Helmet rail with line management

Abstract

A mounting rail couplable with an outer surface of a safety helmet is disclosed. The mounting rail includes a body extending around an ear of a user wearing the safety helmet, an interior surface that mounts to the outer surface of the safety helmet and has a curvature corresponding to a curvature of the outer surface of the safety helmet, and an exterior surface that faces away from the safety helmet. The interior surface includes a channel that retains a line between the mounting rail and the safety helmet.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 480,077 filed Jan. 16, 2023 entitled “Mounting Rail With Cable Management”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present disclosure generally relates to safety helmet mounting rails and, in particular, to a safety helmet mounting rail that may receive and position one or more lines or cables relative to the safety helmet.SUMMARY

[0003] In certain embodiments, a mounting rail couplable with an outer surface of a safety helmet is disclosed. In certain embodiments, the mounting rail comprising a body configured to extend around an ear of a user wearing the safety helmet; an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; and an exterior surface facing away from the safety helmet. In certain embodiments, the interior surface comprises a channel configured to retain a line between the mounting rail and the safety helmet.

[0004] In certain embodiments, the body of the mounting rail comprises at least one entrance aperture proximate a front end and at least one exit aperture proximate a rear end opposite the front end of the body. In certain embodiments, the mounting rail further comprising the line, wherein the line is a power and / or data cable. In certain embodiments, the line enters the mounting rail at one of the at least one entrance apertures, and the line exits the mounting rail at one of the at least one exit aperture. In certain embodiments, the channel defines a groove sized and shaped to receive the line.

[0005] In certain embodiments, the mounting rail further comprising a depression defined on a front portion of the exterior surface of the mounting rail; and an adaptor, the adaptor comprising an adaptor aperture extending therethrough. In certain embodiments, the depression is sized to receive at least a portion of the adaptor, and a fastener extends through the adaptor aperture and the mounting rail, thereby coupling the adaptor to the mounting rail and preventing the adaptor from rotating relative to the mounting rail.

[0006] In certain embodiments, the mounting rail further comprising: a rail accessory including a clip configured to releasably coupled to a slot in the mounting rail. In certain embodiments, the clip is configured to couple a line to the outer surface of the safety helmet. In certain embodiments, the channel comprises a groove defined therein, the groove configured to receive the line. In certain embodiments, the mounting rail further comprising a replacement fastener disposed in the interior surface of the mounting rail.

[0007] In certain embodiments, a safety helmet system is disclosed. In certain embodiments, the safety helmet system comprising: a safety helmet comprising an outer surface; and a mounting rail couplable with the outer surface of the safety helmet. In certain embodiments, the mounting rail comprising: a body configured to extend around an ear of a user wearing the safety helmet; an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; and an exterior surface facing away from the safety helmet. In certain embodiments, the interior surface comprises a channel configured to retain a line between the mounting rail and the safety helmet.

[0008] In certain embodiments, the safety helmet does not include any apertures extending therethrough. In certain embodiments, a shim is coupled to the outer surface of the safety helmet using an adhesive and wherein the shim comprises at least one threaded aperture, and

[0009] wherein the mounting rail is coupled to the shim using at least one shim fastener. In certain embodiments, the safety helmet system further comprising: a wing proximate a front end of the safety helmet extending from an edge band of the safety helmet.

[0010] In certain embodiments, the body of the mounting rail comprises at least one entrance aperture proximate a front end and at least one exit aperture proximate a rear end opposite the front end of the body. In certain embodiments, the safety helmet system further comprising: the line, wherein the line is a power and / or data cable. In certain embodiments, the line enters the mounting rail at one of the at least one entrance apertures and wherein the line exits the mounting rail at one of the at least one exit apertures. In certain embodiments, the channel defines a groove sized and shaped to receive the line.

[0011] In certain embodiments, the safety helmet system further comprising: a depression defined on a front portion of the exterior surface of the mounting rail; and an adaptor, the adaptor comprising an adaptor aperture extending therethrough. In certain embodiments, the depression is sized to receive at least a portion of the adaptor. In certain embodiments, a fastener extends through the adaptor aperture and the mounting rail, thereby coupling the adaptor to the mounting rail and preventing the adaptor from rotating relative to the mounting rail.

