U.S. patent application number 12/898612 was filed with the patent office on 2012-04-05 for hockey helmet with readily removable earpieces.
Invention is credited to Jean-Francois Beland, Guillaume Belanger.
Application Number | 20120079646 12/898612 |
Document ID | / |
Family ID | 45888548 |
Filed Date | 2012-04-05 |
United States Patent
Application |
20120079646 |
Kind Code |
A1 |
Belanger; Guillaume ; et
al. |
April 5, 2012 |
HOCKEY HELMET WITH READILY REMOVABLE EARPIECES
Abstract
A hockey helmet includes earpieces that are readily removable
from the helmet without the need for tools or other objects, and
without the need to remove screws or other components. The
earpieces may be slidably attached to rails on a retention
mechanism embedded in the foam helmet liner or to rails on the
helmet shell itself. The helmet optionally includes an internal
region of EPP foam fused or bonded between two thin polycarbonate
layers, with the retention mechanism embedded within the EPP
foam.
Inventors: |
Belanger; Guillaume;
(Terrebonne, CA) ; Beland; Jean-Francois;
(Ste-Therese, CA) |
Family ID: |
45888548 |
Appl. No.: |
12/898612 |
Filed: |
October 5, 2010 |
Current U.S.
Class: |
2/425 |
Current CPC
Class: |
A42B 3/16 20130101 |
Class at
Publication: |
2/425 |
International
Class: |
A42B 3/04 20060101
A42B003/04 |
Claims
1. A hockey helmet, comprising: a shell including an outer plastic
layer and an inner foam layer; a retention mechanism embedded in
the foam layer, the retention mechanism including a plurality of
spaced apart rails projecting out of the foam layer; and an
earpiece slidably and removably engaged with the rails.
2. The helmet of claim 1 wherein the outer plastic layer comprises
polycarbonate, and the inner foam layer comprises EPP, wherein the
EPP foam is fused or insert molded with the polycarbonate
layer.
3. The helmet of claim 1 further comprising an inner plastic layer
on an inner surface of the inner foam layer.
4. The helmet of claim 3 wherein the outer and inner plastic layers
comprise polycarbonate, and the inner foam layer comprises EPP,
wherein the EPP foam is fused or insert molded with the outer and
inner polycarbonate layers.
5. The helmet of claim 3 wherein the outer and inner plastic layers
each have a thickness of approximately 0.5 mm.
6. The helmet of claim 1 wherein each rail includes a first
retention feature, and the earpiece includes a corresponding second
retention feature at opposed ends of the earpiece, wherein the
first retention features engage the second retention features to
partially resist sliding movement of the earpiece when the earpiece
is in a fully attached position.
7. The helmet of claim 6 wherein the first retention feature
comprises an opening in the rail, and the second retention feature
comprises a projection from the earpiece that is positioned in the
opening when the earpiece is in the fully attached position.
8. The helmet of claim 1 wherein the retention mechanism further
includes a plurality of threaded fasteners projecting outwardly
from a body of the retention mechanism, wherein the threaded
fasteners are positioned in openings in the helmet shell.
9. The helmet of claim 8 wherein the threaded fasteners comprise a
metal material, wherein each of the threaded fasteners is
over-molded by a plastic projection that is integral with the body
of the retention mechanism.
10. The helmet of claim 9 wherein the body of the retention
mechanism includes a plurality of arms extending from the plastic
projections that aid in resisting rotation of the retention
mechanism when screws are threaded into or out of the
fasteners.
11. The helmet of claim 1 wherein the retention mechanism further
comprises a plurality of ear loop supports including openings
through which ear loops may pass.
12. The helmet of claim 1 wherein the retention mechanism further
comprises an attachment element projecting out of the foam layer
into an interior of the shell, wherein the attachment element is
configured for attachment to a fitting element.
13. A sports helmet, comprising: a shell including an outer plastic
layer and an inner foam layer; a retention mechanism on or in the
shell; and an earpiece engaged with the retention mechanism,
wherein the earpiece is removable by hand from the retention
mechanism without the aid of a tool or the need to remove
components from the helmet.
14. The helmet of claim 13 wherein the shell includes an injection
molded lower region, wherein the retention mechanism is integrally
molded with the lower region.
15. The helmet of claim 13 wherein the retention mechanism is
embedded in the foam layer and includes retention members
projecting out of the foam.
16. The helmet of claim 13 wherein one of the earpiece and the
retention mechanism includes a plurality of rails, and the other of
the earpiece and the retention mechanism includes channels
configured to engage the rails, such that the earpiece is slidable
onto and off of the retention mechanism.
