Patent Publication Number: US-10757994-B2

Title: Catcher&#39;s helmet

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 16/019,187, filed Jun. 26, 2018, now pending, which is a continuation of U.S. patent application Ser. No. 15/649,258 filed Jul. 13, 2017, now U.S. Pat. No. 10,085,509, which is a continuation of U.S. patent application Ser. No. 14/878,431 filed Oct. 8, 2015, now U.S. Pat. No. 9,743,702, which claims priority from U.S. Provisional Application Ser. No. 62/159,075 filed May 8, 2015 which is incorporated herein by reference. U.S. patent application Ser. Nos. 16/019,187, 15/649,258 and 14/878,431 and U.S. Provisional Application Ser. No. 62/159,075 are incorporated herein by reference for all purposes. 
    
    
     FIELD AND BACKGROUND OF THE INVENTION 
     The subject technology relates generally to the field of protective helmets and masks, and in particular to helmets and protective masks for baseball, softball, hockey and similar sports. 
     SUMMARY 
     According to the subject technology, protective sports headgear, such as a catcher&#39;s mask, comprises a two-piece shell formed of a suitable material such as polycarbonate or acrylonitrile butadiene styrene plastic and adapted to receive and protect the head of a wearer. The two-piece shell is composed of a rigid front shell, which protects the front, sides, and crown of the head, and a rigid rear shell, which protects the back of the head. The front shell and rear shell are connected by a harness of straps attached to the front shell by snap buckles. 
     The front shell may have through-going ventilation holes including ear holes positioned over the wearer&#39;s ears. The front shell may include a full jaw protector integrally formed as part of front shell. The jaw protector may have ventilation holes. 
     A faceguard for protecting the face of the wearer and comprised of wire members may be removably attached to the front shell with straps and/or nuts. The faceguard may extend over the ear holes to better protect the ear region from blows during sports play. The faceguard may include raised eyebrow areas on the left and right side of the uppermost member of the faceguard. The eyebrow areas may be positioned above a top edge of the face opening of the front shell. 
     The mask includes padding assemblies on the inner surfaces of the front and rear shells for shock absorption, protection, comfort, and to size the mask to the wearer. In the front shell, the padding assemblies include a front liner installed in the brow area, crown area, and side areas of the shell, and a middle liner extending around the rear inner surface of the front shell from the left lower edge to the right lower edge of the front shell. The front liner and middle liner are each comprised of a thermoformed thermoplastic urethane (“TPU”) shock absorbing layer bonded to a inner comfort layer. The inner comfort layer comprises an inner polyvinyl or TPU sheet bonded to the shock absorbing layer, forming pockets therebetween which can be filled wholly or partially with foam material such as a memory foam. A comfortable foam padding assembly is also removably mounted to the inner surface of the jaw protector. A central chin pad comprising a foam member may be removably attached to the center of the inner surface of the jaw protector. 
     In the rear shell, a concave padding assembly is provided. The concave padding assembly is comprised of a concave thermoformed TPU shock absorbing layer, shaped to nest within the rear shell. A concave comfort layer, which may be comprised of foam material is removably attached to the inner surface of the concave shock absorbing layer and is shaped to nest within the concave shock absorbing layer. 
     Further advantages, as well as details of the present invention ensue from the following description of the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a catcher&#39;s mask according to the subject technology. 
         FIG. 2  is a left perspective view of a catcher&#39;s mask according to the subject technology. 
         FIG. 3  is a left perspective view of a front shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 4  is a front view of a front shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 5  is a right side view of a front shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 6  is a top view of a front shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 7  is a right side cross-sectional view of a catcher&#39;s mask according to the subject technology. 
         FIG. 8  is a rear view of a front shell with installed liners of a catcher&#39;s mask according to the subject technology. 
         FIG. 9  is a top view of a front liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 10  is a side view of a front liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 11  is a rear perspective view of a front liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 12  a cross-sectional view of a front liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 13  is a top view of a middle liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 14  is a side view of a middle liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 15  is a rear view of a middle liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 16  is a cross-sectional view of a middle liner of a catcher&#39;s mask according to the subject technology. 