[0012] In certain embodiments, the safety helmet system further comprising: a rail accessory, the rail accessory including a clip configured to releasably couple to a slot in the mounting rail. In certain embodiments, the clip is configured to couple a line to the outer surface of the safety helmet.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The following detailed description of embodiments of the helmet rail with line management, will be better understood when read in conjunction with the appended drawings of an exemplary embodiment. 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 side view of a mounting rail coupled to a safety helmet in accordance with an exemplary embodiment of the present invention;

[0016] FIG. 2 is an exterior side view of the mounting rail of FIG. 1;

[0017] FIG. 3 is an interior side view of the mounting rail of FIG. 1;

[0018] FIG. 4 is a top exterior view of the mounting rail of FIG. 1;

[0019] FIG. 5 is a bottom interior view of the mounting rail of FIG. 1;

[0020] FIG. 6 is a front exterior perspective view of the mounting rail of FIG. 1;

[0021] FIG. 7 is a rear exterior perspective view of the mounting rail of FIG. 1;

[0022] FIG. 8 is an exterior perspective view of a clip that may be used with the mounting rail shown in FIG. 1;

[0023] FIG. 9 is an interior perspective view of the clip of FIG. 8;

[0024] FIG. 10 is a front perspective view of the safety helmet of FIG. 1 shown with the clip of FIG. 8 shown with the NVG, cable, and battery pack removed;

[0025] FIG. 11 is a side view the safety helmet of FIG. 1 shown with the rail and shroud mounts removed;

[0026] FIG. 12A is an interior side view of the mounting rail of FIG. 1 showing a first exemplary line routing position;

[0027] FIG. 12B is an interior side view of the mounting rail of FIG. 1 showing a second exemplary line routing position; and

[0028] FIG. 12C is an interior side view of the mounting rail of FIG. 1 showing a third exemplary line routing position.DETAILED DESCRIPTION

[0029] Helmets for head protection are worn in a variety of environments and for various purposes. Different accessories may be added to the helmet according to the needs of the wearer and the demands of the use environment. Powered accessories, such as Night Vison Goggles (NVGs), lights, and communication headsets that attach to existing helmets, often include a cable or line connecting such accessories to a power supply and / or data communication module located toward the back of the helmet.

[0030] While the increase in the number of accessories and mounting positions has improved the functionality of helmet systems, managing, and controlling the accessory cables has become increasingly challenging. Existing helmet systems may have stand-alone accessories connected to their own power source with lines. In some embodiments, the helmet mounting rail described herein includes line management features allowing one or more lines to be attached relative to, behind, in or on the helmet mounting rail to prevent the line from becoming a snag hazard, impede the attachment or movement of accessories attached to the helmet, and / or reduce the noise of the lines hitting against the helmet during use in the field. The helmet mounting rail described herein may include a channel and / or routing accessories thereby allowing one or more lines to be disposed behind the helmet mounting rail, between the helmet mounting rail and the helmet. The line 28 may be any of a power cable, a data cable, a ribbon cable, a coaxial cable, a twisted pair cable, a connection circuit, a flex printed circuit board (PCB), a conduit for electricity and data, a bungee cord, a rope, a string, a cord, a mechanical cable, an end of a fabric helmet cover with piping, an end of a fabric helmet cover without piping, piping for carrying a fluid, tubing for hydraulic or pneumatic systems, or one or more wires, with varying thickness depending on the power supply and / or data communication module that the accessory is connected to.

[0031] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in FIGS. 1-12C a mounting rail, generally designated 10, in accordance with an exemplary embodiment of the present invention.

[0032] With reference to FIGS. 1-3, a mounting rail 10 couplable with an outer surface of a safety helmet 12 is shown. The safety helmet 12 may be any type of head protection helmet known in the art, for example, those used for sporting, industrial safety, police, or military purposes. In one embodiment, safety helmet 12 is a standard infantry ballistic helmet. In one embodiment, safety helmet 12 is 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), a high cut tactical helmet such as the FAST SF helmet, or an aircrew helmet, such as an HGU-56 / P rotary wing helmet or an HGU-55 / P fixed wing helmet. In one embodiment, safety helmet 12 is a type I, II, and class E, G, or C hard hat. In some embodiments, the helmet 12 is formed of a substrate generally made of a fiber / resin-based ballistic material. It can be rigid, flexible, or partly rigid and partly flexible. In some embodiments, the substrate or a portion of the substrate is made of a material including ultra-high molecular weight polyethylene (UHMWPE), poly-p-phenylene terephthalamide, aramid, or the like, or any combination thereof. The substrate can be of a single layer or a stack or layup of a composite structure including a plurality of layers / plies of one or more materials. For instance, in an embodiment, the substrate includes a single UHMWPE ply.

