Systems for flexible facemask structures

A protective facemask for a helmet includes one or more compression portions. In one aspect, a facemask of a plurality of arcuately curved bars includes a frame portion and lateral bars configured to extend across the frontal opening of the helmet and join to the frame portion at terminal ends. The lateral bars include one or more compression portions which are more compliant to a given force than other portions of the plurality of arcuately curved bars. A compression portion may include a first material that is less rigid than a second material forming the other portions of the arcuately curved bars. A compression portion may further include first and second zones, with the first zone being more compliant to the given force than the second zone. Such compression portions may be positioned within the lateral bars near the point of joining with the frame.

TECHNICAL FIELD

The present disclosure relates to biomechanics aware protective gear.

DESCRIPTION OF RELATED ART

Protective gear such as sports and safety helmets are designed to reduce direct impact forces that can mechanically damage an area of contact. Protective gear will typically include padding and a protective shell to reduce the risk of physical head injury. Liners are provided beneath a hardened exterior shell to reduce violent deceleration of the head in a smooth uniform manner and in an extremely short distance, as liner thickness is typically limited based on helmet size considerations.

Some helmets, such as football helmets, also include facemasks for further protection while allowing visibility. Typical facemasks are heavy and fixed to the helmet, and impacts on face masks can be quite jarring.

Protective gear is reasonably effective in preventing injury. Nonetheless, the effectiveness of protective gear remains limited. Consequently, various mechanisms are needed to improve protective gear in a biomechanically aware manner.

SUMMARY

The following presents a simplified summary of the disclosure in order to provide a basic understanding of certain embodiments of the present disclosure. Provided are examples of mechanisms and processes relating to flexible facemask structures. In one aspect, which may include at least a portion of the subject matter of any of the preceding and/or following examples and aspects, a protective facemask for a helmet comprises a plurality of arcuately curved bars. The plurality of arcuately curved bars includes a frame portion configured to border a frontal opening of the helmet. The plurality of arcuately curved bars further include lateral bars configured to extend across the frontal opening of the helmet. Terminal ends of each lateral bar are joined to the frame portion. The plurality of arcuately curved bars include one or more compression portions which are more compliant to a given force than other portions of the plurality of arcuately curved bars.

The one or more compression portions comprise a first material that is less rigid than a second material comprising the other portions of the plurality of arcuately curved bars. A compression portion of the one or more compression portions may comprise a first zone and a second zone. The first zone is more compliant to a given force than the second zone. A portion of the second zone may be disposed within the first zone. The one or more compression portions may be positioned within the lateral bars near the point of joining with the frame. The facemask may comprise a monolithic structure.

In another aspect, a helmet is provided, which comprises a first shell layer and a facemask coupled to the first shell layer. The facemask comprises a plurality of arcuately curved bars. The plurality of arcuately curved bars includes a frame portion configured to border a frontal opening of the helmet. The plurality of arcuately curved bars further include lateral bars configured to extend across the frontal opening of the helmet. Terminal ends of each lateral bar are joined to the frame portion. The plurality of arcuately curved bars include one or more compression portions which are more compliant to a given force than other portions of the plurality of arcuately curved bars.

The one or more compression portions may comprise a first material that is less rigid than a second material comprising the other portions of the plurality of arcuately curved bars. A compression portion of the one or more compression portions may comprise a first zone and a second zone. The first zone may be more compliant to a given force than the second zone. The one or more compression portions may be positioned within the lateral bars near the point of joining with the frame. In certain aspects, the facemask comprises a monolithic structure.

The frame portion of the facemask may be coupled to the first shell layer by a fastening mechanism. A segment of the frame portion is disposed within a guide shaft of the fastening mechanism such that the segment of the frame portion may move along a length of the guide shaft from a first position to a second position. The fastening mechanism may further comprise a spring mechanism coupled to the segment of the frame portion. The spring mechanism may urge the segment of the frame portion into the first position. The segment of the frame portion may further move perpendicularly within the guide shaft with respect to the direction from the first position to the second position.

In a further aspect, a protective rail structure is provided, which comprises a frame portion and one or more arcuately curved bars. The terminal ends of each curved bar may join to the frame portion. The one or more curved bars may include one or more compression portions which are more compliant to a given force than other portions of the one or more curved bars.

The one or more compression portions may comprise a first material that is less rigid than a second material comprising the other portions of the one or more curved bars. A compression portion of the one or more compression portions may comprise a first zone and a second zone, wherein the first zone is more compliant to a given force than the second zone. A portion of the second zone may be disposed within the first zone. The one or more compression portions are positioned within the one or more curved bars near the point of joining with the frame.

DESCRIPTION OF EXAMPLE EMBODIMENTS

For example, the techniques of the present invention will be described in the context of helmets. However, it should be noted that the techniques of the present invention apply to a wide variety of different pieces of protective gear. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. Particular example embodiments of the present invention may be implemented without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.

Various techniques and mechanisms of the present invention will sometimes be described in singular form for clarity. However, it should be noted that some embodiments include multiple iterations of a technique or multiple instantiations of a mechanism unless noted otherwise. For example, a protective device may use a single strap in a variety of contexts. However, it will be appreciated that a system can use multiple straps while remaining within the scope of the present invention unless otherwise noted. Furthermore, the techniques and mechanisms of the present invention will sometimes describe a connection between two entities. It should be noted that a connection between two entities does not necessarily mean a direct, unimpeded connection, as a variety of other entities may reside between the two entities. For example, different layers may be connected using a variety of materials. Consequently, a connection does not necessarily mean a direct, unimpeded connection unless otherwise noted.

Overview

Protective gear, such as helmets, may include an outer shell layer designed to prevent direct penetration from any intruding or impeding object. Such protective gear may include various energy and impact transformers which absorb impact forces, rotational forces, shear forces, etc., to reduce the impact forces experienced by the user. Such energy and impact transformers may be located within a facemask structure of a helmet. For example, protective gear may include protective facemask structures for protecting the user's face while allowing optimal visibility. A facemask structure, as described herein, may include a frame portion which may be attached to the helmet by one or more fastening mechanisms. One or more lateral bars may extend across a frontal opening of the helmet and attach to the frame at terminal ends. One or more vertical bars, substantially perpendicular to the lateral bars may also be included and join to the lateral bars and/or the frame.

