COMBINED FACE SHIELD AND MASK ASSEMBLY

Abstract

A protective face shield assembly includes a frame member including a central section having a nose bridge, and a pair of temple-contacting arms attached to side portions of the central section. A transparent plastic shield member is attached to the frame member, and is configured to cover a user's face including mouth, nose and eyes. A spacer, disposed between the frame member and the shield member, is formed of a flexible foam material and has a convexly curved front surface. The face shield assembly also includes a neck guard attached to an outer edge portion of the shield member at peripheral side and lower portions thereof. The neck guard is formed of a flexible fabric material configured to permit passage of air therethrough and having an elastic band attached to a free edge portion thereof. The assembly is configured to fit over and accommodate eyeglasses worn by a user.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon, and claims the benefit of priority under 35 USC 119 from U.S. Provisional Patent Application No. 63/116,272, filed Nov. 20, 2020. The entire contents of the referenced priority application are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention pertains to a face shield and mask assembly which may be worn to cover a person's face, including eyes, mouth and nose, so as to prevent or minimize the possibility of transmitting harmful and/or contagious matter and the like to and from the user. The shield and mask assembly hereof minimizes user discomfort while permitting the user to be readily identified.

More particularly, the present invention pertains to such a face shield and mask which sealingly conforms to a user's face and head, which does not impair the user's field of vision, is mostly transparent so that the user's face may be readily identified through the face shield and mask, is lightweight, washable and reusable, and may be manufactured, stored and transported at relatively low cost.

Description of the Background Art

Due to the recent pandemic, there is an enhanced need for personal protective equipment (PPE) that is capable of effectively filtering out germs such as microscopic pathogens. Such need is particularly felt by medical professionals, who are around affected patients on a daily basis, and who may have to work extended or double shifts.

There are many known face masks which people wear in public places to cover their mouths and noses, in order to prevent the users wearing the masks from breathing in any undesirable foreign matter, e.g., dust, dirt, pollen, contagious matter, microscopic particles or larger particles of moisture from the exhaled breath of other people, etc., and to prevent the users' exhaled breath, including any undesirable matter therein, from being directly discharged into the space around them.

In many cases, such face masks are not transparent, such that the portion of a user's face covered by a mask is concealed, and these known face masks also do not protect the eyes of the person wearing the mask.

Further, many known face masks are not form-fitted to, and/or sealed against the face of a person wearing the mask, which limits the effectiveness of such masks. For example, since the edges of such known masks may not securely fit in engagement with a wearer's face, such masks do not fully protect persons wearing the masks from inhaling airborne pathogens which may pass between the edges of the mask and the wearer's face, and such known masks do not protect other persons in the vicinity from any airborne pathogens in the wearer's exhaled breath which escapes between the edges of the mask and the wearer's face.

Unless a face mask is form fitted or extremely tightly engaged to the wearer's face at the edges of the mask, airborne pathogens in inhaled or exhaled breath may pass between the edges of the mask and the wearer's face, rather than being carried by air passing through the mask, where it would be filtered out of the breath.

Besides the known face masks discussed above, there are also many known face shields, which are generally transparent and which people wear to cover their faces including eyes, in somewhat spaced relation thereto, so as to prevent contact with foreign matter at times when such people are in an environment where there is substantial risk of foreign matter contacting their faces, e.g., doctors and other health care personnel who are in close proximity to patients, some cashiers in retail environments, people operating machines which discharge particles, etc.

While conventional face shields allow the wearer's facial features to be seen by others, and protect the wearer from a portion of directly projected liquid and solid airborne materials such as spittle and materials which are projected by a direct cough or sneeze, conventional face shields do not form an enclosed and sealed space around a user's face. Hence, inhaled and exhaled breath, which may contain airborne pathogens, is not effectively filtered by conventional face shields, as the inhaled and exhaled breath passes around the side and bottom edges of these known face shields.

A person wearing a conventional face shield may inhale or otherwise ingest airborne pathogens in the inhaled breath through such person's mouth and nose, and such person's eyes may also be exposed to potentially contaminated air. Similarly, any persons in the vicinity of the persons wearing the conventional face shields are directly exposed to the unfiltered exhaled breath of the shield-wearing person.