[0033] Mounting rail systems that are secured, securable to, or integral with the outer shell of a safety helmet to facilitate convenient positional adjustment, attachment and removal of multiple accessories is described in depth, for example, in U.S. Pat. No. 7,849,517, the entire disclosure of which is hereby incorporated by reference. The mounting rail 10 may be preferably fabricated from at least one of nylon, polypropylene, or other synthetic plastic using injection molding processes. A body 14 of the mounting rail 10, when coupled to the helmet, may extend around an ear of a user wearing the safety helmet 12. The body 14 may be shaped and sized such that a bottom edge of the mounting rail 10 may follow and be spaced just about a bottom edge of the safety helmet 12. A bottom edge of the body 14 may be shaped such that the bottom edge of the body 14 is aligned with a bottom edge of the safety helmet 12. Referring to FIG. 1, the mounting rail 10 may be coupled to the outer surface of the safety helmet 12 using a fastener 20 sized to extend through the safety helmet 12. As shown in FIG. 2, the mounting rail 10 may include a front fastener aperture 22a and a rear fastener aperture 22b, each a fastener aperture 22. Each of the fastener apertures 22 may be sized and shaped to allow a fastener 20 to pass therethrough. In one embodiment, the mounting rail 10 is secured to the safety helmet 12 by a snap fit fastener, hook-and-loop fasteners, magnets, or other releasable fasteners. In one embodiment, the mounting rail 10 extends between the two pre-existing retention strap holes on each side of the safety helmet 12. In some embodiments, the mounting rail 10 is secured to a boltless helmet using fasteners that are mounted to the outer surface of the safety helmet 12 as described in further detail below. In some embodiments, the mounting rail 10 is secured to the safety helmet 12 by a single fastener.

[0034] As shown in FIGS. 3 and 5, the mounting rail 10 may comprise an interior surface 16 configured to mount to the outer surface of the safety helmet 12. The interior surface 16 may have a curvature corresponding to a curvature of the outer surface of the safety helmet 12. The interior surface 16 may be substantially flush with the outer surface of the safety helmet 12. In one embodiment, the interior surface 16 is flat.

[0035] The interior surface 16 may include a plurality of ribs 24 protruding therefrom. The ribs 24 may increase the strength and durability of the mounting rail 10 by increasing the cross-sectional area of sections of the mounting rail 10. The ribs 24 may be fabricated from the same material as the mounting rail 10 and may be formed during the injection molding process. In one embodiment, the ribs 24 may be manufactured separately and coupled to the interior surface 16 with an adhesive.

[0036] A line 28 may be disposed and retained between the mounting rail 10 and the safety helmet 12 when the mounting rail 10 is coupled to the safety helmet 12. The interior surface 16 of the mounting rail 10 may further comprise one or more channels 26 configured to retain a line 28 (as shown in FIGS. 12A-12C) between the mounting rail 10 and the safety helmet 12. In some embodiments, the channel 26 houses or conceals the line 28 between the mounting rail 10 and the safety helmet 12. The body 14 of the mounting rail 10 may comprise at least one entrance aperture 30 proximate a front end and at least one exit aperture 32 proximate a rear end opposite the front end of the body 14. In some embodiments, the channel 26 directs the line 28 from the entrance aperture 30 to the exit aperture 32. While one entrance aperture 30 is shown in the figures appended hereto, it should be appreciated that the body 14 of the mounting rail 10 may comprise more than one entrance aperture 30. The line 28 may enter the mounting rail 10 at one of the at least one entrance aperture 30 and may exit the mounting rail 10 at one of the at least one exit aperture 32. Both the entrance aperture 30 and the exit aperture 32 may be generally rounded and located on an edge of the body 14.

[0037] The entrance aperture 30 and the exit aperture 32 may have a width generally the same as the diameter of the line 28. One of the at least one entrance apertures 30 may have a width larger than the line 28. One of the at least one exit apertures 32 may have a width larger than the line 28. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 0.5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 1 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 1.5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 2 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 2.5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 3 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 3.5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 4 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 4.5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 5 mm wide. The at least one entrance aperture 30 and / or the at least one exit apertures 32 may be at least 5.5 mm wide.

[0038] Given the location on the edge of the body 14 of the mounting rail, the entrance aperture 30 and the exit aperture 32 may contact only a portion of the line 28 extending therethrough. As shown in FIG. 1, at least one of the more than one exit apertures 32 may act as an entrance aperture 30. At least one of the more than one entrance apertures 30 may act as an exit aperture 32. Further, the line 28 may exit the mounting rail 10 at more than one of the exit apertures. The exit aperture 32 that the line 28 extends through may depend on a destination of the line 28. For example, if the destination is near the bottom edge of the safety helmet 12 the line 28 may extend through the exit aperture 32 closest to the bottom edge of the safety helmet 12. If the destination in near a top of the safety helmet 12, the line 28 may extend through the exit aperture 32 closest to the top of the safety helmet 12.