Such facemask structures may include compression zones which may deform when a force is applied to the facemask and act as an energy and impact transformer to absorb impact forces, rotational forces, shear forces, etc. As such, compression zones may act to reduce the amount of force experienced by a user. Such compression zones may comprise material that is less rigid and/or more compliant than the material comprising the other portions of the facemask. The compression zones may be located within the lateral bars and/or vertical bars. In some aspects, the compression zones are located within the lateral bars near or at the location of joining of the lateral bars with the frame portion. Thus, a force applied to the facemask may cause the lateral bars and/or the vertical bars to move with respect to the helmet, while the frame portion remains secured to the helmet by the fastening mechanisms.

In other aspects, the compression zones may comprise two or more zones, each zone including different materials, or combination of materials. The different zones may allow the facemask to deform based on the amount of force applied to the facemask. For example, a first zone may be less rigid and/or more compliant than a second zone. Thus, a minimum force may be sufficient to cause deformation of the first zone, but not in the second zone. If a larger force is applied to facemask, it may cause the second zone to deform, or both the second zone and the first zone to deform. The compression zones and various separate zones within each compression zone may be configured to bend in any direction with respect to the helmet.

Impact and energy transformers may also be included in the fastening mechanisms securing the facemask to the helmet. In some aspects a fastening mechanism may include a housing with a segment of the facemask frame disposed within a guide shaft of the housing. The segment of the facemask frame may be able to move along the guide shaft when force is applied to the facemask. The housing may further include a spring mechanism within coupled to the segment of the facemask frame urging it into a starting position. When force is applied to the facemask and the segment of the facemask frame moved along the guide shaft, the spring mechanism may absorb some of the energy of the applied force.

The outer shell of a helmet may further be connected to one or more interior shell layers with outer energy and impact transformer layers between each shell layer. The outer and inner energy and impact transformer layers flexibly connect the shell layers to absorb impact forces, rotational forces, shear forces, etc., and allow the various shell layers to move and slide relative to the other shell layers. The energy and impact transformer layers may be constructed using gels, fluids, electro-rheological elements, magneto-rheological elements, etc. The protective gear may be formed as helmets or body protection for various activities and may be used to protect users from not only impact and penetrative forces, but rotational and shear forces as well.

Example Embodiments

Protective gear such as knee pads, shoulder pads, and helmets are typically designed to prevent direct impact injuries or trauma. For example, many pieces of protective gear reduce full impact forces that can structurally damage an area of contact such as the skull or knee. Major emphasis is placed on reducing the likelihood of cracking or breaking of bone. However, the larger issue is preventing the tissue and neurological damage caused by rotational forces, shear forces, oscillations, and tension/compression forces.

For head injuries, the major issue is neurological damage caused by oscillations of the brain in the cranial vault resulting in coup-contracoup injuries manifested as direct contusions to the central nervous system (CNS), shear injuries exacerbated by rotational, tension, compression, and/or shear forces resulting in demyelination and tearing of axonal fibers; and subdural or epidural hematomas. Because of the emphasis in reducing the likelihood of cracking or breaking bone, many pieces of protective gear do not sufficiently dampen, transform, dissipate, and/or distribute the rotational, tension, compression, and/or shear forces, but rather focus on absorbing the direct impact forces over a small area, potentially exacerbating the secondary forces on the CNS. Initial mechanical damage results in a secondary cascade of tissue and cellular damage due to increased glutamate release or other trauma induced molecular cascades.

Traumatic brain injury (TBI) has immense personal, societal and economic impact. The Center for Disease Control and Prevention documented 1.4 million cases of TBI in the USA in 2007. This number was based on patients with a loss of consciousness from a TBI resulting in an Emergency Room visit. With increasing public awareness of TBI this number increased to 1.7 million cases in 2010. Of these cases there were 52,000 deaths and 275,000 hospitalizations, with the remaining 1.35 million cases released from the ER. Of these 1.35 million discharged cases at least 150,000 people will have significant residual cognitive and behavioral problems at 1-year post discharge from the ER. Notably, the CDC believes these numbers under represent the problem since many patients do not seek medical evaluation for brief loss of consciousness due to a TBI. These USA numbers are similar to those observed in other developed countries and are likely higher in third-world countries with poorer vehicle and head impact protection. To put the problem in a clearer perspective, the World Health Organization (WHO) anticipates that TBI will become a leading cause of death and disability in the world by the year 2020.

The CDC numbers do not include head injuries from military actions. Traumatic brain injury is widely cited as the “signature injury” of Operation Enduring Freedom and Operation Iraqi Freedom. The nature of warfare conducted in Iraq and Afghanistan is different from that of previous wars and advances in protective gear including helmets as well as improved medical response times allow soldiers to survive events such as head wounds and blast exposures that previously would have proven fatal. The introduction of the KEVLAR® (a type of para-aramid fiber) helmet has drastically reduced field deaths from bullet and shrapnel wounds to the head. However, this increase in survival is paralleled by a dramatic increase in residual brain injury from compression and rotational forces to the brain in TBI survivors. Similar to that observed in the civilian population the residual effects of military deployment related TBI are neurobehavioral symptoms such as cognitive deficits and emotional and somatic complaints. The statistics provided by the military cite an incidence of 6.2% of head injuries in combat zone veterans. One might expect these numbers to hold in other countries.

In addition to the incidence of TBI in civilians from falls and vehicular accidents or military personnel in combat there is increasing awareness that sports-related repetitive forces applied to the head with or without true loss of consciousness can have dire long-term consequences. It has been known since the 1920's that boxing is associated with devastating long-term issues including “dementia pugilistica” and Parkinson-like symptoms (i.e. Mohammed Ali). We now know that this repetitive force on the brain dysfunction extends to many other sports. Football leads the way in concussions with loss of consciousness and post-traumatic memory loss (63% of all concussions in all sports), wrestling comes in second at 10% and soccer has risen to 6% of all sports related TBIs. In the USA 63,000 high school students suffer a TBI per year and many of these students have persistent long-term cognitive and behavioral issues. This disturbing pattern extends to professional sports where impact forces to the body and head are even higher due to the progressive increase in weight and speed of professional athletes. Football has dominated the national discourse in the area but serious and progressive long-term neurological issues are also seen in hockey and soccer players and in any sport with the likelihood of a TBI. Repetitive head injuries result in progressive neurological deterioration with neuropathological findings mimicking Alzheimer's disease. This syndrome with characteristic post-mortem neuropathological findings on increases in Tau proteins and amyloid plaques is referred to as Chronic Traumatic Encephalopathy (CTE).