While the known face masks and face shields, worn one or the other or worn together as two separate garments in conjunction with one another, are generally effective for their intended purposes, the current global pandemic caused by the Covid-19 virus has caused a tremendous increase in usage of face masks and face shields, often required by emergency laws, ordinances, and policies adopted to slow the spread of the Covid-19 virus and this has created some new problems relating to these devices.

For example, many states, as well as public offices and private businesses, require people to wear face masks in order to enter public and private premises, which makes it difficult to identify the people wearing the masks, and such that the people may be required to remove the masks in order to be identified and then replace the masks onto their faces. Similarly, if a deaf person desires to communicate with another person who is wearing a mask, it may be necessary for the person wearing the mask to remove same in order for the deaf person to read the mask wearing person's lips. Face masks may also inhibit the ability of security and law enforcement personnel to identify the people wearing the masks. For example, face masks may interfere with facial recognition software, or may make it difficult to identify faces on security video recordings.

Also, many people find the masks uncomfortable to wear, as the masks directly engage against the peoples' faces causing irritation, smearing makeup, making it difficult to breathe, causing exhaled breath to be discharged onto the wearer's eyeglasses and cause fogging of the eyeglass lenses, etc. In addition, current face masks impact the wearing of medications such as creams, lotions, & oils related to skin maladies such as pimples, blemishes, & acne. Current masks also diminish the wearer's skin from breathing and being properly ventilated.

Due to such discomfort and related issues, some people prefer not to wear face masks or, if they do wear the masks in order to enter a building, they may partially remove the mask after they are in the building, which mostly defeats the intended purpose of the masks. Also, due to the discomfort associated with conventional face masks, many people will use other items in place of face masks, e.g., bandannas and the like, which may be more comfortable, but do not provide as good of protection as other conventional face masks.

Still further, given that many men have significant amounts of facial hair in terms of beards, moustaches, etc. the conventional face masks may not provide sufficient protection as desired because they do not tightly engage against such peoples' faces so that air being breathed in or exhaled out may pass around the edges of the masks.

On the other hand, conventional face shields are typically designed for medical or industrial use and are relatively large, bulky and uncomfortable so that people typically do not want to wear them except in special circumstances where the protection the face shields provide is required, e.g., in hospitals, medical and dental offices where health care professionals must come in close proximity to patients, where people are operating machines which discharge particles which could injure the people's faces, etc.

Hence, the conventional face masks and face shields offer incomplete protection for the wearers of same and for others. Accordingly, people sometimes wear both a conventional face mask and a conventional face shield together, in tandem, in order to protect the wearer's eyes (as is the case primarily with the face shield), as well as to filter breath inhaled and exhaled via the wearer's mouth and nose (as is the case with the face mask). However, the combination of a conventional face mask and a conventional face shield tends to be fairly large in terms of size and weight, and most people are unwilling to wear both of these just for purposes of being out in public, going to a store or the like.

As will be understood, a need still exists for improvement in the conventional protective devices.

There remains a need in the art of personal protection, and the protection of others, for a wearable face shield and mask assembly that is lightweight and compact so that it is generally comfortable to wear, protects the wearer's eyes, mouth and nose while also allowing clear and unobstructed view of the wearer's face and features.

Ideally, a face shield and mask assembly would provide sufficient and proper protection for people wearing same and for others in the vicinity of such people, while at the same time avoiding or minimizing any problems and drawbacks associated with the conventional devices. Preferably, a face shield and mask assembly would be washable and reusable, and capable of being manufactured, stored and transported at relatively low cost.

SUMMARY OF THE INVENTION

An object of the present invention is to satisfy the discussed need in the art.

It is another object of the present invention to provide a combined protective mask and transparent face shield assembly.

According to a first aspect of the present invention, a protective face shield assembly includes a frame member including a central section having a nose bridge, and a pair of temple-contacting arms attached to side portions of the central section.

A transparent plastic shield member is attached to the frame member, and is configured to cover a user's face including mouth, nose and eyes. A spacer, disposed between the frame member and the shield member, is formed of a flexible foam material and has a convexly curved front surface.