         FIG. 17  is a rear view of jaw padding of a catcher&#39;s mask according to the subject technology. 
         FIG. 18  is a side view of jaw padding of a catcher&#39;s mask according to the subject technology. 
         FIG. 19  is a front view of jaw padding of a catcher&#39;s mask according to the subject technology. 
         FIG. 20  is a front view of a chin pad of a catcher&#39;s mask according to the subject technology. 
         FIG. 21  is a side view of a chin pad of a catcher&#39;s mask according to the subject technology. 
         FIG. 22  is a cross-sectional view of a chin pad of a catcher&#39;s mask according to the subject technology. 
         FIG. 23  is a rear view of a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 24  is a rear view of a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 25  is a right perspective view of a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 26  is a right perspective view of a concave padding assembly for a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 27  is a cross-sectional view of a shock absorbing layer for a concave padding assembly for a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 28  is a front view of a shock absorbing layer for a concave padding assembly for a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 29  is a cross-sectional view of a comfort layer for a concave padding assembly for a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 30  is a front view of a comfort layer for a concave padding assembly for a rear shell of a catcher&#39;s mask according to the subject technology. 
         FIG. 31  is a front view of a strap harness for a catcher&#39;s mask according to the subject technology. 
         FIG. 32  is a front view of a face guard for a catcher&#39;s mask according to the subject technology. 
         FIG. 33  is a left perspective view of a face guard for a catcher&#39;s mask according to the subject technology. 
         FIG. 34  is a side view of a face guard for a catcher&#39;s mask according to the subject technology. 
         FIG. 35  is a front view of a face guard for a catcher&#39;s mask according to the subject technology. 
         FIG. 36  is a left perspective view of a face guard for a catcher&#39;s mask according to the subject technology. 
         FIG. 37  is a side view of a face guard for a catcher&#39;s mask according to the subject technology. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings, in which like reference numerals are used to refer to the same or similar elements,  FIGS. 1-8  show an embodiment of the shell, jaw protector, and face guard of the subject technology. Catcher&#39;s mask  1  comprises a rigid single-piece front shell  100  and a rigid single-piece rear shell  200  is adapted to receive and protect the head of a wearer. Each of front shell  100  and rear shell  200  is formed of a suitable material such as polycarbonate or acrylonitrile butadiene styrene plastic. Front shell  100  and rear shell  200  may be fabricated by methods known to those of skill in the art such as injection molding or thermoforming. Front shell  100  may have a thickness in the range of 0.11 inches to 0.14 inches, or 0.11 inches to 0.135 inches, or 0.11 inches to 0.13 inches. Rear shell  200  may have a thickness in the range of 0.11 inches to 0.14 inches, or 0.11 inches to 0.135 inches, or 0.11 inches to 0.13 inches. This is in contrast to a shell for use in football, which may have a thickness in the range of 0.14 inches and up. 
     In general configuration, front shell  100  has an inner surface and an outer surface. Front shell  100  has a front region  111 , a crown region  112 , a rear region  113 , a left side region  114 , and a right side region  115 . Front shell  100  is bordered by an edge comprising top front edge  116 , right front edge  117 , left front edge  118 , bottom edge  119 , and rear edge  120 . 
     Front shell  100  includes an integral full jaw protector  121 . A face opening  122  in the front region  111  is defined by top front edge  116 , right front edge  117  and left front edge  118 . A rear opening is partially defined by rear edge  120 . 
     Front shell  100  may have through-going ventilation holes. Ventilation holes in front shell  100  may include hole  126  centrally located in the crown region  112  and holes  125  located on the left side and right side of crown region  112 . Front shell  100  may have one or more ear holes  123 ,  124  on each of the left side region  114  and right region  115 . Slots  128 ,  129  are formed in front shell  100  for passage of the straps of strap harness  250  to connect rear shell  200  with front shell  100  in use. Jaw protector  121  may have ventilation holes  127 , positioned on a left side and a right side of jaw protector  121 . 