[0039] The line 28 may have a cross sectional diameter of 0.5 mm. The line 28 may have a cross sectional diameter of 1 mm. The line 28 may have a cross sectional diameter of 1.5 mm. The line 28 may have a cross sectional diameter of 2 mm. The line 28 may have a cross sectional diameter of 2.5 mm. The line 28 may have a cross sectional diameter of 3 mm. The line 28 may have a cross sectional diameter of 3.5 mm. The line 28 may have a cross sectional diameter of 4 mm. The line 28 may have a cross sectional diameter of 4.5 mm. The line 28 may have a cross sectional diameter of 5 mm. The line 28 may have a cross sectional diameter of 5.5 mm. The line 28 may have a cross sectional diameter of 6 mm. The line 28 may have a cross sectional diameter of 6.5 mm. The line 28 may have a cross sectional diameter of 7 mm.

[0040] The channel 26 may define a groove 34 sized and shaped to receive the line 28. As shown in FIG. 5, the groove 34 may be generally circular shaped. However, in one embodiment, the groove 34 is a non-circular shape (e.g., oval, rectangular, triangular, hexagonal, octagonal, etc.) to accommodate the line 28. The channel 26 may prevent the line 28 from moving relative to the mounting rail 10 when it is disposed therein. The line 28 may be friction fit within the channel 26 such that the line 28 stays within the groove 34 of the channel 26 until and unless a sufficient force acts upon the line 28 to pull it out of the groove 34. As such, the groove 34 may be sized such that a cross section of the line 28 decreases when inserted into the groove 34. The channel 26 may define a predetermined route to ensure the line 28 avoids interference with any feature of the mounting rail 10 or the safety helmet 12. The channel 26 may prevent the line 28 from snagging. The channel 26 may also provide a preferred appearance, concealing line 28. In one embodiment, the channel 26 is configured to retain the line 28 on an exterior surface 18 of the mounting rail 10.

[0041] As shown in FIGS. 12A-12C, the channel 26 may utilize any of the exit apertures 32 to direct the line 28 out of the mounting rail in order to provide a defined path between the power supply and / or data communication module that the rail accessory 40 is connected to. For example, as shown in FIG. 12A, if the power supply and / or data communication module that the rail accessory 40 is connected to is proximate a top of the mounting rail 10, an exit aperture 32 at the top of the mounting rail 10 may direct the line 28 out of the mounting rail 10. As shown in FIG. 12B, if the power supply and / or data communication module that the rail accessory 40 is connected to is proximate a middle of the mounting rail 10, an exit aperture 32 at the middle of the mounting rail 10 may direct the line 28 out of the mounting rail 10. Further, as shown in FIG. 12C, if the power supply and / or data communication module that the rail accessory 40 is connected to is proximate a bottom of the mounting rail 10, an exit aperture 32 at the bottom of the mounting rail 10 may direct the line 28 out of the mounting rail 10. In some embodiments, the channel 26 may utilize the exit apertures 32 to direct the line 28 out of the mounting rail in order to provide the shortest distance between the power supply and / or data communication module that the rail accessory 40 is connected to. In some embodiments, the line 28 may extend between the entrance aperture 30 and the exit aperture 32 without a defined path. Also, as shown, there may be more than one defined path. The channel 26 may be fully defined (e.g. a continuous groove) or partially defined (e.g., groove segments, walls, and / or ribs that direct the line 28 and hold it in place relative to the mounting rail 10.

[0042] Referring to FIGS. 2 and 4, the mounting rail 10 may comprise an exterior surface 18 facing away from the safety helmet. The exterior surface 18 may further comprise a recessed groove 44 that slideably accepts a complementary engagement member of a potential accessory, which may be secured by tightening a securing member (e.g., a standard screw, or a thumbscrew, tab-and-slot system, or other suitable engagement mechanism). The exterior surface 18 may have a plurality of holes extending therethrough depending on the intended function. For example, holes 46 may extend through the body 14 of the mounting rail 10. The holes 46 may be configured to receive a zip tie or other fastener to attach an object to the mounting rail 10. Every second hole 46 may extend through the body 14 of the mounting rail 10. In one embodiment, every hole 46 extends through the body 14 of the mounting rail 10. In one embodiment, a user selects which holes 46 will extend through the body 14 of the mounting rail 10.