The human brain is a relatively delicate organ weighing about 3 pounds and having a consistency a little denser than gelatin and close to that of the liver. From an evolutionary perspective, the brain and the protective skull were not designed to withstand significant external forces. Because of this poor impact resistance design, external forces transmitted through the skull to the brain that is composed of over 100 billion cells and up to a trillion connecting fibers results in major neurological problems. These injuries include contusions that directly destroy brain cells and tear the critical connecting fibers necessary to transmit information between brain cells.

Contusion injuries are simply bleeding into the substance of the brain due to direct contact between the brain and the bony ridges of the inside of the skull. Unfortunately, the brain cannot tolerate blood products and the presence of blood kicks off a biological cascade that further damages the brain. Contusions are due to the brain oscillating inside the skull when an external force is applied. These oscillations can include up to three cycles back and forth in the cranial vault and are referred to as coup-contra coup injuries. The coup part of the process is the point of contact of the brain with the skull and the contra-coup is the next point of contact when the brain oscillates and strikes the opposite part of the inside of the skull.

The inside of the skull has a series of sharp bony ridges in the front of the skull and when the brain is banged against these ridges it is mechanically torn resulting in a contusion. These contusion injuries are typically in the front of the brain damaging key regions involved in cognitive and emotional control.

Shear injuries involve tearing of axonal fibers. The brain and its axonal fibers are extremely sensitive to rotational forces. Boxers can withstand hundreds of punches directly in the face but a single round-house punch or upper cut where the force comes in from the side or bottom of the jaw will cause acute rotation of the skull and brain and typically a knock-out. If the rotational forces are severe enough, the result is tearing of axons.

FIG. 1below shows how different forces affect axons. Compression101and tension103can remove the protective coating on an axon referred to as a myelin sheath. The myelin can be viewed as the rubber coating on a wire. If the internal wire of the axon is not cut the myelin can re-grow and re-coat the “wire” which can resume axonal function and brain communication. If rotational forces are significant, shear forces105tear the axon. This elevates the problem since the ends of cut axons do not re-attach. This results in a permanent neurological deficit and is referred to as diffuse axonal injury (DAI), a major cause of long-term neurological disability after TBI.

Some more modern pieces of protective gear have been introduced with the awareness that significant injuries besides musculoskeletal or flesh injuries in a variety of activities require new protective gear designs.

U.S. Pat. No. 7,076,811 issued to Puchalski describes a helmet with an impact absorbing crumple or shear zone. “The shell consists of three (or more) discrete panels that are physically and firmly coupled together providing rigid protection under most circumstances, but upon impact the panels move relative to one another, but not relative to the user's head, thereby permitting impact forces to be dissipated and/or redirected away from the cranium and brain within. Upon impact to the helmet, there are sequential stages of movement of the panels relative to each other, these movements initially being recoverable, but with sufficient vector forces the helmet undergoes structural changes in a pre-determined fashion, so that the recoverable and permanent movements cumulatively provide a protective ‘crumple zone’ or ‘shear zone’.”

U.S. Pat. No. 5,815,846 issued to Calonge describes “An impact resistant helmet assembly having a first material layer coupled to a second material layer so as to define a gas chamber there between which contains a quantity that provides impact dampening upon an impact force being applied to the helmet assembly. The helmet assembly further includes a containment layer disposed over the second material layer and structured to define a fluid chamber in which a quantity of fluid is disposed. The fluid includes a generally viscous gel structured to provide some resistance against disbursement from an impacted region of the fluid chamber to non-impacted regions of the fluid chamber, thereby further enhance the impact distribution and dampening of the impact force provided by the helmet assembly.”

U.S. Pat. No. 5,956,777 issued to Popovich describes “A helmet for protecting a head by laterally displacing impact forces, said helmet comprising: a rigid inner shell formed as a single unit; a resilient spacing layer disposed outside of and in contact with said inner shell; and an articulated shell having a plurality of discrete rigid segments disposed outside of and in contact with said resilient spacing layer and a plurality of resilient members which couple adjacent ones of said rigid segments to one another.”

U.S. Pat. No. 6,434,755 issued to Halstead describes a football helmet with liner sections of different thicknesses and densities. The thicker, softer sections would handle less intense impacts, crushing down until the thinner, harder sections take over to prevent bottoming out. Still other ideas relate to using springs instead of crushable materials to manage the energy of an impact. Springs are typically associated with rebound, and energy stored by the spring is returned to the head. This may help in some instances, but can still cause significant neurological injury. Avoiding energy return to the head is a reason that non-rebounding materials are typically used.

Traditional shell layers and lining layers protect the skull nicely and have resulted in a dramatic reduction in skull fractures and bleeding between the skull and the brain (subdural and epidural hematomas). Military helmets use KEVLAR® (a type of para-aramid fiber) to decrease penetrating injuries from bullets, shrapnel etc. Unfortunately, these approaches are not well designed to decrease direct forces and resultant coup-contra coup injuries that result in both contusions and compression-tension axon injuries. Furthermore, many helmets do not protect against rotational forces that are a core cause of a shear injury and resultant long-term neurological disability in civilian and military personnel. Although the introduction of KEVLAR® (a type of para-aramid fiber) in military helmets has decreased mortality from penetrating head injuries, the survivors are often left with debilitating neurological deficits due to contusions and diffuse axonal injury.

Some of the protective gear mechanisms are not sufficiently biomechanically aware and are not sufficiently customized for particular areas of protection. These protective gear mechanisms also are not sufficiently active at the right time scales to avoid damage. For example, in many instances, materials like gels may only start to convert significant energy into heat after significant energy has been transferred to the brain. Similarly, structural deformation mechanisms may only break and absorb energy after a significant amount of energy has been transferred to the brain.

Current mechanisms are useful for particular circumstances but are limited in their ability to protect against numerous types of neurological damage. Consequently, an improved smart biomechanics aware and energy conscious protective gear mechanism is provided to protect against mechanical damage as well as neurological damage.

In addition to various shell configurations for the helmet portion, the construction of a facemask, for example in football helmets, may be improved to provide absorption of mechanical force. According to various embodiments, a facemask may include various strategically placed compression zones which may deform to absorb forces on the facemask. The design of this element could be a part of the smart energy conscious biomechanics aware design for protection. The energy and impact transformer includes a mechanism for the dissipation, transformation, absorption, redirection of force/energy at the right time scales (in some cases as small as a few milliseconds or hundreds of microseconds).

