Patent ID: 12186647

All Figures © Under Armour, Inc. 2020. All rights reserved.

DESCRIPTION

In the following detailed description, reference is made to the accompanying figures which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment”, “an embodiment”, “an exemplary embodiment”, and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, and that such particular feature, structure, or characteristic may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structures, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

Face Guard with Mouthpiece and Integrated Face Mask

With reference toFIGS.1-3, a face guard20is shown. The face guard20(which may also be referred to herein as a “sports guard”) includes a mouthpiece30and an integrated face mask40. Because the face mask40is coupled to the mouthpiece as a unitary device, the face mask40is conveniently worn any time the mouthpiece30is used. The mouthpiece30provides protection for the mouth of the athlete, and the face mask40is comprised of a material that reduces the spread of droplets from the nose and mouth of the athlete.

The mouthpiece30may be provided in any of various forms. For example, the mouthpiece30may be a single arch mouthpiece that includes a single tooth-receiving channel designed to receive either the upper or lower teeth of the human mouth. Alternatively, the mouthpiece30may be a dual arch mouthpiece that includes both upper and lower tooth-receiving channels. Therefore, although a single arch mouthpiece is illustrated inFIG.1, it will be recognized that the mouthpiece may take any of various forms. For example, as shown inFIG.11, the mouthpiece30may be a dual arch mouthpiece that includes an upper tooth-receiving channel32and a lower tooth-receiving channel34. A front wall38is formed along the front of each channel. The front wall is configured to fit between the user's gum and lips, with the lips positioned on the outside of the front wall. An air passage36may be formed in the mouthpiece30between the upper and lower channels32and34to facilitate breathing by the user. The air passages36extend completely through the front of the mouthpiece30, thus allowing air to enter into and be expelled from the mouth of the user. An example of such a mouthpiece is described in further detail in U.S. Pat. No. 8,496,009, issued Jul. 30, 2013, to Manzo, the entire contents of which are incorporated herein by reference.

The mouthpiece30is generally formed from conventional thermoplastic materials commonly used for sporting mouthpieces. For example, the mouthpiece may be formed from conventional “boil and bite” thermoplastic material. As is known in the art, this material softens when heated to a threshold temperature that is greater than body temperature (e.g., a temperature of about 110° to 120°), and then, when cooled as it is fit in the user's mouth, hardens to a more rigid form that is left with an impression of the user's teeth and a custom-fit dental appliance.

With reference again toFIG.1, the face mask40(which may also be referred to herein as a “face shield”) is coupled to the mouthpiece30. The coupling between the mouthpiece30and the face mask40may be permanent, such that the mouthpiece30and face mask40are monolithic, and the face mask40may not be removed from the mouthpiece30without destruction thereof. For example, a post, bracket, wall or other mounting member may extend between the front of the mouth piece30and a rear surface of the frame60. Alternatively, in at least one embodiment, the coupling between the face mask40and the mouthpiece30is releasable such that the face mask40can be repeatedly released from and subsequently re-connected to the mouthpiece30. An example of such an arrangement is shown and described below in association withFIG.11.

With continued reference toFIGS.1-3, the face mask40generally includes a frame60that retains a shield body50. The frame60includes a rim62and a base portion70. The rim62defines a perimeter of the face mask40and provides structural support for the shield body50. The rim62includes an upper portion64that is designed and dimensioned to extend over the nose of the human wearer at a location between the bridge of the nose and the tip of the nose. The rim62also includes side portions66that extend downwardly and outwardly from the upper portion. The side portions66are designed and dimensioned to extend across a region of the wearer's face between the nose and the cheekbones. The rim62also includes a lower portion68that is designed and dimensioned to extend under the mouth of the wearer, between the lower lips and the chin.

The base portion70of the frame60is integrally formed with the lower portion68of the rim62. In the embodiments disclosed herein, the base portion is a shield-like member that is designed and dimensioned to generally cover the lips mouth of the wearer. In the embodiment ofFIG.1, the base portion70is comprised of a continuous surface on the front of the face mask40that is about the size of human lips in a slightly open configuration. Thus, the base portion70may be generally oval shaped with a widest dimension extending from left to right across the front of the frame. In the embodiment ofFIG.1, a grab tab72extends outwardly from the base portion70of the frame60. The grab tab72may be easily accessed and grasped by the user. While the surface of the base portion70is shown as being continuous and uninterrupted in the embodiment ofFIG.1, it will be recognized that the base portion may be differently configured in other embodiments. For example, in other embodiments, such as that ofFIGS.4-10, the base portion may include an air passageway, as described in further detail below.

