Face shield

Abstract

A sport helmet face shield includes a visor including a body extending transversally from left to right visor edges and vertically from lower to upper visor edges. A cage disposed below the visor includes a perimeter wire member defining an outer perimeter with upper, lower, left, and right sides. The cage includes first and second transverse wires extending adjacent the lower or upper visor edge. The cage further includes first and second additional wire members extending from a first end at the lower side to a second end at the left side or the right side. Each of additional wire members curve at a junction with the first transverse wire member. The additional wire members are disposed inwardly of the first transverse wire member at the junction and are spaced apart vertically from the first transverse wire member at the left side or the right side.

Description

FACE SHIELDCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States patent application No. 63 / 581 ,446 filed September s, 2023, the entire content of which is incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to the protective headgear and sports helmets, such as helmets worn during sporting activities, and more particularly to face shields for such sports helmets.BACKGROUND

[0003] Participants in certain sporting activities, such as ice hockey, wear protective headgear or helmets to help prevent head injuries. The headgear may include a face protector that attaches to a helmet to provide additional protection for the player’s face and eyes. By way of example, ice hockey players regularly wear a protective helmet with a face shield, which protects all of a player’s face, or a visor, which protects part of a player’s face, to protect from possible injuries that may be caused by other players, a puck, and sticks.SUMMARY

[0004] According to an aspect, there is provided a face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion disposed below the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and having an upper side, a lower side, a left side, and a right side, the lower cage portion further including transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge, the lower cage portion further including a first additional wire member and a second additional wire member, the first additional wire member extending from a first end at the lower side of the perimeter wire member to a second end at the left side of the perimeter wire member, the second additional wire member extending from a first end at the lower side of the perimeter wire member to a second end at the right side of the perimeter wire member, each of the first and secondadditional wire members curving at a junction with the first transverse wire member, and wherein the first and second additional wire members are disposed inwardly of the first transverse wire member at the junction, the first additional wire member spaced apart vertically from the first transverse wire member at the left side of the perimeter wire member, and the second additional wire member spaced apart vertically from the first transverse wire member at the right side of the perimeter wire member.

[0005] In certain embodiments, the face shield as defined above and described herein includes one or more of the following features, in whole or in part, and in any combination.

[0006] In an embodiment according to any of the previous embodiments, the second end of the first additional wire member is disposed higher along the left side than the first transverse wire member, and the second end of the second additional wire member is disposed higher along the right side than the first transverse wire member.

[0007] In an embodiment according to any of the previous embodiments, the first additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the right side.

[0008] In an embodiment according to any of the previous embodiments, the first additional wire member extends transversely towards the left side between the upwardly curved portion and the left side, and wherein the second additional wire member extends transversely towards the right side between the upwardly curved portion and the right side.

[0009] In an embodiment according to any of the previous embodiments, the first transverse wire member has a non-circular cross sectional shape.

[0010] In an embodiment according to any of the previous embodiments, a width of the cross sectional shape of the first transverse wire member is greater than a height of the cross sectional shape of the first transverse wire member.

[0011] In an embodiment according to any of the previous embodiments, the lower cage portion includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the secondtransverse wire member and one of the first and second additional supporting wire members, before extending back towards and terminating at the perimeter wire member.

[0012] In an embodiment according to any of the previous embodiments, at least one of the U-shaped visor supporting wire members meets both the first transverse wire member and one of the first and second additional supporting wire members, a non-zero angle formed between a first portion of the at least one of the U-shaped visor supporting wire members disposed between the first transverse wire member and the one of the first and second additional supporting wire members and a second portion of the at least one of the U-shaped visor supporting wire members disposed below the one of the first and second additional supporting wire members.

[0013] In an embodiment according to any of the previous embodiments, the lower cage portion further includes a first upper additional wire member extending from the upper side and terminating at the left side and a second upper additional wire member extending from the upper side and terminating at the right side, the first upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, and the second upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

[0014] According to another aspect, there is provided a face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion disposed below and coupled to the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and having an upper side, a lower side, a left side, and a right side, the lower cage portion including a first visor-supporting wire member extending between the lower side of the perimeter wire and the left side of the perimeter wire, and a second visor-supporting wire member extending between the lower side of the perimeter wire and the right side of the perimeter wire, each of the first and second visor-supporting wire members curving at a junction with the lower visor edge, the visor-supporting wire members supporting the visor body with an unsupported portion of the visor body disposed between each junction.

[0015] In certain embodiments, the face shield as defined above and described herein includes one or more of the following features, in whole or in part, and in any combination.

