Patent Publication Number: US-11659883-B2

Title: Facemask for a helmet and faceguard

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application Ser. No. 63/085,410 filed Sep. 30, 2020, the disclosure of which is hereby incorporated in its entirety by reference herein. 
    
    
     TECHNICAL FIELD 
     Various embodiments relate to a face mask for use in a helmet, such as a sports or athletic helmet. 
     BACKGROUND 
     Helmets may be used as a safety device, for example, for sports or athletics. The athletic body may require a helmet for participation by an athlete. These helmets may be provided with a faceguard, such as a wire frame faceguard. Alternatively, different face guards may be attachable to and used with a helmet. The helmet and faceguard are not intended to provide protection against airborne or aerosol particles or pathogens. 
     SUMMARY 
     In an embodiment, a facemask for a helmet with a faceguard is provided. The facemask has a first fabric member having a first end connector, and a second fabric member having a second end connector. The second fabric member is connected to the first fabric member via a central seam such that the first fabric member defines a first end region of the facemask and the second fabric member defines a second end region of the facemask. The first and second fabric members collectively define an upper edge of the facemask. A third fabric member is connected to the first and second fabric members via a transverse seam, with the third fabric member spaced apart from the first and second end region of the facemask. The first, second, and third fabric members collectively define a lower edge of the facemask. An upper connector extends outwardly from the facemask, is positioned between the first and second fabric members, and is connected via the central seam. The upper connector is spaced apart from the upper edge of the facemask and the transverse seam. First and second lower connectors extend outwardly from the facemask, are positioned between the first and third fabric members, and are connected via the transverse seam. Third and fourth lower connectors extend outwardly from the facemask, are positioned between the second and third fabric members, and are connected via the transverse seam. 
     In a further embodiment, each of the first and second end connectors is a clip fastener. 
     In another further embodiment, the upper connector is a hook and loop fastener. 
     In a further embodiment, each of the first, second, third and fourth lower connectors is a hook and loop fastener. 
     In another further embodiment, each of the first, second, third and fourth lower connectors is a clip fastener. 
     In another embodiment, a facemask assembly for a helmet is provided with a facemask extending from a first end region to a second end region opposite to the first end region. The facemask has an upper edge to be adjacent to a nose of a user and a lower edge to be adjacent to a chin of the user when the facemask is connected to the helmet. A first end attachment member is connected to the first end region of the facemask to attach to a faceguard. A second end attachment member is connected to the second end region of the facemask to attach to the faceguard. A series of intermediate attachment members are spaced apart from one another and connected to the facemask between the first and second end regions, with each intermediate attachment member to attach to the faceguard. 
     In a further embodiment, the facemask has a first side member, a second side member, and a lower member connected to one another. The first side member defines the first end region, and the second side member defines the second end region. 
     In another further embodiment, edges of the first and second side members are directly connected to one another along a first seam, the first side member extends from the first seam to the first end region, and the second side member extends from the first seam to the second end region. 
     In a further embodiment, the lower member is directly connected to the first and second side members along a second seam. 
     In another further embodiment, the lower member and the second seam extends along a lower edge of the first and second side members and is spaced apart from the first and second end regions. 
     In a further embodiment, the first seam is positioned between opposite ends of the second seam. 
     In another further embodiment, one intermediate attachment member of the series of intermediate attachments members is connected to the facemask at the first seam, and the one of the intermediate attachment members is spaced apart from the second seam. 
     In a further embodiment, the one intermediate attachment member is a hook and loop fastener. 
     In another further embodiment, at least two intermediate attachment members of the series of intermediate attachment members are connected to the facemask via the second seam. 
     In a further embodiment, each of the at least two intermediate attachment members are hook and loop fasteners. 
     In another further embodiment, each of the at least two intermediate attachment members are clip fasteners, with each clip fastener sized to receive a portion of the faceguard. 
