EP4651753A1

EP4651753A1 - Nape tensioner

Info

Publication number: EP4651753A1
Application number: EP24745059.6A
Authority: EP
Inventors: Matthew Anthony Hanudel; Nathan Winters; Alex DIMARTINO
Original assignee: Gentex Corp Carbondale
Current assignee: Gentex Corp Carbondale
Priority date: 2023-01-16
Filing date: 2024-01-16
Publication date: 2025-11-26
Also published as: KR20250141139A; IL321849A; JP2026502597A; WO2024155581A1; AU2024210417A1

Abstract

A safety helmet adjustment mechanism is disclosed. The safety helmet adjustment mechanism includes a safety helmet having an inner surface, a nape coupled to the inner surface of the safety helmet, and a nape tensioner disposed within the nape. The nape tensioner being coupled to the safety helmet with a cable that extends from the nape tensioner. The nape tensioner includes a housing coupled to the nape, a cable reel rotatably coupled to the housing, the cable engaging the cable, a dial coupled to the cable reel and a spring disposed within the housing. The spring prevents rotation of the cable reel relative to the housing in an expanded configuration. Rotating the dial constricts the spring, thereby allowing rotation of the cable reel relative to the housing.

Description

TITLE

[0001] Nape Tensioner

CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63/480,080 filed January⁷ 16, 2023 entitled “Nape Tensioner’ and U.S. Provisional Patent Application No. 63/607,495 filed December 7, 2023 entitled “Nape Tensioner’', which are incorporated by reference herein in their entirety.

TECHNICAL FIELD

[0003] The present disclosure generally relates to helmet retention systems and, more particularly, to a nape tensioner adjustment mechanism of a helmet retention system.

SUMMARY

[0004] In certain embodiments, a safety helmet adjustment mechanism comprises: a safety helmet comprising an inner surface; a nape coupled to the inner surface of the safety helmet; and a nape tensioner disposed within the nape, the nape tensioner comprising a cable and coupled to the safety⁷ helmet with the cable. In certain embodiments, the cable extends from the nape tensioner. In certain embodiments, the nape tensioner comprises: a housing coupled to the nape; a cable reel rotatably coupled to the housing, the cable reel engaging the cable; a dial coupled to the cable reel; and a spring disposed within the housing. In certain embodiments, the spring prevents rotation of the cable reel relative to the housing in an expanded configuration. In certain embodiments, rotation of the dial constricts the spring, thereby allowing rotation of the cable reel relative to the housing.

[0005] In certain embodiments, the nape tensioner further comprises: a first cable extending from a first side and a second cable extending from a second side thereof. In certain embodiments, the first cable is coupled to a first side and the second cable is coupled to a second side of the inner surface of the safety helmet. In certain embodiments, the nape is coupled to an impact pad coupled to the inner surface of the safety helmet.

[0006] In certain embodiments, the nape tensioner further comprises: a rotation restrictor extending radially inward from the housing and engageable with a reel block of the cable reel. In certain embodiments, the rotation restrictor prevents the cable reel from turning more than 360° relative to the housing. In certain embodiments, the cable is coupled to a cable retainer coupled to the inner surface of the safety helmet. [0007] In certain embodiments, the safety helmet adjustment mechanism of claim 1 further comprises: a screw. In certain embodiments, the housing, the cable reel and the dial are coupled by the screw. In certain embodiments, the nape tensioner is coupled to the nape by the screw.

[0008] In certain embodiments, the cable wraps around a spool of the cable reel when the dial is rotated. In certain embodiments, rotation of the dial in a first direction tightens the nape relative to the safety helmet. In certain embodiments, rotation of the dial in a second direction loosens the nape relative to the safety helmet.

[0009] In certain embodiments, the nape comprises a nape tab extending therefrom, the nape tab couplable to an impact pad. In certain embodiments, the impact pad comprises a pad protrusion configured to be received by a nape tab aperture of the nape tab to couple the nape relative to the impact pad. In certain embodiments, the impact pad is flush relative to the impact pad when the pad protrusion is received by the nape tab aperture.

[0010] In certain embodiments, the cable reel further comprises a reel extension configured to engage the spring during rotation of the dial. In certain embodiments, the reel extension moves the spring from the expanded configuration to a constricted configuration during rotation of the dial. In certain embodiments, the spring moves from the constricted configuration to the expanded configuration when the dial is idle.

[0011] In certain embodiments, a safely helmet adjustment mechanism comprises: a safety helmet comprising an inner surface; a nape coupled to the inner surface of the safety helmet; and a nape tensioner disposed within the nape. In certain embodiments, the nape tensioner comprises: a first cable extending from a first side and a second cable extending from a second side, a housing coupled to the nape; a cable reel rotatably coupled to the housing, the cable reel engaging the first cable and the second cable; a dial coupled to the cable reel; a spring disposed within the housing; and a rotation restrictor extending radially inward from the housing and engageable with a reel block of the cable reel.

[0012] In certain embodiments, the spring prevents rotation of the cable reel relative to the housing in an expanded configuration. In certain embodiments, rotation of the dial constricts the spring, thereby allowing rotation of the cable reel relative to the housing. In certain embodiments, the first cable and the second cable extend from the nape tensioner. In certain embodiments, the first cable is coupled to a first side and the second cable is coupled to a second side of the inner surface of the safety helmet.

