Full-Face Helmet System

This application is a continuation of U.S. patent application Ser. No. 17/184,983, filed Feb. 25, 2021, which claims the benefit of U.S. Provisional Application No. 62/981,701 entitled “Full Face Facemask,” filed Feb. 26, 2020, the entire contents of which are incorporated by reference herein in their entirety.

The present invention relates to methods, devices, and systems for an improved helmet system with a full-face facemask. More specifically, the improved helmet system includes a full-face facemask to improve visibility and weight, but maintain impact performance.

Traditional football helmets have manufactured facemasks with a plurality of metal bars to protect a player's face. The facemask provides a way to protect the face while allowing for limited visibility. Unfortunately, the more protection a player would like (e.g., increased number of bars), the more the player's visibility is reduced and the heavier it becomes. Also, the plurality of bars provides other players the ease of grabbing the facemask or otherwise restraining a player by grabbing the face mask, which is illegal due to the risk of injury.

The improved helmet system comprises a full-facemask that combines the strength of a facemask with a reduced number of metal bars and a polymer-based cover to allow for improved visibility, safety and reduced weight, as well as potentially reduce the players from grabbing onto the facemask to cause injury. The polymer-based cover or reinforcement layer may be disposed over the facemask frame for support and enhance impact performance.

In one embodiment, the full-face facemask comprising: a facemask frame, the facemask frame comprising an external surface and an internal surface, the facemask frame comprising an upper bar and a lower bar; and a reinforcement layer, a portion of the reinforcement layer coupled to the external surface or internal surface of the facemask frame. At least a portion of the reinforcement layer matches or substantially matches the shape of the facemask frame. The reinforcement layer comprises a clear or transparent plastic material. The reinforcement layer comprises at least one vent opening, the at least one vent opening coincident with a player's mouth. The at least one vent opening may include a single opening or a plurality of openings coincident with a player's mouth. The reinforcement layer further comprises a plurality of perforations disposed adjacent to the vent opening. the facemask frame further comprises a middle bar. The facemask frame further comprises one or more vertical bars that extend between the middle bar and the lower bar. The facemask frame further comprises one or more vertical bars that extend between the upper bar and middle bar.

In another embodiment, the full-face helmet system comprising: a helmet, the helmet comprises an outer shell; a facemask frame, the facemask frame comprising an external surface and an internal surface, the facemask frame comprising an upper bar and a lower bar; and a reinforcement layer, the reinforcement layer coupled to the external surface or internal surface of the facemask frame, at least a portion of the reinforcement layer substantially matches the shape of the facemask frame. The helmet further comprises an impact mitigation layer, the impact mitigation layer coupled to an inner surface of the outer shell. The helmet further comprises an inner shell and an impact mitigation layer, the impact mitigation layer disposed between the outer shell and inner shell. The helmet further comprises a stabilizer pad system, the stabilizer pad system coupled to the outer shell. At least a portion of the facemask frame is coupled to the stabilizer pad system. The reinforcement layer comprises a clear or transparent plastic material. The at least one vent opening comprises a plurality of openings. The reinforcement layer further comprises a plurality of openings adjacent to the at least one vent opening. The facemask frame further comprises a middle bar. The facemask frame further comprises one or more vertical bars that extend between the middle bar and the lower bar. The facemask frame further comprises one or more vertical bars that extend between the upper bar and middle bar. The least a portion of the facemask frame protrudes into the at least one vent opening.

depict side views of different embodiments of a Full-Face Helmet System,,. The full-face helmet system,,comprises a helmet,, a reinforcement layer, a facemask or facemask frame. The helmet,comprises an outer shell. The helmet,further comprises an impact mitigation layer, the impact mitigation layer coupled to an inner surface of the outer shell. The helmet,further comprises an inner shell and an impact mitigation layer, the impact mitigation layer disposed between the outer shell and inner shell. The helmet,further comprises a stabilizer pad system, the stabilizer pad system coupled to the outer shell. The helmet,comprises a front region, a right region, a left region, a crown region, a back region, and/or any combination thereof. Refer tofor further helmet details.