[0016] In an embodiment according to any of the previous embodiments, the first visorsupporting wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second visor-supporting wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the right side.

[0017] In an embodiment according to any of the previous embodiments, the lower cage portion further includes a first upper wire member extending from the upper side and terminating at the left side, and a second upper wire member extending from the upper side and terminating at the right side, the first upper wire member extending downwardly from the upper side, operatively coupled to and curving at the upper visor edge and extending in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, the second upper wire member extending downwardly from the upper side, operatively coupled to and curving at the upper visor edge and extending in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

[0018] In an embodiment according to any of the previous embodiments, the lower cage portion further includes transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge.

[0019] In an embodiment according to any of the previous embodiments, the lower cage portion further includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the second transverse wire member and one of the first and second supporting wire members, before extending back towards and terminating at the perimeter wire member.

[0020] According to a further aspect, there is provided a face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion operatively coupled to the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and havinga lower side, an upper side, a left side, and a right side, the lower cage portion further including transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge, the lower cage portion further includes a first upper additional wire member extending from the upper side and terminating at the left side and a second upper additional wire member extending from the upper side and terminating at the right side, the first upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, the second upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

[0021] In certain embodiments, the face shield as defined above and described herein includes one or more of the following features, in whole or in part, and in any combination.

[0022] In an embodiment according to any of the previous embodiments, the lower cage portion further includes a first lower additional wire member extending from a first end at the lower side to a second end at the left side and a second lower additional wire member extending from a first end at the lower side to a second end at the right side, each of the first and second lower additional wire members curving at a junction with the first transverse wire member, the first and second additional wire members disposed inwardly of the first transverse wire member at the junction, the first additional wire member spaced apart vertically from the first transverse wire member at the left side, the second additional wire member spaced apart vertically from the first transverse wire member at the right side.

[0023] In an embodiment according to any of the previous embodiments, the second end of the first lower additional wire member is disposed higher along the left side than the first transverse wire member, and the second end of the second lower additional wire member is disposed higher along the right side than the first transverse wire member.

[0024] In an embodiment according to any of the previous embodiments, the first lower additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second lower additional wire member includesa downwardly curved portion and an upwardly curved portion between the junction and the right side.

[0025] In an embodiment according to any of the previous embodiments, the lower cage portion includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the second transverse wire member and one of the first and second additional supporting wire members, before extending back towards and terminating at the perimeter wire member.

[0026] In an embodiment according to any of the previous embodiments, at least one of the U-shaped visor supporting wire members meets both the first transverse wire member and one of the first and second lower additional supporting wire members, a non-zero angle formed between a first portion of the at least one of the U-shaped visor supporting wire members disposed between the first transverse wire member and the one of the first and second lower additional supporting wire members and a second portion of the at least one of the U-shaped visor supporting wire members disposed below the one of the first and second lower additional supporting wire members.

[0027] Many further features and combinations thereof concerning the present improvements will appear to those skilled in the art following a reading of the instant disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a schematic three-dimensional view of a head of a wearer;

[0029] FIG. 2 is a schematic side view of the head of the wearer of FIG. 1 ;

[0030] FIG. 3 is a schematic three-dimensional view of a sports helmet for the head;

[0031] FIG. 4 is a schematic front view of a face shield for a sports helmet;

[0032] FIG. 5 is a schematic side view of the face shield of FIG. 4;

[0033] FIGS. 6A and 6B are rear and enhanced rearviews, respectively, of the face shield of FIG. 4;

[0034] FIG. 7 is a schematic enhanced, partial cutaway view of the face shield of FIG. 4; and

[0035] FIG. 8 is a front, partially-transparent view of the face shield of FIG. 4.DETAILED DESCRIPTION

[0036] Figs. 1 and 2 show a wearer's head comprising a front region FR, right and left side regions RS, LS, a rear region RR, and a top region TR. The front region FR includes a face F of the wearer, eyes E, a nose N and a mouth M of the wearer’ face F, a chin C, and a forehead FH. The right and left side regions RS, LS are located between the front region FR and the rear region RR of the head and include right and left temples and ears and right and left lateral parts of the head in right and left temporal bone areas of the head. The rear region RR has a rear upper part and an occipital region OR comprising an occipital protuberance in a parietal bone area and occipital bone area.