BRIEF DESCRIPTION OF THE DRAWINGS [0013] The following detailed description of embodiments of the nape tensioner, will be better understood when read in conjunction with the appended drawings of exemplary embodiments. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

[0014] In the drawings:

[0015] Fig. 1 is a front view of a nape tensioner mounted to a helmet in accordance with a first exemplary embodiment of the present invention;

[0016] Fig. 2 is a partial rear perspective view of the nape tensioner of Fig. 1 ;

[0017] Fig. 3 is a rear view of the nape tensioner of Fig. 1;

[0018] Fig. 4 is a front view of the nape tensioner of Fig. 1;

[0019] Fig. 5 is a perspective interior view of the nape tensioner of Fig. 1;

[0020] Fig. 6 is a perspective view of a cable reel of the nape tensioner of Fig. 1 ;

[0021] Fig. 7 is a side view of the cable reel of Fig. 5;

[0022] Fig. 8 is a front view of a helmet having the nape tensioner of Fig. 1;

[0023] Fig. 9 is a zoomed in partial view' of Fig. 7;

[0024] Fig. 10 is a front view of a nape tensioner mounted to a helmet in accordance w ith a second exemplar}' embodiment of the present invention;

[0025] Fig. 11 is a rear view of the nape tensioner of Fig. 10;

[0026] Fig. 12 is a rear view of the nape tensioner and a cable retainer of Fig. 10;

[0027] Fig. 13 is a perspective interior view of the nape tensioner of Fig. 10;

[0028] Fig. 14 is a bottom view' of the cable retainer receiving the cables of the nape tensioner of Fig. 10;

[0029] Fig. 15 is a front view a cable of the nape tensioner of Fig. 10;

[0030] Fig. 16 is a zoomed in rear view of the nape tensioner of Fig. 10 with a partially transparent cable reel;

[0031] Fig. 17 is a front view of the nape tensioner of Fig. 10 coupled to an impact pad;

[0032] Fig. 18 is a rear perspective view of the impact pad of Fig. 10;

[0033] Fig. 19 is a zoomed in partial view of the cable retainer of Fig. 10;

[0034] Fig. 20 is a zoomed in view of an electrical cable disposed in electrical cable runners in accordance w ith an exemplary embodiment of the present invention; and

[0035] Fig. 21 is a bottom perspective view of the nape tensioner of Fig. 10.

DETAILED DESCRIPTION

[0036] Headgear retention and suspension systems are worn in a variety of environments and for various purposes. Headgear suspensions allow' protective equipment, such as face shields and helmets, to be properly fitted and/or suspended away from the head. A common element of headgear suspensions is the headband, usually fabricated from a thin band of plastic material formed into a generally circular or semi-circular shape with ends overlapping and joined at the back of the head. Various systems have been devised to adjust the girth of the headband to the extent necessary to fit the variety of head shapes and sizes of different wearers. One such system is an adjustable nape contacting the back of a user’s head, which can be manipulated to move forward or backward relative to the user’s head depending on the size of the user’s head.

[0037] However, current adjustable napes often rely on a ratchet mechanism and a knob which may produce noises and the mechanical elements associated therewith may significantly contribute to the overall weight on the user’s head. The size and weight of the ratchet mechanism and the knob have disadvantages in some applications. For example, in order to access the knob in a protective helmet, the knob must be positioned below the edge of the helmet shell. Alternatively, the helmet shell must be significantly distanced from the wearer’s head to provide room for the knob and to allow the wearer’s fingers to operate the knob inside the helmet shell volume.

[0038] Considering the above, there is a need for a safety helmet adjustment mechanism that can be operated by the wearer while on the wearer’s head and that is quieter, smaller, easier to operate, and lighter w eight than conventional ratchet mechanisms.

[0039] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in Figs. 1-9 a nape tensioner, generally designated 10, in accordance with a first exemplary embodiment of the present invention.

[0040] In some embodiments, the nape tensioner 10 is designed to provide an adjustment mechanism to ensure a snug and stable fit of a safety helmet 12. The safety helmet 12 may be a helmet shell for use in a variety of environments and for various purposes including, but not limited to, adventure activities, sporting, industrial safety, and police or military purposes. In some embodiments, the safety helmet 12 may be any type of head protection helmet shell known in the art. For example, safety helmet 12 may be included in a standard infantry ballistic helmet, an advanced combat helmet (ACH) an enhanced combat helmet (ECH), a modular integrated communications helmet (MICH), a tactical ballistic helmet (TBH), a lightweight marine helmet, police general duty helmet, a personnel armor system for ground troops (PASGT), or an aircrew helmet, such as an HGU-56/P rotary wing helmet or an HGU 55/P fixed wing helmet.