The facemask framecomprising an external surface and an internal surface, the facemask framefurther comprising an upper barand a lower bar. The upper barincluding a first raised section, a second raised section and a central section, the central section between a first and second raised section. Each of the plurality of raised sections are raised relative to the central section. The facemask framefurther comprises a middle bar, the middle bardisposed between the upper barand the lower bar. The facemask framefurther comprises one or more vertical barsthat extend between the middle barand the lower bar. The least a portion of the facemask frameprotrudes into the at least one vent opening. The lower barand/or middle baris horizontal or substantially horizontal. At least a portion of the facemask frameis coupled to the stabilizer pad system via a facemask connector. Alternatively, the facemask framemay be coupled to the outer shell via a facemask connector. The different configurations of facemasks or facemask frames shown in.

The reinforcement layercomprises a material, the material is a clear or transparent plastic material. The material may comprise a uniform thickness or a non-uniform thickness. The thickness of the material may be based on the position-specific player's needs. The material may further comprise a coating, the coating may include an anti-reflective coating, a polarized coating, a scratch resistant coating, an anti-fog coating, an anti-microbial or anti-viral coating, an ultraviolet (UV) protection coating, a photochromic coating, a tinted coating, a mirror coating, a prescriptive coating or material and/or any combination thereof.

The reinforcement layeris coupled to the external surface of the facemask frameand/or the reinforcement layeris disposed over the facemask frame, which a portion of the internal surface of the reinforcement layercontacts a portion of the external surface of the facemask frame. Alternatively, the reinforcement layeris coupled to the internal surface of the facemask frame, and/or the facemask frameis disposed over the reinforcement layer, which the internal surface of the facemask framecontacts a portion of the outer surface of the reinforcement layer. Coupling to the different points on the internal surface or the external surface of the facemask frameallows the facemask frameto support the reinforcement layerin different regions to reduce or prevent the reinforcement layer from deforming towards the player's face and/or it further provides better distribution of the impact forces across the facemask frame. At least a portion of the reinforcement layersubstantially matches the shape of the facemask frame. Alternatively, at least a portion of the reinforcement layersubstantially matches one or more contours of the facemask frame. In another embodiment, the reinforcement layermay be over molded to the external surface or the internal surface of the facemask frame.

The reinforcement layercomprises a body, a first plurality of connecting membersand a second plurality of connecting members. Each of the first or second plurality of connecting members,located or disposed on the right and left regions of the helmetand/or body. The first plurality of connecting membersextending outwardly from the body, the plurality of connecting memberscouple to or attach to a portion of the outer shell of the helmet,,. Each of the first plurality of connecting membersextending outwardly to couple to or attach to the vent openingsor within the vent openingson the outer shell of the helmet,,. The second plurality of connecting membersmay couple or attach to the outer shell and/or may couple or attach to the stabilizer pad system (not shown). The first and/or the second plurality of connecting membersmay comprise one or more openings, the one or more openings sized and configured to receive a mechanical connector. The mechanical connector may comprise a screw, a rivet, a dowel pin, and/or any connectors known in the art.

The reinforcement layeror the bodycomprises at least one vent opening. The at least one vent openingcomprises a plurality of openings (not shown) or a single vent opening. The at least one vent openingcomprises a shape, the shape includes a circle, an oval, a regular polygon and/or an irregular polygon. The shape may further include a “U” shape, “D” shape, a hemispherical shape, or an arch shape. The reinforcement layerfurther comprises a plurality of openingsadjacent to the at least one vent opening. The plurality of openingsincluding a width smaller than the at least one vent opening width. The at least one vent openingmay be coincident or aligned with a player's mouth. Alternatively, the at least one vent openingmay be in front of the player's mouth. At least a portion of the facemask frameprotrudes or extends into or through the at least one vent opening. The top portion of the bodyof the reinforcement layermay be coupled to the front bumperlocated in the front region of the helmet,,. Mechanical connectors may be inserted into the one or more openingsof the reinforcement layerdisposed at the top region of the reinforcement layeror the body.

Accordingly, the bottom portion of the bodyof the reinforcement layermay be coupled using one or more bumper connectors. The one or more bumper connectorscomprises a first portion and a second portion. The first portion comprises longitudinal members, the longitudinal membersextending perpendicularly or normal from the first portion. The longitudinal membersbeing inserted into a plurality of holeson the reinforcement layerand connected to second portion of the one or more bumper connectors. The one or more bumper connectorsmay comprise a plastic, foam, an elastomeric foam, rubber, and/or any material that facilitates the absorption of impacts and/or vibrations.