In particular embodiments, a facemask as described by the present disclosure may be attached to a helmet comprising a container mechanism which provides structure to allow use of an energy and impact transformer. The container mechanism may be two or three shells holding one or more layers of energy and impact transformer materials. That is, a multiple shell structure may have energy and impact transformer materials between adjacent shell layers. The shells may be designed to prevent direct penetration from any intruding or impeding object. In some examples, the outer shell may be associated with mechanisms for impact distribution, energy transformation, force dampening, and shear deflection and transformation. In some examples, the container mechanism can be constructed of materials such as polycarbonate, fiberglass, KEVLAR® (a type of para-aramid fiber), metal, alloys, combinations of materials, etc.

According to various embodiments, the energy and impact transformer provides a mechanism for the dissipation, transformation, absorption, and redirection of force and energy at the appropriate time scales. The energy and impact transformer may include a variety of elements. In some examples, a mechanical transformer element connects multiple shells associated with a container mechanism with mechanical structures or fluids that help transform the impact or shear forces on an outer shell into more benign forces or energy instead of transferring the impact or shear forces onto an inner shell.

In some examples, a mechanical transformer layer is provided between each pair of adjacent shells. The mechanical transform may use a shear truss-like structure connecting an outer shell and an inner shell that dampens any force or impact. In some examples, shear truss structure layers connect an outer shell to a middle shell and the middle shell to an inner shell. According to various embodiments, the middle shell or center shell may slide relative to the inner shell and reduce the movement and/or impact imparted on an outer shell. In particular embodiments, the outer shell may slide up to several centimeters relative to the middle shell. In particular embodiments, the material used for connecting the middle shell to the outer shell or the inner shell could be a material that absorbs/dissipates mechanical energy as thermal energy or transformational energy. The space between the outer shell, the middle shell, and the inner shell can be filled with absorptive/dissipative material such as fluids and gels.

According to various embodiments, the energy and impact transformer may also include an electro-rheological element. Different shells may be separated by an electro-rheological element with electric field dependent viscosity. The element may essentially stay solid most of the time. When there is stress/strain on an outer shell, the electric field is activated so that the viscosity changes depending on the level of stress/strain. Shear forces on an inner shell are reduced to minimize impact transmission.

In particular embodiments, the energy and impact transformer also includes a magneto-rheological element. Various shells may be separated by magneto rheological elements with magnetic field dependent viscosity. The element may essentially stay solid most of the time. When there is stress/strain on an outer shell, the magnetic field is activated so that the viscosity changes depending on the level of stress/strain. Shear forces on an inner shell are reduced to minimize impact transmission.

Electro-rheological and magneto-rheological elements may include smart fluids with properties that change in the presence of electric field or a magnetic field. Some smart fluids undergo changes in viscosity when a magnetic field is applied. For example, a smart fluid may change from a liquid to a gel when magnets line up to create a magnetic field. Smart fluids may react within milliseconds to reduce impact and shear forces between shells.

In other examples, foam and memory foam type elements may be included to absorb and distribute forces. In some examples, foam and memory foam type elements may reside beneath the inner shell. A magnetic suspension element may be used to actively or passively reduce external forces. An inner core and an outer core may be separated by magnets that resist each other, e.g. N-poles opposing each other. The inner and outer cores naturally would want to move apart, but are pulled together by elastic materials. When an outer shell is impact and the magnets are pushed closer, forces between the magnets increase through the air gap.

According to various embodiments, a concentric geodesic dome element includes a series of inner shells, each of which is a truss based geodesic dome, but connected to the outer geodesic through structural or fluidic mechanisms. This allows each geodesic structure to fully distribute its own shock load and transmit it in a uniform manner to the dome underneath. The sequence of geodesic structures and the separation by fluid provides uniform force distribution and/or dissipation that protects the inner most shell from these impacts.

In particular embodiments, a fluid/accordion element would separate an inner shell and an outer shell using an accordion with fluid/gel in between. This would allow shock from the outer core to be transmitted and distributed through the enclosed fluid uniformly while the accordion compresses to accommodate strain. A compressed fluid/piston/spring element could include piston/cylinder like elements with a compressed fluid in between that absorbs the impact energy while increasing the resistance to the applied force. The design could include additional mechanical elements like a spring to absorb/dissipate the energy.

In still other examples, a fiber element involves using a rippled outer shell with texture like that of a coconut. The outer shell may contain dense coconut fiber like elements that separate the inner core from the outer core. The shock can be absorbed by the outer core and the fibrous filling. Other elements may also be included in an inner core structure. In some examples, a thick stretchable gel filled bag wrapped around the inner shell could expand and contract in different areas to instantaneously transfer and distribute forces. The combination of the elasticity of a bag and the viscosity of the gel could provide for cushioning to absorb/dissipate external forces.

According to various embodiments, a container device includes multiple shells such as an outer shell, a middle shell, and an inner shell. The shells may be separated by energy and impact transformer mechanisms. In some examples, the shells and the energy and impact transformer mechanisms can be integrated or a shell can also operate as an energy and impact transformer.

FIG. 2illustrates one example of a multiple shell system. An outer shell201, a middle shell203, and an inner shell205may hold energy and impact transformative layers211and213between them. Energy and impact transformer layer211residing between shells201and203may allow shell201to move and/or slide with respect to middle shell203. By allowing sliding movements that convert potential head rotational forces into heat or transformation energy, shear forces can be significantly reduced.

Similarly, middle shell203can move and slide with respect to inner shell205. In some examples, the amount of movement and/or sliding depends on the viscosity of fluid in the energy and impact transformer layers211and213. The viscosity may change depending on electric field or voltage applied. In some other examples, the amount of movement and/or sliding depends on the materials and structures of materials in the energy and impact transformer layers211and213.

According to various embodiments, when a force is applied to an outer shell201, energy is transferred to an inner shell205through a suspended middle shell203. The middle shell203shears relative to the top shell201and inner shell205. In particular embodiments, the energy and impact transformer layers211and213may include thin elastomeric trusses between the shells in a comb structure. The energy and impact transformer layers211and213may also include energy dampening/absorbing fluids or devices.

According to various embodiments, a number of different physical structures can be used to form energy and impact transformer layers211and213. In some examples, energy and impact transformer layer211includes a layer of upward or downward facing three dimensional conical structures separating outer shell201and middle shell203. Energy and impact transformer layer213includes a layer of upward or downward facing conical structures separating middle shell203and inner shell205. The conical structures in energy and impact transformer layer211and the conical structures in energy and impact transformer layer213may or may not be aligned. In some examples, the conical structures in layer211are misaligned with the conical structures in layer213to allow for improved shear force reduction.

In some examples, conical structures are designed to have a particular elastic range where the conical structures will return to the same structure after force applied is removed. The conical structures may also be designed to have a particular plastic range where the conical structure will permanently deform if sufficient rotational or shear force is applied. The deformation itself may dissipate energy but would necessitate replacement or repair of the protective gear.

