# Patent

## Title
Catcher's helmet

## Abstract

A catcher's mask comprises a two-piece plastic shell composed of a rigid front shell and a rigid rear shell. The front and rear shells are connected by a strap harness attached to the front shell and have padding assemblies. The front shell has ventilation holes including dual ear holes positioned over the wearer's ears and a full jaw protector integrally formed as part of front shell. A wire faceguard is removably attached to the front shell extending over the ear holes. A front liner is installed in the brow area, crown area, and side areas of the front shell, a middle liner extending around the rear inner surface of the front shell, a suspended foam jaw pad, and a central chin pad. The rear shell has a concave padding assembly comprised of a concave TPU shock absorbing layer, and a nested concave comfort layer.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Application Ser. No. 62/159,075 filed May 8, 2015 which incorporated herein by reference.


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'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'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 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's mask according to the subject technology.
FIG. 2 is a left perspective view of a catcher's mask according to the subject technology.
FIG. 3 is a left perspective view of a front shell of a catcher's mask according to the subject technology.
FIG. 4 is a front view of a front shell of a catcher's mask according to the subject technology.
FIG. 5 is a right side view of a front shell of a catcher's mask according to the subject technology.
FIG. 6 is a top view of a front shell of a catcher's mask according to the subject technology.
FIG. 7 is a right side cross-sectional view of a catcher's mask according to the subject technology.
FIG. 8 is a rear view of a front shell with installed liners of a catcher's mask according to the subject technology.
FIG. 9 is a top view of a front liner of a catcher's mask according to the subject technology.
FIG. 10 is a side view of a front liner of a catcher's mask according to the subject technology.
FIG. 11 is a rear perspective view of a front liner of a catcher's mask according to the subject technology.
FIG. 12 a cross-sectional view of a front liner of a catcher's mask according to the subject technology.
FIG. 13 is a top view of a middle liner of a catcher's mask according to the subject technology.
FIG. 14 is a side view of a middle liner of a catcher's mask according to the subject technology.
FIG. 15 is a rear view of a middle liner of a catcher's mask according to the subject technology.
FIG. 16 is a cross-sectional view of a middle liner of a catcher's mask according to the subject technology.
FIG. 17 is a rear view of jaw padding of a catcher's mask according to the subject technology.
FIG. 18 is a side view of jaw padding of a catcher's mask according to the subject technology.
FIG. 19 is a front view of jaw padding of a catcher's mask according to the subject technology.
FIG. 20 is a front view of a chin pad of a catcher's mask according to the subject technology.
FIG. 21 is a side view of a chin pad of a catcher's mask according to the subject technology.
FIG. 22 is a cross-sectional view of a chin pad of a catcher's mask according to the subject technology.
FIG. 23 is a rear view of a rear shell of a catcher's mask according to the subject technology.
FIG. 24 is a rear view of a rear shell of a catcher's mask according to the subject technology.
FIG. 25 is a right perspective view of a rear shell of a catcher'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'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'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'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'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's mask according to the subject technology.
FIG. 31 is a front view of a strap harness for a catcher's mask according to the subject technology.
FIG. 32 is a front view of a face guard for a catcher's mask according to the subject technology.
FIG. 33 is a left perspective view of a face guard for a catcher's mask according to the subject technology.
FIG. 34 is a side view of a face guard for a catcher's mask according to the subject technology.
FIG. 35 is a front view of a face guard for a catcher's mask according to the subject technology.
FIG. 36 is a left perspective view of a face guard for a catcher's mask according to the subject technology.
FIG. 37 is a side view of a face guard for a catcher'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'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.
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'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.
An alternative face guard 620 for use in the catcher'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'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 193 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'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 releaseably 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 233 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.