[0043] Further, the exterior surface 18 may include any number of slots extending therethrough. An accessory may be inserted into an accessory slot 36 of the mounting rail 10 thereby coupling the accessory to the mounting rail 10. The accessory slot 36 may be located proximate the edge of the body 14. In one embodiment, the accessory slot 36 may be located in a central portion of the body 14. A rail accessory 40 may be received by an accessory slot 36 on a top or a bottom of the body 14. As shown in FIG. 3, the interior surface 16 may include an accessory receiver 38 sized and shaped to receive a coupling arm 42 (as seen in FIGS. 8 and 9) of the rail accessory 40. The channel 26 may route the line 28 such that the line 28 does not block or interfere with function of the accessory receiver 38. For example, the channel 26 may route the line 28 above, below, in front of, behind or around the accessory receiver 38 to allow a rail accessory 40 be inserted therein while a line 28 is disposed in the channel 26. The rail accessory 40 may include, for example but is not limited to, a mandible shield, a ballistic panel or applique, a visor, a goggle, a communication system, a retention system including a chin strap, a light, a camera, a helmet cover, a battery, and / or a gas supply mask.

[0044] In certain instances, the line28 or an additional line may need to be routed alongside or outside the mounting rail 10. For example, a rail accessory 40 may need to be added to the mounting rail 10 or swapped out for another rail accessory 40 in the field. In this case, it may not be practical to remove the mounting rail 10 to release the line 28 from the channel 26. Referring to FIGS. 8 and 9, the rail accessory 40 may be a clip 60 configured to releasably couple to a slot in the mounting rail 10. The clip 60 may comprise a coupling arm 42 configured to be inserted into an accessory slot of the mounting rail 10 (as shown in FIG. 10). The clip 60, when coupled to the mounting rail 10, may extend in a generally horizonal direction on both sides relative to the coupling arm 42. At an end of each extension, the clip 60 may include a clasp 62 configured to receive the line 28. The clip 60 may be used in conjunction with the channel 26, in the case of multiple lines 28 needing to be managed. In one embodiment, the clip 60 is used in place of the channel 26 to subvert the need to remove the mounting rail 10 to replace the line 28. In one embodiment, the clip 60 accommodates more than one line 28.

[0045] The clip 60 may be sized such that a clearance is provided to other rail accessories 40. For example, a rail accessory 40 coupled to the mounting rail 10 using the recessed groove 44 (e.g., tactical hearing protection) may extend above the mounting rail 10 without interacting with the clip 60. Further, the clip 60 may be configured to couple the line 28 to the outer surface of the safety helmet 12. The clasp 62 may be sized such that there is no gap between the outer surface of the safety helmet 12 and the clasp 62 of the clip 60. The clasp 62 may be generally arcuate or C-shaped. However, in one embodiment, the clasp 62 is a non-arcuate shape (e.g., rectangular, triangular, hexagonal, octagonal, etc.) to accommodate the line 28.

[0046] To provide additional protection against impact, safety helmets 12 without any apertures extending therethrough are becoming more common and preferential in the field. However, previous mounting rails relied on the apertures used to anchor the straps and inner padding couple the mounting rail to the safety helmet 12. As such, in some embodiments, the mounting rails are coupled to the safety helmet 12 without fasters extending through an aperture of the helmet.

[0047] Referring now to FIGS. 1 and 10-11, in some embodiments, the safety helmet 12 is boltless, meaning the helmet 12 does not include any apertures extending therethrough. The boltless safety helmet 12 may provide heightened protection for the user by removing any apertures that may compromise the structural integrity of the safety helmet 12. A shim 50 may be provided to allow components, such as the mounting rail 10 or shroud 11, to couple to the safety helmet 12. A shroud shim 13 may be provided to allow a shroud 11 to be coupled to a boltless safety helmet 12. The shim 50 may overlap at least a portion of the edgeband 15 of the safety helmet 12. The edgeband 15 may extend around an edge of the safety helmet 12 to prevent unintended exposure of any sharp edges produced during manufacturing or wear. The edgeband 15 may be formed of a rubber or deformable plastic. The shim 50 may define a space 17 between the shim 50 and the edgeband 15 on the outer surface of the safety helmet 12. The mounting rail 10 may cover the space 17 when the mounting rail 10 is coupled to the safety helmet 12. In some embodiments, the mounting rail 10 covers only a portion of the space 17 when the mounting rail 10 is coupled to the safety helmet 12. In one embodiment, the shim 50 is coupled to the outer surface of the safety helmet 12 using an adhesive. The adhesive may be a two-component urethane or polyurethane structural adhesive. The adhesive may have a chemical composition of isocyanate prepolymer and polyol curative with a 1:1 ration. In one embodiment, the adhesive is any of a methacrylate, glue, epoxy, or liquid cement.