The combined face shield and mask assembly according to the first aspect hereof also includes a neck guard attached to an outer edge portion of the shield member at peripheral side and lower portions thereof, the neck guard formed of a flexible fabric material configured to permit passage of air therethrough and having an elastic band attached to a free edge portion thereof.

The combined face shield and mask assembly is configured to fit over and accommodate eyeglasses worn by a user, if the user wears eyeglasses.

According to a second aspect of the invention, in addition to the first aspect, the shield member is formed in a shape resembling a half moon having a flattened edge portion which is disposed at a top portion of the combined face shield and mask assembly

According to a third aspect of the invention, in addition to the first aspect, the flexible face shield is at least partially concave and is configured to enclose the user's face extending from the user's forehead along sides of the user's face slightly forward of the user's ears and down to the user's throat rearward of the user's chin.

According to a forth aspect of the invention, in addition to the first and third aspects, a seal is provided at the periphery of the shield member on top of the frame member, to seal the top of the assembly and to restrict or prevent air passage therepast.

According to another aspect of the invention, the shield member has a pair of holes formed therein which receive rear portions of the temple-contacting arms therethrough.

According to another aspect of the invention, the combined face shield and mask assembly is provided with a vent, separate from the neck guard, and through which exhaled breath of the user may also be discharged from the face shield assembly, the vent including a check valve which prevents air from passing inwardly through the vent during use.

Other objects, features and advantages of the present invention may be found from a review of the following detailed description section. For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.

Intent of Disclosure

Although the following disclosure offered for public dissemination is detailed to ensure adequacy and aid in understanding of the invention, this is not intended to prejudice that purpose of a patent which is to cover each new inventive concept therein no matter how it may later be disguised by variations in form or additions of further improvements. The claims at the end hereof are the chief aid toward this purpose, as it is these that meet the requirement of pointing out the improvements, combinations and methods in which the inventive concepts are found.

There have been chosen specific embodiments of a face shield assembly according to the invention and specific alternative embodiments and modifications thereto, the embodiments chosen for the purposes of illustration and description of the composition and method of the invention are shown in the accompanying drawings forming a part of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front plan view of a face shield and mask assembly according to a first illustrative embodiment of the present invention.

FIG. 2 is a rear plan view of the combined face shield and mask assembly of FIG. 1.

FIG. 3 is a perspective side view of the combined face shield and mask assembly of FIGS. 1-2.

FIG. 4 is a perspective top view of a frame member and spacer which are component parts of the combined face shield and mask assembly of FIGS. 1-3.

FIG. 5 is a front plan view of a shield member which is another component of the combined face shield and mask assembly of FIGS. 1-3, shown before assembly.

FIG. 6 is a top plan view of the combined face shield and mask assembly of FIGS. 1-3, also showing an optional seal member and optional one-way valve.

FIG. 7 is a detail perspective view of the shield member and frame member assembled together.

FIG. 8 is a detail perspective view showing an attachment member which is part of the frame member.

FIG. 9 is a front plan view of a first user wearing the combined face shield and mask assembly of the first embodiment.

FIG. 10 is a side plan view of the first user wearing the combined face shield and mask assembly of the first embodiment.

FIG. 11 is a front plan view of a second user wearing the combined face shield and mask assembly along with traditional glasses, which may be prescription glasses or sunglasses.

FIG. 12A is a front plan view of a face shield and mask assembly according to a second illustrative embodiment of the present invention.

FIG. 12B is a rear plan view of the combined face shield and mask assembly of FIG. 12A.

FIG. 13 is a side plan view of the first user wearing the combined face shield and mask assembly of the second embodiment.

FIG. 14 is a front plan view of a first user wearing the combined face shield and mask assembly of the second embodiment.

FIG. 15 is a rear perspective view of the combined face shield and mask assembly of the second embodiment.

FIG. 16 is a front plan view of a bumper which is a component part of the the combined face shield and mask assembly of the second embodiment, the bumper shown before assembly.

FIG. 17 is a detail view showing a cinch strap and locking structure which is a component part of the combined face shield and mask assembly of the second embodiment.

FIG. 18A is a front perspective view of a combined face shield and mask assembly according to a third embodiment.

