CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure is a PCT International Application of United States Patent Application No. 62/839,201 filed on April 26, 2019. The entire disclosure of the application referenced above is incorporated herein by reference.

FIELD

[0002] The present disclosure relates to a sporting helmet having a removable earpiece.

BACKGROUND

[0003] This section provides background information related to the present disclosure and is not necessarily prior art.

[0004] Sporting helmets such as hockey helmets, for example, generally include earpieces for protecting ears of a user. In some of the helmets, the earpieces are removable. In such helmets, the earpieces are difficult to attach to and detach from the helmet.

[0005] The present disclosure provides a sporting helmet that has earpieces that can be conveniently and easily attached to and detached from the helmet.

SUMMARY

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In one form, the present disclosure provides an earpiece for a sporting helmet. The earpiece includes a body, a rail and a locking feature. The body includes first and second opposing sides. The rail extends outwardly from the first side of the body. The locking feature extends from the second side of the body and includes an attachment. The attachment is laterally offset from the body and is configured to be removably attached to the sporting helmet.

[0008] In some configurations of the earpiece of the above paragraph, the body, the rail and the locking feature are made of a Surlyn® material. [0009] In some configurations of the earpiece of any one or more of the above paragraphs, the body includes an opening formed therein.

[0010] In some configurations of the earpiece of any one or more of the above paragraphs, the rail includes a bulbous portion.

[0011] In some configurations of the earpiece of any one or more of the above paragraphs, the locking feature includes an extension that extends from the second side of the body. The attachment extends perpendicularly from an end of the extension.

[0012] In some configurations of the earpiece of any one or more of the above paragraphs, the attachment is laterally offset from the body by the extension.

[0013] In some configurations of the earpiece of any one or more of the above paragraphs, the attachment includes a first portion and a second portion. The first portion includes a thickness that is thicker than a thickness of the second portion.

[0014] In some configurations of the earpiece of any one or more of the above paragraphs, the second portion includes at least one opening formed therein.

[0015] In another form, the present disclosure provides a sporting helmet that includes a shell and an earpiece. The shell has a side region. The side region of the shell includes an earpiece opening. The earpiece is removably attached to the shell at the side region. The earpiece opening includes a body, a rail and a locking feature. The body includes first and second opposing sides. The rail extends outwardly from the first side of the body. The locking feature extends from the second side of the body and includes an attachment. The body is received in the earpiece opening and the attachment is received in a recess formed in an inner surface of the shell when the earpiece is attached to the shell.

[0016] In some configurations of the sporting helmet of any one or more of the above paragraphs, the shell has a foam layer and an outer layer attached to each other. The recess is formed in the inner surface of the foam layer.

[0017] In some configurations of the sporting helmet of any one or more of the above paragraphs, the attachment is flush with the inner surface of the foam layer when the attachment is received in the recess.

[0018] In some configurations of the sporting helmet of any one or more of the above paragraphs, a post is embedded within the foam layer of the shell. The post includes a surface that has a track formed therein. [0019] In some configurations of the sporting helmet of any one or more of the above paragraphs, the earpiece opening is partially defined by a plurality of lateral sides. The surface of the post is flush with one of the lateral sides.

[0020] In some configurations of the sporting helmet of any one or more of the above paragraphs, the rail includes a bulbous portion. The bulbous portion is received in the track when the earpiece is attached to the shell.

[0021] In some configurations of the sporting helmet of any one or more of the above paragraphs, the locking feature includes an extension that extends from the second side of the body. The attachment extends perpendicularly from an end of the extension.

[0022] In some configurations of the sporting helmet of any one or more of the above paragraphs, the attachment is laterally offset from the body by the extension.

[0023] In some configurations of the sporting helmet of any one or more of the above paragraphs, the attachment includes a first portion and a second portion. The first portion includes a thickness that is thicker than a thickness of the second portion.

[0024] In some configurations of the sporting helmet of any one or more of the above paragraphs, the second portion includes at least one opening formed therein.

[0025] In some configurations of the sporting helmet of any one or more of the above paragraphs, a fastener extends through the at least one opening and at least partially through the shell to attach the earpiece to the shell.

[0026] In some configurations of the sporting helmet of any one or more of the above paragraphs, the shell includes another side region having another earpiece opening. Another earpiece is removably attached to the shell at the another side region.

[0027] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0028] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0029] Figure 1 is a perspective view of a sporting helmet with earpieces attached; [0030] Figure 2 is a side view of the sporting helmet of Figure 1 with the earpieces attached;

[0031] Figure 3 is a partial perspective view of the sporting helmet of Figure 1 showing one of the earpieces attached thereto;

[0032] Figure 4 is a side view of the sporting helmet showing one of the earpieces detached therefrom;

[0033] Figure 5 is a partial perspective view of the sporting helmet showing the one of the earpieces detached therefrom;

[0034] Figure 6 is a perspective view of one of the earpiece openings of the sporting helmet;

[0035] Figure 7 is a cross-sectional view of the helmet taken along line 8-8 of Figure 2;

[0036] Figure 8 is a perspective view of one of the earpieces;

[0037] Figure 9 is another perspective view of the one of the earpieces shown in

Figure 8;

[0038] Figure 10 is an exterior perspective view including a temple portion of the helmet and one of the earpieces; and

[0039] Figure 11 is an interior perspective view including the temple portion of the helmet and one of the earpieces.

