TITLE OF THE INVENTION

BREATH GUARD FOR HELMET PROVIDED WITH A FACE SHIELD

FIELD OF THE INVENTION

[0001] The present invention generally relates to moderate to cold climate protective headwear such as motorcycle and snowmobile helmets provided with a face shield. More particularly but not exclusively, the present invention is concerned with a breath guard for such helmets in view of decreasing the fogging of the inside surface of the face shield.

BACKGROUND OF THE INVENTION

[0002] The so-called "full-face helmets" are widely known in the art.

They usually come in two different styles, the conventional style where the shell and the chin bar of the helmet are integrally formed and the flip-up style where the chin bar is hingedly mounted to the shell for movements between closed and open positions. The full-face helmets are provided with a clear or tinted shield.

[0003] When full-face helmets are used in moderate to cold climates, the moisture contained in the user's breath tends to fog the inside surface of the shield which may present a safety hazard.

[0004] Breath guards to be mounted to a full face helmet in order to prevent fogging of the inside surface of the faceshield are known. These breath guards includes a body made of flexible plastic material and a shielding member made of an elastic rubber material. The shielding member can be deformed in order to conform to the shape of the wearer's facial features. The

breath guard is mounted inside a full-face helmet to direct the user's breath downwardly and therefore prevent fogging. These breath guards are mounted to the top portion of the chin covering element of the helmet.

OBJECTS OF THE INVENTION

[0005] An object of the present invention is to provide a breath guard for helmet provided with a face shield.

SUMMARY OF THE INVENITON

[0006] In accordance with an aspect of the invention, there is provided a breath guard for a protective headwear, the protective headwear including a shell, a face shield and a chin bar, the breath guard comprising: a face contacting region for sealingly contacting at least a portion of the face of a protective headwear user; a chin bar contacting section for contacting the chin bar; and connectors for mounting the breath guard to the shell, wherein when the breath guard is mounted to the protective headwear, the breath of the user of the protective headwear is directed downwardly away from the face shield.

[0007] In accordance with an other aspect of the present invention, there is provided a protective headwear comprising: a shell; a face shield mounted to the shell; a chin bar mounted to the shield; and a breath guard comprising: a face contacting region for sealingly contacting at least a portion of the face of a protective headwear user; a chin bar contacting section for contacting the chin bar, and connectors for mounting the breath guard to the shell, wherein when the breath guard is mounted to the protective headwear, the breath of the user of the protective headwear is directed downwardly away from the face shield.

[0008] In an embodiment, the breath guard forwardly protrudes from the shell. In an embodiment, the breath guard further comprises a nose portion for covering the nose of the user having a size such as to provide for the user to wear conventional glasses. In an embodiment, the breath guard further comprises an inner plate, a frame and an outer covering. In an embodiment, the inner plate comprises deformable material. In an embodiment, the inner plate is configured to be positioned in a nose area of the breath guard. In an embodiment, the inner plate is so deformable as to adequately fit the nose of the user. In an embodiment, the inner plate includes apertures for improving mechanical bonding to the outer covering. In an embodiment, the frame comprises a plurality of small apertures for improving the mechanical bonding of the outer covering thereunto. In an embodiment, the frame comprises a rigid material. In an embodiment, the frame comprises a resilient material. In an embodiment, the outer covering comprises a flexible material. In an embodiment, the outer covering comprises a resilient material.

[0009] In an embodiment, the chin bar is moveably mounted to the shell, wherein when moving the chin bar, the connectors are so mounted to the shell as to maintain the breath guard in place so as to continue to direct the breath of the user downwardly away from the face shield.

[0010] In an embodiment, the connectors are integrally mounted to the shell. In an embodiment, the connectors are adhesively mounted to the shell. In an embodiment, the connectors are bonded to the shell. In an embodiment, the connectors are removably mounted to the shell. In an embodiment, the connectors comprise ball members for being removably mounted to complementary receptors positioned on the shell. In an embodiment, the connectors comprise two ball members. In an embodiment, the connectors comprise a ball member positioned at each longitudinal end of the breath guard. In an embodiment, the receptors comprise a respective

socket for each ball member. In an embodiment, each receptor comprises a sloping ramp above a socket for guiding of a respective ball member. In an embodiment, the connectors further comprise a respective at least one stopper to limit the pivot action of the breath guard when mounted to the shell. In an embodiment, each connector comprises a top stopper positioned above a respective ball member and a bottom stopper positioned below a respective ball member.