The frame60is generally made of a material that provides support for the body50, but is relatively soft and comfortable against the skin of the wearer. In at least one embodiment, the frame60is made of a thermoplastic material such as polyurethane. In at least one embodiment the frame60is made of the same material as the mouthpiece30, such as the aforementioned “boil and bite” material. This allows the rim62to be easily adjusted to the contours of the face of the wearer at the same time the mouthpiece30is heated and custom fit to the user's mouth. This provides an effective fit for the face mask40against the wearer's face. However, in at least some embodiments, the frame60is comprised of a different thermoplastic material than the mouthpiece30such that the frame is not easily malleable at the same relatively low threshold temperature as that of the mouthpiece. In such embodiment, the frame60may include a flexible metal wire or other membrane that is encased within the thermoplastic material or other material, such as a soft fabric covering. The metal wire and thermoplastic material may be easily bent such that the rim62matches the contours of the face of the wearer. After the rim62is bent, the metal retains its shape, thus allowing the rim62to maintain engagement with the face of the wearer.

The shield body50is connected to and extends across the frame60. The shield body is generally formed of at least one sheet of material with air filtration and air permeability qualities that render the material appropriate for a face mask. The sheet of material may be provided from a single piece of fabric or multiple pieces of fabric or other material. For example, the sheet of material may be provided by a tightly woven fabric made of cotton, polyester, other material, or a blend thereof. As explained in further detail below with reference toFIG.7, in at least one embodiment, the shield body is comprised of a three-layer sheet of material including a foam layer positioned between two fabric layers. The multi-layer construction may be a molded textile formed into a desired shape that provides a generally convex contour to the body50(when viewed from the outside). The multi-layer construction may alternatively include stitching at various locations across the body in order to add additional structure to the body50. In at least one embodiment, at least one layer of the body50is provided by a relatively soft and flexible stretch fabric material configured for comfort when placed against the skin of the wearer, such as Iso-Chill Heat Gear® fabric sold by Under Armour, Inc. As noted above, this soft and flexible stretch fabric material may extend to and encase the rim62to provide comfort to the face of the user when the mouth piece is in utilized. In particular, the fabric material may cover the interior portion of the rim62such that the fabric material is the portion of the mouth piece that abuts the skin of the user at the nose and cheeks during use.

The body50is connected to the frame60using any of various methods for connecting a fabric material to a thermoplastic. In at least one embodiment, the body50is connected to the frame60by stitching. In another embodiment, the body50is connected to the frame by heat welding or by use of adhesives. The perimeter edges of the body50may be arranged to fit exactly within the rim, or may be made to cover either the inner portion or the outer portion of the rim.

With particular reference now toFIG.2, in order to don the face guard20, the athlete simply places the mouthpiece30in their mouth with the teeth in the tooth-receiving channels of the mouthpiece30. With the mouthpiece30properly positioned in the athlete's mouth, the face mask40is automatically positioned on the face of the athlete. In particular, the face mask40completely covers the orifices of the mouth and nose of the athlete, thus blocking or abating the discharge of fluids from the mouth and nose of the athlete during a competition or other sporting event. At the same time, the face mask40provides an effective barrier that reduces the number of pathogens that would otherwise be inhaled by the athlete during the sporting event.

As shown inFIG.3, the size of the face guard20is such that it may be easily used in association with other athletic equipment, such as a football helmet18. The face guard20fits on the athlete's face with a relatively low profile such that it does not interfere with the cage of the helmet18in any way. Furthermore, the chin strap of the helmet may easily extend across the chin of the athlete without contacting the face guard20. Because the face guard20can be mounted on the face of the athlete without straps that extend to the ears or the back of the head, there is also no interference with the padding on the interior of the helmet. Moreover, the face guard20may be easily inserted into and removed from the face of the wearer without the need to remove the helmet18.

Face Guard with Air Passage Included in Mouthpiece and Face Mask

With reference now toFIGS.4-6an alternative embodiment of the face guard20is shown. The embodiment ofFIGS.4-6is similar to that ofFIGS.1-3. However, in the embodiment ofFIGS.4-6the base portion70of the face mask40specifically includes an air passage76that extends completely through the base portion70. The air passage76leads into an air passage in the connected mouthpiece30, thus allowing the athlete to breathe through the air passage76when the faceguard20is worn. Although the mouth piece30is not shown in any ofFIGS.4-6, it will be recognized that the mouthpiece is directly behind the base portion70of the frame60in these figures. The mouthpiece30in this embodiment is similar to the dual arch mouthpiece30shown inFIG.11, including an air passage36configured to align with an air passage76in the base70of the frame60of the face mask40.