[0048] The shim 50 may be shaped and sized to fit beneath the mounting rail 10 when the mounting rail 10 is coupled thereto. The shim 50 may have a thickness of approximately 0.125 mm. The shim 50 may have a thickness of approximately 0.5 mm. The shim 50 may have a thickness of approximately 1 mm. The shim 50 may have a thickness of approximately 1.5 mm. The shim 50 may have a thickness of approximately 2 mm. The shim 50 may have a thickness of approximately 2.5 mm. The shim 50 may have a thickness of approximately 3 mm. The shim 50 may have a thickness of approximately 3.5 mm. The shim 50 may have a thickness of approximately 4 mm. The shim 50 may have a thickness of approximately 4.5 mm. The shim 50 may have a thickness of approximately 5 mm. The shim 50 may have a thickness of approximately 5.5 mm. The shim 50 may have a thickness of approximately 6 mm. The shim 50 may have a thickness of approximately 6.5 mm. The shim 50 may have a thickness of approximately 7 mm. The shim 50 may have a thickness of approximately 7.5 mm. The shim 50 may have a thickness of approximately 8 mm. The shim 50 may have a thickness of approximately 8.5 mm. The shim 50 may have a thickness of approximately 9 mm. The shim 50 may have a thickness of approximately 9.5 mm. The shim 50 may have a thickness of approximately 10 mm. The shim 50 may have a thickness of approximately 10.5 mm. The shim 50 may have a thickness of approximately 11 mm.

[0049] Referring to FIG. 11, the shim 50 may comprise at least one threaded aperture 52 extending therethrough. The shim 50 may include one threaded aperture 52 on a front portion and one threaded aperture 52 on a rear portion. In one embodiment, the shim 50 has one threaded aperture 52. In one embodiment, the shim 50 has one or more threaded apertures 52. The shim 50 may include at least one interlocking feature 53 defined thereon. The interlocking feature 53 may be a generally circular feature extending through the shim 50. In some embodiments, the shim 50 includes two interlocking features 53 spaced apart from each other. The interlocking feature 53 may assist with locating the shim 50 during assembly of the safety helmet 12. In some embodiments, the interlocking feature 53 assists with attaching the shim 50 to the edge band 70 of the safety helmet 12.

[0050] Referring to FIG. 10, the mounting rail 10 may be coupled to the shim 50 using at least one shim fastener 54. The shim fastener 54 may be a screw or a bolt. In one embodiment, the shim fastener is one of a snap fit fastener, hook-and-loop fasteners, magnets, or other releasable fasteners. Since the shim fastener 54, in some embodiments, is not coupled to the safety helmet 12 by a nut or other locking mechanism, it is possible for the shim fastener 54 to be lost. To remedy a lost shim fastener 54, the replacement aperture 56 may comprise a replacement shim fastener 45 threadedly coupled to the replacement aperture 56. As shown in FIG. 3, the interior surface 16 of the mounting rail 10 may comprise a replacement aperture 56 extending at least partially therethrough. The replacement aperture 56 may be formed during the injection molding process. In one embodiment, the replacement aperture 56 may be separately manufactured and coupled to the interior surface 16. During the manufacture of the replacement aperture 56, it may not be possible to include threading on an interior surface thereof. As such, the shim fastener 54 may create the thread in the replacement aperture 56 when screwed in. The replacement aperture 56 may be shaped and sized to receive a shim fastener 54, with a generally cylindrical shape. A slight taper may be included in the replacement aperture 56 to promote the creation of the threading therein when the shim fastener 54 is screwed in. The replacement aperture 56 may comprise at least one flat wall, further promoting the creation of the threading therein when the shim fastener 54 is screwed in.

[0051] FIGS. 10 and 11, the safety helmet 12 may comprise a wing 58 extending from an edge band 70 of the safety helmet 12, the wing 58 may be proximate a front end of the safety helmet 12. The wing 58 may extend generally away from the safety helmet 12. In one embodiment, the wing 58 extends from the safety helmet 12 from the shim 50. The wing 58 may be shaped and sized to prevent movement of an accessory relative to the safety helmet 12. For example, the frame of a goggle or visor (e.g., face shields, night vision goggles, and / or a protective visor) may engage the wing 58 to align the visor with the safety helmet 12 and reduce the amount of pressure being exerted on the user's face by the visor. In some embodiments, a traditional bolted helmet may be used instead of a boltless safety helmet (e.g., safety helmet 12).