[0041] The safety helmet 12 may be a ballistic protection helmet made of composite materials having a helmet shell. The composite materials may combine the benefits of multiple materials, such as the substrate (e.g., ultra-high molecular weight polyethylene (UHMWPE)), the ultrahard particles (e.g., ceramics), the non-elastomeric polymer binder, and/or the polymeric layer, and enhances the performance of the article against high-velocity ballistic threats or the like. [0042] This design may allow a single cable 14 to run through the cable housing 36 and thus have two ends of the cable 14 (e.g., left and right) extending therefrom, which can tighten and loosen the nape 16 at the same time when the dial 30 is rotated. When the dial 30 is rotated, the reel extension may engage a tab 58 of the spring 54, thereby constricting the spring 54, which allows the cable reel 40 to shorten or lengthen the cable 14 with little to no noise or friction. When the dial 30 is released, the spring 54 disposed within the nape tensioner 10 automatically expands into the sidewalls of the clutch tube 50, thereby locking the nape tensioner 10 with the coiled spring 54. This disclosure has a variety of use cases on a safety helmet 12 but is not limited to just helmets.

[0043] Referring to Figs. 1-2, the safety helmet 12 may include a nape tensioner 10 mounted to the interior surface of the safety helmet 12 and configured to adjust the fit of the safety helmet 12 by changing the length of a cable 14 extending from the nape tensioner 10. The nape tensioner 10 disclosed herein may provide the necessary fit adjustment functionality by preventing the nape 16 from extending past a set threshold while producing little or no noise during adjustment.

[0044] In some embodiments, the nape tensioner 10 and nape 16 are pivotably coupled to the safety⁷ helmet 12. The nape tensioner 10 may be coupled to the nape 16 at a nape aperture 18 extending through the nape 16. The nape aperture 18 may be located at a center of the nape 16 proximate a bottom edge thereof. The nape 16 may flex to conform to the specific safety helmet 12 it is coupled to and the user’s head/neck. The nape 16 may be positioned in the rear of the safety’ helmet 12 and may extend beyond the lower edge of the safety helmet 12 such that the nape 16 engages the user’s neck when the user pivots his head up relative to the body (e.g., looking up while the user is standing or looking forward while the user is prone). The nape 16 may interact with the back of the user’s neck when the user pivots his head up thereby restricting movement of the head or causing irritation/pain on the neck. As shown in Fig. 2, the bottom edge of the nape 16 may be curved towards the nape aperture 18 to reduce the distance the nape 16 extends beyond the edge of the safety helmet 12, thereby reducing interference with the user’s neck when the user pivots the head up. In some embodiments, the bottom edge of the nape 16 may include a curved lower portion 17 to prevent interference with the user’s neck. The nape 16 may have a lip 20 extending around the nape aperture 18 on an outer surface of the nape 1 . The lip 20 may provide a housing for the nape tensioner 10 to protect the mechanics and prevent movement of the nape tensioner 10 relative to the nape 16. The lip 20 may comprise a lip aperture 22 extending therethrough, configured to allow the cable 14 to pass therethrough. The lip aperture 22 may have a cross section larger than the cable 14 to prevent interfering with the nape tensioner 10.

[0045] In some embodiments, one or more helmet components or accessories may be attached to or routed through the nape 16. The nape 16 may further comprise a strap mount 24 extending therefrom, the strap mount 24 comprising one or more cable runners 26. The strap mount 24 may receive and route webbing 29 or other sections of a webbing retention system (e g., chin strap). The strap mount 24 may be removably coupled to the nape 16. The strap mount 24 may be disassembled from the nape 16 for repair or replacement. The cable runner 26 may direct the cable 14 toward an inner surface of the safety helmet 12. The cable runner 26 may direct the cable 14 toward the edge of the safety helmet 12. The cable runner 26 may be generally tubular. In some embodiments, the cable runner 26 may be an adjustable sleeve that is movable between an open position and a closed position. The cable runner 26 may receive the cable 14 in the open position and may retain the cable 14 in the closed position. The cable runner 26 may be shaped and sized to create friction between the cable runner 26 and the cable 14. The cable runner 26 may route the cable 14 between the cable runner 26 and the nape tensioner 10 to ensure the cable 14 is spaced from and does not interfere with the webbing 29 or other accessories of the safety⁷ helmet 12. The tension created by the cable runner 26 may be adjustable. For example, a circumference or diameter of the cable runner 26 may be adjusted by a user to increase or decrease the tension on the cable 14. The nape tensioner 10 may further include an electrical cable runner 27 (not shown). The electrical cable runner 27 may be used for the routing of data, power or other electrical cables around a rear end of the safety helmet 12 away from a user’s ears. The cable runner 26 and electrical cable runner 27 may route the respective cable to an interior or an exterior of the safety helmet 12 to reach the required destination.

[0046] The cable 14 may be made of a flexible steel and can be easily routed around the safety helmet 12 with one or more cable runners 26. The cable 14 may be made from a stainless steel material that provides anti-corrosion, heat resistance, adequate strength, and sanitation. The cable 14 may be a wire rope. The cable 14 may comprise a plurality of strands twisted together to form a generally helical configuration. In some embodiments, the cable 14 is a braided wire whereby a plurality of strands are intertwined.