     In a further embodiment, two intermediate attachment members of the series of intermediate attachment members are connected to the facemask via the second seam and are positioned between the first end region and the first seam. Another two intermediate attachment members of the series of intermediate attachment members are connected to the facemask via the second seam and are positioned between the second end region and the first seam. 
     In another further embodiment, the first and second side members cooperate to form the upper edge of the facemask. 
     In a further embodiment, the lower member forms at least a portion of the lower edge of the facemask. 
     In another further embodiment, each of the first and second side members has a concave upper edge. 
     In a further embodiment, the facemask comprises a fabric. 
     In another further embodiment, the facemask comprises a woven fabric and/or a knitted fabric. 
     In a further embodiment, the facemask comprises one of a polyester knit fabric, a cotton knit fabric, a polyester-lycra knit fabric, and a nylon woven fabric. 
     In another further embodiment, the first end attachment member is sized to extend through a first aperture formed by one of the helmet and the faceguard to attach to the faceguard. The second end attachment member is sized to extend through a second aperture formed by one of the helmet and the faceguard to attach to the faceguard. 
     In a further embodiment, the facemask is positioned inboard of a faceguard of a helmet assembly. The helmet assembly is provided with the faceguard attached to a helmet. 
     In another further embodiment, a chin strap connected to the helmet, the chin strap positioned inboard of the facemask. 
     In a further embodiment, the helmet is one of an American football helmet, a hockey helmet, a lacrosse helmet, and a baseball catcher helmet. 
     In an embodiment, a method of forming a facemask is provided. A first facemask member is provided and extends from a first edge to a first end region. A second facemask member is provided and extends from a second edge to a second end region. A third facemask member is provided. The first edge of the first facemask member is connected to the second edge of the second facemask member to collectively define an upper edge of the facemask. The third facemask member is connected to the first and second facemask members opposite to the upper edge. A first side connector is connected to the first end region. A second side connector is connected to the second end region. A first intermediate connector is connected to the first and second facemask members between the first and second edges. A second intermediate connector is connected to the first facemask member and the third facemask member. A third intermediate connector is connected to the second facemask member and the third facemask member. 
     In another embodiment, a method of attaching a facemask to a helmet is provided. A facemask is positioned on an inboard side of a faceguard connected to a helmet. A first end region of the facemask is positioned through a first side aperture formed by one of the helmet and the faceguard, and a first side connector is connected to the faceguard. A second end region of the facemask is positioned through a second side aperture formed by the one of the helmet and the faceguard, and a second side connector is connected to the faceguard. A series of intermediate connectors of the facemask are directly connected to the faceguard. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic front view of a helmet assembly according to an embodiment; 
         FIG.  2    is a schematic side view of the helmet assembly of  FIG.  1   ; 
         FIG.  3    is a pattern schematic view for use with a facemask according to an embodiment; 
         FIG.  4    is a top perspective view of a facemask according to an embodiment; 
         FIG.  5    is a front perspective view of the facemask of  FIG.  4   ; 
         FIG.  6    is a bottom perspective view of a facemask according to another embodiment; 
         FIGS.  7 A,  7 B, and  7 C  are schematic views for a method of assembling a facemask to a helmet and faceguard according to an embodiment and to form a helmet assembly. 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present disclosure are provided herein; however, it is to be understood that the disclosed embodiments are merely examples and may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure. 
       FIGS.  1 - 2    illustrate schematic views of a helmet assembly  10  having a helmet  12 , faceguard  14 , and facemask  20  according to the present disclosure. The helmet  12  illustrated is an American football helmet; however, other helmets that use or incorporate a faceguard are also contemplated for use with the facemask according to the present disclosure. For example, the helmet  12  may be another type of sports or athletic helmet, or other helmet that uses a faceguard. Other non-limiting examples of helmets for use with the present disclosure include a hockey helmet, a lacrosse helmet, and a baseball catcher helmet. 
     The faceguard  14  may be integrally formed with the helmet  12 , or may be attachable to or connected to the helmet. In some examples, different size or different configuration faceguards  14  may be used with the helmet. In one example, the faceguard  14  is a wireframe faceguard as shown. 