[0011] In an embodiment, the face contacting region comprises hypo-allergenic material.

[0012] In an embodiment, the chin bar contacting section comprises interconnecting elements for being connected to the chin bar.

[0013] In accordance with a further aspect of the present invention, there is provided a method of manufacturing a breath guard for a protective headware comprising: molding a rigid frame; cutting an inner plate; inserting the inner plate in the rigid frame thereby providing a sub-assembly; and forming a flexible plastic layer onto the sub-assembly.

[0014] The term "protective headware" is construed herein to include without limitation a helmet, protective headgear and the like as is understood by a person having skill in the art.

[0015] Other objects, advantages and features of the present invention will become more apparent upon reading of the following non- restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In the appended drawings:

[0017] Figure 1 is a perspective view illustrating a flip-up helmet with its face shield in an open position and including a breath guard according to a first illustrative embodiment of the present invention;

[0018] Figure 2 is a perspective view illustrating the helmet of Figure

1 with its chin bar open; the breath guard being exploded therefrom;

[0019] Figure 3 is a perspective view of the breath guard of Figure 1 ;

[0020] Figure 4 is a perspective exploded view of the breath guard of Figure 3;

[0021] Figure 5 is a perspective view of a conventional stype full face helmet provided with a breath guard according to a second illustrative embodiment of the present invention;

[0022] Figure 6 is a perspective view of the breath guard of the helmet of Figure 5;

[0023] Figure 7 is a perspective exploded with of the breath guard of

Figure 5;

[0024] Figure 8 is a side sectional view taken along line 8-8 of

Figure 5; and

[0025] Figure 9 is a sectional view taken along line 9-9 of Figure 8.

DETAILED DESCRIPTION OF THE ILLUSTRATUVE EMBODIMENT

[0026] Generally stated, the present invention is concerned with a breath guard for full-face helmets designed to sealingly contact a portion of the user's face in view of directing the moisture laden breath of the user away from the face shield of the helmet, i.e., downwardly.

[0027] Turning first to Figures 1 to 4 of the appended drawings, a breath guard 20 designed to be used in the flip-up style of full-face helmets will be described.

[0028] Figure 1 illustrates, in a perspective view, a flip-up style full- face helmet 22 comprising a shell 24 to which is hinged a chin bar 26. Since the construction and operation of such helmet vary from one manufacturer to another and since these helmets are believed to be well known in the art, they will not be described in details herein for concision purpose.

[0029] A breath guard 20 according to a first illustrative embodiment of the present invention is mounted to the shell 24. The breath guard 20 forwardly protrudes from the shell 24.

[0030] As can be better seen from Figure 3, the breath guard 20 includes a face contacting region 28, a chin bar contacting section 30 and first and second identical connectors 32 and 34 used to removably mount the breath guard 20 to the shell 24.

[0031] The shell 24 is provided with two breath guard receptors 36

(Figure 2) that are mounted on either side of the face shield area of the shell 24.

[0032] The connectors 32 and 34 and the receptors 36 are provided with corresponding interconnecting elements to allow the breath guard to be removably mounted to the shell 24. More specifically, the connectors 32 and

34 are provided with a ball 38 and the receptors 36 are provided with a corresponding socket 40. Insertion of the balls 38 in the sockets 40 mount the breath guard 20 to the receptors 36 and thus to the shell 24. The receptors 36 include a sloping ramp 41 above the socket 40 to facilitate the guiding of the ball 38 into the socket 40 when the user's wears the helmet 22.

[0033] It is to be noted that the nature of the ball and socket interconnection makes it possible to let the breath guard hang from one of the receptors 36 when not in use (not shown).

[0034] Turning now to Figure 4, the construction of the breath guard

20 will be discussed. The breath guard 20 is made of three elements, an inner plate 46 which is made of deformable material such as aluminum, a rigid frame 48 made of resilient material such as, for example PP, PU, ABS or PVC and an outer flexible plastic covering 50 made of resilient material such as, for example, silicone, low density PP. It is to be noted that the materials forming the rigid frame 48 and the covering 50 should be compatible and bond well together.

[0035] The inner plate 46 is designed to be positioned in the nose area of the breath guard 20 in view of allowing the user to deform it in order to adequately fit the user's nose. Its aluminum construction allows such a deformation and help maintain the desired shape. The inner plate 46 includes

apertures 47 designed to improve the mechanical bonding of the outer flexible plastic covering thereonto. It is to be noted that other materials could be used to form the inner plate 46.