With continued reference toFIG.4, in this embodiment of the face guard20, the shield body50is configured to cover and/or abut the entire rim62of the frame60, including covering the base portion70of the frame and the associated air passage76. Because the body50covers the air passage76, the transfer fluids and pathogens that would otherwise move through the air passage are abated. At the same time, the body50also covers the nose of the wearer and abates the transfer of fluids and pathogens through the nose.

As also shown inFIG.4, a gasket80is provided that covers the perimeter of the shield body50. The gasket is comprised of a relatively rigid and durable thermoplastic material, such as polyurethane or polyvinylchloride. Accordingly, the gasket provides durability and protection for the face mask40. The gasket80may be connected to the shield body50and the frame60in any of various ways. For example, the gasket80may be a stitch down gasket that is coupled to the body50and the frame60using various stitches along the body. In another embodiment, the gasket80may be coupled to the body50and the frame60using adhesive, heat welding, or any of various other means for coupling the gasket to the body50and frame60. The gasket80not only provides additional protection for the perimeter of the body50and frame60, but also adds a clean look to the face mask by trimming out the perimeter edges of the body50and frame60.

FIGS.5and6show the face guard20ofFIG.4worn by an athlete. Advantageously, the face mask40completely covers the mouth and nose of the athlete when the mouthpiece30is inserted into their mouth. There is no need for straps or other means for mounting the face mask40on the athlete. As best shown inFIG.6, the base portion70encircles and covers the lips of the athlete on the athlete's face. However, the air passage76provides a sufficient opening to allow for air to pass therethrough. Therefore, because of the air passage76in the base portion70of the frame60, the athlete can easily breathe from both the nose and mouth during use. At the same time, the shield body50filters fluids and pathogens from being expelled-from or breathed-in by the athlete.

Three Part Shield Body

With reference now toFIG.7, in at least one embodiment, the shield body50is advantageously comprised of a multi-layer construction that limits the transmission of moisture from the wearer's mouth and nose while also offering increased breathability relative to conventional face masks. In particular, as shown inFIG.5, the body50includes an outer layer52, a middle layer54and an inner layer56.

The outer layer52of the body50provides an airgap spacer on an exterior side of the face mask40. The outer layer52is comprised of a material that offers both structure for the face shield as well as a moisture barrier. The material of the outer layer52is generally a lightweight fabric, but still provides the face mask40with sufficient structure and body to keep the face mask largely separated from the mouth, nose, and surrounding skin of the wearer at the interior of the face mask40. This separation provides for a mask that is significantly more comfortable for the wearer than conventional face masks and also allows for better airflow. The material of the outer layer also provides good moisture holding capacity for moisture vapor, while also inhibiting moisture from passing therethrough.

In at least one embodiment, the outer layer52is comprised of a circular knit spacer that is itself a three layer fabric made of 100% polyester. The circular knit spacer includes a first knit fabric layer provided parallel to a second knit fabric layer and separated by a space defined by another yarn. The polyester threads that form the first knit fabric layer provide for a generally smooth first surface that is parallel to a generally smooth second surface provided by the polyester threads of the second knit fabric layer (i.e., if the threads of the first knit fabric layer are considered to be in a first plane, the threads of the second knit fabric layer may be considered to be in a second plane that is parallel to the first plane). A number of crossing threads/yarns extend through the space and connect the first and second knit fabric layers (i.e., the crossing threads may be considered to extend perpendicular to the threads of the first knit fabric layer and the second knit fabric layer). The crossing threads are interknitted with the threads of the first and second knit fabric layers such that the first knit fabric layer is bound to the second knit fabric layer without the need for glues or other adhesives. The crossing threads provide the fabric with air pockets that add significant body to the fabric, resulting in a structure that has greater strength and maintains its form better than most fabrics. An exemplary construction of such a three layer fabric is disclosed in U.S. Pat. No. 4,785,558 to Shiomura, the entire contents of which are incorporated herein by reference. It will be recognized that in at least some embodiments the outer layer52is a stitched fabric layer, not a molded layer. This provides the mask with many of the advantages of fabrics, including increased comfort, flexibility, breathability, washability, and sustainability, and does not incorporate the downsides of molded structures, such as stiffness, limited airflow, and single use. In at least one embodiment, the yarns that form the first and second fabric layers are provided by a 100 denier 100% polyester yarn, and the crossing threads are provided by a 30 denier 100% polyester yarn.

In addition to the three layer fabric structure, the outer surface of the outer layer52is treated with a durable water repellent (DWR) finish. This DWR finish inhibits moisture from penetrating the outer layer52and moving into the mask. This provides the wearer with additional protection against moisture droplets that may be deposited on the face shield30from an outside source. In at least one embodiment, the DWR finish is provided by a C0 DWR material that prevents absorption from the outside while also making the finish more environmentally friendly.