[0037] Referring to Fig. 3, a sport helmet in accordance with one embodiment is shown at 10. Variants, examples and preferred embodiments of the present disclosure are described hereinbelow. More particularly, FIG. 3 show a sport helmet 10 for protecting the wearer’s head in accordance with an embodiment of the present disclosure. In this embodiment, the sport helmet 10 is a hockey helmet 10 for protecting the head of the wearer who is a hockey player. However, the present disclosure is not limited to any particular type of sport helmet 10. For example, a sport helmet 10 constructed using principles described herein in respect of the sport helmet 10 may be used for protecting the head of a player of another type of contact sport in which there are significant impact forces on the player due to player-to-player and / or player-to-object contact (lacrosse or football for instance). It is also understood that the sport helmet 10 may be for protecting the head of a wearer involved in a sport other than a contact sport (e.g., bicycling, motorcycle, skiing, snowboarding, horseback riding or another equestrian activity, etc.).

[0038] The sport helmet 10 defines a cavity for receiving the wearer's head to protect the head when the sport helmet 10 is impacted (e.g., when the sport helmet 10 hits a board, ice or other playing surface or is struck by a puck, ball, a lacrosse or hockey stick, or when the player is receiving a hit (e.g., body check) by another player and the head of the player is hit directly or indirectly).

[0039] The sport helmet 10 has a longitudinal axis LA, a transversal axis TA and a vertical axis VA that respectively define a front-back direction, a left-right direction and a vertical direction of the sport helmet 10. The longitudinal axis LA may be seen as an axis that resides within an imaginary longitudinal plan that bisects the helmet 10 and that defines left and right sides on each side of the plane.

[0040] The sport helmet 10 has an outer shell 12 comprising a first or front shell 14 and a second or rear shell 16 at least partially enclosing an inner padding 18. The first and second shells 14, 16 may be made of a relatively rigid material, such as polyethylene, nylon, polycarbonate materials, thermoplastics, or thermosetting resins or any other suitable material. The outer shell 12 has an outer surface 12a defined by the first and second shells 14, 16. The sport helmet 10 may also comprise ear loops and a chinstrap for securing the sport helmet 10 to the wearer's head. The sport helmet 10 may further comprise ear protectors for protecting the left and right ears of the wearer.

[0041] The sport helmet 10 is herein an adjustable sport helmet 10 wherein the outer shell 12 and the inner padding 18 are adjustable to adjust the fit of the sport helmet 10 on the wearer's head. To that end, the first shell 14 and its inner padding are movable relative to the second shell 16 and its inner padding in a longitudinal direction defined by the longitudinal axis LA to adjust the fit of the sport helmet 10 on the wearer's head. It is understood that the expression “the first shell moves relative to the second shell” covers movements of the first and second shells in relation to each other wherein both shells are movable in relation to each other, wherein only the first shell is movable in relation to the second shell or wherein only the second shell is movable in relation to the first shell. Relative movement of the first and second shells for adjustment purposes may be along the longitudinal axis in the front-back direction of the sport helmet 10 such that the front-back internal dimension of the cavity of the sport helmet 10 is adjusted. The above-described sport helmet 10 is exemplary in nature, and the present disclosure is applicable to other sport helmets.

[0042] Referring now to FIGS. 4 and 5, a face shield 20 according to an embodiment of the present disclosure is provided for the sport helmet 10. The face shield 20, also referred to as a face mask or face guard, may be used to protect some or all of the face F of the wearer when the helmet 10 is worn. As will be discussed in further detail below, the face shield 20 includes an upper visor portion 30, which may be generally transparent or translucent (e.g., tinted) and is configured for covering and protecting the eyes and upper portion of the wearer’sface, and a lower cage portion 40, which may be formed of metal wires and is configured for covering and protecting the lower portion of the wearer’s face F (e.g., the wearer’s nose, mouth and jaw). The metal wires of the lower cage portion 40 may for instance be made of steel or titanium wires that are bent and welded or otherwise formed, to create the metal cage. In the shown embodiment, the lower cage portion 40 may also protect a portion of the top and side of the wearer’s face F. The visor may be secured at various points of the outer shell 12 of the helmet 10, as will be discussed below. The left temple region 12b and the right temple region 12c, which may also be referred to as the left flap and the right flap respectively, substantially cover the temples of the head of the wearer. Such a face shield 20 is securable, for instance, to a lower portion 14a of the first shell 14 as well as to left and right sides of the outer shell 12 of the helmet 10, for instance to each of the left temple region 12b and the right temple region 12c. Other means for securing the face shield 20 to the helmet 10 may be contemplated.