17. The helmet of claim 13 wherein each rail includes a first
retention feature, and each channel includes a corresponding second
retention feature, wherein the first retention features engage the
second retention features to partially resist sliding movement of
the earpiece when the earpiece is in a fully attached position.
18. The helmet of claim 13 further comprising an inner plastic
layer on an inner surface of the inner foam layer.
19. A sports helmet, comprising: a shell; means for retaining an
earpiece on the shell; and an earpiece including means for slidably
engaging the retaining means such that the earpiece may be removed
from the retaining means by sliding it along the retaining means.
Description
BACKGROUND
[0001] Modern hockey helmets typically include a solid, high
density polyethylene shell with internal padding for protecting the
wearer's head. Hockey helmets also generally include a fit system
to aid in properly fitting a helmet on a wearer. For example, many
modern helmets include two-piece shells that are longitudinally
movable relative to each other, and an internal lateral fit system,
for adjusting the fit of the helmet on the wearer's head. An
example of such an adjustable helmet is described in U.S. patent
application Ser. No. 12/191,000, filed Aug. 13, 2008, which is
incorporated herein by reference.
[0002] Hockey helmets also typically include earpieces for
protecting a wearer's ears. In some helmets, these earpieces are
attached to the helmet shell via multiple screws, threaded
fasteners, and other components such that they are removable (in
other helmets, the earpieces are molded as part of the shell and
are not removable). Players commonly remove the earpieces to
improve the overall comfort of the helmet and to improve
communication with other players, coaches, and game officials. To
remove the earpieces, players or trainers first need to remove the
screws and other components. During this process, the screws,
threaded fasteners, or other components frequently fall out of the
helmet or into the helmet itself, making the removal process
cumbersome.
SUMMARY
[0003] A hockey helmet includes earpieces that are readily
removable from the helmet without the need for tools or other
objects, and without the need to remove screws or other components.
Other features and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] In the drawings, wherein the same reference number indicates
the same element throughout the views:
[0005] FIG. 1 is a side-perspective view of a hockey helmet
including removable earpieces.
[0006] FIG. 2 is a bottom-perspective view of the helmet shown in
FIG. 1.
[0007] FIG. 3 is a side-perspective view of the removable earpiece
and earpiece retention mechanism of the helmet shown in FIGS. 1 and
2.
[0008] FIG. 4 is a top-perspective view of the removable earpiece
and earpiece retention mechanism shown in FIG. 3.
[0009] FIG. 5 is a rear-perspective view of the removable earpiece
and earpiece retention mechanism shown in FIGS. 3 and 4.
[0010] FIG. 6 is a rear view of one element of the retention
mechanism shown in FIGS. 3-5.
[0011] FIG. 7 is a side-perspective view of the helmet shown in
FIG. 1 with the earpieces removed.
DETAILED DESCRIPTION
[0012] Various embodiments of the invention will now be described.
The following description provides specific details for a thorough
understanding and enabling description of these embodiments. One
skilled in the art will understand, however, that the invention may
be practiced without many of these details. Additionally, some
well-known structures or functions may not be shown or described in
detail so as to avoid unnecessarily obscuring the relevant
description of the various embodiments.
[0013] The terminology used in the description presented below is
intended to be interpreted in its broadest reasonable manner, even
though it is being used in conjunction with a detailed description
of certain specific embodiments of the invention. Certain terms may
even be emphasized below; however, any terminology intended to be
interpreted in any restricted manner will be overtly and
specifically defined as such in this detailed description
section.
[0014] Where the context permits, singular or plural terms may also
include the plural or singular term, respectively. Moreover, unless
the word "or" is expressly limited to mean only a single item
exclusive from the other items in a list of two or more items, then
the use of "or" in such a list is to be interpreted as including
(a) any single item in the list, (b) all of the items in the list,
or (c) any combination of items in the list.
[0015] Turning in detail to the drawings, as shown in FIG. 1, a
hockey helmet 10 includes a shell 12 having a front region 14, side
regions 16, a rear region 18, and a crown region 20. As shown in
FIG. 2., in one embodiment, the shell structure includes a foam
layer 22 (or a layer of another suitable impact-absorbing material)
sandwiched between a thin plastic outer layer 24 and a thin plastic
inner layer 26.
[0016] The foam layer is preferably an expanded polypropylene
("EPP") material but could alternatively be an expanded
polyethylene ("EPE") material, or a combination of these materials,
or could be any other suitable energy-absorbing material or
combination of materials. The thin plastic layers 24, 26 may be
made of polycarbonate or another suitable material. The thin
plastic layers 24, 26 may each be formed from a single piece of
plastic or may be formed from multiple pieces of plastic that are
molded together. While other materials may be used, for ease of
description, an EPP foam layer 22 sandwiched between two
polycarbonate layers 24, 26 will be described herein.