The reinforcement layermay further comprise one or more ribs (not shown). The one or more ribs are disposed onto the external surface or internal surface of the reinforcement layer. The one or more ribs extend away from the external or internal surface of the reinforcement layer. Alternatively, the one or more ribs extend perpendicularly or substantially perpendicular from the external or internal surface of the reinforcement layer. The one or more ribs having a length and a width. The one or more ribs may have a horizontal orientation or a vertical orientation. In one embodiment, if the one or more ribs are in a vertical orientation, the one or more ribs sized and configured to fit within the entirety of the spacing of the one or more vertical bars,and/or at least a portion of the spacing of the one or more vertical bars,. The one or more ribs may have a horizontal orientation or a vertical orientation.

depicts various facemasks or facemask frames,,,,,that may be used with the full-face helmet system or full-face facemask. The facemasks or facemask frames,,,,comprise a top portion, a middle portionand a lower portion. The top portionmay be coupled to the helmet. The middle portionincludes the field of view for the player. The lower portionincludes different bar configurations to protect the nose, and lower half of the face of the player.

The facemasks or facemask frames,,,,comprises an upper barand a lower bar. The facemask or facemask frames,,,may further comprise a middle bar. The upper barincludes a first raised section, a second raised section and a central section, the central section between a first and second raised section. Each of the plurality of raised sections are raised relative to the central section. The facemasks or facemask frames,,,,further includes a first intermediate barsand a second intermediate bar. The first intermediate baris spaced apart from the upper barto create a space or an opening. The first intermediate baris horizontal or substantially horizontal. One or more connecting elementsmay be disposed within the space or opening below the central section to couple the upper barto the intermediate bar. Alternatively, the first intermediate barand the second intermediate barcan be disposed between the upper barand the middle bar.

The facemasks or facemask frames,,,,may further one or more vertical bars,. The one or more vertical bars,may extend between the first intermediate barand the middle bar. The one or more vertical bars,may extend between the middle barand the lower bar. The one or more vertical bars,may extend between the first intermediate barand middle barand extend between the middle barand the lower bar. Each of the one or more vertical bars,are spaced apart from the adjacent one or more vertical bars,to create a space. The one or more vertical bars,that extend between the first intermediate barand the middle barare offset or are not aligned with the one or more vertical bars,that extend between the middle barand the lower bar.

depicts various views of a helmet. The helmetcomprises a front region, a right region, a left region, a crown region, a back region, and/or any combination thereof. The helmetcomprises an outer shell. The helmetfurther comprises an impact mitigation layer, the impact mitigation layercoupled to an inner surface of the outer shell. The helmetfurther comprises an inner shell, the impact mitigation layerdisposed between the outer shelland inner shell. The helmetfurther comprises a removable stabilizer pad system, the stabilizer pad systemcoupled to the right and left regions of the outer shell. The helmetmay further comprise a plurality of pad assemblies that are attached or coupled to an inner surface of the helmetand/or an inner surface of the inner shell. The plurality of pad assemblies comprises at least a portion of a surface that contacts the player's head. The helmetmay further comprise different accessories, including a visor, chincups with straps and different facemask or facemask frame configurations.

The outer shellis constructed from a flexible plastic material that desirably permits significant local deformationwhen impacted with a sufficient external force as shown in. The outer shellcomprises a generally spherically shaped body with complex contours on an upper portion thereof, which defines a pair of medialand lateralraised bands that extend from the front region towards the back region of the outer shellwith a centrally positioned recessed band between the medialand lateralraised bands. The outer shellfurther includes a plurality of vent holes,(i.e., perforations in the outer shell which allow gases to pass through the shell body), and an ear hole on each side of the outer shellto allow sound transmission to the wearer's ears. Accordingly, the outer shellincludes a raised side bandthat extends from the edge of the outer shelltowards the back region. The outer shellincludes a raised side bandthat extends from the edge of the outer shellin an upwardly direction towards the back region.

The impact mitigation layercomprises a plurality of deformable structures positioned inside of and mechanically fastened to inner surface of the outer shell, which prevents relative movement between the impact mitigation layerand the outer shell. The impact mitigation layercomprises a plurality of impact mitigating structures, the plurality of impact structures comprises at least one of a plurality of filaments (not shown), a plurality of laterally supported filaments (LSFs) (not shown), a plurality of undulated structures (not shown) and/or a foam layer (not shown).