     A faceguard  600  for protecting the face of the wearer and comprised of wire members arranged as a grid may be removably attached to the shell  100  with straps and/or nuts, as shown. For example, faceguard  600  may be removably attached to shell  100  by loop straps connected by screws, nuts, and/or bolts to shell  100  through holes formed therein. 
     Faceguard  600  is a grid of wire members including horizontal wire members and vertical wire members connected together by, for example, welding. The wire members may be composed of steel or titanium. Faceguard  600  may be coated in a plastic or elastomer layer by, for example, dipping. Horizontal wire members may extend from a point rearward of ear holes  123 ,  124 , in the left side region  114 , across the face opening, to a point rearward of the ear holes  123 ,  124 , in the left side region  115 . In this manner, faceguard  600  may provide coverage over the area of the ear holes and thereby protect that area from blows sustained during sports play. 
     Faceguard  600 , best seen in  FIGS. 33-34 , comprises an upper pair of horizontal members, particularly, top upper member  601  and bottom upper member  602 . Top upper member  601  is removably connected to front shell  100  by a pair of loop straps positioned in the front region  111  of front shell  100  above top front edge  116 . When guard  601  is thus installed, bottom upper member  602  is positioned at, or slightly below, or slightly above top front edge  116 , while top upper member  601  is positioned above top front edge  116 . Top upper member  601  and bottom upper member  602  are connected to each other by vertical wire members  606 ,  607 . 
     Faceguard  600  comprises a further three horizontal members, specifically, top lower member  603 , middle lower member  604 , and bottom lower member  605 . Members  603 ,  604 , and  605  are connected to each other by vertical members  608 ,  609 ,  610 . Bottom lower member  605  is removably connected to front shell  100  by a loop straps positioned in the front region  111  of front shell  100  below right front edge  117  and left front edge  118 . 
     Top upper member  601 , bottom upper member  602  and top lower member  603  are connected to each other by vertical members  611 ,  612 . A gap  613  is defined between bottom upper member  602  and top lower member  603 , registering approximately with the wearer&#39;s eyes, to permit the wearer to better see through the mask. 
     Top upper member  601 , bottom upper member  602  and bottom lower member  605  extend substantially past right front edge  117  and left front edge  118  (i.e., substantially past the edges of face opening  122 ) and meet at or beyond ear hole  123  to cover ear hole  123  and protect that area. More specifically, bottom lower member  605  is bent upwards at that point and top upper member  601  and bottom upper member  602  are joined to it. 
     Top upper member  601  comprises a center bar part  614 , a left side bar part  615  bent upwardly with respect to the center bar part  614  to form an integral left eyebrow area, and a right side bar part  616  bent upwardly with respect to the center bar part  614  to form an integral right eyebrow area. The left side bar part  615  and right side bar part  616  may be bent upwardly to such an extent that they are above the center bar part  614  by at least a multiple of a diameter of the center bar part  614 . As seen in  FIG. 1 , when faceguard  600  is installed on front shell  100 , the left eyebrow area and right eyebrow area may be positioned above a top edge of the face opening. 
     An alternative face guard  620  for use in the catcher&#39;s mask  1  of the subject technology is shown in  FIGS. 35-37 . Face guard  620  is similar in structure and application to face guard  600 , with the addition of right upward-sweeping members  621 ,  622 ,  623 ,  624  and left upward-sweeping members  625 ,  626 ,  627 ,  628 . The provision of upward-sweeping members  621 ,  622 ,  623 ,  624 ,  625 ,  626 ,  627 ,  628  provides additional protection from frontal blows to the mask  1 . Upward-sweeping members  621 ,  622 ,  623 ,  624 ,  625 ,  626 ,  627 ,  628  are joined together at their lower ends by bottom upper member  602 , cross over and join with top upper member  601 , and are joined together at their upper ends by crown arch member  629 . Crown arch member  629  spans from the left side region, over the crown region, to the right side region, and joins top upper member  601  near its meeting points with bottom lower member  605 . 