With continued reference toFIG.7, the middle layer54of the body50is sandwiched between the outer layer52and the inner layer56. The middle layer54is comprised of a reticulated open cell foam. In at least one embodiment, the foam is 100% polyurethane. The open cell structure of the foam facilitates air-flow. At the same time, the structure of the foam has a high moisture holding capacity. Moisture droplets that enter the foam tend to remain in the foam until they are is flushed out; moisture does not wick into or out of the foam. The middle layer54is about ⅛ inch (3.17 mm) in thickness, and typically between 1/16 and ¼ inch (1.58 mm-6.35 mm). Accordingly, the middle layer is sufficiently thick to retain moisture, but not so thick that it is overly insulative and limits breathability.

The inner layer56is comprised of a relatively soft and flexible stretch fabric material configured for comfort when placed against the skin of the wearer, such as Iso-Chill Heat Gear® fabric sold by Under Armour, Inc. The material is further configured to wick moisture and cool the skin. Because the inner layer56faces the wearer, the inner layer56wicks moisture from the mouth and nose of the wearer into the middle layer54, where the moisture is retained until it is flushed from the mask during washing. As a result, the inner layer56tends to remain relatively dry and does not become saturated with moisture droplets during use. In at least one embodiment, the inner layer is comprised of a knit warp fabric having a tricot construction and comprising 77% Polyamide, 23% Spandex. The fabric not only wicks, but is also configured to provide a cooling effect, drawing both moisture and heat away from the skin of the wearer.

In at least one embodiment, the fabric providing the inner layer56and/or the outer layer52is treated with an antiviral/antimicrobial compound designed to kill harmful viruses and/or other microbes that may be dispelled from the mouth and nose of the wearer. For example, the inner layer56may be treated with an antiviral chemical, such as PROTX2 AV, produced by Intelligent Fabric Technologies of North America. In tests PROTX2 AV has destroyed 99.9% of COVID-19 within 10 minutes, with residual killing power for 24 hours. In some embodiments, the antimicrobial compound may be mechanical and/or chemical in nature, such a crystalline structure that may be bonded to the surface, or a chemical treatment applied to the surface, as will be recognized by those of ordinary skill in the art. In at least some embodiments, the antimicrobial compound may be conveniently applied during the textile finishing process without requiring additional machinery or steps.

In at least some embodiments, the inner layer56, middle layer54, and outer layer52of the face shield body50are all tethered together at various locations with stitching extending through each of the layers. This stitching also assists in properly shaping the mask when in use in order to provide a structure that spaces the mask away from the face, and particularly the nostrils and mouth of the wearer. It this embodiment, there is no fastening or other connection between the layers52,54,56of the body other than the stitching. Accordingly, the layers of the body can somewhat shift and/or slide relative to one another at locations removed from the stitching. No glues or other adhesives that might limit breathability/air flow are included on the face mask40.

An example of a face shield with a three-layer construction including an inner layer56, middle layer54, and outer layer52, such as that described above, is disclosed in U.S. patent application Ser. No. 17/087,866, entitled “Breathable Face Mask”, and filed on Nov. 3, 2020, the entire contents of which are incorporated herein by reference.

Face Mask with Floating Supports

With particular reference now toFIGS.8-10, an alternative embodiment of the face guard20is shown. The embodiment ofFIGS.8-10is similar to that ofFIGS.4-6. However, in the embodiment ofFIGS.4-6the upper portion64of the rim62is absent, resulting in two truncated side portions66. These side portions66result in two cantilevers that extend upwardly and inwardly from opposite sides of base portion70and act as floating supports for the body50of the frame60. Instead of the more rigid upper portion64a softer, malleable nose portion74is provided that extends between two the truncated ends on the side portions66of the frame60, thus acting as a bridge between the two cantilevers on opposite sides of the base portion70.

In at least one embodiment, the nose portion74is comprised of one or more layers of a relatively soft and flexible stretch fabric material configured for comfort when placed against the skin of the wearer, such as Iso-Chill Heat Gear® fabric sold by Under Armour, Inc. The flexible nature of the fabric used for the nose portion74allows the truncated side portions to float and more closely engage the contours along the side of the athlete's face. Additionally, the soft nature of the fabric provides significant additional comfort to the athlete when wearing the mask because no relatively rigid or hard materials contact the unpadded cartilage area of the nose.

