Integral Metal Facemask for Athletic Helmet
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Solution Overview
Problem
Conventional facemasks in athletic helmets face limitations due to materials with lower strength properties, leading to increased weight, restricted design aesthetics, and potential weld failures under impact, which hinder optimal protection and weight reduction.
Innovation Solution
A facemask design featuring intersecting, integral metal supports with varying cross sections and external geometries, manufactured using high-strength stainless steel alloys via investment casting, eliminating the need for welding and allowing for optimized strength-to-weight ratio and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lower strength metals are used for conventional facemasks, then ease of bending and welding is improved, but weight increases to meet performance requirements
Solution Approach 1:
The patent changes the material parameter from conventional carbon steel to high-strength stainless steel alloys, fundamentally altering the strength-to-weight ratio. This enables the use of thinner gauge materials (reducing weight) while maintaining structural integrity and meeting performance requirements through the superior strength properties of the alloy material.
Solution Approach 2:
The patent implements variable cross-sectional areas in different portions of the facemask bars. High-impact areas utilize larger cross sections for maximum strength, while low-impact areas use smaller cross sections to reduce weight. This localized optimization of material distribution achieves weight reduction without compromising protection where needed.
2Ease of manufacture
If uniform cross section wire bars are used, then manufacturing simplicity is improved, but strength optimization at high impact locations is limited
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of the facemask bars according to impact requirements. Different sections of the same bar feature different cross-sectional dimensions, with larger areas positioned at high-impact locations (such as the front and lower portions) and smaller areas at low-impact locations, optimizing strength distribution throughout the structure.
Solution Approach 2:
The patent transitions from one-dimensional uniform wire to three-dimensionally varied cross-sections. The bars incorporate rectangular and oval cross sections with different dimensions at different locations along their length, adding dimensional complexity to optimize structural performance while maintaining aesthetic appearance.
3Stability of the object's composition
If welding is used to assemble facemask components, then structural assembly is achieved, but risk of separation by impact and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate wire components into a single integral formed bar structure. The facemask is manufactured as one continuous piece of metal that is subsequently cut into segments, eliminating all weld joints. This integration ensures that impact forces are distributed continuously through the material without weak points at connection locations.
Solution Approach 2:
The patent performs the forming operation preliminarily, creating the complete three-dimensional facemask structure as a single integral piece before any cutting or assembly takes place. This preliminary formation establishes continuous material flow and structural integrity that cannot be achieved through post-assembly welding of separate components.
4Strength
If more material is used to meet performance requirements, then protective capability is improved, but weight of the facemask increases
Solution Approach 1:
The patent changes the fundamental material parameter from conventional steel to high-strength stainless steel alloy, which provides superior strength properties. This material substitution allows the facemask to achieve required protective capability with less material volume, directly reducing weight while maintaining or enhancing protective performance.
Solution Approach 2:
The patent optimizes material distribution by varying cross-sectional areas locally throughout the facemask structure. Material is concentrated in high-impact zones where protection is most needed and reduced in low-impact zones, achieving optimal protective capability with minimum overall material usage and weight.
Data Source
AI summary
A facemask for a helmet. The helmet includes a forehead area and two side areas. The facemask comprises a plurality of intersecting, integral metal supports forming a face protection area. The face protection area includes a top section, two side attachment sections and a front section. The top section can be shaped to conform to and attached to the forehead area of the helmet while each side attachment section can be shaped and formed to attach to one of the side areas of the helmet. Further, the front section can extend from the top section and each attachment section.