[0040] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0041] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0042] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. [0043] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," “including,” and“having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0044] When an element or layer is referred to as being "on,"“engaged to,” "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," “directly engaged to,” "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0045] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as“first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0046] Spatially relative terms, such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0047] As shown in Figures 1 and 2, a sporting helmet 10 such as a hockey helmet or a lacrosse helmet, for example, may include a shell 12 having a front region 14, a crown region 16, a rear region 18 and side regions 20. With reference to Figures 1 -5, the shell 12 may define an inner cavity 21 (Figure 1 ) and may include an earpiece opening 22 at each respective side region 20. The shell 12 may also have a foam layer 23 and an outer layer 24 attached to each other via an adhesive (e.g., glue), for example, or in another suitable manner (e.g., fused). The foam layer 23 may be made of an expanded polypropylene (EPP) material, an expanded polyethylene (EPE) material, a combination of the EPP and EPE materials, or any other suitable energy absorbing material. The foam layer 23 may have a thickness that is thicker than the outer layer 24. The outer layer 24 may be a single, unitary piece and may be made of a polymeric material, for example. The outer layer 24 may be formed by an injection molding process or using another suitable process.

[0048] As shown in Figure 1 , a pair of retaining devices 26 may be embedded within the shell 12. Each retaining device 26 may be embedded within the foam layer 23 of the shell 12 at a respective side region 20 of the shell 12. Each retaining device 26 may include a first retaining member 28 (Figures 1 -6) and a second retaining member 30 (Figures 1 , 2 and 4) that are spaced apart from each other. The first retaining member 28 may be located on one side (e.g., a rear side) of earpiece opening 22 while the second retaining member 30 may be located on the other side (e.g., a front side) of the earpiece opening 22. One retaining device 26 is provided with each earpiece opening 22.

[0049] The first retaining member 28 may be made of a polymeric or metallic material, for example, and may be embedded within the foam layer 23 by a co-molding process, for example. As shown in Figures 1 -6, the first retaining member 28 may include a post 32, a loop 34 and an arm 36. The post 32 may have a surface 37 that is substantially flush with a first lateral side 40 of the foam layer 23 (Figure 6; the first lateral side 40 of the foam layer 23 partially defines the earpiece opening 22 at the respective side region 20 of the shell 12). As shown in Figure 6, a circular (cylindrical) shaped track or groove 38 may be formed in the surface 37 of the post 32 and may extend at least partially a length of the post 32. The track 38 may have another suitable shape (e.g., square, rectangular, triangular, etc.) instead of being circular/cylindrical. As shown in Figures 1 -5, the loop 34 may extend from the post 32 and may have projections 44 (Figures 1 and 2) extending from a surface 46 of the loop 34. The arm 36 may also extend from the post 32. The loop 34, the projections 44 and the arm 36 may provide for stability of the first retaining member 28 within the foam layer 23. For example, the loop 34, the projections 44 and the arm 36 may help retain the first retaining member 28 within the foam layer 23.

[0050] The second retaining member 30 may be made of a polymeric or metallic material, for example. The second retaining member 30 may be embedded within the foam layer 23 by a co-molding process, for example. The second retaining member 30 may include an intermediate portion 48, an ear loop portion 50 and a connecting portion 52. The intermediate portion 48 may be positioned between the ear loop portion 50 and the connecting portion 52 and may include a plurality of fastener housings 54 (Figure 7). As shown in Figure 7, the fastener housings 54 may be vertically aligned with each other. Each fastener housing 54 may have a stepped opening 56.

[0051] The ear loop portion 50 may be rectangular-shaped. A chin strap may be connected to the ear loop portions 50 and used to retain the helmet on a player’s head. As shown in Figure 7, an opening 60 may extend through the ear loop portion 50 and the shell 12 (i.e., the outer layer 24 and the foam layer 23). In this way, one end of an ear loop (not shown) may extend through the opening 60 and another end of the ear loop may extend through another opening 64 of the shell 12 (i.e., the foam layer 23 and the outer layer 24), thereby securing the ear loop to the helmet 10. The connecting portion 52 may define a plurality of openings 70 and may provide for stability of the second retaining member 30 within the foam layer 23.

[0052] As shown in Figures 1 -3, an earpiece 74 may be removably attached to the shell 12 at a respective side region 20 such that the earpiece 74 is received in the earpiece opening 22. The earpiece 74 may be formed by injection molding, for example, and may be made of a polymeric material (e.g., Surlyn®). The earpiece 74 may include a body 76, a rail 78 and a locking feature 80. [0053] With reference to Figures 1 -3, 5, 8 and 9, the body 76 may be received within the earpiece opening 22 when the earpiece 74 is attached to the shell 12 (Figures 1 -3) and may include a plurality of sides 82a, 82b, 82c, 82d. The sides 82a and 82b are opposing each other and the sides 82c and 82d are opposing each other. When the earpiece 74 is attached to the shell 12, the side 82a may face a second lateral side 84 of the foam layer 23 (i.e. , the second lateral side 84 of the foam layer 23 partially defines the earpiece opening 22) and the side 82b may face the first lateral side 40 of the foam layer 23. The body 76 may include an opening 86 formed therein that facilitates handling of the earpiece 74, for example.