## Claims

1. A catcher's mask comprising:
a two-piece plastic shell composed of a front shell and a rear shell, the front shell being rigid and composed of plastic, the rear shell being rigid, concave, and composed of plastic, the front shell and a rear shell joined by an elastic strap harness, the two-piece plastic shell being adapted to receive and protect the head of a wearer;
the front shell having an inner surface, an outer surface, a front region, a crown region, a rear region, a left side region, and a right side region;
the front shell further having a face opening defined by a top front edge, a left front edge, and a right front edge;
the front shell further having a rear opening partially defined by a rear edge;
a front liner removably attached to the inner surface of the front shell;
the front liner comprising a first shock absorbing layer, the first shock absorbing layer comprising a first base sheet of thermoplastic polyurethane formed into a first plurality of clusters, each cluster of said first plurality of clusters comprising a first plurality of hollow protrusions protruding from the first base sheet and distributed over an area of the cluster, each hollow protrusion of said plurality of hollow protrusions having a sidewall and a peak, the sidewall being collapsible for absorbing shocks, the first plurality of clusters joined by and spaced apart by regions of the first base sheet having no protrusions;
the front liner further comprising a first inner plastic sheet bonded to the first base sheet and registering with the first base sheet;
the front liner further comprising a first plurality of pockets formed in the first inner plastic sheet, each of the pockets of said plurality of pockets overlaying and registering with a cluster and containing a foam pad, such that the cluster, pocket, and pad together comprise a front liner cushion;
the front liner further comprising a central row of front liner cushions comprising, in order, a first central cushion, a second central cushion, a third central cushion a fourth central cushion, and a fifth central cushion;
the front liner further comprising a first jaw cushion connected to the first central cushion and a second jaw cushion connected to the fifth central cushion;
the front liner further comprising a first crown cushion connected to the second central cushion, a second crown cushion connected to the fourth central cushion, and a third crown cushion connected to the second crown cushion;
the front liner removably attached to the inner surface of the front shell such that the central row is positioned above the top front edge to register approximately with the brow of the wearer, the third central cushion positioned to register approximately with the middle brow of the wearer, the first jaw cushion and second jaw cushion positioned to register approximately with the jaws of the wearer, and the third crown cushion to register approximately with an apex of the crown region of the front shell.

2. The catcher's mask of claim 1 further comprising:
a middle liner removably attached to the inner surface of the front shell;
the middle liner comprising a second shock absorbing layer, the second shock absorbing layer comprising a second base sheet of thermoplastic polyurethane formed into a second plurality of clusters, each cluster of said second plurality of clusters comprising a second plurality of hollow protrusions protruding from the second base sheet and distributed over an area of the cluster, each hollow protrusion of said second plurality of hollow protrusions having a sidewall and a peak, the sidewall being collapsible for absorbing shocks, the second plurality of clusters joined by and spaced apart by regions of the second base sheet having no protrusions;
the middle liner further comprising a second inner plastic sheet bonded to the second base sheet and registering with the second base sheet;
the middle liner further comprising a second plurality of pockets formed in the second inner plastic sheet, each of the pockets of said second plurality of pockets overlaying and registering with a cluster and containing a foam pad, such that the cluster, pocket, and pad together comprise a middle liner cushion;
the middle liner further comprising a row of middle liner cushions;
the middle liner removably attached to the inner surface of the front shell such that the middle liner is positioned along the rear edge of the front shell extending from the left side region to the right side region.

3. The catcher's mask of claim 1 further comprising:
a concave padding assembly removably attached to and nested within a concave inner surface of the rear shell;
the concave padding assembly comprising a third shock absorbing layer, the third shock absorbing layer comprising a third base sheet of thermoplastic polyurethane formed into a third plurality of hollow protrusions protruding from the third base sheet and distributed over an area of the third base sheet, each hollow protrusion of said third plurality of hollow protrusions having a sidewall and a peak, the sidewall being collapsible for absorbing shocks; the peaks of the third plurality of hollow protrusions being formed at angles with respect to their respective sidewalls such that the peaks lie in a convex surface conforming to the concave inner surface of the rear shell so that the peaks contact the concave inner surface of the rear shell without substantial deformation of the protrusions; the middle liner having an inner surface;
the concave padding assembly further comprising a concave comfort layer removably attached to and nested within the concave inner surface of the third shock absorbing layer, the concave comfort layer comprising a molded pad of foam material.