[0017] In one embodiment, the inner polycarbonate layer 26 may be
partially or entirely omitted, particularly in a helmet in which a
relatively thicker outer layer 24 is used. The inner polycarbonate
layer 26, for example, may cover only certain regions of the EPP
foam 22, such as the front, rear, and lower side regions of the EPP
foam 22. Including an inner polycarbonate layer 26 on at least some
regions of the EPP foam 22 is generally desirable, as it provides a
more stable, better energy-absorbing structure than does a shell
that does not include any inner polycarbonate layer 26. Comfort
foam or other comfort padding is preferably included on an interior
surface of the EPP foam 22 or polycarbonate layer 26 to provide a
comfortable fit for the wearer.
[0018] In one embodiment, the polycarbonate layers 24, 26 may be
vacuum formed and trimmed to a desired shape, then put into a mold
with a pre-molded EPP layer 22 for bonding or fusing the
polycarbonate layers 24, 26 to the EPP layer 22. In another
embodiment, the polycarbonate layers 24, 26 may be placed into an
EPP mold and then insert molded or "in-molded" with the EPP foam.
In an alternative embodiment, the polycarbonate layer or layers may
be injection molded and then bonded to a liner of EPP foam.
[0019] Vacuum forming or insert molding generally are preferred
over injection molding, as these processes allow for lighter and
thinner plastic layers than does a typical injection molding
process. It has been found, for example, that the inner and outer
polycarbonate layers 24, 26 may be formed from sheets having a
thickness as low as 0.7 mm (which may become approximately 2 mm
thinner after undergoing a vacuum forming and molding process),
whereas traditional injection molded helmets typically include a
plastic shell having a thickness of approximately 1.8 to 3 mm. Any
of the processes described herein, or another suitable process,
however, may be used to construct the helmet shell 12.
[0020] In some embodiments, the polycarbonate layers may be formed
using combinations of two or more of these processes. For example,
the outer layer 24 may be formed using an injection molding process
while the inner layer may be formed using a vacuum forming process.
As another example, the upper regions of the outer layer 24 may be
formed using an insert molding process while lower regions of the
outer layer 24 may be formed using an injection molding
process.
[0021] As is best shown in FIGS. 1 and 3-6, in one embodiment, the
helmet 10 includes a removable earpiece 30 on each side of the
helmet 10. The earpiece 30 is preferably made of a plastic material
but could be made of any other suitable material. The earpiece 30
may be transparent, translucent, or opaque. The earpiece 30
preferably includes an opening 31 through which sound may be
transmitted to the wearer's ear.
[0022] Each earpiece 30 is removably secured to a retention
mechanism 35, which preferably is made of a nylon or plastic
material, or another suitable material. The retention mechanism 35
may be embedded within the EPP foam layer 22 during molding of the
helmet 10. The retention mechanism 35 alternatively may be an
integral part of the plastic portion of the helmet shell itself,
particularly if all or part of the shell is a thicker, injection
molded component. In one embodiment, for example, the helmet shell
may be a hybrid including thin, plastic layers on upper regions of
the EPP foam, and including thicker, injection molded plastic
layers on lower regions of the EPP foam, with the retention
features to which the earpieces 30 are attachable integrally molded
with the lower injection molded regions. In this embodiment, the
injection molded lower regions may be bonded or mechanically
attached, via rivets or other attachment elements, to the EPP foam
layer 22.
[0023] The retention mechanism 35 may include a single piece or
multiple pieces. In the illustrated embodiments, the retention
mechanism 35 includes a first retention element 36 and a second
retention element 38 spaced apart from the first retention element
36. The first and second retention elements 36, 38 each include a
rail 34 or other suitable retention member projecting into the
space between the retention elements 36, 38. The earpiece 30
correspondingly includes a pair of longitudinal openings or
channels 32 that slidably engage the rails 34. In an alternative
embodiment, the rails may be included on the earpiece, and the
corresponding channels may be included in the retention elements
36, 38, such that the rails will not be apparent on the shell when
the earpieces are removed.
[0024] As shown in FIG. 6, one or more of the rails 34 optionally
include an opening 40. In this embodiment, the earpiece 30 includes
arms 42 having tabs or similar structures on inner surfaces thereof
for engaging the openings 40 when the earpiece 30 is positioned on
the rails 34. Such an arrangement allows the earpiece 30 to snap or
click into place such that it remains in position on the rails 34
when the helmet 10 is subjected to contact. Other arrangements,
such as including corresponding raised ridges or bumps on the rails
34 and on internal regions of the channel-defining portions of the
earpiece 30, may alternatively be used to hold the earpiece 30 in
position.