[0043] The upper visor portion 30 has a visor body 32 extending from a lower edge 32a to an upper edge 32b opposed the bottom edge 32a and extending from a left edge 32c to a right edge 32d opposed to the left edge 32c. Herein, the expression “left” and “right” are in relation to the wearer of the sports helmet 10. Each of the left edge 32c and the right edge 32d extends from the lower edge 32a to the upper edge 32b. When secured to the helmet 10, the upper edge 32b lays above a front edge of the outer shell 12 and the lower edge 32a is located proximate the nose N (Fig. 1) of the wearer. Each of the left edge 32c and the right edge 32d is located adjacent a respective one of the left temple region 12b (Fig. 3) and the right temple region 12c (Fig. 3) of the outer shell 12 ofthe helmet 10. The body 32 ofthe upper visor portion 30 defines an inner surface 32e (see FIGS. 6A-6B) facing toward the wearer and an opposed outer surface 32f opposed the inner surface 32e and facing away from the wearer.

[0044] The upper visor portion 30 is a light-transmitting shield covering at least some of the face F of the wearer. In the embodiment shown, the upper visor portion 30 is adapted to substantially protect the top of the face F as well as a part of the forehead FH of the wearer. When the helmet 10 is worn, the visor 22 thus extends from the lower forehead of the wearer to, or below, the nose N, and rearwardly on the sides of the head to coverthe temple and rear parts of the jaw. It will be appreciated that the upper visor portion 30 can take other configurations as well. For example, the upper visor portion 30 can be larger or be smaller than the embodiment shown. It will also be appreciated that the lower parts of the face may be protected by the lower cage portion 40, as will be discussed in further detail below. Theupper visor portion 30 can be made from any suitable type of polymer or glass material, for example capable of withstanding one (or more) impact from an object, such as a hockey puck or a ball. Alternatively, various injected or thermoformed transparent plastic materials may be contemplated for the upper visor portion 30. The visor body 32 may have a curved shape that contours an upper portion of the face F of the wearer, which may provide both a low profile and a wide field of vision for the wearer.

[0045] The lower cage portion 40 is connected to and disposed below the upper visor portion 30, as will be discussed in further detail below, and includes various wire members. Various wire members may intersect one another, forming openings or apertures in the lower cage portion 40 in a grid-like pattern, with the wire members secured to one another (e.g., via welds) at their intersection points. In particular, a perimeter wire member 42 defines an outer perimeter of the face shield 20 and includes a lower side 42a, an upper side 42b, a left side 42c and a right side 42d. In the shown case, the perimeter wire member 42 is formed of a single, bent wire member having four sides (42a-42d) and thus forming a closed outer perimeter of the lower cage portion 40. In other cases, the perimeter wire member 42 may be formed of two or more wire members operatively coupled (e.g., welded) to one another at ends thereof.

[0046] The lower cage portion 40 further includes transverse wire members 44 and visorsupporting wire members 46. The visor-supporting wire members 46 are generally U-shaped, having two major portions which extend substantially vertically and an upper portion (shown in broken lines in Fig. 4), which extends behind the upper visor portion 30. As such, these visor-supporting wire members 46 may also be referred to as U-shaped visor-supporting wire members 46. The “transverse” and “vertical” directions of the various wire members 44, 46 may be generally taken to be in relation to the transverse axis TA and vertical axis VA of the sport helmet 10 when the face shield 20 is installed thereon. Such “transverse” and “vertical” designation does not preclude the various wire members from additionally having a longitudinal component, as will be discussed in further detail below. A first transverse wire member 44a extends transversely between the left side 42c and right side 42d and is disposed adjacent the lower edge 32a of the visor body 32, while a second transverse wire member 44b extends transversely between the left side 42c and right side 42d and is disposed adjacent the upper edge 32b of the visor body 32. In the shown embodiments, the first and second transverse wire members 44a, 44b respectively follow similar curvilinear patterns as the lower and upper edges 32a, 32b of the visor body 32, for instance to contour the face Fof the wearer, with the first transverse wire member 44a having an upwardly-directed portion 44a1 at a midpoint thereof. Other shapes for the first and second transverse wire members 44a, 44b may be contemplated. In the shown embodiment, two additional transverse wire members 44c, 44d extend transversely between the left side 42c and right side 42d and are disposed between the first transverse wire member 44a and the lower side 42a, although other numbers and locations of transverse wire members 44 may be contemplated.

