Paintball Mask Foam Retention via Segmented Locking

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Solution Overview

Problem

Conventional protective face masks for sports like paintball face issues with non-replaceable and uncomfortable foam, leading to hygiene concerns, poor fit, and discomfort due to adhesive and Velcro-based mounting systems.

Innovation Solution

A protective face mask with a removable and cushioned face engagement element made of rigid material, securely locked onto a support frame using engagement means, and a lens locking system with clips, along with a strap and temple support elements for improved fit and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the foam is glued into the frame, then the foam is securely fixed, but it cannot be easily replaced and causes hygiene concerns

Engineering Contradiction:

Improvesecure fixation of foamVSAvoidreplaceability of foam

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The face mask is divided into separate functional components: a reusable frame and replaceable foam inserts. The foam is no longer permanently attached but can be independently removed and replaced, allowing the frame to be reused while the foam can be exchanged for hygiene and comfort reasons.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The foam portion is extracted from the permanent structure and made into a separate, removable component. This allows the foam to be taken out, cleaned, or replaced independently from the main mask frame, solving the hygiene and replaceability issue while maintaining secure fixation when installed.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If Velcro bands are used to retain the foam, then the foam can be interchanged, but the bands cause noticeable ridges and discomfort

Engineering Contradiction:

Improveinterchangeability of foamVSAvoidridges and discomfort to wearer

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The Velcro retention system is completely removed from the design. Instead of using adhesive strips that create ridges, the foam inserts are designed to be held in place by the structural geometry of the frame itself, eliminating the source of discomfort while maintaining ease of interchange.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The frame incorporates localized retention features at specific points where foam contact is needed, rather than using continuous adhesive bands across the entire foam surface. This provides secure retention only where necessary while leaving the rest of the foam surface smooth and comfortable against the skin.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If intermittent Velcro bands are used, then the foam can be attached, but the foam can easily dislodge during game play

Engineering Contradiction:

Improvesimplicity of attachment systemVSAvoidsecure retention of foam during use

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The retention system is segmented into multiple discrete contact points distributed around the foam perimeter, rather than relying on a few intermittent Velcro bands. This distributes the retention force across many small points, preventing dislodgement while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame and foam are designed with complementary curved surfaces that provide natural mechanical retention. The foam conforms to the curved geometry of the frame, creating friction and geometric interlocking that prevents dislodgement during active use, replacing the need for adhesive bands.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Reliability

If glued foam is used, then the foam is fixed, but it cannot be adapted to various physical traits of different players

Engineering Contradiction:

Improvesecure fixation of foamVSAvoidadaptability to various face shapes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The foam portion is segmented into multiple interchangeable inserts with different sizes, shapes, and densities. Players can select and swap between different foam variants to match their specific facial anatomy, while the frame remains a consistent, reusable component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame is designed as a universal platform that can accommodate multiple types of foam inserts. This allows a single frame to serve multiple players with different face shapes and sizes by simply changing the foam insert, achieving versatility without requiring multiple custom frames.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8104095B2Protective face mask

Publication Date: 2012.01.31 KORE OUTDOOR LTD

AI summary

The present invention relates to a protective mask adapted to be worn by a person engaging in the game of paintball. The mask has a main body to cover the front, sides, mouth and ears of a user's face. It also has a removable flexible transparent lens that locks into a rigid support frame formed in the mask. The mask also has a strap to securely support the mask on a wearer's head, and a removable face engaging element provided to accommodate a face of the wearer. This face engagement element evenly engages around the wearer's face in a cushioned manner because its face engagement portion is made of foam that engages the user's face along the entire perimeter of the face engagement element. The face engagement element is securely locked onto the mask by locking clips that fit into openings on both sides of the face engagement element.