[0025] The earpiece 30 may be attached or removed from the helmet
10 by sliding the channels 32 along the rails 34 in the appropriate
direction. If the rails include openings 40 or other mating regions
that engage with the arms 42 or other portions of the earpiece 30,
a small amount of force will be required to move the earpiece 30
into and out of the fully attached position. FIG. 7 shows the
helmet 10 with the earpieces 30 removed from the helmet 10.
[0026] The retention mechanism 35 may include ear loop supports 50
that define openings through which ear loops 52 may pass. The ear
loop supports 50 provide structural anchors to which the ear loops
52 may be secured. The ear loop supports 50 are particularly
beneficial when the helmet includes an EPP layer 22 and one or more
thin polycarbonate layers 24, 26 (or no polycarbonate layers at
all), since the EPP and thin polycarbonate layers 24, 26 do not
provide as much structural support for the ear loop attachments as
does a thicker, injection molded shell. The ear loop supports 50,
which are preferably embedded in the EPP layer 22, provide strong
anchors for the ear loops that aid the helmet 10 in meeting
certification standards.
[0027] The retention mechanism 35 optionally further includes
threaded fasteners 55 for receiving screws used to attach an
optional visor or faceguard (or other component) to the helmet 10.
The threaded fasteners 55 are preferably made of a metal material
but may be made of any other suitable material. Each threaded
fastener is preferably over-molded in a plastic housing 56 that
projects outwardly from the retention mechanism 35. The upper, flat
surface of each housing 56 acts as a shoulder against which a screw
head or attached visor or faceguard may rest. The housings 56 are
preferably attached to teeth or arms 57 that aid in resisting
rotation of the retention mechanism 35 when screws are threaded
into or out of the fasteners 55. Because the retention mechanism 35
is embedded in the EPP foam 22, the threaded fasteners 55 will not
fall into the helmet 10 or otherwise move when screws are removed
from the fasteners 55.
[0028] In the illustrated embodiment, the helmet shell includes
three openings or holes 58 on each side of the helmet in which
three fastener housings 56 are positioned. Any number of holes 58
may be included but most existing face guards require two or three
attachment points on each side of the helmet 10 for connecting the
visor or faceguard to the helmet 10. To attach a visor or faceguard
to the helmet, the screws (if present) may be threaded out of the
fasteners 55 and the openings in the visor or face guard may be
aligned with the holes 58. The screws may then be threaded back
into the fasteners 55 to secure the visor or face guard to the
helmet 10 (in some instances, longer screws than the original
helmet screws may be required to accommodate the thickness of a
given visor or face guard).
[0029] Each retention mechanism 35 optionally includes a rear tab
60 or other attachment element including an opening 62 that
provides an attachment point for a fitting element in the interior
of the helmet. In this embodiment, each the tab 60 preferably
projects through an opening or slit in the EPP foam 22 into the
helmet's interior. A projecting post or similar feature on a
fitting element may be secured to the tab 60 by pushing it through
the large region of the opening 62 and pulling it into the smaller
region of the opening 62. One or more adjustable bands or similar
fitting devices may be attached between two fitting elements to
provide an adjustable fit system.
[0030] The helmet features described herein provide for a
lightweight helmet that optionally may be molded into one piece as
opposed to a traditional two-piece shell. When molded in one piece,
the helmet does not include the gaps that are generally present in
a two-piece adjustable shell. Thus, it provides added head coverage
and protection, and also provides a helmet which generally has an
increased lateral stiffness. A one-piece shell also generally
includes fewer moving parts that could potentially come loose,
rattle, and so forth. Additionally, the earpieces 30 are much
easier to remove and re-attach than are conventional earpieces,
since they do not require tools or other objects to effectuate
their removal.
[0031] One or more of the helmet features described herein may be
used in other helmets, such as batters' helmets, pitchers' helmets,
catchers' helmets, lacrosse helmets, football helmets, and so
forth. For example, a batter's helmet could be constructed by
in-molding a layer of EPP foam between a pair of thin polycarbonate
layers. Furthermore, a retention mechanism including threaded
fasteners for attachment of a visor or face guard could be embedded
in the EPP foam of the batter's helmet.
[0032] Any of the above-described embodiments may be used alone or
in combination with one another. Furthermore, the helmet may
include additional features not described herein. While several
embodiments have been shown and described, various changes and
substitutions may of course be made, without departing from the
spirit and scope of the invention. The invention, therefore, should
not be limited, except by the following claims and their
equivalents.
* * * * *