In at least one embodiment, the malleable nose portion74also includes a nose bride encapsulated within the fabric that forms the nose portion74. The nose bridge may be provided by a flexible metal membrane (such as aluminum) arranged within a plastic carrier. The carrier is stitched to the nose portion74in order to hold the nose bridge in place. The nose bridge is generally bendable and exhibits little resilience. Accordingly, the structure of the nose bridge is such that it may be easily conformed/bent to match the contours of the wearer's nose. Once the wearer bends the nose bridge, the nose bridge maintains its shape and helps maintain the engagement of the face guard20against the face of the wearer. While the nose bridge has been described herein as being comprised of a flexible metal membrane and carrier, it will be recognized that other configurations of the nose bridge are possible. For example, in at least one embodiment, the nose bridge is comprised of a tape member such as the BEMIS™ ST104 Seam Sealing Tape. In at least one embodiment, the nose bridge is comprised of a flexible silicone material that easily forms to the unique shape of the wearer's face and gradually cures over time, thus resulting in a mask that is eventually customized for a single user.

Mouthpiece Coupling to Face Mask

With particular reference now toFIG.11, an exemplary connection between the mouthpiece30and the frame60of the face mask40is shown. The mouthpiece30is a dual arch mouthpiece that includes an upper tooth-receiving channel32and a lower tooth-receiving channel34. An air passage36is included on the front of the mouthpiece between the upper and lower-tooth receiving channels32,34. The air passage36is of sufficient size to allow the athlete to easily breathe from the mouth with the mouthpiece positioned therein.

The base portion70of the frame60includes a central insert86that is designed and dimensioned to be received within the air passage36of the mouthpiece. The base portion70also includes an air passage76that extends completely through the base portion70at the central insert86. The air passage76is also of sufficient size to allow the athlete to easily breathe from the mouth with the frame60inserted in the mouthpiece30. When the mouthpiece is worn by the athlete, the base portion is positioned on the exterior of the face and cover the athlete's lips. While not shown inFIG.11, a shield body50, similar to that shown in the embodiments ofFIGS.1-10is retained on the frame60. As explained above, the shield body effectively abates the transmission of fluids and pathogens that may be transferred from and to the user during a sporting event.

Advantageously, in the embodiment ofFIG.11, the mouthpiece30and frame60may be either permanently coupled together or releasably coupled together. When permanently coupled together, the central insert86may be formed within the air passage36at the time of manufacture, such as by molding the components together as one piece. The components30and60may also be manufactured as two different pieces and subsequently coupled together using heat, adhesives, or any other suitable means for permanently coupling the components together. Alternatively, when configured for a releasable coupling, the components30and60are manufactured as separate parts and no permanent coupling is made. In such embodiment, a friction-fit, clip, shoulder abutment, or other type of coupling may be used to temporarily secure the face mask40to the mouthpiece30.

When the athlete wishes to add the face mask40to the mouthpiece30, the central insert86of the frame60is simply inserted into the air passage36of the mouthpiece30such that the two pieces are secured together (e.g., with a friction-fit, or any of various other means for non-permanent coupling the components). The fit is sufficiently tight such that the two components30and60are not releasable without significant pulling of the two components in opposite directions. In this manner, the mouthpiece30and face mask40may be repeatedly coupled and uncoupled and used in different configurations (i.e., the mouthpiece30with or without the face mask40). At the same time, the central insert86serves as an extension to distance the base portion70of the face mask40from the front wall38of the mouthpiece30such that the wearer's lips may be comfortably positioned between the mouth piece30and the face mask40(i.e., forward of the front wall38of the mouthpiece30and rearward of the base portion70of the face mask40). Accordingly, the central insert86will be recognized as one embodiment of an “extension” from the front of the mouthpiece30.

While the central insert86is shown inFIG.11as being releasable from the mouthpiece30, it will be recognized that in other embodiments noted herein, the central insert86may instead be provided as a mounting member that is integrally formed with and non-removable from the mouthpiece30. In such embodiments, the mounting member86permanently connects the face mask40to the mouthpiece30in a spaced relation. In particular, the mounting member serves to extend between the rear surface of the base portion70of the face mask40and the front surface of the mouth guard30, thus arranging the mouth guard30and the face mask40in a predetermined spaced relation (e.g., between1cmand3cmapart).

The foregoing detailed description of one or more embodiments of a face guard has been presented herein by way of example only and not limitation. It will be recognized that there are advantages to certain individual features and functions described herein that may be obtained without incorporating other features and functions described herein. Moreover, it will be recognized that various alternatives, modifications, variations, or improvements of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be desirably combined into many other different embodiments, systems or applications. Presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by any appended claims. Therefore, the spirit and scope of any appended claims should not be limited to the description of the embodiments contained herein.