[0052] Referring to FIGS. 1, 2, 4 and 6, the mounting rail 10 may include an adaptor 68 for attaching the line 28 to an accessory such as an NVG 19 (See FIG. 1). Coupling the adaptor 68 may help to streamline the attachment of the adaptor 68 and prevent the connection from bouncing against the safety helmet 12 and reduces the amount of lose line 28 that is exposed. The adaptor 68 may be configured to cover some or all of the line 28. The adaptor 68 may be configured to cover the line 28 between the mounting rail 10 and a battery pack 21. The line 28 and the battery pack 21 may be coupled at connection 71. Connection 71 may be configured to receive and retain the line 28 to electrically couple the line 28 and the battery pack 21. The connection 71 may be located on a bottom of the battery pack 21. In some embodiments, the connection 71 is on a front, rear, top, side or bottom of the battery pack 21. The adaptor 68 may electrically couple an accessory (e.g., NVG 19) to the power source (e.g., battery pack 21). The adaptor 68 may prevent the line 28 from moving relative to the helmet 12 to prevent snags and distractions during use. As described in more detail below, the adaptor 68 may be configured to accommodate a variety of accessories depending on the specific application required by the user.

[0053] Referring to FIG. 1, the length of line 28 extending between the adaptor 68 and the NVG 19 may be at least partially concealed by a concealer 69 extending from the adaptor 68 to further reduce line 28 exposure. In some embodiments, the concealer 69 extends from the shroud 11. In some embodiments, the length of line 28 extending between the adaptor 68 and the NVG 19 is fully concealed by the concealer 69 to further reduce line 28 exposure. In some embodiments, the length of line 28 extending between the adaptor 68 and the NVG 19 is at least partially concealed by the edge band 70 to further reduce line 28 exposure. In some embodiments, the length of line 28 extending between the adaptor 68 and the NVG 19 is at least partially concealed by the shroud 11 or a feature (e.g., concealer 69) extending from the shroud 11 to further reduce line 28 exposure.

[0054] The mounting rail 10 may include a depression 64 on a front portion thereof. The adaptor 68 may be configured to couple to the depression 64. The depression 64 may extend partially through the body 14 of the mounting rail 10. The walls of the depression 64 may be non-parallel. The depression 64 may be sized and shaped to receive at least a portion of the adaptor 68 (as shown in FIG. 10). The adaptor 68 may comprise an adaptor aperture 66 extending therethrough. The adaptor aperture 66 may align with the front fastener aperture 22a on the mounting rail 10. In one embodiment, the adaptor aperture 66 and the front fastener aperture 22a do not align and separately receive a fastener 20. Referring to FIG. 2, the depression 64 may include a depression recess 65 defined thereon extending into the body 14 of the mounting rail 10. The depression recess 65 may be extend only partially into the body 14 of the mounting rail 10. In some embodiments, the depression recess 65 extends through the body 14 of the mounting rail 10. The depression recess 65 may be shaped and sized to receive an adaptor extension 67 (not shown) extending from the adaptor 68. The engagement of the depression recess 65 and the adaptor extension 67 may prevent rotation of the adaptor 68 relative to the mounting rail 10. The depression recess 65 may have a depth sufficient to receive the adaptor extension 67 and allow the adaptor 68 to sit flush on the depression 64. The fastener 20 may extend through the adaptor aperture 66 and the mounting rail 10, thereby coupling the adaptor 68 to the mounting rail 10 and preventing the adaptor 68 from rotating relative to the mounting rail 10. The adaptor 68 may be a line connector (e.g., 9-Pin Fischer Clip) to electrically connect the line 28 to an accessory. In some embodiments, the adaptor 68 may be a circular connector, a rectangular connector, a multipin connector, a push-pull connector, a modular connector, a coaxial connector, or other acceptable electrical connector to achieve the specific application of the adaptor 68.

[0055] 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.

[0056] 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.

[0057] 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 written, and one skilled in the art can readily appreciate that the steps may be performed in any practical order.

Claims

1. A mounting rail couplable with an outer surface of a safety helmet, the mounting rail comprising:a body configured to extend around an ear of a user wearing the safety helmet;an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; andan exterior surface facing away from the safety helmet,wherein the interior surface comprises a channel configured to retain a line between the mounting rail and the safety helmet.

2. The mounting rail of claim 1, wherein the body of the mounting rail comprises at least one entrance aperture proximate a front end and at least one exit aperture proximate a rear end opposite the front end of the body.