FIG. 18B is a side plan view of the combined face shield and mask assembly according to the third embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Overview

Exemplary embodiments of the present invention will now be described in some detail, with reference to the drawings. It should be understood that only structures considered necessary for clarifying the present invention are described herein. Other conventional structures, and those of ancillary and auxiliary components of the system, are assumed to be known and understood by those skilled in the art. Also, it will be understood that features described in relation to specific ones of the several exemplary embodiments are not limited for use in only the specific ones of the embodiments and modified embodiments, but may also be used in the other exemplary embodiments and modified embodiments.

Referring to FIGS. 1-3, there is shown a combined face shield and mask assembly 10 according to a first exemplary embodiment of the present invention. As will be described in further detail, the primary components of the combined face shield and mask assembly 10, in this first embodiment, include a frame member 20, a shield member 30, a spacer 40 (FIG. 3) and a neck guard 50, which is attached to the shield member. The neck guard 50 is configured to filter incoming and outgoing air therethrough, in a manner similr to a surgical mask. Each of these primary components will be described in further detail herein.

Frame Member

As shown in the drawings, the frame member 20 bears some resemblance to a set of frames used for optical glasses, except without any lower section which would, if present, be situated for placement near the upper cheekbones of a user. The frame member 20 is formed from a flexibly resilient plastic, which may be transparent or opaque.

As illustrated in FIGS. 3-4, the frame member 20 includes a brow-contacting central section 22 having a nose bridge 24 extending downwardly thereon, and a pair of temple-contacting arms 26, 28 attached to opposite sides of the central section. The temple-contacting arms 26, 28 may be hingedly attached to the central section 22 or, alternatively, may be integrally formed with the central section.

Shield Member

The combined face shield and mask assembly 10 according to the first embodiment also includes a shield member 30 attached to the frame member 20. The method of attaching the shield member 30 to the frame member 20 is illustrated in FIGS. 7-8 and is described below. The shield member 30 is formed of a flexible, transparent plastic material. The shield member is partially concave in the assembled configuration thereof, such that it will cover much of a user's face including mouth, nose and eyes.

The shield member 30 is shown separately, before assembly, in FIG. 5. As shown in FIG. 5, the shield member 30 is formed generally in a half-moon shape, and may, optionally, have indicia 33 thereon, such as a logo including one or more trademarks and/ or a brand name, sports team name/logo, advertising, various messages or other custom ornamentation.

As best shown in FIGS. 3, 6, and 7, the shield member 30, as shaped by the spacer 40, may correspond to and define the overall shape of the combined face shield and mask assembly 10 which covers much of a user's face.

As best seen in FIG. 7, during installation of the frame member 20 into the shield member 30, rearward end portions of each of the temple-contacting arms 26, 28, respectively, are slid outwardly through first oval openings 32 and then back inwardly through second oval openings 34 provided at the side edges of the shield member 30, to connect the frame member 20 and the shield member 30 together, and to maintain the shield member in a curved orientation.

FIGS. 7-8 depict a modification to the combined face shield and mask assembly 10, in which the face shield 30 and frame member 20 are configured to be selectively connected together and separated from each other, in which FIGS. 7 and 8 are perspective detail views showing the face shield 30 and frame member 20 being assembled together. As depicted, in the modification, the forward-facing outer surfaces of the temple-contacting arms 26, 28 have flexibly resilient projections 70 provided thereon, and the face shield 30 may have oval openings 34 provided along an upper portion thereof which are configured to be securely attached to and detached from the projections 70. Each projection 70 extends outwardly through the corresponding oval opening 34, and includes a small plug 72 (FIG. 8) which fits into a small round opening 36 formed in the shield member 30 for that purpose. The small round opening 36 may have a diameter slightly smaller than the outer diameter of the plug 72, so that the plug remains engaged therein by friction fit. The projections 70 may be formed of a silicone rubber or similar flexible material.

The modification in FIGS. 7-8 is desirable for a couple of reasons. One reason is that the face mask and shield may be disassembled for easier, more compact storage and transportation. Another reason is that the disassembled components may be washed/cleaned more easily and thoroughly when disassembled.