[0047] The cable 14 may have a diameter of approximately 0.05”. In some embodiments, the cable 14 has a diameter of approximately 0.02”, approximately 0.025”, approximately 0.03”, approximately 0.035”, approximately 0.04”, approximately 0.045”, approximately 0.05”, approximately 0.055”, approximately 0.06”, approximately 0.065”, approximately 0.07”, approximately 0.075”, approximately 0.08”, approximately 0.085”, approximately 0.09”, or approximately 0.095”. In some embodiments, the cable 14 has a diameter of at least 0.02”, at least 0.025”, at least 0.03”, at least 0.035”, at least 0.04”, at least 0.045”, at least 0.05”, at least 0.055”, at least 0.06”, at least 0.065”, at least 0.07”, at least 0.075”, at least 0.08”, at least 0.085”, at least 0.09”, or at least 0.095”. In some embodiments, the cable 14 has a diameter between 0.2” and 0.95”, between 0.25” and 0.9”. between 0.3” and 0.85”, between 0.35” and 0.8”, between 0.4” and 0.75”, between 0.45” and 0.7”, between 0.5” and 0.65”, or between 0.55” and 0.6”.

[0048] In some embodiments, the cable 14 may be coated to reduce friction in the nape tensioner 10 and reduce the development of rust on the cable 14. The cable 14 may be coated with a plastic, a rubber, a wax, or other acceptable coating to achieve reduced friction and increased risk prevention. The coating may provide the cable 14 with better impact resistance, abrasion resistance, and fatigue resistance. The coating may increase the effective diameter of the cable 14 by approximately 1/64”. The cable runners 26 may be coupled to an inner surface of the safety' helmet 12 and may be a generally cylindrical shape and coupled relative to the helmet and guide the cable 14 to an attachment point or anchor 28. In one embodiment, the cable runners 26 may be coupled to an impact liner 60. Movement of the impact liner 60 relative to the safety helmet 12 may allow adjustment of the nape 16 relative to the safety' helmet 12 and user. This provides opportunities to reduce hot spots from fit bands and headbanded communications by discreetly- guiding the cable 14 between the shell of the safety helmet 12 and the impact liner 60. In some embodiments, the cable runners 26 may route the cable 14 to an anchor 28 located on an interior surface of the safety⁷ helmet 12. In some embodiments, the cable runners 26 may route the cable 14 to an anchor 28 located on an exterior surface of the safety helmet 12.

[0049] The cable 14 may extend from the nape tensioner 10 to an anchor 28 located on the safety helmet 12. In one embodiment, the cabl e 14 extends from the nape tensioner 10 to an anchor 28 located on a component bonded, or otherwise coupled, to the inner surface of the safety helmet 12, as shown in Fig. 14 and described in more detail below. In one embodiment, the cable 14 extends from the nape tensioner 10 to an anchor 28 located on a molded edgeband bonded, or otherwise coupled, to the safety helmet 12. The edgeband may be plastic molded. In one embodiment, the cable 14 extends from the nape tensioner 10 to an anchor 28 located on the impact liner 60.

[0050] Organizing and managing the location of the cable 14 in the safety' helmet 12 can reduce snagging and prevent accidental tightening and loosening of the helmet relative to the user’s head. A plurality of cable runners 26 may be disposed proximate the inner surface of the safety helmet 12 to guide the cable 14 to the anchor 28 without interfering with any of the other components of the safety helmet 12. The anchor 28 may be on the inner surface or the outer surface of the safety' helmet 12 at a portion of the safety helmet 12 closer to the front of the helmet than the nape tensioner 10. There may be two anchors 28 at the same location on opposite sides of the safety helmet 12 (e.g., right and left) to allow the nape 16 to pivot relative to the safety⁷ helmet 12 during an adjustment by the nape tensioner 10. In one embodiment, there is only one anchor 28. The anchor 28 may be an existing fastener extending through the safety helmet 12. In one embodiment, in the case of a boltless helmet, the anchor 28 may be a shim coupled to the safety helmet 12 with an adhesive. In one embodiment, the anchor 28 may be the cable 14 disposed within an edge band of the safety helmet 12.

[0051] A user may adjust the fit of the helmet by interacting with the nape tensioner 10. Referring to Fig. 2. the exterior side of the nape 16 may comprise a dial 30 of the nape tensioner 10 rotatably coupled thereto. The dial 30 may be rotated by the user to adjust the nape 16 to increase or decrease the length of cable between the nape tensioner 10 and the anchor 28. The dial 30 may be generally circular and have a plurality of dial protrusions 32 around a circumference thereof. The dial protrusions 32 may provide friction with the user’s fingers to allow for reliable grip and rotation of the dial 30. The dial 30 may include indicia 34 in a center thereof. The indicia 34 may be a logo, shape, word(s) or any combination thereof.

[0052] Referring to Fig. 3, the nape tensioner 10 may be coupled to the nape 16 in the nape aperture 18. A cable housing 36 of the nape tensioner 10 may include at least one housing protrusion 38 extending therefrom, the housing protrusion 38 configured to align with the shape of the nape aperture 18 thereby preventing rotation of the cable housing 36 relative to the nape 16. [0053] The cable housing 36 may surround a cable reel 40 disposed therein. The cable reel 40 may be sized and shaped to fit within the cable housing 36. The cable reel 40 may include a reel aperture 42 (shown in Fig. 7) extending therethrough to allow the cable 14 to pass through the cable reel 40. However, to ensure the cable 14 is adjusted evenly on both sides of the nape 16, the cable reel 40 may comprise a central slot 44 extending through an outer surface of the cable reel 40. A reel protrusion 46 may extend from the outer surface of the cable reel 40. A central portion of the cable 14 may be configured to pass through the central slot 44 and around the reel protrusion 46, thereby promoting the cable 14 to wrap evenly around the cable reel 40 when rotated. The cable reel 40 may comprise a spool 48 configured to collect and contain the cable 14 during rotation of the nape tensioner 10. The spool 48 may be a generally recessed portion of the cable reel 40 with a diameter smaller than the surrounding portions of the cable reel 40. The spool 48 may have a generally rounded shape to promote the cable 14 to a center thereof.