Conical structures are effective in reducing shear, rotational, and impact forces applied to an outer shell201. Conical structures reduce shear and rotational forces applied from a variety of different directions. According to various embodiments, conical structures in energy and impact transformer layers211are directed outwards with bases situated on middle shell203and inner shell205respectively. In some examples, structures in the energy and impact transformer layer may be variations of conical structures, including three dimensional pyramid structures and three dimensional parabolic structures. In still other examples, the structures may be cylinders.

FIG. 3illustrates one example of a piece of protective gear, in accordance with or more embodiments. According to various embodiments, helmet301may include one or more shell layers. As shown inFIG. 3, helmet301includes an outer shell layer303, an outer energy and impact transformer305, a middle shell layer307, an inner energy and impact transformer309, and an inner shell layer311. The helmet301may also include a lining layer within the inner shell layer311. In particular embodiments, the inner shell layer311includes attachment points315for a chin strap for securing helmet301. In particular embodiments, the outer shell layer303includes attachment points315for a visor, chin bar, face guard, face cage, facemask and/or other face protection mechanism generally. In some examples, the inner shell layer311, middle shell layer307, and outer shell layer303includes ridges317and/or air holes for breathability. The outer shell layer303, middle shell layer307, and inner shell layer311may be constructed using plastics, resins, metal, composites, etc. In some instances, the outer shell layer303, middle shell layer307, and inner shell layer311may be reinforced using fibers such as aramids. The energy and impact transformer layers305and309can help distribute mechanical energy and shear forces so that less energy is imparted on the head.

According to various embodiments, a chin strap321is connected to the inner shell layer311to secure helmet positioning. The various shell layers are also sometimes referred to as containers or casings. In many examples, the inner shell layer311covers a lining layer (not shown). The lining layer may include lining materials, foam, and/or padding to absorb mechanical energy and enhance fit. A lining layer may be connected to the inner shell layer311using a variety of attachment mechanisms such as glue or VELCRO® (a type of hook-and-loop fastener). According to various embodiments, the lining layer is pre-molded to allow for enhanced fit and protection. According to various embodiments, the lining layer may vary, e.g. from 4 mm to 40 mm in thickness, depending on the type of activity a helmet is designed for. In some examples, custom foam may be injected into a fitted helmet to allow for personalized fit, as further described below. In other examples, differently sized shell layers and lining layers may be provided for various activities and head sizes.

The middle shell layer307may only be indirectly connected to the inner shell layer311through energy and impact transformer309. In particular embodiments, the middle shell layer307floats above inner shell layer311. In other examples, the middle shell layer307may be loosely connected to the inner shell layer311. In the same manner, outer shell layer303floats above middle shell layer307and may only be connected to the middle shell layer through energy and impact transformer305. In other examples, the outer shell layer303may be loosely and flexibly connected to middle shell layer307and inner shell layer311. The shell layers303,307, and311provide protection against penetrating forces while energy and impact transformer layers305and309provide protection against compression forces, shear forces, rotational forces, etc. According to various embodiments, energy and impact transformer layer305allows the outer shell303to move relative to the middle shell307and the energy and impact transformer layer309allows the outer shell303and the middle shell307to move relative to the inner shell311. Compression, shear, rotation, impact, and/or other forces are absorbed, deflected, dissipated, etc., by the various layers.

According to various embodiments, the skull and brain are not only provided with protection against skull fractures, penetrating injuries, subdural and epidural hematomas, but also provided with some measure of protection against direct forces and resultant coup-contra coup injuries that result in both contusions and compression-tension axon injuries. The skull is also protected against rotational forces that are a core cause of a shear injury and resultant long-term neurological disability in civilian and military personnel.

In some examples, the energy and impact transformer layers305and309may include passive, semi-active, and active dampers. According to various embodiments, the outer shell303, middle shell307, and the inner shell311may vary in weight and strength. In some examples, the outer shell303has significantly more weight, strength, and structural integrity than the middle shell307and the inner shell311. The outer shell303may be used to prevent penetrating forces, and consequently may be constructed using higher strength materials that may be more expensive or heavier.

As previously described, in various embodiments, the lining layer is pre-molded to allow for enhanced fit and protection. In some examples, the lining layer may be custom formed to provide a personalized fit for an individual's head shape. Current lining layers may include foam padding, inflatable bladders, and other lining materials. Such lining layers are the same for each helmet regardless of the shape of the individual's head. This may cause an uneven fit including gaps or high pressured areas between the head and the lining layer and/or the inner shell layer causing discomfort, as well as unwanted movement of the helmet. For example, upon impact, a helmet with an uneven fit may shift and cause the lining layer and/or inner shell layer to further impact the head. Furthermore, such uneven fit may cause an uneven distribution of force upon impact which may result in a larger impact force being focused on a portion of the head.

A more form fitting lining layer may provide an increased comfort in fit eliminating any gaps or pressure points. Furthermore, a more form fitting lining layer may also provide a more secure fit resulting in increased protection by keeping the inner shell layer more stable relative to the head.

FIGS. 4B and 4Billustrate a helmet401with attached facemask400, in accordance with one or more embodiments. In some embodiments, helmet400may be helmet301. As depicted inFIGS. 4A and 4B, helmet401includes shell layer403, liner413, chin strap410, straps412, and attachment points414. In some embodiments shell layer403may be outer shell layer303. In some embodiments attachment points414may be attachment points315for chin strap410for securing helmet401, as described with reference toFIG. 3. In some embodiments chinstrap410may include straps412which secure chin strap410to attachment points414by a buckle, snap, or other similar securing mechanism414-A. In some embodiments, chin strap410may be chinstrap321.

As further depicted, facemask400includes frame402and lateral bars404-A,404-B, and404-C. Frame402may be arcuately curved and shaped to border the frontal opening of helmet401. In some embodiments frame402may be shaped to lie along the curved surface of helmet401. Lateral bars404-A,404-B, and404-C extend across the frontal opening of helmet401and join the frame402at terminal ends. For example, lateral bar404-A joins frame402at terminal end404-A1on one side of helmet401and at terminal end404-A2on the other side of helmet401. Similarly, lateral bar404-B joints frame402at terminal ends404-B1and404-B2, and lateral bar404-C joints frame402at terminal ends404-C1and404-C2. In some embodiments, lateral bars404-A,404-B, and404-C may be arcuately curved to form a cage like structure in front of the frontal opening of helmet401.