     In some examples, and as shown, the helmet  12  defines first and second side apertures  16 ,  18  that may be on opposed sides of the helmet, e.g. generally aligned with or adjacent to the ears of a user. In other examples, the faceguard  14  itself may define first and second side apertures  16 ,  18  that may be on opposed sides of the faceguard  14 , e.g. generally aligned with or adjacent to the ears of a user. 
     In various examples, the helmet  12  may have a chin strap  19  connected to the helmet, and the chin strap  19  is used to secure the helmet  12  to the head of a user. 
     The facemask  20  is positioned between the face of a user and the faceguard  14 . The facemask  20  is therefore on an inboard side of the faceguard  14 . This protects the facemask  20  from possible abrasions or contact with another person or outside object during use. 
     The facemask  20  is in contact with or adjacent to the nose of the user. The facemask  20  is also adjacent to the chin and the jawline of the user. The facemask  20  is connected to the helmet  12  and/or faceguard  14 , and is also shaped to form a pocket or cavity  22  such that the facemask is spaced apart from and generally not in contact with the mouth or lips of a user. 
     The chin strap  19  may be positioned between a chin of the user and the facemask  20  when the chin strap  19  is connected on both ends to the helmet  12 . 
     The facemask  20  may act as a mask to prevent or reduce the transfer of particles and/or aerosols across the facemask. 
       FIG.  3    illustrates a pattern for the facemask  20 , and  FIGS.  4 - 5    illustrate the facemask  20  according to an embodiment. In one embodiment, the body of the facemask  20  is formed using the pattern as shown in  FIG.  3   . 
     The facemask  20  extends from a first end region  30  to a second end region  32  opposite to the first end region. The facemask has an upper edge  34  to be adjacent to a nose of a user and a lower edge  36  to be adjacent to a chin or a jawline of the user when the facemask is connected to a helmet. 
     The facemask  20  has a first end attachment member  40  connected to the first end region  30  of the facemask  20  to attach the facemask to a faceguard  14 . The facemask  20  also has a second end attachment member  42  connected to the second end region  32  of the facemask to attach the facemask to the faceguard  14 . The first and second end regions  30 ,  32  extend through the first and second side apertures  16 ,  18 , respectively, from inside the cavity  22  of the helmet  12  and then connect to the faceguard  14  via the first and second end attachment members  40  and  42 , respectively. The first and second end regions  30 ,  32  therefore wrap around a portion of the helmet  12  and/or the faceguard  14 . 
     The facemask  20  has a series of intermediate attachment members  44  spaced apart from one another and connected to the facemask  20  between the first and second end regions  30 ,  32 . Each intermediate attachment member  44  is used to attach the facemask  20  to the faceguard  14 . 
     As shown in  FIG.  3   , the facemask  20  may be formed from a first side member  50 , a second side member  52 , and a lower member  54  that are connected to one another. In one example, the facemask  20  has only three fabric members  50 ,  52 ,  54  that form the main body of the facemask. In other examples, the facemask  20  may be formed from more than three members that are connected to one another to form the body of the facemask. In yet other examples, the facemask  20  may be formed from less than three members, such as a single member. 
     Each of the members  50 ,  52 ,  54  may be formed from a fabric material according to various embodiments. Each member  50 ,  52 ,  54  may be formed from a woven fabric or material such as a woven fabric, an interwoven fabric, and/or a knitted fabric. The members may have elasticity in the fabric. The first, second, and/or third member of the facemask  20  may be formed or cut as a pattern from a woven fabric and/or a knitted fabric. In various examples, the first, second, and/or third member of the facemask  20  may be formed or cut as a pattern from a polyester knit fabric, a cotton knit fabric, a polyester-lycra knit fabric, a nylon woven fabric, or the like. 
