Polycarbonate Facemask with Integrated Eye Shield
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Solution Overview
Problem
Existing protective facemasks for contact and non-contact sports fail to provide adequate protection for the eyes, nose, mouth, teeth, and head, particularly against high-speed impacts from sports equipment and body contact, and do not effectively absorb and dissipate impact forces or perspiration, while also lacking UV protection.
Innovation Solution
A universal protective facemask made from a single mold of polycarbonate polymer with a glare-proof, transparent eye shield and impact-absorbing materials, designed to cover the forehead, cheeks, and chin, featuring ventilation to prevent fogging and secure straps to prevent dislodging, which exceeds ASTM standards for impact resistance and includes UV-absorbing compounds for sun protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing face protection masks are used, then some facial protection is provided, but they do not provide full protection for the eyes, nose, mouth and teeth, and the straps are not effective to hold the facemask in place when struck by high-speed objects
Solution Approach 1:
The patent combines multiple protective functions into a single integrated facemask structure that simultaneously protects the eyes, nose, mouth, and teeth. The facemask integrates a protective cage design with built-in eye protection and a breathing shield, eliminating the need for separate protective devices while providing comprehensive facial coverage against high-speed impacts
Solution Approach 2:
The facemask is divided into distinct functional segments including a protective cage portion, an eye protection portion, and a breathing shield portion. Each segment is designed to address specific protection needs while working together as a unified system, allowing the mask to provide targeted protection for different facial areas without requiring a single complex monolithic structure
2Reliability
If the facemask provides comprehensive coverage for full facial protection, then protection effectiveness is improved, but ventilation may be reduced causing fogging and discomfort
Solution Approach 1:
The breathing shield portion of the facemask incorporates a porous or mesh-like structure that allows air to pass through while maintaining protective coverage. This porous design enables ventilation and prevents fogging of the eye protection area by allowing moisture and heat to escape, while the material structure remains strong enough to provide impact protection
Solution Approach 2:
Different portions of the facemask have different structural qualities optimized for their specific functions. The eye protection and main cage areas use solid, impact-resistant materials for maximum protection, while the breathing shield area uses a more open, porous structure to facilitate air flow. This local differentiation of material properties allows the mask to provide both comprehensive protection and adequate ventilation
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 facemask effectively reduces the risk of eye, face, dental, and head injuries, including sub-concussive and full concussive brain injuries, while providing unobstructed vision, glare resistance, and UV protection, outperforming existing solutions in impact tests and meeting stringent safety standards.
Implementation Method 1
impact-absorbing materials, designed to cover the forehead, cheeks, and chin... effectively reduces the risk of eye, face, dental, and head injuries... outperforming existing solutions in impact tests
Implementation Method 2
includes UV-absorbing compounds for sun protection... providing unobstructed vision, glare resistance, and UV protection
Implementation Method 3
featuring ventilation to prevent fogging... The opposite sides of the eye shield are open to allow air flow into the facemask and behind the eye shield, while also providing increased ventilation when the wearer is breathing heavy
Data Source
AI summary
A protective non-helmeted single molded facemask for sports includes a frame structure formed of a polycarbonate polymer and an integrally molded rigid eye shield formed of a transparent polycarbonate polymer composition. The peripheral frame structure is structured and configured to engage a user's forehead, side and cheek facial structure and chin. An arrangement of vertical and horizontal bars in the lower portion of the face area of the facemask are structured and configured to protect the users nose and mouth from direct contact with external objects, while the rigid eye shield on the upper face area of the facemask protects the users eyes from direct impact and contact with external objects. Upper and lower straps extend from slotted openings on the sides of the facemask and are positioned and arranged to extend around the lower back of the wearer's head to secure the facemask on the wearer's head.