Protective mask system and method of manufacture

Abstract

A protective mask system and a method of manufacturing a foam/fabric mask face shield having a three-dimensional geometry. The mask system has a lens frame and a compression-molded composite sheet, which is formed by multiple layers. 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

1 . A protective mask system with a 3-D geometry for users engaging in physical sporting activity, comprising: 
 a lens frame, said lens frame having a rim;    a mask formed by at least one composite sheet, said composite sheet comprising at least two layers of material heated and compression-molded into a predetermined 3-D shape, said mask forming a trimmed edge for attaching to the rim of said lens frame.    
   
   
       2 . A mask system of  claim 1 , wherein said composite sheet has an outward facing top layer, and said outward facing top layer has a predetermined pattern for the outward facing top layer.  
   
   
       3 . A protective mask system of  claim 2 , wherein said layers are bonded together by one of the following methods: 
 by lamination;    by a bonding agent;    by heat bonded.    
   
   
       4 . A protective mask system of  claim 3 , wherein said layers comprise: 
 a layer of thermoplastic foam;    a layer of with thermoplastic urethane (TPU) film;    a layer of fabric being inserted between the foam and TPU film.    
   
   
       5 . A protective mask system of  claim 4 , wherein said layer of fabric is one of: 
 a mesh material formed from one of nylon, polyester, poly-cotton, cotton, acetate, and acrylic.    
   
   
       6 . A protective mask system of  claim 4 , wherein said thermo-formable foam is one of polyethylene foam and polypropylene foam.  
   
   
       7 . A protective mask system of  claim 3 , wherein said mask comprises additional vents at predetermined locations thereon for receiving perforated plastic pieces for ventilation purposes.  
   
   
       8 . A protective mask system of  claim 3 , wherein said layers comprise: 
 a first layer of cloth material;    a second layer of thermoplastic foam, and    a third player of cloth material, where the cloth material is one of the following: felt, wool, fur, hair, polyester, nylon, cotton, acetate, and acrylic.    
   
   
       9 . A protective mask system of  claim 7 , wherein said mask is made of an integral body of the composite sheet, said protective mask further comprising: 
 a left ear protection piece and a right ear protection piece, each being made of one of injection-molded plastic pieces and compression-molded fabric pieces, adapted to be stitched to the mask.    
   
   
       10 . A protective mask system of  claim 7 , wherein said lens frame is fastened to said mask using one of stitching, screws/screw bosses and tabs/mounting tab retention holes.  
   
   
       11 . A method of making a protective mask system for users engaged in active physical sports, said mask system comprising a face shield and a lens frame, the face shield having a desired 3-D geometry, the method comprising: 
 forming a substantially planar composite sheet from a plurality of layers;    heating the composite sheet;    compression molding the composite sheet into a desired 3-D geometry for the face shield;    attaching the lens frame to the compression-molded composite sheet.    
   
   
       12 . The method of  claim 11 , wherein the lens frame is fastened to the compression-molded composite sheet by at least one of stitching, screws/screw bosses and tabs/mounting tab retention holes.  
   
   
       13 . The method of  claim 12 , wherein said composite sheet of the plurality of layers is formed by one of the following: 
 by lamination;    by a bonding agent;    by heat bonded.    
   
   
       14 . The method of  claim 13 , wherein the composite sheet comprises: 
 a first layer of thermo-formable material;    a second layer of thermoplastic urethane, and    a third layer of mesh fabric interposed between the first and second layers.    
   
   
       15 . The method of  claim 13 , wherein the composite sheet comprises: 
 at least two layers of cloth material;    a layer of thermoplastic foam interposed in-between the layers of cloth material,    wherein said layers are needled punched and threaded together.    
   
   
       16 . The method of  claim 14 , wherein one of said first and second layers has predetermined pattern and color.  
   
   
       17 . The method of  claim 15 , wherein one of said layers of cloth material has predetermined pattern and color.  
   
   
       18 . The method of  claim 16 , wherein said composite sheet is compression molded by the following: 
 positioning said composite sheet in a first mold member, said mold member having a cavity;    compressing said composite sheet in the cavity with a second mold member;    heating said composite sheet one of before positioning into said first mold member and after positioning to said first mold member.    
   
   
       19 . A protective mask system with a 3-D geometry, comprising: 
 a lens frame, said lens frame having a rim;    a mask, said mask having a predetermined three-dimensional shape, said mask comprising a plurality of layers of material heated and compression-molded into said three-dimensional shape, at least one of said plurality of layers being a thermo-formable material.    
   
   
       20 . A protective mask system of  claim 19 , wherein said lens frame is attached to said mask using one of stitching, screws/screw bosses and tabs/mounting tab retention holes.  
   
   
       21 . A protective mask system of  claim 19 , wherein said composite sheet has an outward facing top layer, and said outward facing top layer has a predetermined pattern for the outward facing top layer.  
   
   
       22 . A protective mask system of  claim 20 , wherein said 3-D mask comprises additional openings at predetermined locations thereon for receiving perforated plastic pieces for ventilation purposes.  
   
   
       23 . A protective mask system of  claim 22 , wherein said layers are bonded together by one of the following methods: 
 by lamination;    by a bonding agent;    by heat bonded.    
   
   
       24 . A protective mask system of  claim 23 , wherein said layers comprise: 
 a layer of thermoplastic foam;    a layer of with thermoplastic urethane (TPU) film;    a layer of fabric being inserted between the foam and TPU film.    
   
   
       25 . A protective mask system of  claim 24 , wherein said fabric is one of: 
 a mesh material formed from one of nylon, polyester, poly-cotton, cotton, acetate, and acrylic.    
   
   
       26 . A protective mask system of  claim 24 , wherein said thermo-formable foam is one of polyethylene foam and polypropylene foam.  
   
   
       27 . A protective mask system of  claim 26 , wherein said mask comprises additional indentations at predetermined locations thereon for receiving perforated plastic pieces for ventilation purposes.  
   
   
       28 . A protective mask system of  claim 23 , wherein said layers comprise: 
 a first layer of cloth material;    a second layer of thermoplastic foam, and    a third player of cloth material, where the cloth material is one of the following: felt, wool, fur, hair, polyester, nylon, cotton, acetate, and acrylic.