     The first side member  50  defines the first end region  30 , and extends from a first edge  60  to the first end region  30 . The second side member  52  defines the second end region  32 , and extends from a second edge  62  to the second end region  32 . The first and second side members  50 ,  52  may be connected to one another via a first seam  64  or a central seam along the first and second edges  60 ,  62 , and furthermore may be directly connected to one another. As used herein, a seam refers to a connection between two members, and preferably a connection between two fabric members. The seam may be provided via sewing, or alternatively, may be provided by an adhesive or via a fusing or welding process. If sewn to one another via a seam, stiches such as a stretch stitch for joining may be used to allow for stretching of the seam along with stretching of the fabric. 
     Therefore, when assembled to one another, the first side member  50  extends from the first seam  64  to the first end region  30 , and the second side member  52  extends from the first seam  64  to the second end region  32 . 
     The first and second members  50 ,  52  collectively define an upper edge  34  of the facemask  20  to be positioned adjacent to a nose of a user. Each of the first and second members  50 ,  52  may be provided by a three-sided pattern as shown. Each of the first and second members  50 ,  52  may be provided with a concave upper edge  66 . When connected to one another, the first and second members  50 ,  52  form a contoured upper edge  34  for the facemask  20  that extends over the nose while providing line-of-sight or visibility for the user. 
     The third member  54  or lower member may be directly connected to the first and second side members  50 ,  52  along a second seam  70  or transverse seam. An edge  72  of the third member is sewn or otherwise connected to the lower edges  68  of the first and second members  50 ,  52  via the second seam  70 . The third facemask member  54  is connected to the first and second facemask members  50 ,  52  opposite to the upper edge  34 . The lower member  54  and the second seam  70  extend along a lower edge  68  of the first and second side members  50 ,  52  and is spaced apart from the first and second end regions  30 ,  32 . The lower member  54  and second seam  70  are also spaced apart from the upper edge  34  of the facemask  20 . The first seam  64  is positioned between opposite ends of the second seam  70 . 
     The third member  54  may be formed from a substantially hemi-spherically shaped or arch shaped pattern as shown. 
     The lower member  54  forms at least a portion of the lower edge  36  of the facemask  20  to be positioned adjacent to a chin and jawline of a user. The first, second, and third fabric members  50 ,  52 ,  54  collectively define the lower edge  36  of the facemask. 
     In the example shown, the first seam  64  intersects upper edge  34  of facemask, and ends such that it is spaced apart from the lower edge  36  of the facemask. The second seam  70  intersects the lower edge  36  of the facemask at both ends, and is positioned between the upper edge  34  and the lower edge  36  of the facemask. The first seam  64  may meet or abut the second seam  70  in an intermediate region of the second seam  70 . 
     The first and second end attachment members  40 ,  42  or end connectors are connected to the first and second end regions  30 ,  32  of the facemask  20 , respectively. In one example, and as shown, the first and second end connectors  40 ,  42  are each provided by a clip, e.g. a clip fastener that is sized to receive a portion of the faceguard. In another example, the first and second end connectors  40 ,  42  may each be provided by a hook and loop fastener. 
     According to one example, the first end attachment member  40  is sized to extend through a first aperture  16  formed by one of the helmet  12  and the faceguard  14  to attach to the faceguard from an outboard side of the faceguard  14 . The second end attachment member  42  is sized to extend through a second aperture  18  formed by one of the helmet  12  and the faceguard  14  to attach to the faceguard from the outboard side of the faceguard  14  and on an opposite side of the faceguard relative to the first end attachment member  40 . 
     The facemask  20  has a series of intermediate attachment members  44  or intermediate connectors that are connected to the facemask and extend outwardly therefrom. The intermediate connectors  44  may be positioned between the first and second end regions  30 ,  32  of the facemask, and are spaced apart from one another. In various examples, the intermediate connectors  44  may be equally spaced from one another, or may have variable spacing. 