     In the embodiment of  FIGS. 35-37 , face guard  620  has eight upward-sweeping members, as shown. In alternative embodiments, face guard  620  may have two, four, six, or ten, or twelve upward sweeping members. 
     Catcher&#39;s mask  1  is provided with padding assemblies mounted to the inner surface of front shell  100  and rear shell  200  for shock absorption, to cushion blows sustained to mask  1  during sporting play, to size the mask to the wearer, and to provide comfort for the wearer. The padding assemblies are advantageously removably mounted to the inner surfaces of front shell  100  and rear shell  200  to enable replacement of worn padding, and to enable the use of padding of different sizes to custom-fit the mask to the wearer. The padding assemblies may be removably attached to the shell by hook-and-loop fasteners or by assemblies of screws and T-nuts passing through holes formed in the respective shells, as hereinafter described. 
     As shown in  FIGS. 7-8  and as hereinafter described, front shell  100  may be provided with padding comprising front liner  130 , middle liner  160 , jaw padding  180 , and chin pad  190 . 
     Turning to  FIGS. 7-12 , front liner  130  comprises inner layer  131  and shock absorbing layer  132 , both layers consisting of a durable, smooth, substantially non-porous material such as thermoplastic polyurethane (“TPU”). 
     Protective arrangements for helmets formed of injection molded TPU parts are disclosed in U.S. Pat. No. 8,069,498, and the shock absorbing layers  132 ,  161 , and  221  of the front liner  130 , middle liner  160 , and rear liner  230  of the subject technology may be constructed as in that patent, the entirety of which is incorporated by reference. Suitable TPU material is available from Bayer. Layer  131  may be fabricated by thermoforming. Layer  131  has a plurality of spaced-apart, projecting, hollow, generally conical protrusions  133  protruding from a base sheet  134  and distributed over the coverage area. Protrusions  133  are grouped into a plurality of clusters  135  spaced apart by regions  136  of the base sheet having no protrusions. Each protrusion  133  has an open, preferably circular larger diameter base at the sheet  134  from which it extends, and a smaller diameter, preferably flat circular peak  137 , and a preferably curved or straight frustoconical side wall  138  that tapers from the open base to the closed peak  137 . Side wall  138  may define an angle of 10 degrees or approximately 10 degrees. A circular peak may be formed with a peak opening therein. Each side wall  138  is collapsible for absorbing shocks which may be transmitted to each protrusion  133 . The protrusions  133  within each cluster  135  are spaced apart from each other for distributing the shock-absorbing effects of the protrusions  133  over the coverage area of each respective cluster  135 . The height of the protrusions  133  may be 0.50 inches or approximately 0.50 inches. The inner diameter of the base of a protrusion  133  may be 0.34 inches or approximately 0.34 inches. The diameter of peak  137  may be 0.26 inches or approximately 0.26 inches. The thickness of base sheet  134 , side walls  138 , and peaks  137 , may be 0.035 inches or approximately 0.035 inches. 
     Inner layer  131  may be composed of a thin sheet of TPU material. Inner layer  131  may be formed by thermoforming and has the same general shape as shock absorbing layer  132  such that layer  131  can overlay and register with layer  132 . Pockets  139  are formed in inner layer  131 , in such locations and with such shapes as to generally overlay and register with clusters  135  of protrusions  133 . Pockets  139  may taper slightly from base to crown. Foam pads  140  may be provided in pockets  139 . Foam pads  140  may be of any suitable material including foam rubber, shock foam, or memory foam. Suitable materials for foam pads  140  include Omalon® foam, available from Carpenter Co. of Richmond, Va. Foam pads  140  may have a thickness of 0.50 inches or approximately 0.50 inches. Preferably, inner layer  131  should be fully sealed to layer  132  except where pockets  139  are provided. 