With reference to FIGS. 3, 6 and 9-11, it will be seen that the shield member 30 is at least partially curved or concave in the assembled configuration of the assembly 10, and shaped such that when the combined face shield and mask assembly 10 is worn by a user, the shield member 30 may extend along the user's forehead, downward along both sides of the user's face slightly forward of the user's ears, and in front of the user's throat. Also, a portion of the face shield 30 which covers the user's chin may be disposed at a lowest level when the face shield assembly 10 is worn by a user, e.g., as shown in FIGS. 9-11, the face shield may extend downward to an area below the user's chin.

The shield member 30 may be formed of any appropriate flexible, non-porous, lightweight material such as plastics and plastic sheet material, and is at least partially transparent such that a user may see through the face shield with little or no obstruction, and such that the user's face may be clearly visible to others through the face shield.

In the depicted embodiment, essentially the entire shield member 30 is transparent, other than at the periphery thereof. For example, the shield member 30 may be made from clear polyvinyl chloride (PVC) sheet material which is 1-12 mils thick, although any other clear, flexible plastic sheet material may be used with any desired or appropriate thickness.

Also, because the shield and mask assembly 10 will substantially cover the user's entire face such that moist exhaled breath from the user will be contained between the non-porous shield member 30 and the user's face, the surface of the shield member which faces toward the user may have a coating or treatment of fog-suppressing material applied thereto so as to prevent or minimize fogging of the shield member 30 by the user's exhaled breath. Such a coating or treatment of a fog-suppressing material is not shown in the drawing as this would be very thin and transparent, but there are many commercially available agents and coatings which provide such anti-fogging effect and any of these may be used which are compatible with the plastic material of the face shield.

Alternatively, the chemical compounds used to make the plastic shield material may contain additives which provide anti-fogging qualities to the plastic making up the shield member. Further, additional amounts of anti-fogging treatments may be provided with the face shield and mask, e.g., in a spray bottle or moistened towelette, which the user may selectively apply to the inside surface of the shield member 30 when desired.

Optionally, as shown in FIG. 3, but not necessarily, a peripheral outer edge portion of the flexible plastic sheeting constituting the shield member 30 may have a, flexible strap 35 provided therewith for adjusting or cinching the peripheral edges of two opposite sides of the shield member into sealing engagement with a wearer's head.

Spacer

Referring to FIGS. 3, 4 and 6, the face shield and mask assembly 10 also includes a flexible spacer 40 disposed between the frame member 20 and the shield member 30. The spacer 40 is attached to the front surface of the frame member 20 at an upper edge of the central section 22, as shown in FIG. 3. The spacer 40 is formed of a flexible foam material, and is configured to keep the shield member from directly engaging the user's face, except at the periphery of the shield member. The spacer 40 has a convexly curved front surface 42, as shown, and this surface contacts the inner surface of the shield member 30 when the face shield assembly is assembled and worn.

According to an aspect of the present invention, the spacer 40 projects inwardly from the shield member 30 by a sufficient distance, or in other words the spacer has a sufficient width, to ensure that during use, except for the peripheral side edges thereof, the shield member 30 will be spaced outwardly away from the user's face when the face shield assembly 10 is worn by the user, so that most of the shield member 30 will not contact the user's face, nose or any eyeglasses when the face shield assembly 10 is being worn by the user. This is important for minimizing any discomfort and distraction caused by the face shield assembly 10 to the user.

Also, the spacer 40 may have a varying thickness, and possibly a varying height as well, as it extends along and around the user's forehead so as to assure proper spacing from the user's face. For example, at a lateral center of the spacer 40, the thickness of the spacer may be 0.5-2.0 inches thick and 0.5-2.0 inches high, and then taper so as to be smaller in thickness and/or height as the padding extends to the lateral edges of the face shield assembly 10, so that the peripheral sides of the shield member 30 may engage the user's face, e.g., the thickness at the lateral edges of the padding may be 0.1-0.25 inches.

The spacer 40 may be made of any appropriate lightweight, non-toxic material. For example, foam plastic materials, foam rubber or elastomer, cloth fabrics and combinations of these may be used.