3. The mounting rail of claim 2 further comprising:the line, wherein the line is a power and / or data cable.

4. The mounting rail of claim 3, wherein the line enters the mounting rail at one of the at least one entrance apertures, andwherein the line exits the mounting rail at one of the at least one exit aperture.

5. The mounting rail of claim 3, wherein the channel defines a groove sized and shaped to receive the line.

6. The mounting rail of claim 1, further comprising:a depression defined on a front portion of the exterior surface of the mounting rail; andan adaptor, the adaptor comprising an adaptor aperture extending therethrough,wherein the depression is sized to receive at least a portion of the adaptor, andwherein a fastener extends through the adaptor aperture and the mounting rail, thereby coupling the adaptor to the mounting rail and preventing the adaptor from rotating relative to the mounting rail.

7. The mounting rail of claim 1 further comprising:a rail accessory including a clip configured to releasably coupled to a slot in the mounting rail, andwherein the clip is configured to couple a line to the outer surface of the safety helmet.

8. The mounting rail of claim 1, wherein the channel comprises a groove defined therein, the groove configured to receive the line.

9. The mounting rail of claim 1 further comprising:a replacement fastener disposed in the interior surface of the mounting rail.

10. A mounting rail couplable with an outer surface of a safety helmet, the mounting rail comprising:a body partially extending around an ear of a user wearing the safety helmet;an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; andan exterior surface facing away from the safety helmet,wherein the interior surface comprises a channel configured to retain a line between the mounting rail and the safety helmet,wherein the body of the mounting rail comprises at least one entrance aperture proximate a front end and at least one exit aperture proximate a rear end opposite the front end of the body.

11. A safety helmet system, the safety helmet system comprising:a safety helmet comprising an outer surface; anda mounting rail couplable with the outer surface of the safety helmet, the mounting rail comprising:a body configured to extend around an ear of a user wearing the safety helmet;an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; andan exterior surface facing away from the safety helmet,wherein the interior surface comprises a channel configured to retain a line between the mounting rail and the safety helmet.

12. The safety helmet system of claim 11, wherein the safety helmet does not include any apertures extending therethrough.

13. The safety helmet system of claim 12, wherein a shim is coupled to the outer surface of the safety helmet using an adhesive and wherein the shim comprises at least one threaded aperture, andwherein the mounting rail is coupled to the shim using at least one shim fastener.

14. The safety helmet system of claim 13 further comprising:a wing proximate a front end of the safety helmet extending from an edge band of the safety helmet.

15. The safety helmet system of claim 11, wherein the body of the mounting rail comprises at least one entrance aperture proximate a front end and at least one exit aperture proximate a rear end opposite the front end of the body.

16. The safety helmet system of claim 15 further comprising:the line, wherein the line is a power and / or data cable.

17. The safety helmet system of claim 16, wherein the line enters the mounting rail at one of the at least one entrance apertures and wherein the line exits the mounting rail at one of the at least one exit apertures.

18. The safety helmet system of claim 16, wherein the channel defines a groove sized and shaped to receive the line.

19. The safety helmet system of claim 11, further comprising:a depression defined on a front portion of the exterior surface of the mounting rail; andan adaptor, the adaptor comprising an adaptor aperture extending therethrough,wherein the depression is sized to receive at least a portion of the adaptor,wherein a fastener extends through the adaptor aperture and the mounting rail, thereby coupling the adaptor to the mounting rail and preventing the adaptor from rotating relative to the mounting rail.

20. The safety helmet system of claim 11 further comprising:a rail accessory, the rail accessory including a clip configured to releasably couple to a slot in the mounting rail,wherein the clip is configured to couple a line to the outer surface of the safety helmet.

21. A safety helmet system comprising:a safety helmet comprising an outer surface;a cable configured to transmit data and / or power between accessories mounted to the safety helmet; anda mounting rail coupled to the outer surface, the mounting rail comprising:a body partially extending around an ear of a user wearing the safety helmet;an interior surface configured to mount to the outer surface of the safety helmet and having a curvature corresponding to a curvature of the outer surface of the safety helmet; andan exterior surface facing away from the safety helmet,wherein the interior surface comprises a channel retaining at least a portion of the cable between the mounting rail and the safety helmet,wherein the body of the mounting rail comprises at least one entrance aperture routing the cable into channel proximate a front end and at least one exit aperture routing the cable out of the channel proximate a rear end opposite the front end of the body,wherein the safety helmet does not include any apertures extending therethrough,wherein a shim is coupled to the outer surface of the safety helmet using an adhesive and wherein the shim comprises at least one threaded aperture extending therethrough, andwherein the mounting rail is coupled to the shim using at least one threaded fastener.

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