[0047] The lower cage portion 40 further includes additional visor-supporting wire members 48, also referred to herein as additional wire members 48, with both transverse and vertical components as will be explained. The depicted face shield 20 includes four additional wire members 48, although other numbers of additional wire members 48 may be contemplated. Two such additional wire members 48 may be referred to as lower additional wire members 48a and extend from first ends 48a1 at the lower side 42a to second ends at either the left side 42c or the right side 42d, with a curved portion 48a3 acting as a transition between vertical and transverse sections. The curved portion 48a3 is also referred to as a junction 48a3, as it is where a respective lower additional wire member 48a meets the first transverse wire member 44a. The depicted curved portion 48a3 includes a downwardly curved portion and an upwardly curved portion, as will be discussed. In the shown case, the lower additional wire members 48a are operatively coupled to the first transverse wire member 44a at the junctions 48a3 via welds.

[0048] The transverse portions of the lower additional wire members 48a extend transversely towards the left side 42c or the right side 42d, adjacent the lower edge 32a of the visor body 32, alongside yet offset from the first transverse wire member 44a in a dual arc configuration. Stated differently, from the junction 48a3, the transverse portions of the lower additional wire members 48a and the first transverse wire member 44a extend alongside one another and reach the left side 42c or right side 42d at different vertical positions or elevations thereon. Illustratively, the transverse portions of the lower additional wire members 48a reach the left side 42c and right side 42d at a higher position than the first transverse wire member 44a. There is thus at least a partial overlap between the first transverse wire member 44a and the lower additional wire members 48a between the junctions 48a3 and the left side 42c or the right side 42d. In addition, at the junctions 48a3, the lower additional wire members 48a are disposed inwardly, i.e., closer to the face F of the wearer, than the first transverse wire member 44a, whereas the lower additional wire members 48a and the first transverse wiremember 44a each meet the outer perimeter wire member 42 (at the left side 43a or the right side 42d, respectively), at a same distance from the face F of the wearer.

[0049] In the embodiment shown in FIG. 4, each lower additional wire member 48a follows the following trajectory from the first end 48a1 at the lower side 42a to the second end 48a2 at either the left side 42c or the right side 42d: the lower additional wire member 48a first extends upwardly from the lower side, 42a. At the junction 48a3, the lower additional wire member 48a bends or curves towards either the left side 42c or the right side 42d. This is illustratively a downward gradual curve (i.e., a downwardly curved portion) that leaves the lower additional wire member 48a extending in a diagonal direction towards both the lower side 42a and the left side 42c or right side 42d. The lower additional wire member 48a then curves slightly again, now in an upward direction (i.e., an upwardly curved portion), so that it extends transversely towards either the left side 42c or the right side 42d. Other specific trajectories for the lower additional wire members 48a may be contemplated.

[0050] The depicted face shield 20 further includes two upper additional wire members 48b. The upper additional wire members 48b illustratively extend from the upper side 42b and include various vertical and transversal components (with curved portions 48b1 , also referred to as junctions 48b1 , providing said changes in direction), before terminating at another location along the perimeter wire member 42. Illustratively, each upper additional wire member 48b descends from the upper side 42b in a downward direction, curves at the upper edge 32b of the visor body 32 and extends in a same direction as the upper edge 32b toward one of the left side 42c and the right side 42d, and then curves again in a downward direction until they reach a lower portion of the left side 42c or the right side 42d (i.e., a point below the visor body 32). Alternatively, the upper additional wire members 48b may extend towards the lower side 42b rather than to the left / right sides 42c, 42d.

[0051] While the depicted face shield 20 includes four additional wire members 48 (two lower additional wire members 48a and two upper additional wire members 48b), other numbers and permutations may be contemplated. For instance, in some embodiments the face shield 20 may include only the two lower additional wire members 48a, or the two upper additional wire members 48b, with additional visor-supporting wire members 46 provided as needed. Other permutations may be contemplated as well. In the embodiment of FIG. 4, a portion of the additional wire members 48 (denoted by broken lines) are disposed behind the visor body 32 (i.e., between the visor body 32 and the face F of the wearer).

