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Protective mask system and method of manufactureRelated Patent Categories: Apparel, Guard Or Protector, For Wearer's Head, FaceProtective mask system and method of manufacture description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060085883, Protective mask system and method of manufacture. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATION [0001] The present application claims priority based on Provisional Application filed Oct. 25, 2004, entitled "FABRIC PAINTBALL MASK," Ser. No. 60/623,585, by inventors hereof. The entire disclosure of the provisional application is incorporated as if fully set forth herein. FIELD OF THE INVENTION [0002] The present invention relates to a protective head gear and more particularly, to a protective mask system incorporated with structural fabric to the head gear, adapted to provide protection and comfort for people engaging in physical activities, such as paintball battle games. ART BACKGROUND [0003] A wide variety of protective head gears such as masks are available for use in activities where physical danger to the head of the user is inherent. An example of such an activity is the game of paintball where players try to hit their opponents by projecting paintballs in a battle-like environment. Despite the recreational nature of the games, paintballs are projected at high enough speed to injure the players, if they are hit at the head or eyes. In order to protect the player's head, components are designed to protect various parts of the head such as the eyes, nose, forehead, cheeks and ears. These components are assembled to form a mask. [0004] A conventional mask typically has a lens, a lens frame (or goggle), and a face shield. The face shield can also be divided into a section for the mouth and cheek areas, and two sections covering the left and right ears. The lens sits on or inside of the goggle, and the assembly is then attached to the face shield to form the mask. An elastic strap assembly, comprising of attachment features, is then attached to the mask. A user will then wear the mask over the head, with the elastic strap providing tension on the bark of the head, thus securing the mask on the head. [0005] The lens, goggle and the face-shield are traditionally made from plastic by the injection molding process. The assembled lens and goggle is then attached to the face shield with tabs and mating tab retention holes. Some manufacturers, in order to simplify the production and assembly processes, have proposed the fabrication of a one-piece lens frame and face shield. The lens will then attach to the lens frame/face shield piece to form the mask. Also, in order to create a more unique look and feel to the mask, certain areas are secondarily injected in the mold with a different plastic material and/or color. [0006] Whether the lens frame and face shield are assembled separately or made in one complete piece, injection molded plastic remains the primary material used in the fabrication of the face-shield area. The use of such plastic over a large volume makes the mask heavy and rigid, which causes discomfort to the user over a period of time during their activities. [0007] Some manufacturers have incorporated the use of stamped sheet foam material or synthetic rubber such as neoprene in their masks. An example is the Proflex series by JT USA. Even though such material is light and can be cheaply made without the need for injection molded plastics, they are less structural than plastics and so are limited to use in the rear areas of the face shield, which comes in contact with the head and ears and are thus supported without the need for them to be as structural as other parts of the face shield. [0008] Also, it is apparent that the colors of paint ball masks colors are determined by the color of the plastic resins being injection molded, or the color of the foam material. Secondary printing processes are required in order to incorporate multiple colors or print patterns (such as a camouflage pattern) onto the mask, which adds considerable cost to manufacturing. [0009] Another disadvantage of a conventional mask is that plastic do not absorb perspiration from the face. Over time, perspiration sticking onto plastic inner surfaces of the face shield adds further discomfort to the player. [0010] Further, it is apparent to one ordinarily skilled in the art of mold-making that fabrication of a plastic infection mold for the mask is challenging, due to the size and complexity of a typical mask design. There are several features in a typical mask that cannot be reached or created with a simple "core-and-cavity" type of mold. These features are commonly referred to as "undercuts," which require multiple "sliders" in the mold to access. Moreover, masks often have integrated air-vents for ventilation. It is also apparent to people skilled in the art of mold-making that the plurality of air-vents creates further difficulty in making sure all parts of the mold, i.e. core, cavity and sliders, close to form a tight fit without plastic over-flowing into the vents. SUMMARY OF THE INVENTION [0011] The invention is directed to a novel protective head gear system with the use of alternative materials for masks, specifically foam and/or fabric, and methods of assembling the masks. [0012] Foam and fabric is significantly lighter than injection-molded plastics of a similar volume. Although a piece of foam or fabric by itself is not inherently or naturally structural, a three-dimensional geometry can be formed by compressing and heating a composite sheet from two or more layers. [0013] Alternatively, multiple pieces of foam/fabric material can be stitched together so that the resulting form is able to hold a three-dimensional geometry. The shape of each of the sub-pieces is calculated so that when the adjacent edges of each piece is sewn together, the end result is a form that mimics the shape of the face shield. (just like the construction of shoes) [0014] It will also be apparent to one ordinarily skilled in the art that molds for compression forming are simpler to fabricate than molds for injection molding. This will help lower overall tooling costs in production of the masks. [0015] Various patterns and colors can be incorporated onto the mask simply with the choice of patterned fabric used for the composite sheet, without the need for a secondary printing process to create a similar color effect. For example, a camouflage printed fabric material can be used for the outward facing top layer of the composite sheet to create a camouflaged-patterned mask. [0016] In accordance with one aspect, the present invention provides a method of manufacturing a foam/fabric mask face shield having a three-dimensional geometry. The method includes the steps of forming a composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the face shield. The composite sheet can be formed by the lamination of two or more layers. The layers can be bonded together by a bonding agent, can be heat bonded, or can be laminated together by other means. [0017] It is preferable that one or more of the layers forming the composite sheet includes a thermo-formable material. In one preferred embodiment, the composite sheet comprises a first layer of thermoplastic foam and a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. The thermoplastic foam can be, for example, ethylene vinyl acetate (EVA) foam. A third layer of fabric can be interposed between the first and second layers. Suitable fabrics can include a mesh fabric formed from nylon, polyester, poly-cotton, cotton, acetate, or acrylic. [0018] The composite sheet can also comprise a first layer of cloth material, a second layer of thermoplastic foam, and a third layer of cloth material. The cloth material can be formed from felt, wool, fur, hair, polyester, nylon, cotton, acetate, or acrylic. In one embodiment, the composite sheet can be formed by needle punching the first, second, and third layers to thread the fibers forming the cloth material of the first and third layer through the second layer, thereby coupling the three layers together. [0019] In accordance with a further aspect of the present invention, the step of compression molding has the steps of positioning the composite sheet in a first mold member having a mold cavity and compressing the composite sheet in the mold cavity with a second mold member. The composite sheet can be heated prior to positioning the composite sheet into the first mold member, or after the composite sheet is positioned in the first mold member, for example when the composite sheet is positioned in the mold cavity of the first mold member. The composite sheet can be compression molded into separate sections which are assembled after molding to form the face shield. Alternatively, the composite sheet can be compression molded into a seamless, unitary face shield that requires minimal assembly for completion. [0020] A method of manufacturing a mask in accordance with the present invention has the steps of constructing a face shield by forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the face shield. Continue reading about Protective mask system and method of manufacture... Full patent description for Protective mask system and method of manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Protective mask system and method of manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Protective mask system and method of manufacture or other areas of interest. ### Previous Patent Application: Monolithic paintball mask Next Patent Application: Sports lifting aid Industry Class: Apparel ### FreshPatents.com Support Thank you for viewing the Protective mask system and method of manufacture patent info. 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