     One of the series of intermediate connectors  44 , also referred to as an upper connector  80 , extends outwardly from the facemask  20 , is positioned between the first and second fabric members  50 ,  52 , and is connected via the first seam  64  or the central seam. The upper connector  80  is spaced apart from the upper edge  34  of the facemask, the upper connector  80  may also be spaced apart from the second seam  70  or transverse seam. The upper connector  80  may be positioned to attach to a vertical bar on the faceguard  14  to limit transverse movement of the facemask  20 . The upper connector  80  may also pull or tension the facemask  20  upwardly and away from the nose of a user. 
     In the example shown, the upper intermediate attachment member or upper connector  80  is a hook and loop fastener that is attached to the facemask  20  via the first seam  64 . In another example, the upper intermediate attachment member or upper connector  80  is a clip with a non-woven extension that may be attached to the facemask via the first seam  64 . The clip may be a clip fastener that is sized to receive a portion of the faceguard  14 , e.g. a bar portion of the faceguard. 
     Other members of the series of intermediate attachment members  44 , or lower connectors  82 , are connected to and extend outwardly from the facemask  20  via the second seam  70  or the transverse seam.  FIG.  3    illustrates the attachment locations  44   a ,  82   a  for the lower connectors  82  relative to the third member  54 . In the example shown in  FIGS.  4 - 5   , the lower connectors  82  are provided as clip fasteners, with each clip fastener sized to receive a portion of the faceguard  14 , e.g. a bar region of the faceguard. The clip fastener of the lower connector  82  may be provided with a non-woven fabric tail that is attached to the facemask  20  via the second seam  70 . In another example, the lower connectors  82  may be provided as hook and loop fasteners, or a combination of clip fasteners and hook and loop fasteners. 
     In the example shown, the facemask  20  has four lower connectors  82 , with two of the lower connectors  82  positioned between the first end region  30  and the first seam  64 , positioned between the first and third fabric members  50 ,  54 , and connected to the facemask via the second, transverse seam  70 . Another two of the lower connectors  82  are positioned between the second end region  32  and the first seam  64 , positioned between the second and third fabric members  52 ,  54 , and connected to the facemask via the second transverse seam  70 . 
     The lower connectors  82  may be positioned to attach to a horizontal bar on the faceguard  14  to limit vertical movement of the facemask  20 . The lower connectors  82  may also pull or tension the facemask  20  outwardly and downwardly and away from the face and chin of a user. 
     The shape of the facemask  20  as provided by the first, second, and third members  50 ,  52 ,  54 , the elasticity of the material used to form the first, second, and third members  50 ,  52 ,  54 , and the use of the connectors  40 ,  42 ,  44  allows for the facemask  20  to be securely fastened to the faceguard  14  while creating a pocket or cavity  22  to receive a portion of a face. In one non-limiting example, the material used to form the first, second and third members  50 ,  52 ,  54  may have a 75% to 100% stretch capability. The facemask  20  is tensioned and held in position so that it is generally spaced apart from the face in order to provide enhanced comfort and use during sporting activities or the like. 
     In one example, and as shown, the facemask  20  may be mirror symmetric about the first seam  64 . 
     Although the first, second, and third members  50 ,  52 ,  54  are shown as providing a single layer for the facemask  20 , it is also contemplated that one or more of the members may be formed using multiple plies or layers of fabric. When using multiple layers, the layers may be connected to one another, for example, as a quilted layer, to prevent the layers moving relative to one another. 
     The first, second, and third members  50 ,  52 ,  54  may be hemmed or otherwise finished along the edges to prevent fraying of the fabric. A zig zag stitch or a stretch stitch may be used to hem or finish the members  50 ,  52 ,  54  according to one non-limiting example. 
     In further embodiments, the facemask  20  may be provided with vents. In another embodiment, the facemask  20  may be provided with a disposable or replaceable filter insert that attaches to the facemask. 