[0036] The rigid frame 48 is a molded element. It includes the balls 38 of the connectors 32 and 34. As can be seen in this figure, each connector

32 and 34 also includes a top stopper 51 and a bottom stopper 52 used to limit the pivot action of the breath guard 20 when mounted to the shell 24. The rigid frame 48 includes a plurality of small apertures 54 designed to improve the mechanical bonding of the outer flexible plastic covering thereunto as will be described hereinbelow.

[0037] The manufacturing steps of the breath guard are as follows.

First, a rigid frame 48 is molded according to conventional molding techniques. Then the inner plate 46, which has been stamp cut, anodized and deformed, is inserted in the rigid frame. More specifically, a tongue 56 of the inner plate 46 is configured and sized as to enter a central aperture 58 of the rigid frame 48. Once this is done, this sub-assembly may be inserted into another molding equipment so that the outer flexible plastic layer 50 is formed thereunto. The outer flexible covering will cover all the apertures 47 and 54, thereby improving the mechanical integrity of the breath guard 20. The result of this second molding operation is a finished breath guard 20 as can be seen from Figure 3.

[0038] Since molding techniques are believed well known in the art, they will not be further discussed herein.

[0039] It is to be noted that the outer flexible plastic layer 50 allows for the breath guard 20 to be deformed according to the user's facial features and to sealingly contact the chin bar 26 to thereby create an airtight seal between the user's mouth and the face shield of the helmet 22 when the chin

bar 26 is closed. Accordingly, the humidity contained in the user's breath does not fog the inside surface of the face shield.

[0040] It is to be noted that the relative small size of the finished nose portion of the breath guard 20 allows conventional glasses to be worn by the user while wearing the breath guard 20. Furthermore, the breath guard 20 stays in place when the chin bar 26 is flipped up to open the helmet 22 and allows access to the user's mouth. The user may therefore talk to others while the breath guard 20 is in place.

[0041] The face contacting region 28 is entirely made of the outer flexible plastic layer 50 which may be made of hypo-allergenic material and offers minimal contact with the skin.

[0042] The breath guard 20 forwardly protrudes from the shell 24 of the helmet 22. Accordingly, when the user has flipped up the chin bar 26 the user's breath is still deflected away from the inside surface of the face shield, thereby reducing the fogging of this surface.

[0043] Turning now to Figures 5 to 9 of the appended drawings, a breath guard 100 designed to be used with the conventional style of full-face helmets will be described.

[0044] Figure 5 shows a conventional full face helmet 102 to which is mounted the breath guard 100.

[0045] The breath guard 100 is very similar to the breath guard 20 shown in Figures 1 to 5 and described hereinabove. Accordingly, only the difference between these two breath guards will be described hereinbelow.

Generally stated, there are two main difference between the breath guard 100 and the breath guard 20. First, since the helmet 102 is a conventional full face helmet, the breath guard 100 may be semi-permanently installed to the fixed chin bar 104. Secondly, since it is semi-permanently installed to the fixed chin bar 104, it is not necessary for the breath guard 100 to have a flexible chin bar contacting portion corresponding to portion 30 (see Figure 3).

[0046] As can be better seen from Figure 6, the breath guard 100 has a face contacting region 106 made of flexible plastic material.

[0047] The front portion 108 of the breath guard 100 is configured and sized to be mounted to the fixed chin bar 104 via interconnecting elements provided on both the front portion 108 and the chin bar 104. More specifically, the front portion 108 includes lateral hooks 110 (only one shown) configured and sized to be inserted between padding 112 and a sealing element 114 as can be seen from the sectional view of Figure 9. The front portion 108 also includes a flange 111 configured and sized as to be inserted under the inner vent spoon 113 of the helmeti 02.

[0048] Turning now briefly to Figure 7, the breath guard 100 is constructed as is constructed the breath guard 20, i.e. it includes an inner plate 120 which is made of deformable material such as aluminum, a rigid frame 122 and an outer flexible plastic covering 124.

[0049] The breath guards of the present invention are configured to be mounted to a variety of protective headwear such as helmets and the like.

[0050] The various features of the various breath guards described and illustrated herein can be combined in a variety of ways within the scope of the invention.

[0051] It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present invention has been described hereinabove by way of embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject invention as defined in the appended claims.