[0054] Referring to Fig. 5, the nape tensioner 10 may further comprise a clutch tube 50 disposed within the cable housing 36. The clutch tube 50 may be a generally cylindrical shape, sized and shaped to fit between the cable housing 36 and the cable reel 40. The clutch tube 50 may further be shaped and sized to fit on a rim 52 the cable reel 40.

[0055] A silent adjustment of the nape tensioner 10 may provide improved safety for a user in the field. The nape tensioner 10 may further comprise a spring 54 disposed between the clutch tube 50 and a reel extension 56. The spring 54 may have a diameter larger than the clutch tube 50 in an expanded configuration. However, when rotated, the spring 54 may have a diameter smaller than the clutch tube 50 in a constricted configuration. The spring 54 may include one or more tab 58 protruding toward a center of the nape tensioner 10. The spring 54 may include one tab 58 on a start of the spring 54 and one tab 58 on an end of the spring 54. When the dial 30 is rotated, the reel extension 56 may engage the tab 58 of the spring 54, thereby reducing the diameter of the spring 54 and allowing rotation of the cable reel 40 relative to the cable housing 36. When the dial 30 is not rotated, the reel extension 56 does not engage the tab 58 of the spring 54 and the circumference of the spring 54 may expand such that the friction between the spring 54 and the clutch tube 50 prevents further rotation of the cable reel 40 relative to the cable housing 36 thereby locking the nape tensioner 10 and cable 14. This interaction between the spring 54 and the clutch tube 50 may provide little or no noise during use.

[0056] Referring to Figs. 4-9, the nape tensioner 10 may include a screw 39 disposed therein. The screw 39 may be shaped and sized to extend through the nape tensioner 10. The screw 39 may secure the nape tensioner 10 to the nape 16. The screw 39 may engage a receiver (not shown) of the dial 30 to urge the cable reel 40 and the dial 30 toward each other. The nape aperture 18 may be received between the components of the nape tensioner 10 to prevent the nape tensioner 10 from moving relative to the nape 16.

[0057] The nape 16 may be coupled to an inner surface of the safety helmet 12. Referring to Figs 8-9, the nape 16 may extend through the impact liner 60 of the safety helmet 12. The nape 16 may be coupled to the safety helmet 12 using a fastener or an adhesive. In one embodiment, the nape 16 is coupled to the impact liner 60 of the safety helmet 12.

[0058] Referring to Figs. 10-21, there is shown a second exemplary' embodiment of the nape 16 and nape tensioner 10, generally designated 116 and 110. respectively. The nape 116 and nape tensioner 110 are similar to the first embodiment of the nape 16 and nape tensioner 10 except, for example, the nape tensioner 110 is configured to anchor a plurality of cables 114 (e.g., cable 114a and cable 114b) therein, as described in more detail below. Nape tensioner 110 may be configured to receive two cables 114. In some embodiments, nape tensioner 110 may be configured to receive two cables 114, three cables, 114. four cables, 114, five cables 114. or six cables 114 in crimp receiver 157, as described in more detail below.

[0059] Referring to Figs. 10, 12, 17 and 21, the nape 116 may be coupled to an impact pad 160 to couple a portion of the nape 116 relative to the safety helmet 12. In some embodiments, the nape 116 is removably coupled to the impact pad 160. A nape tab 164 extending from the nape 116 may extend through the impact pad 160 and engage a pad protrusion 168 of the impact pad 160 to couple the nape tab 164 thereto. The nape tab 164 may be disposed through the impact pad 160 from an interior side and extend through to an exterior side. The nape 116 may be shaped to allow the nape tab 164 to flushly engage the exterior side of impact pad 160 while the nape 116 flushly engages the interior side of the impact pad 160. Referring to Figs. 17 and 21, the interior side of the impact pad may have a recessed portion sized and shaped to receive the nape 1 16 and ensure the head-facing surfaces are flush. A comfort pad or other padding may be removably coupled to the flush surface of the nape 116 and impact pad 160. Referring to Figs. 17 and 21, the flush surface of the nape 116 and the impact pad 160 may include adhesive patches 172 coupled thereto. The adhesive patches 172 may be configured to couple a comfort pad or other padding to the flush surface. The adhesive patches 172 may include hook-and-loop or other acceptable forms of removable coupling.

