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.

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.