In some embodiments, vertical bars408are coupled to one or more lateral bars404-A,404-B, and/or404-C. In some embodiments, vertical bars408are positioned substantially perpendicular to lateral bars404-A,404-B, and/or404-C. As depicted, lateral bar404-C extends across the frontal opening and curves upward at the terminal ends404-C1and404-C2. In some embodiments, such terminal ends404-C1and404-C2may be curved such that portions of lateral bar404-C may be substantially parallel to vertical bars408. In some embodiments, lateral bar404-C may also be coupled to lateral bars404-A and/or404B.

Various embodiments of helmet401may include various configurations of lateral bars and vertical bars. For example, there may be more or less lateral bars than depicted inFIGS. 4A and 4B. In some embodiments, the lateral bars may be joined to frame402at other portions of frame402. Similarly, there may be more or less vertical bars408than depicted inFIGS. 4A and 4B. In some embodiments, vertical bars408may be coupled to lateral bars404-A,404-B, and/or404-C at different portions. For example, a vertical bar408may only be coupled to lateral bars404-A and404-B. In some embodiments, vertical bars408may also join to frame402. In some embodiments vertical bars408may additionally, and/or alternatively, include compression zones450-A1,450-A2,450-B1,450-B2,450-C1, and450-C2, as further described below.

In some embodiments, frame402, vertical bars408, and lateral bars404-A,404-B, and404-C of facemask400may comprise a suitable base material. In some embodiments, the core of facemask400may be constructed of materials such as polycarbonate, fiberglass, KEVLAR® (a type of para-aramid fiber), metal, alloys, combinations of materials, etc. For example, the structure of facemask400may be stamped from a metal core. The core may be made from a high strength, durable, shock resistant, stampable, aluminum alloy of a high aluminum content such as aluminum alloy 2024 T-3. In other embodiments, the core may be constructed via traditional machining processes. In yet further embodiments, the core may be constructed via various additive manufacturing processes, including fused deposition manufacturing.

In various embodiments, the core is surrounded with a tough durable coating. For example, the core may be covered by a plastic coating, which is softer than the core. Such coating may be added by dipping the facemask into polyethylene powder. In some embodiments, the core may be covered by a rubber coating. Such rubber coating may comprise composite reinforced rubber, combining a rubber matrix and a reinforcing material, such as a fiber. Such rubber coating may be constructed by molding or various other machining methods, including cryogenic machining. In some embodiments, the coating may comprise another metal or metal alloy. In other embodiments, the coating may comprise various other materials with desired elasticity and strength properties.

Facemask400is coupled to shell403of helmet400via fastening mechanisms416. As depicted inFIGS. 4A and 4Bthere are four fastening mechanisms416, two at the front securing the middle portion of frame402and one fastening mechanism416on each side of helmet401securing the lateral portions of frame402. In some embodiments, more or less fastening mechanisms416may be included secure facemask400to helmet401. In some embodiments, fastening mechanisms may additionally include an energy transformer system to absorb forces applied to facemask400. Such embodiments will be further described below with reference toFIGS. 9A and 9B.

In various embodiments, facemask400may include one or more compression portions. As used herein, the term “compression zone” may be used interchangeably with “compression portion.” As depicted inFIGS. 4A and 4B, facemask400includes six compression zones450-A1,450-A2,450-B1,450-B2,450-C1, and450-C2. For example, compression zone450-A1is located at terminal end404-A1of lateral bar404-A, and compression zone450-A2is located at terminal end404-A2of lateral bar404-A. Compression zone450-B1is located at terminal end404-B1of lateral bar404-B, and compression zone450-B2is located at terminal end404-B2of lateral bar404-B. Compression zone450-C1is located at terminal end404-C1of lateral bar404-C, and compression zone450-C2is located at terminal end404-C2of lateral bar404-C.

In various embodiments, there may be more or less compression zones as shown inFIGS. 4A and 4B. For example, facemask400may only include compression zones at the terminal ends of lateral bars404-A and404-B. In various embodiments, compression zones may be located in various other portions of lateral bars404-A,404-B, and404-C. For example, compression zones may additionally, and/or alternatively be located at portions of the lateral bars away from the terminal ends. In other embodiments, some compression zones may be located at terminal ends of lateral bars, while other compression zones are not. In other embodiments, compression zones may additionally, and/or alternatively, be located at the center of each lateral bar. In some embodiments, compression zones may be located on the frame402.

In various embodiments, compression zones, such as compression zones450-A1,450-A2,450-B1,450-B2,450-C1, and450-C2, allow facemask400to deform, such as by bending and/or flexing, with respect to helmet401and the user's head therein. In some embodiments, this flexing of the facemask may act as an impact transformer to absorb at least some force directed to the facemask and reduce the impact of such force onto the user. As previously discussed with reference to helmet layers, such impact transforming compression zones may include a mechanism for the dissipation, transformation, absorption, redirection of force/energy. The structure of compression zones are further discussed with reference toFIGS. 5A-5B, 6A-6B, 7A-7E, and 8A-8B.

FIGS. 5A and 5Billustrate the movement of a compression zone550of a facemask500, in accordance with one or more embodiments. In some embodiments, facemask500may be facemask400.FIGS. 5A and 5Bdepict a bar504of facemask500coupled to a frame502of facemask500. In some embodiments, frame502may be frame402. In some embodiments, bar504may be lateral bar404-A,404-B, and/or404-C joined to frame402. Bar504includes compression zone550. In some embodiments, compression zone550may be compression zone450-A1,450-A2,450-B1,450-B2,450-C1, and/or450-C2. Bar portion540indicates the other portions of bar504that are not a part of compression zone550. Longitudinal axis590is an axis running through the center of bar504.

In some embodiments, compression zone550comprises a material, or a combination of materials, that is less rigid than the material, or combination of materials, comprising the other bar portion540of bar504and/or frame502. Thus, a smaller minimum force would be required to cause compression zone550to deform.FIG. 5Ashows the positioning and shape of bar504with no force and/or an inadequate force applied to facemask500. InFIG. 5A, no portion of bar504is deformed.

FIG. 5Bshows the positioning and shape of bar504with a sufficient amount of force applied to facemask500to deform compression zone550. As can be seen, the force causes compression zone550to deform, while frame502and bar portion540rigidly remain in their original straight placement. Such deformation may act as an impact transformer for the dissipation, transformation, absorption, redirection of the applied force/energy, thereby reducing the force/energy experienced by the user wearing the helmet. After the impact force has dissipated, the elastic characteristics of compression zone550may allow facemask500to return to the original form, as depicted inFIG. 5A. As shown inFIGS. 5A-5B, compression zone550has deformed in a direction relative to longitudinal axis590. However, in some embodiments, compression zone550may be able to deform in any direction around longitudinal axis590.