4. The catcher's mask of claim 1 further comprising:
jaw padding comprising a thin, flexible, roughly kidney-shaped elongated foam member enclosed in a fabric comfort layer and removably suspended to the inner surface of the first shell from two points above a lower edge of the front shell to register approximately with the lower jaw of the wearer.

5. The catcher's mask of claim 1 further comprising:
a full jaw protector integrally formed with the front shell and having an inner surface;
a chin pad removably attached to the inner surface of the full jaw protector to register approximately with the mental protuberance of the chin of the wearer;
the chin pad comprising a roughly rectangular foam pad having sides tapering from a base to a peak;
the chin pad curved so as to conform to an inner curvature of the full jaw protector.

6. The catcher's mask of claim 1 further comprising:
a face guard comprised of a plurality of wire members joined together to form a protective grid, the face guard removably connected to the front shell so as to cover at least the face opening;
the plurality of wire members comprising a top horizontal upper member and a bottom horizontal upper member;
the plurality of wire members further comprising a top horizontal lower member, a middle horizontal lower member, a bottom horizontal lower member, and a first vertical member connecting the top horizontal lower member, middle horizontal lower member, and bottom horizontal lower member;
the plurality of wire members further comprising a second vertical member and a third vertical member connecting the bottom horizontal upper member and top horizontal lower member;
wherein the bottom horizontal upper member and top horizontal lower member define a vision gap therebetween;
wherein the top upper member is removably connected to the front shell at points above the top front edge and the bottom lower member is removably connected to the front shell at points below the right front edge and left front edge; and
wherein the top upper member, bottom upper member and bottom lower member extend substantially past the right front edge and the left front edge to meet at or beyond ear holes formed in the left region and right region of the front shell, thereby extending the face guard over the ear holes and protecting an area surrounding the ear holes.

7. The catcher's mask of claim 6 wherein the plurality of wire members further comprises:
a crown arch member spanning from the left side region, over the crown region, to the right side region, the crown arch member joining the top upper member near its meeting points with the bottom lower member, and
a plurality of upward-sweeping members joined together at a first set of ends by the crown arch member and at a second set of ends by the bottom upper member and between the first set of ends and second set of ends by the top upper member.

8. A face guard adapted to be installed on the shell of a catcher's mask having a face opening defined by edges and further having a left region, a right region, a crown region and ear holes in the left region and right region, the face guard comprising:
a plurality of wire members joined together to form a protective grid, adapted to cover at least the face opening;
the plurality of wire members comprising a top horizontal upper member and a bottom horizontal upper member;
the plurality of wire members further comprising a top horizontal lower member, a middle horizontal lower member, a bottom horizontal lower member, and a first vertical member connecting the top horizontal lower member, middle horizontal lower member, and bottom horizontal lower member;
the plurality of wire members further comprising a second vertical member and a third vertical member connecting the bottom horizontal upper member and top horizontal lower member a crown arch member spanning from the left side region, over the crown region, to the right side region, the crown arch member joining the top upper member near its meeting points with the bottom lower member, and a plurality of upward-sweeping members joined together at a first set of ends by the crown arch member and at a second set of ends by the bottom upper member and between the first set of ends and second set of ends by the top upper member;
said plurality of upward-sweeping members comprises four right upward-sweeping members and four left upward-sweeping members;
wherein the bottom horizontal upper member and top horizontal lower member define a vision gap therebetween; and
wherein the top upper member, bottom upper member and bottom lower member are adapted to extend substantially past edges of the face opening to meet at or beyond the ear holes, thereby being adapted to extend the face guard over the ear holes and protect an area surrounding the ear holes.