In one embodiment, the impact mitigating structures can comprise a plurality of filamentsas shown in. The plurality of filamentsmay be thin, longitudinally extending members or be shaped and configured to deform non-linearly in response to an impact force. The plurality of filamentsmay comprise an aspect ratio of 3:1 or greater, which the height is greater than the width. The non-linear deformation behavior is expected to provide improved protection against high-impact forces, and/or oblique forces. The non-linear deformation behavior is described by the filaments stress-strain profile. The non-linear stress-strain profile illustrates that there can be an initial rapid increase in force (region I) followed by a change in slope that may be flat, decreasing or increasing slope (region II), followed by a third region with a different slope (region III).

The filaments undergo a buckling responseto an incident force, where bucklingmay be characterized by a localized, sudden failure of the filament structure subjected to high compressive stress, where the actual compressive stress at the point of failure is less than the ultimate compressive stress that the material is capable of withstanding. Furthermore, the plurality of filamentsmay be configured to deform elastically, allowing the at least a portion of the filamentsto substantially return to their initial configuration once the external force is removed. The at least a portion of filamentsmay extend between two surfaces, the at least a portion of filaments having at least one end coupled to the outer layer and/or the inner layer. The plurality of filamentsmay include be solid or hollow.

In another embodiment, the impact mitigating structures can comprise a plurality of laterally supported filaments (LSF) structures,,as shown in. The LSF structures,,comprise a plurality of filamentsthat are interconnected by laterally positioned walls or sheetsin a polygonal configuration. Polygonal structures and/or configurations known in the art may be contemplated, including triangular, square, pentagonal, hexagonal, septagonal, octagonal, and/or any combination thereof. A plurality of sheets or lateral wallscan be secured between adjacent pairs of filamentswith each filamenthaving a pair of lateral wallsattached thereto. Alternatively, each of the plurality of filamentsmay comprise a lateral wallextending outwardly therefrom to at least one adjacent filament. In the disclosed embodiment, the lateral wallscan be oriented approximately 120 degrees apart about the filament axis, with each lateral wallextending substantially along the longitudinal length of the filament. The plurality of LSF structures,,can be arranged in one or more rows or in an array, each of the one or more rows may be aligned or offset. The impact mitigation structures may comprise a plurality of LSF structures,,and a base layer, the plurality of LSF structures,,disposed on the base layer and spaced apart. The impact mitigation structures may comprise a plurality of LSF structures,,, a first base layer and a second base layer, the plurality of LSF structures,,spaced apart and extend between the first and second base layer.

Accordingly, the orientation of the lateral wallsmay be asymmetric, which at least one lateral wallmay be oriented approximately 75 to 135 degrees apart about the filamentaxis. The shape, wall thickness or diameter, height, and configuration of the lateral wallsand/or filamentsmay vary to “tune” or “tailor” the structures to a desired performance. For example, one embodiment of a polygonal LSF structure,,may have a tapered configuration as shown in. The polygonal LSF structure,,can have a top surface and a bottom surface, with the bottom surface perimeter (and/or bottom surface thickness/diameter of the individual elements) that may be larger than the corresponding top surface perimeter (and/or individual element thickness/diameter). In another example, the polygonal LSF structure,,can have an upper ridge or upper plate. The upper plateis planar and extends across to the adjacent filament. The upper platecontacts at least one end of the plurality of filamentsand/or each of the plurality of filaments. The upper platemay further comprise an opening. The upper platemay comprise a solid material or hollow material. The upper platecan also facilitate connection to another structure, such as an inner surface of a helmet, an item of protective clothing, and/or a mechanical connection (e.g., a grommet or plug having an enlarged tip that is desirably slightly larger than the opening in the upper ridge of the polygonal element).

In another embodiment, the impact mitigation layer may further comprise at least one foam layer or a portion of a foam layer (not shown). The at least one foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam (e.g., VN600),), Ethylene Vinyl Acetate foam (EVA), Ariaprene foam, latex rubber foam, convoluted foam (“egg create foam”), Evlon foam, impact hardening foam, 4.0 Custula comfort foam (open cell low density foam) and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The at least one foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.