[0052] As discussed above, the lower cage portion 40 includes a plurality of visorsupporting wire members 46. Each visor-supporting wire member 46 begins and ends at the perimeter wire member 42, illustratively at the lower side 42a or the upper side 42b, and includes a curved portion 46a, i.e., a transition portion that allows each visor-supporting wire member 46 to be redirected to the same side of the perimeter wire member 42 where it originated. In the shown case, the lower cage portion 40 includes two sets of visor-supporting wire members 46 disposed below the visor body 32 and engaging the visor body 32 just above the lower edge 32a, and two sets of visor-supporting wire members 46 disposed above the visor body 32 and engaging the visor body just below the upper edge 32b. The visorsupporting wire members 46 are disposed behind the visor body 32 (i.e., between the visor body 32 and the face F of the wearer relative to the longitudinal axis LA) to support the visor body 32, for instance to provide additional support against frontal impact. The lower cage portion 40 further includes an additional wire member 46’ that engages the second transverse member but does not engage the visor body 32 (thereby not hindering visibility through the center portion of the visor body 32), and thus does not support the upper visor portion 30. Each “set” refers to the complete wire member 46, 46’ including the curved portion 46a, although other numbers and locations for the visor-supporting wire members 46 may be contemplated. In the shown case, curved portions 46a are disposed at, and for instance welded to, one of the additional wire members 48. In other cases, the curved portions 46a may be welded to the first transverse wire member 44a or the second transverse wire member 44b. As shown in FIG. 5, the various wire members, whether vertically or transversally oriented, may have an additional longitudinal component, for instance to better contour the face F of the wearer.

[0053] Referring to FIGS. 5-6B, a visor mount 50 is shown for operatively coupling the upper visor portion 30 to the lower cage portion 40. The depicted face shield 20 includes two visor mounts 50: a first visor mount 50 operatively coupling the left edge 32c of the visor body 32 to the left side 42c of the perimeter wire member 42, and a second visor mount 50 operatively coupling the right edge 32d of the visor body 32 to the right side 42d of the perimeter wire member 42. In the shown embodiment, each visor mount body 52 includes separate inner plate 52a and outer plate 52b, each having one or more apertures 54 disposed therethrough (illustratively three apertures 54 disposed through each plate 52a, 52b). The inner plate 52a is disposed against and operatively coupled to (e.g., welded to) wire members of the lower cage portion 40, and the outer plate 52b is disposed against the outer surface 32fof the visor body 32. With the apertures 54 of the inner and outer plates 52a, 52b aligned, fasteners such as screws (not shown) may be passed therethrough to compressibly retain the upper visor portion 30 to the lower cage portion 40. Other retention means may be contemplated.

[0054] Still referring to FIG. 6B, a spacer 56 may be provided between the inner and outer plates 52a, 52b of each visor mount 50. As the lower cage portion 40 may be configured for closely contouring the face F of the wearer (i.e., more closely than the upper visor portion 30 may comfortably be disposed against the wearer’s eyes E), a gap G may form between the two plates 52a, 52b. The spacer 56 may securely fill the gap G and further secure the retention provided by the visor mount 50.

[0055] Referring to FIGS. 6A and 6B, the face shield 20 also comprises right and left connectors 60a, 60b for mounting the face shield 20 to a front portion of the sport helmet 10, for instance to lower portion 14a of first shell 14. Each of the right and left connectors 60a, 60b comprises a base portion 62 defining a substantially cylindrical aperture (not shown) for receiving a wire member (illustratively upper side 42b) and a leg 64 extending from the base portion 62, the leg 64 having a hole 66 for allowing passage of a screw (not shown) therethrough. The screws may be received in corresponding apertures 14b in the lower portion 14a of the first shell 14 of the sport helmet 10 for mounting the face shield 20 to the sport helmet 10. The face shield 20 may further include straps 70 or other like ties for securing a lower portion of the face shield 20 to the sport helmet 10. The straps 70 may be tied or otherwise secured to the perimeter wire member 42 at a first end and have snaps or other fastening means at a second end that are securable to the sport helmet 10, for instance at the left and right temple regions 12b, 12c. Other connector types may be contemplated. As shown in FIGS. 6A-6B, an optional chin guard 80 may be provided for additional protection and / or comfort.

[0056] Referring to FIG. 7, a partial cross-sectional view of an exemplary face shield 20 is shown, in which it can be seen that each visor-supporting wire member 46 intersects, towards the lower edge 32a of the visor body 32, both the first transverse wire member 44a and one of the lower additional wire members 48a. As such, an angle 0, more specifically an obtuse angle between 90 and 180 degrees, is formed between the portion of the visorsupporting wire member 46 disposed between the first transverse wire member 44a and one of the lower additional wire member 48a and the portion of the visor-supporting wire member46 disposed below the lower additional wire member 48a. Due to angle 0, first transverse wire member 44a and lower additional wire members 48a are disposed in different cylindrical (i.e., circumferential) planes. The angle 0 may vary, for instance to line-up wire members 44a, 48a one behind another when looked at by the wearer, thereby improving visibility from the perspective of the eyes of the wearer. Other considerations for angle 0 may be contemplated, however the angle 0 cannot be 180 degrees (i.e. a flat wire). As shown in FIG. 7, in the depicted embodiment, the first transverse wire member 44a has a non-circular cross-sectional shape. Illustratively, the cross-sectional shape of the first transverse wire member is flattened, i.e., its width is greater than its height. As such, visibility through the upper visor portion 30 is improved. Other cross-sectional shapes for the first transverse wire member 44a may be contemplated.