[0060] Referring to Figs. 12 and 18, the impact pad 160 may include a pad protrusion 168 extending therefrom. The pad protrusion 168 may be a generally rectangular shape and may be raised from a pad recess 175 extending around the pad protrusion 168. The pad recess 175 may be a generally rectangular shape. The pad recess 175 may be shaped and sized to receive the nape tab 164. In some embodiments, the pad protrusion 168 is a rounded shape. The pad protrusion 168 may be received in a nape tab aperture 170 extending through the nape tab 164. The pad protrusion 168 and the nape tab aperture 170 may be sized and shaped to engage each other. In some embodiments, the nape 116 is coupled to the impact pad 160 prior to the impact pad 160 being coupled to the safety helmet 12. The impact pad 160 may include a lower extension 177 extending from a lower end thereof. As shown in Fig. 18, the impact pad 160 may include two lower extensions 177. The space between the two lower extensions 177 may be a generally triangular shape. The lower extensions 177 may have a recess (Figs. 10 and 12) shaped and sized to receive at least a portion of the nape 116. The nape 116 may be prevented from moving backward relative to the user's head by the lower extensions, but the nape 116 may be freely movable toward the user's head.

[0061] Referring to Fig. 13, the nape tensioner 110 may include a cable housing 136 surrounding a cable reel 140, similar to the components described above. The cable reel 140, however, may include reel extension 156 including one or more crimp receiver 157. The crimp receiver 157 may be an aperture extending through the cable reel 140. The crimp receiver 157 may be shaped and sized to receive the first crimp 1 15a of the cable 114. The crimp receiver 157 may couple the first end of the cable 114 to the cable reel 140. Referring to Fig. 13, the cable reel 140 may include more than one crimp receivers 157. In some embodiments, the cable reel 140 includes two crimp receivers 157, three crimp receivers 157, four crimp receivers 157, five crimp receivers 157 or six crimp receivers 157. The first end of the cables (e.g., 114a and 114b) being coupled to the cable reel 140 ensures equal adjustment of all cables 114 coupled thereto. Rotation of the cable reel 140 may cause the cable 114 to wrap around the spool 148 (not shown) of the cable reel 140, as described above in connection with spool 48. [0062] Referring to Figs. 11-12 the nape 116 may further comprise a strap mount 124 extending therefrom. As shown in Fig. I I . the strap mount 124 may receive one or more webbing 129 (e.g., a strap, cable, tether, or other material) as part of the chin strap. The area of the nape 116 below the strap mount 124 may include an opening 125 extending therethrough. The strap mount 124 may be a bridge extending over the opening 125 and may be coupled to the nape 116 on either side of the opening 125. The opening 125 may allow for ventilation to a user’s neck during use. The strap mount 124 may be spaced from the plane of the opening 125. In one embodiment, offsetting the strap mount 124 from the opening 125 helps with accommodating the webbing 129 and/or ring 131. The strap mount 124 may have a non-uniform width along its length to accommodate the webbing 129. For example, a first end of the strap mount 124 may be wider than the second end. One end of the strap mount 124 being wider than the other may promote engagement betw een the webbing 129 and the strap mount 124 and prevent the w ebbing 129 disposed thereon from bunching. The nonuniform width of the strap mount 124 may route the webbing 129 toward a destination, such as the chin for the chin strap. In some embodiments, the strap mount 124 may be sized to allow' one or more webbing 129 to pass thereunder.

[0063] As shown in Fig. 11, w'ebbing 129 may include a ring 131 connecting one or more portions of the webbing 129. The ring 131 in Fig. 11 may not be properly illustrated. The location of ring 131 may be accurate but the structure may not be. The ring 131 may adjust a length of the webbing 129. The strap mount 124 and opening 125 may be shaped and sized to allow the ring 131 to pass through. In one embodiment, allowing the ring 131 to pass through the strap mount 124 may allow the ring 131 and/or webbing 129 to be removable from the nape 116. In one embodiment, allowing a retention strap and webbing 129 to be removeable from the nape 116 allows for components to be more easily removed. For example, the chin straps may be replaced without having to remove the nape 116 from the safety helmet 12. The strap mount 124 may receive and route sections of a w ebbing retention system (e.g., chin strap). The strap mount 124 may be removably coupled to the nape 116.

[0064] An electrical cable runner 127, as shown in Fig. 20. may be used for the routing of data, power or other electrical cables 179 around a rear end of the safety helmet 12 away from a user’s ears. The electrical cable runner 127 may be me coupled to a cable retainer 163 (described in more detail below) on or proximate a bottom edge thereof. The electric cable runner 127 may be a generally cylindrical member along its length with an opening defined along its length to enable an electrical cable 179 to pass therethrough. The electric cable runner 127 may have a diameter smaller than that of the electrical cable 179 and may flex outwardly when the electrical cable 179 is passed therethrough. The electric cable 179 may be friction fit within the electric cable runner 127. The cable electric cable runner 127 may be coupled to the cable retainer 163 at the cable latch 133 of the cable retainer 163. The cable latch 133 may be an elongate member coupled to and spaced apart from the cable retainer 163. The cable latch 133 may be shaped and sized to receive the electric cable runner 127 therethrough to secure the electrical cable 179 to the cable retainer 163.

[0065] The strap mount 124 may include a cable runner 126 proximate a lower end thereof. The strap mount 124 and the cable runner 126 may be separate components. In some embodiments, the strap mount 124 and the cable runner 126 are integrally formed. The cable runner 126 and electrical cable runner 127 may route the respective cable to an interior or an exterior of the safety helmet 12 to reach the required destination.