     In general configuration, front liner  130  is comprised of cushions integrally formed in the liner, each cushion formed of a cluster  135  of protrusions  133  and its associated pocket  139  and pad  140 . Cushions are connected by the interpositioned portions of layers  131  and  132  as shown. In the embodiment of the subject technology shown in  FIGS. 7-12 , front liner  130  comprises a central row  142  of cushions. Central row  142  comprises five cushions, including middle central cushion  150 , side central cushions  143 , and intermediate central cushions  144 . Middle central cushion  150  may have an oval shape to cover a wider area in the center of central row  142 . Side central cushions  143  and intermediate central cushions  144  may have round shapes. Intermediate central cushions  144  may have a smaller diameter than side central cushions  143 . Intermediate central cushions  144  may have an inner diameter of 1.6 inches or approximately 1.6 inches. Side central cushions  143  may have an inner diameter of 2.0 inches or approximately 2.0 inches. 
     In the embodiment of the subject technology shown in  FIGS. 7-12 , front liner  130  further comprises jaw cushions  145  connected to side central cushions  143  of central row  142 . Front liner  130  further comprises first crown cushion  146  connected at the location of an intermediate central cushion  144 , and second crown cushion  147  and third crown cushion  148 , attached in a row, at the location of the other intermediate central cushion  144 . Jaw cushions  145  may have the same diameter or approximately the same diameter as side central cushions  143 . Third crown cushion  148  may have the same diameter or approximately the same diameter as intermediate central cushions  144 . 
     Front liner  130  is installed in front shell  100  by removable attachment to the inner surface of front shell  100 , as follows. Front liner  130  is disposed on the inner surface of front shell  100  so that central row  142  is positioned above top front edge  116  to register approximately with the brow of the wearer. Middle central cushion  150  is positioned in the middle brow area to absorb impacts to that area. On either side of middle central cushion  150 , central row  142  is curved inward somewhat to conform to the concave inner surface of front shell  100 . Intermediate central cushions  144  are so spaced apart from middle central cushion  150 , and so sized, so that when front liner  130  is installed in front shell  100 , intermediate central cushions  144  are touching or are nearly touching middle central cushion  150  to provide continuous or nearly continuous protection for the middle brow area. Jaw cushions  145  are positioned over the upper jaw areas to absorb impacts to those areas. First crown cushion  146 , second crown cushion  147  and third crown cushion  148  are positioned in the crown area to absorb impacts to that area. First crown cushion  146 , second crown cushion  147 , and third crown cushion  148  are curved inward somewhat to conform to the concave inner surface of front shell  100 , with third crown cushion  148  positioned at the apex of the crown area. 
     Front liner  130  may be removably attached front shell  100  by hook-and-loop fasteners, screw-and-nut assemblies passing through holes formed in front shell  100  and layer  131 , or both. In the embodiment of the subject technology shown in  FIGS. 7-12 , front liner  130  is removably attached by T-nuts and snap screws connected to the jaw cushions  145 , the snap screws also serving as attachment points for strap  253  of strap harness  250 ; by a pair of T-nuts and screws connected to the middle central cushion  150 , the screws also serving as attachments points for two loop straps connecting face guard  600  to shell  100 ; and by pads of hook-and-loop fastener material connected to first crown cushion  146  and third crown cushion  148 . 
     Turning now to  FIGS. 13-16 , middle liner  160  comprises shock absorbing layer  161  and inner layer  169 , both layers consisting of a durable, smooth, substantially non-porous material such as TPU. The construction of middle liner  160  is similar to front liner  130 . Layer  161  has a plurality of spaced-apart, projecting, hollow, generally conical protrusions  162  protruding from a base sheet  163  and distributed over the coverage area. Protrusions  162  are grouped into a plurality of clusters  174  spaced apart by regions  164  of the base sheet having no protrusions. Each protrusion  162  has an open, preferably circular larger diameter base  165  at the sheet  163  from which it extends, and a smaller diameter, preferably flat circular peak  166 , and a preferably curved or straight frustoconical side wall  167  that tapers from the open base  165  to the closed peak  166 . Side wall  167  may define an angle of 10 degrees or approximately 10 degrees. Each side wall  167  is collapsible for absorbing shocks which may be transmitted to each protrusion  162 . The protrusions  162  within each cluster  174  are spaced apart from each other for distributing the shock-absorbing effects of the protrusions  162  over the coverage area of each respective cluster  174 . The height of the protrusions  162  may be 0.25 inches or approximately 0.25 inches. The inner diameter of base  165  may be 0.344 inches or approximately 0.344 inches. The diameter of peaks  166  may be 0.311 inches or approximately 0.311 inches. The thickness of base sheet  163 , side walls  167 , and peaks  168 , may be 0.035 inches or approximately 0.035 inches. 
