Foam Face Mask With Mesh Eye Shield
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Solution Overview
Problem
Existing protective face masks for sporting activities are often heavy, expensive, difficult to clean, prone to fogging, and limited in size, with internal padding that absorbs sweat and grime, and the clear polymer eye shield frequently fogs during physical exertion.
Innovation Solution
A foam face mask with an integral mesh eye shield that is adjustable to fit various sizes, constructed using injection or compression molding processes, featuring a closed-cell foam that prevents moisture absorption and includes a strap system for secure fit, and a mesh eye shield made of metals or plastics to prevent fogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clear polymer eye shield is used to provide eye protection, then eye protection is improved, but the eye shield is prone to fogging during physical exertion
Solution Approach 1:
The patent changes the optical property of the eye shield from transparent to mesh pattern, preventing fogging while maintaining eye protection. The mesh structure allows visibility while eliminating the fogging issue associated with clear polymer shields.
2Ease of operation
If internal padding with cloth or similar lining is used, then comfort and fit are improved, but the lining absorbs sweat and grime during sporting activities
Solution Approach 1:
The patent uses closed-cell foam material that provides the necessary padding and comfort while resisting sweat and grime absorption. The closed-cell structure prevents liquid penetration while maintaining the cushioning properties needed for comfort during sporting activities.
3Adaptability or versatility
If multiple pieces joined via screws or detachable fasteners are used, then adjustability and fit are improved, but the mask becomes difficult to clean and maintenance is more complex
Solution Approach 1:
The patent integrates the adjustable features directly into the foam structure, eliminating detachable fasteners and multiple separate pieces. The foam material itself provides the adjustment mechanism through its compressible nature, creating a seamless, easy-to-clean unitary structure.
4Reliability
If traditional protective mask materials are used, then protection is provided, but the masks are heavy and expensive to manufacture
Solution Approach 1:
The patent uses closed-cell foam material that provides adequate protection while being significantly lighter than traditional protective mask materials. The foam's cellular structure offers cushioning and impact resistance at reduced weight, and the manufacturing process is more cost-effective.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The foam face mask provides lightweight, durable, and easy-to-clean protection with adjustable sizing and a fog-free mesh eye shield, enhancing user comfort and visibility during sporting activities.
Implementation Method 1
constructed using injection or compression molding processes, featuring a closed-cell foam that prevents moisture absorption
Data Source
AI summary
One form of the present application is directed to a protective foam face mask which includes a frontal portion structured to cover at least a portion of a face of a user, wherein the frontal portion defines an ocular cavity. The foam face mask further includes two side portions astride the ocular cavity extending rearwardly from the frontal portion, wherein the side portions are structured to cover the ears of a user, and wherein the frontal portion and the side portions are constructed of a foam. The foam face mask further comprises a mesh eye shield extending across the ocular cavity, wherein an outer perimeter of the mesh eye shield is encased in the foam of the frontal portion and the side portions, and wherein the frontal portion, the side portions, and the mesh eye shield form a unitary face mask structure.