[0066] To manage the locations and movement of the cable 114, one or more cable runner 126 may be included between the nape tensioner 110 and the anchor 28. The one or more cable runner 126 may be coupled to the safety⁷ helmet 12, the impact pad 160, or another component that is coupled to the safety helmet 12. Referring to Fig. 20, the electrical cable runner 127 may be an adjustable sleeve that is movable between an open position and a closed position. In some embodiments, the electrical cable runner 127 may be a snap-fastener, a button, a magnetic fastener, a buckle, a strap, a hook-and-eye fastener, or other acceptable fastener moveable between an open position and a closed position to receive and retain an electrical cable 179 therein. The electrical cable runner 127 may receive the electrical cable 179 in the open position and may retain the electrical cable 179 in the closed position. The electrical cable runner 127 can be opened and closed repeatedly, unlike using zip ties to secure the electrical cable 179, for example. In some embodiments, the cable runner 126 is generally tubular. The cable runner 126 may be shaped and sized to create friction between the cable runner 126 and the cable 114. The cable runner 126 on the strap mount 124 proximate the nape tensioner 110 may route the cable 114 between the cable runner 126 and the nape tensioner 110 to ensure the cable 114 is spaced from and does not interfere with the webbing 129 or other accessories of the safety helmet 12. The tension created by the cable runner 126 may be adjustable. For example, a circumference or diameter of the cable runner 126 may be adjusted by a user to increase or decrease the tension on the cable 114.

[0067] To allow the nape 116 to pivot relative to the safety helmet 12 or the impact pad 160, the cable 114 must be coupled to a location forward of the nape tensioner 110 relative to the safety helmet 12. Referring to Figs. 14 and 21, the cable 114 may be anchored to an anchor 28 located on a cable retainer 163 bonded, or otherwise coupled, to the inner surface of the safety helmet 12. The anchor may be a hook or protrusion shaped to prevent the cable 1 14 from dislodging therefrom. The cable retainer 163 may extend around a portion of the inner surface of the safety helmet 12. The cable retainer 163 may be include a fastener receiver 165 extending therethrough. The fastener receiver 165 may be shaped and sized to receive a fastener 167 extending from the inner surface of the safety helmet 12. Referring to Fig. 14, the fastener receiver 165 may include more than one fastener receiver 165 to accommodate various sized helmets. For example, as shown in Fig. 19, a fastener receiver 165 located closest to the anchor 28 may accommodate a larger safety helmet 12 (e.g., XXL) than the fastener receiver 165 located furthest from the anchor 28 (e.g., M).

[0068] Referring to Figs. 14 and 19, indicia 173 may be included on the cable retainer 163 proximate each of the one or more fastener receiver 1 5 denoting the size of helmet that each fastener receiver 165 corresponds to. Including more than one fastener receiver 165 may allow' for the cable retainer 163 to accommodate two or more helmet sizes. In some embodiments, cable retainer 163 can accommodate helmet sizes small (S) through extra-extra-large (XXL) (e.g., one size fits all). Referring to Fig. 19, the cable retainer 163 may include a cable lead 169 located proximate the anchor 28. The cable lead 169 may extend from the cable retainer 163 and may be shaped and sized to receive the cable 114 therein. The cable lead 169 may act to prevent the cable 114 from moving proximate the anchor 28 during use to reduce the occurrence of the cable 114 dislodging from the anchor 28. The cable lead 169 may have a generally cylindrical shape with an opening along its length to allow' the cable 114 to pass therethrough. The cable retainer 163 may include one or more cable runner 126 or electric cable runner 127 coupled thereto to route cables away from a user’s ears and head.

[0069] The cable 1 14, as shown in Fig. 15, may be secured by at least one crimp 115. In some embodiments, the cable 114 is secured by two crimps (e.g., crimp 115a and crimp 115b). A first crimp 115a may be coupled to a first end of the cable 114. The first crimp 115a may have a larger cross-section than the cable 114, thereby creating a larger engagement surface for the nape tensioner 110 to engage. As described in more detail below, the first crimp 115a may be anchored to the nape tensioner 110. A second crimp 1 15b may be coupled to a second end of the cable 114. The second crimp 115b may create a loop 117 of cable 114 extending therefrom. Loop 117 may be shaped and sized to be received in an anchor 28 located on or proximate the safety helmet 12. [0070] To avoid confusion as to the direction a user must rotate the dial 130 to tighten or loosen the nape 116, each direction may perform a single adjustment function. Referring to Fig. 16, the cable housing 136 may include a rotation restrictor 161. The rotation restrictor 161 may be a protrusion extending radially inward from the cable housing 136. In some embodiments, more than one rotation restrictor 161 may be included in the cable housing 136. The rotation restrictor 161 may engage a reel block 162 of the cable reel 140 to prevent the cable reel 140 from rotating relative to the cable housing 136 beyond a predetermined rotation threshold. In some embodiments, the predetermined rotation threshold is less than 360°. In some embodiments, the predetermined rotation threshold is less than 320°, less than 300°, less than 280°, less than 260°, less than 240°, less than 220°. less than 200°. less than 180°. less than 160°. less than 140°. less than 120°, or less than 100°. The rotation restrictor 161 may prevent the nape tensioner 110 from being rotated in a first direction to a fully loosened state, and continuing rotation in the first direction to tighten the nape 116. The rotation restrictor 161 may ensure that rotation in a first direction tightens the cable 114 and rotation in a second direction loosens the cable 114.