[0057] Referring to FIG. 8 in addition to FIG. 4, the visor body 32 can be conceptually divided into three contiguous and uninterrupted portions, namely two supported portions 32g, illustratively disposed on the lateral sides of the visor and thus adjacent each of the left edge 32c and right edge 32d, and an unsupported central portion 32h towards a center of the visor body 32 between the two supported portions 32g. By “supported” and “unsupported”, it is understood that respective portions of the visor body 32 do or do not have one or more overlapping wire members engaged therewith and disposed behind the visor body 32 (i.e., between the visor body 32 and the face F of the wearer relative to the longitudinal axis LA). Such support may provide the upper visor portion 30 with additional impact resistance, for instance against an incoming hockey puck, ball or other projectile. Illustratively, each supported portion 32g is supported by the lower additional wire members 48a and the lower visor-supporting wire members 48 at the lower edge 32a, the upper additional wire members 48b and the upper visor-supporting wire members 48 at the upper edge 32b, and the upper additional wire members 48b at each of the left side 42c and right side 42d. Advantageously, as the unsupported portion 32h is not directly coupled to any wire members, visibility through the unsupported portion 32h (i.e., through the center portion of the visor body 32) is uncompromised. In the embodiment shown in FIG. 8, the unsupported portion 32h is illustratively represented by a trapezoidal cross-sectional area, extending between junctions 48a3 at the lower edge 32a and junctions 48b1 at the upper edge 32b. Other shapes for the unsupported portion 32h may be contemplated.

[0058] In various embodiments, the additional wire members 48, in combination with the transverse wire members 44, may provide the face shield 20 with additional strength, stiffness,rigidity and support at the sides of the upper visor portion 30, which may negate the need for support towards the center of the upper visor portion 30. As such, visibility for the wearer may be improved, as the overlap between the upper visor portion 30 and lower cage portion 40 is minimized. The lower cage portion 40 may thus be disposed closerto the face F of the wearer, and smaller wire members may be used, which may provide for better visibility through the upper visor portion 30, lower weight, and lower manufacturing costs.

[0059] As can be seen therefore, the examples described above and illustrated are intended to be exemplary only. The scope is indicated by the appended claims.

Claims

WHAT IS CLAIMED IS:1 . A face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion disposed below the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and having an upper side, a lower side, a left side, and a right side, the lower cage portion further including transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge, the lower cage portion further including a first additional wire member and a second additional wire member, the first additional wire member extending from a first end at the lower side of the perimeter wire member to a second end at the left side of the perimeter wire member, the second additional wire member extending from a first end at the lower side of the perimeter wire member to a second end at the right side of the perimeter wire member, each of the first and second additional wire members curving at a junction with the first transverse wire member, and wherein the first and second additional wire members are disposed inwardly of the first transverse wire member at the junction, the first additional wire member spaced apart vertically from the first transverse wire member at the left side of the perimeter wire member, and the second additional wire member spaced apart vertically from the first transverse wire member at the right side of the perimeter wire member.

2. The face shield as defined in claim 1 , wherein the second end of the first additional wire member is disposed higher along the left side than the first transverse wire member, and the second end of the second additional wire member is disposed higher along the right side than the first transverse wire member.

3. The face shield as defined in claim 1 or 2, wherein the first additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the right side.

4. The face shield as defined in claim 3, wherein the first additional wire member extends transversely towards the left side between the upwardly curved portion and the left side, and wherein the second additional wire member extends transversely towards the right side between the upwardly curved portion and the right side.

5. The face shield as defined in any one of claims 1 to 4, wherein the first transverse wire member has a non-circular cross sectional shape.

6. The face shield as defined in claim 5, wherein a width of the cross sectional shape of the first transverse wire member is greater than a height of the cross sectional shape of the first transverse wire member.

7. The face shield as defined in any one of claims 1 to 6, wherein the lower cage portion includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the second transverse wire member and one of the first and second additional supporting wire members, before extending back towards and terminating at the perimeter wire member.

