extends down both sides of the Level 1 shell, and is connected from one side to the other by a section of the Level 2 shell extending around the lower extremities.

34. A kit as claimed in any one of claims 29 to 33 wherein a preferred form the Level 2 helmet has a face shield/visor/eye protector for said intended user that attach to the

Level 2 shell rather than to a Level 1 helmet.

35. A kit as claimed in claim 34 wherein said face and eye protection may be affixed to the Level 2 shell either internally (between the Level 1 and 2 shells) or externally on the outside of the Level 2 shell.

36. A kit as claimed in any one of claims 29 to 35 wherein there is a Level 3 component to be associated with the Level 1 helmet and the Level 2 component.

37. A helmet comprising or including an inner protective shell configured to be worn on its own as a helmet 5 an outer protective shell configured to be fitted or nested over the inner shell, and complementary formations on the outside of the inner protective shell and the inside of the outer protective shell which provide a friction and/or interface fit as an interengagement feature when the shells are fitted together or nested together thereby to allow the donning or doffing of the outer shell by the user by (i) a simple placement and 10 pressing or pulling down of the outer shell or to remove the outer protective (ii) uplifting respectively.

38. A Level 1 shell helmet suitable for use in a combination or a kit of the present invention.

39. A Level 2 component for association with a Level 1 shell helmet, said Level 2 15 component and/or Level 1 shell helmet being substantially as claimed with or without reference to any one or more of the accompanying drawings.

40. A Level 2 component for association with a Level 1 shell helmet as claimed in claim 39 wherein the Level 2 shell is the addition of a further component to improve the impact and thermal protection of the Level 2 combination.

20 41. A Level 2 component for association with a Level 1 shell helmet as claimed in claim 39 or 40 wherein an addition to the internal surface of the Level 2 shell is an inner middle shell manufactured from polyurethane or other energy absorbing and thermal resistant materials, moulded and shaped with reference to both the external surface and shape of the Level one shell and the internal shape of the Level two shell.

25 42. A Level 2 component for association with a Level 1 shell helmet as claimed in claim 41 wherein an addition function of the inner middle shell is to locate and position the Level 1 helmet in relationship to the Level 2 shell in conjunction with the engagement friction devices hereinafter described.

43. A Level 3 component for association with both a Level 1 shell helmet and Level 2 component of the present invention, any aspect being substantially as claimed herein with reference to any one or more of the accompanying drawings.

44. A helmet system enabling tuning, by choice of component association (directly or 5 indirectly) with a base helmet, the level of protection to be afforded.

45. A helmet system as claimed in claim 44 wherein at least one component is a Level 1 shell helmet in accordance with the present invention.

46. A helmet system as claimed in claims 44 or 45 wherein a further component is a Level 2 component in accordance with the present invention.

10 47. A helmet system as claimed in claims 44 to 46 wherein a further component is a Level 3 component in accordance with the present invention.

48. The use of a helmet assembly, a helmet system or helmet components or a combination or kit of the present invention so as to provide for different levels of protection.

15 49. The use of a helmet assembly, a helmet system or helmet components or a combination or kit as claimed in claim 48 wherein a lapping arrangement restricts movement in some other directions.