FIGS. 6A-6Bare schematic cross-sectional views of a compression zone550of a facemask, in accordance with one or more embodiments.FIG. 6Aillustrates a particular embodiment of a facemask500-A. In some embodiments, facemask500-A may be facemask500. A detailed view of a portion of facemask500-A is shown, including frame502and terminal end of a bar504joining frame502. InFIG. 6A, the dashed lines delineate the structure of frame502from bar504. Frame502and bar portion540of bar504include a core544. As previously described, core544may be constructed by traditional machining processes, additive manufacturing processes, and/or stamped from a metal alloy, such as a high strength, durable, shock resistant, stampable, aluminum alloy of a high aluminum content such as aluminum alloy 2024 T-3. As also previously described, core544is surrounded by coating542.

In some embodiments, compression zone550may not include a core structure. Instead, compression zone550may comprise completely of the material comprising coating542. As such, compression zone550may comprise a solid piece of the material comprising coating542, which may be continuous with coating portions542surrounding bar portion540and frame502. In some embodiments, coating542may comprise a material that is less rigid and/or more compliant than the combination of materials comprising bar portion540, allowing it to deform with a smaller minimum force. Once the minimum force has dissipated, the elasticity of the materials, or combination of materials, comprising compression zone550may allow facemask to return to its original form.

A facemask500, as depicted inFIG. 6Amay be constructed by first forming the coating542. Such coating542may be formed by traditional machining methods, including molding, casting, turning, milling, drilling, grinding, etc. Furthermore, cavities or channels may be created within coating542by machining methods to allow insertion of core544. Any remaining openings may be covered by additional coating material542to fully enclose the inserted core material544. In some embodiments, the core542located within frame portion502may be the same as the core material544located within bar portion540of bar504. In other embodiments, the core material542located within frame portion502may differ from the core material544located within bar portion540of bar504.

FIG. 6Billustrates a particular embodiment of a facemask500-B. In some embodiments, facemask500-B may be facemask500. As inFIG. 6A, a detailed view of the frame502and terminal end of a bar504joining frame502is shown inFIG. 6B. Frame502and bar portion540of bar504include a core544surrounded by a coating542. As further depicted inFIG. 6B, compression zone550includes a compression core546within coating542. Compression core546may comprise a material that is less rigid and/or more compliant than core544, allowing it to deform with a smaller minimum force. Once the minimum force has dissipated, the elasticity of the materials, or combination of materials, comprising compression core546may allow facemask to return to its original form.

Compression core546may be attached to the core544within frame502and bar portion540by glue, adhesive, and/or by welding processes. Plastic welding may be implemented for cores544and compression cores546constructed of thermoplastic material. In some embodiments, cores544and compression cores546constructed from metals may be welded by shield metal arc welding, gas tungsten arc welding, gas metal arc welding, flux-cored arc welding, submerged arc welding, electroslag welding, or other known welding processes. In some embodiments, compression core546and cores544of facemask500comprise a monolithic structure after attachment. Subsequently, coating542may be added to cover the compression core546and core544structures.

In some embodiments, the compression zone of a facemask may include multiple segments (or zones) comprising materials, or combination of materials, with varying rigidity and/or compliance.FIGS. 7A-7Eillustrate the movement of a compression zone750with multiple zones, in accordance with one or more embodiments.FIG. 7A-7Eillustrate a portion of facemask700. In some embodiments, facemask700may be facemask400. As shown inFIG. 7A, facemask700may include a bar704of facemask700coupled to a frame702of facemask700. In some embodiments, frame702may be frame402. In some embodiments, bar704may be lateral bar404-A,404-B, and/or404-C joined to frame402. Bar704includes compression zone750. In some embodiments, compression zone750may be compression zone450-A1,450-A2,450-B1,450-B2,450-C1, and/or450-C2, as described inFIGS. 4A-4B. Bar portion740indicates the other portions of bar704that are not a part of compression zone750. Longitudinal axis790is an axis running through the center of bar704.

As further depicted inFIG. 7A, compression zone750may include a first zone752and a second zone754. In some embodiments, the first zone752is more compliant than the second zone754. As such, a minimum sufficient force may cause deformation of the first zone752, but not in the second zone754. Further, the second zone754is more compliant than the frame702and/or bar portion740. As such, a larger minimum force will be required to cause a deformation of the second zone754, but not in frame702and/or bar portion740.FIG. 7Adepicts the positioning and shape of bar704with no force and/or an inadequate force applied to facemask700, such that no deformation of any portion or zone of bar704occurs.

Thus, in some embodiments, when sufficient minimum force required to deform the first zone752is applied to facemask700, the first zone752may deform by bending and/or flexing, as depicted inFIG. 7B. As shown inFIG. 7B, first zone752of compression zone750is bending in one direction relative to longitudinal axis790, while the second zone754remains in its original straight position. In some embodiments, first zone752of compression zone750may be able to deform in any direction around longitudinal axis790.

In some embodiments, when a sufficient minimum force required to deform the second zone754is applied to facemask700, both the first zone752and the second zone754may deform by bending and/or flexing, as depicted inFIG. 7C. As shown inFIG. 7C, second zone754of compression zone750is bending in one direction relative to longitudinal axis790. However, in some embodiments, second zone754of compression zone750may be able to deform in any direction around longitudinal axis790.FIG. 7Ddepicts facemask700with second zone754bending and/or flexing in another direction relative to longitudinal axis790. In various embodiments, first zone752and second zone754may additionally bend in any direction relative to one another.

Both the first zone752and second zone754inFIGS. 7C and 7Dare deformed due to an applied force. However, in some instances, when a sufficient minimum force required to deform the second zone754is applied to facemask700, only the second zone754may deform by bending and/or flexing, as depicted inFIG. 7E. As shown inFIG. 7E, first zone752and bar portion740of facemask700remain in their original straight position.

In some embodiments, the second zone754may be more compliant than the first zone752. In such embodiments, a sufficient minimum force will be sufficient to cause deformation of the second zone754, but not in the first zone752. Further, a larger minimum force will be required to cause a deformation of the first zone752, but not in frame702and/or bar portion740. The degree of deformation depicted in the previousFIGS. 5A-5B, and 7A-7Eare for descriptive purposes and may not be to scale and/or show actual amount of bending of facemasks500and/or700.