The helmetfurther comprises an inner shell. The inner shellis constructed from a rigid or relatively rigid plastic material. The inner shellthat is more rigid than the outer shellmaterial. The inner shellis also mechanically secured to various portions of the impact mitigation layer to prevent relative movement between the inner shelland the impact mitigation layer. The inner shellfurther comprises a plurality of openings, into which various attachment assemblies of the plurality of pad assemblies are securely attached. The helmetfurther comprises a plurality of pod assemblies that are removably coupled to the inner surface of the inner shell. The plurality of pod assemblies includes multi-layered foams (e.g., an impact foam layer and a comfort foam layer) that sizes the helmetto the wearer's head and also provides additional impact protection and comfort. The plurality of pod assemblies comprises a first material layer, a second material layer, one or more foam layers and a connection mechanism. The first material layer and/or the second material layer may comprise a 2-way stretch material, a 4-way stretch material, and/or a foam layer. Additionally, the first material layer and/or the second material layer may further comprise a polymeric material, such as polypropylene, polyethylene, polyester, nylon, PVC, PTFE, and/or any combination thereof. Furthermore, the first material and/or the second material layer may be breathable and wick away moisture easily from the skin while carrying out various sporting and athletic activities. The first material layer may be the same or different than the second material layer. The one or more foam layers are disposed between the first and second material layer. At least a portion of the connection mechanism is disposed between the first and second material layer.

The one or more pad assemblies can be modular and removably coupled into any configuration within the helmet. Each of the one or more pod assemblies may be positioned proximate to an adjacent to the one or more pad assemblies, such that the perimeter of each of the one or more pad assemblies may be parallel to the adjacent one or more pod assemblies. The plurality of liner pad assemblies may include regions such as one or more of the following: a frontal assembly (or front), an occipital assembly (or lower-back), a mid-back assembly (right and/or left sides), a parietal assembly (or midline), and a temporal assembly (right and/or left sides), and/or any combination(s) thereof.

The plurality of pad assemblies can comprise a generally triangular shaped body with rounded corners (an isosceles triangle, for example), although a variety of other shapes, including other shaped triangles, squares, pentagons, hexagons, septagons and/or octagon shapes, could be utilized in a variety of embodiments. In a similar manner, alternative shapes having rounded and/or sharp corners and/or edges may be utilized, as well as irregular and/or re-entrant shaped bodies, if desired. The plurality of pad assemblies can be provided in a series of sizes and/or thicknesses, including a ¼″ thickness progressively up to 1″ or 1.25″ or greater thickness. Desirably, the different thickness triangular pods bodies can be provided with similar external dimensions (i.e., height and/or width), with only the thickness differing to any substantial degree, allowing different thickness pods to be “mixed and matched” for use with a single helmet liner or other component, and/or other item of protective clothing.

The helmetfurther comprises a stabilizer system. The stabilizer systemcomprises at least two different pad assemblies that are positioned on the right and left regions of outer shell. The stabilizer systemincludes a bridge pad assembly and a stabilizer pad assembly. A bridge pad assembly is secured to an inner surface of the outer shelladjacent to and below the ear hole on the right and left sides, and a stabilizer pad assembly is secured to an inner surface of the outer shellat locations forward of the ear hole. The stabilizer pad assemblies are available in different thicknesses—0.5 inch or greater; 1.0 inch or greater; or 0.5 inch to 2 inches. Portions of the stabilizer pad assembly desirably project forwardly to protect various regions of the wearer's skull, which can include portions of the zygoma (cheek bone), portions of the maxilla and portions of the mandible (e.g., the coronoid process, the condyle, and a portion of ramus) of the wearer. Each of the stabilizer pad assemblies are mounted to the stabilizer plates. Each stabilizer plate also includes a facemask mount which secures and couples to a lower attachment point on the facemask or facemask frame. Each of the stabilizer pad assembly and the bridge pad assembly comprises a plate and one or more foam layers, the one or more foam layers coupled to the plate.

The helmetmay further comprise one or more facemask clip styles or facemask bumper styles—a standard facemask clip and a quick release facemask clip. The standard facemask clip requires tooling for placement and removal. However, the quick release facemask clip requires limited tooling for placement and easy, repeatable manual release. The helmetcan further include a variety of accessories, including a visor and/or a chincup/strap. The chincup can be a standard chincup that is known in the art.