     Inner layer  169  of middle liner  160  may be composed of a thin sheet of TPU material. Inner layer  169  may be formed by thermoforming and has the same general shape as shock absorbing layer  161  such that layer  162  can overlay and register with layer  161 . Pockets  170  are formed in inner layer  162 , in such locations and with such shapes as to generally overlay and register with clusters  174  of protrusions  162 . Pockets  170  may taper slightly from base to crown. Foam pads  171  may be provided in pockets  170 . Foam pads  171  may be of any suitable material including foam rubber, shock foam, or memory foam. Suitable materials for form pads  171  include Omalon® foam. Foam pads  171  may have a thickness of 0.25 inches or approximately 0.25 inches. Preferably, inner layer  169  should be fully sealed to shock absorbing layer  161  except where pockets  170  are provided. 
     Middle liner  160  is installed in front shell  100  by removable attachment to the inner surface of front shell  100 , as follows. Middle liner  160  is disposed on the inner surface of front shell  100  so that it is positioned along rear edge  120 . In the embodiment of the subject technology shown in  FIGS. 7, 8, and 13-16 , middle liner  160  is removably attached by T-nuts and snap screws connected to central cushions  175  and side cushions  176 , the snap screws also serving as attachment points for strap  252  of strap harness  250 ; and by pads of hook-and-loop fastener material connected to end cushions  177 . 
     Turning now to  FIGS. 17-19 , jaw padding 180 comprises a thin, flexible, roughly kidney-shaped elongated foam member  182  enclosed in a comfort layer  181 . Foam member  182  may be made of any suitable foam material such as polyurethane foam, memory form, or Omalon® foam. Comfort layer  181  may be made of any suitable, comfortable cloth material such as tricot or terrycloth. Jaw padding 180 may be removably attached to the inner surface of the full jaw protector by two pads  183  of hook-and-loop fastener material as shown in  FIGS. 7, 8 , suspended between the two attachment points such that comfort layer  181  is in contact with the chin of the wearer. 
     Turning now to  FIGS. 20-22 , chin pad  190  is removably attached to the inner surface of the full jaw protector, and is positioned to overlay the mental protuberance of the chin and absorb blows to the chin area. Chin pad  190  may comprise a single, roughly rectangular foam pad, tapering from base  191  to peak  192 . The foam material of the chin pad may be ethylene-vinyl acetate (EVA) foam. Chin pad  190  may be removably attached to the inner surface of the full jaw protector by, for example, a pad of hook fastener material. Chin pad  190  may be backed with fabric material  183  such as tricot, and be removably attached thereby to a pad of hook material adhered to the inner surface of integral full jaw protector  121 . Chin pad  190  is preferably curved so as to conform to the inner curvature of full jaw protector  121  where chin pad  190  is connected. 
     Turning now  FIGS. 23-30 , showing an embodiment of the rear shell and its associated padding assemblies, rear shell  200  is formed of a suitable material such as polycarbonate or acrylonitrile butadiene styrene plastic. Rear shell  200  has a concave configuration shaped to generally conform to the contour of the back of the wearer&#39;s head. Rear shell  200  has a plurality of through-going slots  201 ,  202 ,  203  formed therein for receiving straps of strap harness  250  to releasably attach rear shell  200  to front shell  100  as hereinafter described. A lip or flange  204  may be provided around the edge of rear shell  200 . 