       FIG.  6    illustrates a bottom view of the facemask  20  according to another embodiment. The pattern as shown in  FIG.  3    may be used to form the facemask  20  of  FIG.  6   . Elements that are the same as or similar to those described above with respect to  FIG.  3 - 5    are not described again with respect to  FIG.  6   , and may be given the same reference numbers as those used above for simplicity. The facemask  20  may be used with the helmet assembly  10  as described with respect to  FIGS.  1 - 2    according to an embodiment. 
     The lower connectors  82  or lower intermediate members may be each provided as hook and loop fasteners, and may be sewn or connected to the facemask  20  via the second seam  70 . The upper connector  80  and end connectors  40 ,  42  may be provided as described above with respect to  FIGS.  3 - 5   . 
     In other examples, the facemask  20  may be provided with other combinations or other numbers of connectors  40 ,  42 ,  44  such as clips, hook and loop, snaps, button and buttonhole, or other fasteners for use in connecting the facemask to the helmet  12  and faceguard  14 . 
       FIGS.  7 A-C  illustrate a schematic series of figures showing a method of attaching the facemask to a helmet and faceguard, and may be used with the facemask  20 , helmet  12 , and faceguard  14  as described above to provide a helmet assembly. According to various embodiments, the method may have greater or fewer steps than described below, and the steps may be performed in another order. 
     As shown in  FIG.  7 A , the facemask  20  is positioned on an inboard side of a faceguard  14  connected to a helmet  12 . One of the intermediate connectors  44 , such as the upper intermediate connector  80  is directly connected to the faceguard  14 . 
     In  FIG.  7 B , the remainder of the series of intermediate connectors  44 , e.g. the lower intermediate connectors  82 , of the facemask  20  are connected directly to the faceguard  14 . 
     As shown in  FIG.  7 C , each of the first and second side connectors  40 ,  42  are attached or connected to the faceguard  14 . According to one non-limiting example, a first end region  30  of the facemask  20  is positioned through a first side aperture  16  formed by one of the helmet  12  and the faceguard  14  such that it extends outwardly from the inboard side or cavity of the helmet  12 , the first end region  30  is wrapped or moved towards the outer side of the faceguard  14 . The first side connector  40  is then attached or connected to the faceguard  14 . 
     Likewise, the second side connector  42  is attached or connected to the faceguard  14 . According to one non-limiting example, a second end region  32  of the facemask  20  is positioned through a second side aperture  18  formed by the one of the helmet  12  and the faceguard  14  such that it extends outwardly from the inboard side or cavity of the helmet  12 , the second end region  32  is wrapped or moved towards the outer side of the faceguard  14 . The second side connector  42  is then attached or connected to the faceguard  14 . 
       FIG.  7 C  therefore illustrates a partial perspective view of a helmet assembly  10  with a helmet  12 , faceguard  14 , and facemask  20  according to the present disclosure, and with the facemask  20  connected to the helmet  12  using the method as described and shown with respect to  FIG.  7   . 
     According to one example, a method of forming a facemask, such as a facemask  20  as described above with respect to  FIGS.  1 - 7    is provided. A first facemask member  50  is provided, and the first facemask member extends from a first edge  60  to a first end region  30 . A second facemask member  52  is provided, and the second facemask member extends from a second edge  62  to a second end region  32 . A third facemask member  54  is also provided. 
     The first edge  60  of the first facemask member  50  is connected to the second edge  62  of the second facemask member  52  such that the first and second members  50 ,  52  cooperate to form or collectively define an upper edge  34  of the facemask  20 . The third facemask member  54  is connected to the first and second facemask members  50 ,  52  opposite to the upper edge  34 . 
     A first side connector  40  is attached or connected to the first end region  30 . A second side connector  42  is attached or connected to the second end region  32 . 
     A first intermediate connector  44 ,  80  is attached or connected to the first and second facemask members  50 ,  52  between the first and second edges  60 ,  62 . A second intermediate connector  44 ,  82  is attached or connected to the first facemask member  50  and the third facemask member  54 . A third intermediate connector  44 ,  82  is attached or connected to the second facemask member  52  and the third facemask member  54 . 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure and/or invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.