[0071] The term '‘about” or “approximately” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number, which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number. It should be appreciated that all numerical values and ranges disclosed herein are approximate values and ranges, whether “about” is used in conjunction therewith. It should also be appreciated that the term “about,” as used herein, in conjunction with a numeral refers to a value that may be ±0.01% (inclusive), ±0.1% (inclusive), ±0.5% (inclusive), ±1% (inclusive) of that numeral, ±2% (inclusive) of that numeral, ±3% (inclusive) of that numeral, ±5% (inclusive) of that numeral, ±10% (inclusive) of that numeral, or ±15% (inclusive) of that numeral. It should further be appreciated that when a numerical range is disclosed herein, any numerical value falling within the range is also specifically disclosed.

[0072] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. [0073] Specific features of the exemplary' embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may’ be combined. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. Finally, unless specifically set forth herein, a disclosed or claimed method should not be limited to the performance of their steps in the order w ritten, and one skilled in the art can readily appreciate that the steps may be performed in any practical order.

Claims

CLAIMS What is claimed is:

1. A safety helmet adjustment mechanism comprising: a safety helmet comprising an inner surface; a nape coupled to the inner surface of the safety helmet; and a nape tensioner disposed within the nape, the nape tensioner comprising a cable and coupled to the safety helmet with the cable, wherein the cable extends from the nape tensioner, wherein the nape tensioner comprises: a housing coupled to the nape; a cable reel rotatably coupled to the housing, the cable reel engaging the cable; a dial coupled to the cable reel; and a spring disposed within the housing, wherein the spring prevents rotation of the cable reel relative to the housing in an expanded configuration, and wherein rotation of the dial constricts the spring, thereby allowing rotation of the cable reel relative to the housing.

2. The safety helmet adjustment mechanism of claim 1, wherein the nape tensioner further comprises: a first cable extending from a first side and a second cable extending from a second side thereof.

3. The safety helmet adjustment mechanism of claim 2, wherein the first cable is coupled to a first side and the second cable is coupled to a second side of the inner surface of the safety helmet.

4. The safety helmet adjustment mechanism of claim 1, wherein the nape is coupled to an impact pad coupled to the inner surface of the safety helmet.

5. The safety helmet adjustment mechanism of claim 1, wherein the nape tensioner further comprises: a rotation restrictor extending radially inward from the housing and engageable with a reel block of the cable reel.

6. The safety helmet adjustment mechanism of claim 5, wherein the rotation restrictor prevents the cable reel from turning more than 360° relative to the housing.

7. The safety helmet adjustment mechanism of claim 1, wherein the cable is coupled to a cable retainer coupled to the inner surface of the safety helmet.

8. The safety helmet adjustment mechanism of claim 1 further comprising: a screw, wherein the housing, the cable reel and the dial are coupled by the screw, and wherein the nape tensioner is coupled to the nape by the screw.

9. The safety helmet adjustment mechanism of claim 1, wherein the cable wraps around a spool of the cable reel when the dial is rotated.

10. The safety helmet adjustment mechanism of claim 9, wherein rotation of the dial in a first direction tightens the nape relative to the safety helmet, and wherein rotation of the dial in a second direction loosens the nape relative to the safety helmet.

11. The safety helmet adjustment mechanism of claim 1 , wherein the nape comprises a nape tab extending therefrom, the nape tab couplable to an impact pad.

12. The safety helmet adjustment mechanism of claim 1 1. wherein the impact pad comprises a pad protrusion configured to be received by a nape tab aperture of the nape tab to couple the nape relative to the impact pad.

13. The safety helmet adjustment mechanism of claim 12. wherein the impact pad is flush relative to the impact pad when the pad protrusion is received by the nape tab aperture.

14. The safety helmet adjustment mechanism of claim 1, wherein the cable reel further comprises a reel extension configured to engage the spring during rotation of the dial.

15. The safety helmet adjustment mechanism of claim 14, wherein the reel extension moves the spring from the expanded configuration to a constricted configuration during rotation of the dial.

16. The safety helmet adjustment mechanism of claim 15. wherein the spring moves from the constricted configuration to the expanded configuration when the dial is idle.

17. A safety helmet adjustment mechanism comprising: a safety helmet comprising an inner surface; a nape coupled to the inner surface of the safety helmet; and a nape tensioner disposed within the nape, the nape tensioner comprising: a first cable extending from a first side and a second cable extending from a second side, a housing coupled to the nape; a cable reel rotatably coupled to the housing, the cable reel engaging the first cable and the second cable; a dial coupled to the cable reel; a spring disposed within the housing; and a rotation restrictor extending radially inward from the housing and engageable with a reel block of the cable reel wherein the spring prevents rotation of the cable reel relative to the housing in an expanded configuration, wherein rotation of the dial constricts the spring, thereby allowing rotation of the cable reel relative to the housing, wherein the first cable and the second cable extend from the nape tensioner, and wherein the first cable is coupled to a first side and the second cable is coupled to a second side of the inner surface of the safetv helmet.