     A concave padding assembly  220  is provided on the inner surface of rear shell  200 . Concave padding assembly  220  comprises a concave thermoformed TPU shock absorbing layer  221 , shaped to nest within rear shell  200 . Shock absorbing layer  221  has a plurality of spaced-apart, projecting, hollow, generally conical protrusions  222  protruding from a base sheet  223  and distributed over the coverage area. Each protrusion  222  has an open, preferably oval, larger-diameter base  224  at the sheet  223  from which it extends, a smaller-diameter peak  225 , and a preferably curved or straight frustoconical side wall  226  that tapers from the open base  224  to the closed peak  225 . Peaks  225  are oriented to form an angle with respect to their respective side walls  226 , such that the peaks lie in a convex surface conforming to the concave inner surface of rear shell  200 , so that when installed, the peaks  225  contact the inner surface of rear shell  200  without substantial deformation of the protrusions. Each side wall  226  is collapsible for absorbing shocks which may be transmitted to each protrusion  222 . The protrusions  222  are spaced apart from each other for distributing the shock-absorbing effects of the protrusions  222  over the coverage area. The height of the protrusions  222  may be 0.50 inches or approximately 0.50 inches. The thickness of base sheet  133 , side walls  137 , and peaks  138 , may be 0.035 inches or approximately 0.035 inches. 
     A concave comfort layer  230 , which may be comprised of a molded pad  231  of foam material, for example, ethylene-vinyl acetate (EVA) foam material, with a backing  232  of tricot fabric is removably attached to the inner surface of the concave shock absorbing layer  221  and is shaped to nest within the concave shock absorbing layer  221 . Molded pad  231  may have a thickness of 0.15 inches or approximately 0.15 inches. Hook pads may be adhered to the inner surface of shock absorbing layer  221  to removably connect with the tricot fabric backing  232  of concave comfort layer  230 , for removable attachment. Slot  234  is formed in comfort layer  230  to register with slot  228  in concave padding assembly  220 . Slots  235  are formed in comfort layer  230  to register with slots  229  in concave padding assembly  220 . 
     Rear shell  200  is removably attached to front shell  100  by a strap harness  250 . In the embodiment shown in  FIG. 31 , strap harness  250  is a generally H-shaped harness comprising central strap  251 , top strap  252 , and bottom strap  253 . Central strap  251  may be doubled back and partially bonded to itself to form integral loops  255 ,  256  for slidable passage therethrough of top strap  252 , and bottom strap  253  to form the general H-shaped configuration. The ends of central strap  251 , top strap  252 , and bottom strap  253  are provided with snap buckles  254  for removable attachment to snap screws provided on front shell  100 . Central strap  251 , top strap  252 , and bottom strap  253  are preferably formed of elastic strapping material. Top strap  252  and bottom strap  253  may be comprised of two straps of elastic strapping material partially overlaid and stitched together to form a stronger strap. 
     In use, central strap  251 , top strap  252 , and bottom strap  253  pass through slots formed for that purpose in rear shell  200  and concave padding assembly  220 , and front shell  100  as hereinafter described. Central strap  251  passes through slots  201 ,  228 ,  234  and  128 , to emerge from front shell  100  and attach by its snap buckle  254  to the snap nut attached to cushion  175  of middle liner  160 . Top strap  252  passes through slots  202 , emerges through a gap between concave padding assembly  220  and rear shell  200 , then passes through slots  129  to emerge from front shell  100  and attach by its snap buckles  254  to the snap nuts attached to cushions  176  of middle liner  160 . Bottom strap  253  passes through slots  203 ,  229  and  235 , then passes through lower ear holes  124  to emerge from front shell  100  and attach by its snap buckles  254  to the snap nuts attached to jaw cushions  145  of front liner  130 . 
     While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. It will also be understood that the present invention includes any combination of the features and elements disclosed herein and any combination of equivalent features. The exemplary embodiments shown herein are presented for the purposes of illustration only and are not meant to limit the scope of the invention. Thus, all the features of all the embodiments disclosed herein are interchangeable so that any element of any embodiment may be applied to any of the embodiments taught herein.