8. The face shield as defined in claim 7, wherein at least one of the U-shaped visor supporting wire members meets both the first transverse wire member and one of the first and second additional supporting wire members, a non-zero angle formed between a first portion of the at least one of the U-shaped visor supporting wire members disposed between the first transverse wire member and the one of the first and second additional supporting wire members and a second portion of the at least one of the U-shaped visor supporting wire members disposed below the one of the first and second additional supporting wire members.

9. The face shield as defined in any one of claims 1 to 8, wherein the lower cage portion further includes a first upper additional wire member extending from the upper side and terminating at the left side and a second upper additional wire member extending from the upper side and terminating at the right side, the first upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, and the second upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

10. A face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion disposed below and coupled to the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and having an upper side, a lower side, a left side, and a right side, the lower cage portion including a first visor-supporting wire member extending between the lower side of the perimeter wire member and the left side of the perimeter wire member, and a second visorsupporting wire member extending between the lower side of the perimeter wire member and the right side of the perimeter wire member, each of the first and second visor-supporting wire members curving at a junction with the lower visor edge, the first and second visor-supporting wire members supporting the visor body with an unsupported portion of the visor body disposed between each junction.11 . The face shield as defined in claim 10, wherein the first visor-supporting wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second visor-supporting wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the right side.

12. The face shield as defined in claim 10 or 11 , wherein the lower cage portion further includes a first upper wire member extending from the upper side and terminating at the left side, and a second upper wire member extending from the upper side and terminating at the right side, the first upper wire member extending downwardly from the upper side, operatively coupled to and curving at the upper visor edge and extending in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, the second upper wire member extending downwardly from the upper side, operatively coupled to and curving at the upper visor edge and extending in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

13. The face shield as defined in any one of claims 10 to 12, wherein the lower cage portion further includes transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge.

14. The face shield as defined in claim 13, wherein the lower cage portion further includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the second transverse wire member and one of the first and second supporting wire members, before extending back towards and terminating at the perimeter wire member.

15. A face shield for a sport helmet, comprising: an upper visor portion including a visor body extending transversally from a left visor edge to a right visor edge and vertically from a lower visor edge to an upper visor edge; and a lower cage portion operatively coupled to the upper visor portion, the lower cage portion including a perimeter wire member defining an outer perimeter of the face shield and having a lower side, an upper side, a left side, and a right side, the lower cage portion further including transverse wire members, a first transverse wire member of the transverse wire members extending adjacent the lower visor edge and a second transverse wire member of the transverse wire members extending adjacent the upper visor edge, the lower cage portion further includes a first upper additional wire member extending from the upper side and terminating at the left side and a second upper additional wire member extending from the upper side and terminating at the right side, the first upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the left side, the second upper additional wire member extending downwardly from the upper side, curving at the upper visor edge and extending, below the second transverse wire member, in a same direction as the upper visor edge, and curving again and extending in a downward direction to the right side.

16. The face shield as defined in claim 15, wherein the lower cage portion further includes a first lower additional wire member extending from a first end at the lower side to a second end at the left side and a second lower additional wire member extending from a first end at the lower side to a second end at the right side, each of the first and second lower additional wire members curving at a junction with the first transverse wire member, the first and second additional wire members disposed inwardly of the first transverse wire member at the junction, the first additional wire member spaced apart vertically from the first transverse wire memberat the left side, the second additional wire member spaced apart vertically from the first transverse wire member at the right side.

17. The face shield as defined in claim 16, wherein the second end of the first lower additional wire member is disposed higher along the left side than the first transverse wire member, and the second end of the second lower additional wire member is disposed higher along the right side than the first transverse wire member.

18. The face shield as defined in claim 16 or 17, wherein the first lower additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the left side, and the second lower additional wire member includes a downwardly curved portion and an upwardly curved portion between the junction and the right side.

19. The face shield as defined in any one of claims 16 to 18, wherein the lower cage portion includes U-shaped visor supporting wire members extending from the perimeter wire member towards, and curving at, one of the first transverse wire member, the second transverse wire member and one of the first and second additional supporting wire members, before extending back towards and terminating at the perimeter wire member.

20. The face shield as defined in claim 19, wherein at least one of the U-shaped visor supporting wire members meets both the first transverse wire member and one of the first and second additional supporting wire members, a non-zero angle formed between a first portion of the at least one of the U-shaped visor supporting wire members disposed between the first transverse wire member and the one of the first and second additional supporting wire members and a second portion of the at least one of the U-shaped visor supporting wire members disposed below the one of the first and second additional supporting wire members.

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