Full-face helmet system

Abstract

The full-face helmet system comprises a full-facemask that combines the strength of a facemask frame and a reinforcement layer to allow for improved visibility, safety and impact performance, while reducing weight. The full-facemask comprises a reinforcement layer and a facemask frame, the reinforcement layer may be coupled to the external surface or internal surface of a facemask frame. The reinforcement layer may match or substantially match one or more contours of the facemask frame.

What is claimed is: 
     
         1 . A football helmet comprising:
 an outer shell;   an impact mitigation layer coupled to an inner surface of the outer shell;   a facemask frame coupled to the outer shell, the facemask frame including a lower bar; and   a transparent reinforcement layer comprising an upper portion coupled to at least one of the outer shell and the facemask frame, wherein a lower portion of the transparent reinforcement layer is external to an external surface of the lower bar of the facemask frame.   
     
     
         2 . The football helmet of  claim 1 , wherein the lower portion of the transparent reinforcement layer is coupled to the external surface of the lower bar of the facemask frame. 
     
     
         3 . The football helmet of  claim 1 , wherein the facemask frame comprises an outer loop without inner cross bars. 
     
     
         4 . The football helmet of  claim 1 , wherein the upper portion of the transparent reinforcement layer is disposed between an upper bar of the facemask frame and the outer shell. 
     
     
         5 . The football helmet of  claim 1 , wherein the transparent reinforcement layer is disposed within a field of view between a front region of the outer shell and the lower bar of the facemask frame. 
     
     
         6 . The football helmet of  claim 1 , wherein the upper portion of the transparent reinforcement layer is coupled to an internal surface of an upper bar of the facemask frame. 
     
     
         7 . The football helmet of  claim 1 , further comprising
 a first facemask connector coupling a lower portion of the facemask frame to a first side of the outer shell; and   a second facemask connector coupling the lower portion of the facemask frame to a second side of the outer shell.   
     
     
         8 . The football helmet of  claim 7 , wherein:
 a first portion of the transparent reinforcement layer is disposed between an upper portion of the facemask frame and the outer shell above the first facemask connector; and   a second portion of the transparent reinforcement layer is disposed between the upper portion of the facemask frame and the outer shell above the second facemask connector.   
     
     
         9 . The football helmet of  claim 8 , wherein the lower portion of the transparent reinforcement layer is external to the external surface of the lower bar of the facemask frame below the first and second facemask connectors. 
     
     
         10 . The football helmet of  claim 1 , wherein at least a portion of the upper portion of the transparent reinforcement layer extends above a front edge of the outer shell. 
     
     
         11 . The football helmet of  claim 1 , wherein at least a portion of the upper portion of the transparent reinforcement layer extends above an upper bar of the facemask frame. 
     
     
         12 . The football helmet of  claim 1 , wherein the lower portion of the transparent reinforcement layer contacts the external surface of the lower bar of the facemask frame. 
     
     
         13 . The football helmet of  claim 1 , wherein the lower bar of the facemask frame supports the transparent reinforcement layer to reduce deformation and distribute impact forces across the facemask frame. 
     
     
         14 . The football helmet of  claim 1 , wherein the transparent reinforcement layer comprises a body and a plurality of connecting members extending outwardly from the body. 
     
     
         15 . The football helmet of  claim 1 , wherein the upper portion of the transparent reinforcement layer is coupled to a front bumper located in a front region of the outer shell. 
     
     
         16 . The football helmet of  claim 1 , wherein the upper portion of the transparent reinforcement layer comprises one or more openings for mechanical connectors to couple the upper portion of the transparent reinforcement layer to the at least one of the outer shell and the facemask frame. 
     
     
         17 . The football helmet of  claim 1 , further comprising one or more bumper connectors to coupling the lower portion of the transparent reinforcement layer to the lower bar of the facemask frame. 
     
     
         18 . The football helmet of  claim 17 , wherein:
 the one or more bumper connectors facilitate absorption of impact; and   the lower bar of the facemask frame supports the transparent reinforcement layer to distribute the impact across the facemask frame.   
     
     
         19 . A football helmet comprising:
 an outer shell;   a facemask frame coupled to the outer shell; and   a reinforcement layer coupled to at least one of the outer shell and the facemask frame, wherein at least a portion of the reinforcement layer is outside an external surface of the facemask frame.   
     
     
         20 . The football helmet of  claim 19 , wherein:
 the facemask frame comprises a lower metal bar; and   the reinforcement layer comprises a transparent rigid polymer coupled to the external surface of the lower metal bar and extending vertically from the lower metal bar to at least a front edge of the outer shell.