[0054] As shown in Figures 5, 8 and 9, the rail 78 may extend outwardly from the side 82b of the body 76 and may include a bulbous portion 88. As the earpiece 74 is being attached the shell 12, the bulbous portion 88 is received in and slides along the track 38 of the post 32. The locking feature 80 may include an extension 90 and an attachment 92. The extension 90 may extend from the side 82a of the body 76 toward the cavity 21 of the shell 12. The attachment 92 may extend perpendicularly from an end of the extension 90 and may be received in a recess 94 formed in an inner surface 96 of the foam layer 23 when the earpiece 74 is attached to the shell 12. The attachment 92 may be laterally offset from the body 76 by the extension 90. As shown in Figures 5, 8 and 9, the attachment 92 may include a first portion 98 and a second portion 100. The first portion 98 may have a thickness that is thicker than a thickness of the second portion 100. The first portion 98 may be substantially flush with the inner surface 96 of the foam layer 23 when the earpiece 74 is attached to the shell 12. The second portion 100 may include a plurality of openings 102 formed therein.

[0055] A locking member 108 may be made out of a metallic material, for example, and may include a rectangular-shaped locking plate 110 (Figures 1 , 3 and 5) and a plurality of hubs 112 (Figures 5 and 7) extending therefrom. The locking plate 110 may have another shape. Each hub 112 may include an inner diametrical surface 113 that is threaded. Each hub 112 may also extend through a respective one of the openings 102 of the second portion 100 and at least partially through respective openings 56, 104 of the fastener housing 54 and foam layer 23, respectively. In this way, the locking plate 110 abuts against the second portion 100 and may be substantially flush with the first portion 98 and the inner surface 96 of the foam layer 23. A threaded fastener 114 may extend through respective openings 106, 56 of the outer layer 24 and the fastener housing 54, respectively, and at least partially through a respective hub 112. In this way, the earpiece 74 is attached to the shell 12 at the respective side region 20.

[0056] With continued reference to Figures 1 -9, attachment and detachment of one of the earpieces 74 to the shell 12 will be described in detail. An installer (not shown) may insert the bulbous portion 88 of the rail 78 in the track 38 and may slide the bulbous portion 88 along the track 38 until a top portion of the bulbous portion 88 abuts (stops) against a seat (not shown) of the track 38. Once the bulbous portion 88 abuts against the seat of the track 38, the attachment 92 may be received in the recess 94 of the inner surface 96 of the foam layer 23 such that the first portion 98 is substantially flush with the inner surface 96 of the foam layer 23.

[0057] Next, as shown in Figure 7, each hub 112 of the locking member 108 may extend through the respective opening 102 of the second portion 100 and at least partially through the respective openings 56, 104 of the fastener housing 54 and the foam layer 23, respectively. In this way, the locking plate 110 abuts against the second portion 100 and is substantially flush with the first portion 98 and the inner surface 96 of the foam layer 23. The threaded fastener 114 may extend through the respective openings 106, 56 of the outer layer 24 and the fastener housing 54, respectively, and at least partially through the respective hub 112. In this way, the earpiece 74 is attached to the shell 12 at the respective side region 20.

[0058] To detach the earpiece 74 from the shell 12, the fasteners 114 is/are removed from the respective openings 106, 56 of the outer layer 24 and the fastener housing 54, respectively, and the hub 112. In this way, the attachment 92 may be removed from the recess 94 and the bulbous portion 88 may be slid out of the track 38, thereby detaching the earpiece 74 from the shell 12.

[0059] The earpieces 74 of the present disclosure provide the benefit of being conveniently attached to and detached from the shell 12. The earpieces 74 of the present disclosure are also light-weight and inexpensive.

[0060] In various implementations, as illustrated in Figures 10 and 11 , the foam layer 23 may not extend down into a temple portion 200 of the shell 12. A lower end 204 of the foam layer 23 may be located vertically above the locking feature 80 of the earpiece 74. With this arrangement, the connecting portion 52 is retained within the foam layer 23, while the intermediate portion 48 and the ear loop portion 50 are exposed and not covered by foam. In this example, the thicknesses of the first portion 98 and the second portion 100 may be equal. The temple portion 200 of the shell 12 may include an overmolded plastic or another suitable material. The lack of the foam layer 23 in the temple portion 200 may allow the shell to be thinner, stronger, and less obtrusive to a wearer of the helmet. Also, as shown, the intermediate portion 48 may be shaped to fit to outer walls 208 of the temple portion 200. The fit may be, for example, a clearance fit, a transition fit, or an interference fit, such as a sliding fit, a location fit, a tight fit, a similar fit, a fixed fit, or a press fit. In this example, the locking feature 80 of the earpiece 74 is received is a recess between the walls 208 of the temple portion 200.

[0061] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.