FIGS. 8A-8Care schematic cross-sectional views of a compression zone750comprising two zones, in accordance with one or more embodiments.FIG. 8Aillustrates a particular embodiment of a facemask700-A. In some embodiments, facemask700-A may be facemask700. A detailed view of a portion of facemask700-A is shown, including frame702and terminal end of a bar704joining frame702. Frame702and bar portion740of bar704include a core744. Core744is surrounded by coating742.

First zone752and second zone754of compression zone750are further depicted inFIG. 8A. First zone752includes a first zone core746and second zone754includes a second zone core748. First zone core746may comprise a material that is less rigid and/or more compliant than second zone core748, allowing it to deform with a smaller minimum force. Once such force has dissipated, the elasticity of the materials, or combination of materials, comprising first zone core746may allow facemask700-A to return to its original form. A larger minimum force may cause second zone core748and/or the first zone core746to deform. Once such force has dissipated, the elasticity of the materials, or combination of materials, comprising second zone core748and/or first zone core746may allow facemask700-A to return to its original form.

As previously described, the core materials in first zone746second zone748, bar portion740, and frame702may be attached to each other. For example, first zone core746may be attached to the second zone core748and core744within bar portion740by glue, adhesive, and/or by welding processes, previously described. In some embodiments, second zone core748may be similarly attached to core744within frame702by glue, adhesive, and/or by welding processes, previously described. In some embodiments, first zone core746, second zone core748, and cores744of facemask700-A comprise a monolithic structure after attachment. Subsequently, coating742may be added to cover first zone core746, second zone core748, and cores744.

FIG. 8Billustrates another embodiment of a facemask700-B. In some embodiments, facemask700-B may be facemask700. A detailed view of a portion of facemask700-B is shown, including frame702and terminal end of a bar704joining frame702. As previously described with reference toFIG. 8A, frame702and bar portion740of bar704include a core744. Furthermore, first zone752includes a first zone core746and second zone754includes a second zone core748. As also previously described, first zone core746may be attached to the second zone core748and cores744within bar portion740and frame702by glue, adhesive, and/or by welding processes, previously described.

In some embodiments, a portion of second zone core748may be disposed within first zone core746, as illustrated inFIG. 8B. In some embodiments, such configuration may provide added stability and/or improved attachment between materials. For example, second zone core748may comprise material that may be welded to core744in frame702. A portion of second zone core748may further be disposed within first zone752and welded to core744within bar portion740. First core zone746may then be formed around a portion of second core zone748, such that a portion of second zone core748is located within the center of first core zone746. In some embodiments, first zone core746may be formed as separate pieces and attached together around the portion of second zone core748. In some embodiments, first core zone746may additionally be attached to core744and/or second zone core748, by methods previously described above. In other embodiments, first core zone746is not additionally attached to core744and/or second zone core748. In some embodiments, a portion of first zone core746may be disposed within second zone core748. For example, first zone core746may extend through the center of second zone core748and attach to cores744within frame702and bar portion740.

In some embodiments, the material comprising first zone core746and/or second zone core748may be the same material comprising coating742. Such embodiment would be as if first zone752did not include any first zone core746, or as if second zone754did not include any second zone core748, respectively. For example,FIG. 8Cdepicts a particular embodiment of a facemask700-C where second zone754does not include a second zone core748. In some embodiments, facemask700-C may be facemask700. A detailed view of a portion of facemask700-C is shown, including frame702and terminal end of a bar704joining frame702.

As depicted inFIG. 8C, second zone754may include only material comprising coating742. Such embodiment may be formed similarly to facemask500-A inFIG. 6A, and may comprise similar materials as described with reference toFIG. 6A. In some embodiments, first zone752may not include a core746, but instead comprise only of material comprising coating746, while second zone754does include a second zone core748. In various embodiments, a compression zone750may include additional zones than as depicted inFIGS. 7A-7D and 8A-8C. In various embodiments, a helmet, such as helmet401may include any combination of compression zones, as described herein, within any of the lateral bars comprising a facemask400.

In some embodiments, spring mechanisms may be disposed within a fastening mechanism, such as fastening mechanism416.FIGS. 9A and 9Bdepict a schematic view of an impact transforming fastening mechanism900, in accordance with one or more embodiments. In some embodiments, fastening mechanism900may be fastening mechanism416. As illustrated inFIGS. 9A-9B, fastening mechanism900includes housing902, guide shaft904, and spring mechanism906. In some embodiments, housing902may be fully enclosed. However, inFIGS. 9A and 9B, a front panel950of housing902is depicted as transparent with dashed lines.

As further depicted inFIGS. 9A and 9B, a segment of frame402of facemask400is disposed within guide shaft904. In some embodiments, the segment of frame402may move along a length of the guide shaft from a first position to a second position.FIG. 9Ashows frame402in a first position within guide shaft904.FIG. 9Bshows frame402in a second position with guide shaft904. In some embodiments, frame402may move from the first position to the second position due to a force acting on facemask400in direction A, shown inFIG. 9B.FIG. 9Adepicts spring mechanism in an expanded state, whereasFIG. 9Bdepicts spring mechanism906in a compressed state.

In some embodiments, fastening mechanism900further includes spring mechanism906. In various embodiments, spring mechanism906may act as an energy and impact transformer for the dissipation, transformation, absorption, redirection of force/energy. For example, spring mechanism906may compress due to force in direction A, which allows fastening mechanism900to absorb at least some of the force acting on facemask400in direction A. In various embodiments, the elastic force from spring mechanism906further urges frame402back to the first position. In some embodiments, spring mechanism906is under compression, even when frame402is in the first position and spring mechanism is in an expanded state.

It should be recognized that various spring mechanisms may be implemented within with various embodiments of fastening mechanism900. For example, spring mechanism906comprises a helical spring designed for compression and/or tension. In some embodiments the helical spring may comprise metal, metal alloys, and/or a combination thereof. Other classifications of springs that may be implemented in fastening mechanism900include other known spring mechanisms, such as coil springs, flat springs, machined springs, serpentine spring, volute spring, etc. In other embodiments, spring mechanism may comprise piece of elastic material, such as plastic foam and/or rubber, that can absorb compressive forces, but which elastic properties allow it to expand back to its original shape.

In some embodiments, fastening mechanism900may also allow lateral movement of frame402in the B direction and C direction. Referring back toFIGS. 4A and 4B, this added range of motion may allow movement of frame420within a particular fastening mechanism900where frame402is moved to a second position within another fastening mechanism900due to a force applied to facemask400.