The spacer 40 may be attached to an upper portion or edge of the frame member 20 and/or an upper portion of the shield member 30 by any appropriate means. For example, the spacer 40 may adhesively bonded to the upper portion or upper edge of the flexible face shield 30 or frame member 20 with any appropriate adhesive, or may be melt bonded with heat. The spacer 40 provides additional strength and mass to the upper portion of the face shield assembly 10, noting that other components such as the shield member 30 may be made of flexible, lightweight materials such as flexible plastic sheeting as discussed above.

Optionally, if desired, the spacer 40 may be provided with a vent 45, separate from the neck guard, and through which exhaled breath of the user may also be discharged from the face shield assembly 20, the vent including a one-way check valve which allows air to leave outwardly, but which prevents outside air from passing inwardly through the vent during use.

Neck Guard

The combined face shield and mask assembly 10 also includes a neck guard 50 attached to an outer edge portion of the shield member 30, as shown, extending from the sides of the shield member near the frame member 20 down to the lowermost central portion of the shield member. The neck guard 50 functions as a breathing mask, in a manner similar to a surgical mask, in order to filter pathogens and contaminants out of air passing therethrough.

The neck guard 50 is formed of a flexible, porous fabric material configured to permit passage of air therethrough, and has an elastic band 52 sewn into, or otherwise attached to a free edge portion 54 thereof. During use, the elastic band 52 allows the free edge portion 54 of the neck guard 50 to tightly contact, or “hug” against the neck of a user, as seen in FIG. 10, creating a substantially air tight seal in a manner somewhat similar to how a shower cap fits on a user's head.

As an alternative to the elastic band 52, and as shown in FIG. 17, a manually adjustable strap 208 may be substituted if desired. Where used, the strap 208 may be provided with, and attached to the peripheral side and lower portions of the flexible face shield 20, e.g., it may have ends which are also attached to or near the lateral ends of the neck guard 50, extend along sides of the user's face slightly forward of the user's ears and down to the user's neck or throat rearward of the user's chin when the face shield and mask assembly 10 is being worn by the user.

Where used, the strap 208 may be movably attached to the neck guard 50 near the lower edge thereof, such that the strap 208 can be moved relative to the periphery of the shield member 20, for selectively drawing or cinching the neck guard 50 in close engagement with the user's neck, and for loosening the neck guard when desired.

Optionally, the strap 208 may also include a locking mechanism 214 so that the strap 208 may be readily manipulated by the user such that the periphery of the neck guard snugly engages the user's neck. These types of spring-loaded locking mechanisms are well known and understood in the art.

For movably attaching the strap 208 to the neck guard 50, a peripheral edge of the neck guard may be folded over and sewn on to, or otherwise bonded to an adjacent portion of the neck guard so as to form a generally tubular channel through which portions of the strap may be movably extended. Also, grommets 216, made of a rigid material such as metal or plastic, may be provided at openings defined in the folded peripheral edge of the neck guard 50 where portions of the strap are extended into the tubular channel, such as shown in FIG. 17. The grommets 216, where used, are helpful to prevent the strap 208 from ripping or otherwise damaging the openings of the folded peripheral edge of the neck guard 50.

Referring now to FIG. 2, the fabric panel 56 making up the neck guard 50 be formed of various porous, breathable materials through which a user's breath may pass, and which may be constructed or treated to possess some type of anti-bacterial function for killing any bacteria, virus or the like contained in the breath. For example, the fabric panel 56 may be formed of porous paper similar to a normal surgical mask.

Alternatively, the fabric panel 56 may be formed of a natural fabric such as cotton or silk, or synthetic fabrics such as polychiffon, polyester, nylon, rayon, etc. which would not cause any abrasion or irritation to the user's skin, and the anti-bacterial function may be provided by including appropriate anti-bacterial materials in the fabrics and/or by applying a coating of anti-bacterial materials to the fabric.

The fabric panel 56 making up the main body of the neck guard 50 may include multiple materials, multiple layers of material and may have various thicknesses, either for the entire panel or parts thereof, e.g., the lower portions of the panel 56 may include larger pores than other portions of the panel to permit a user's breath to pass more easily through such lower portions than through the other portions.

The particular material(s), thicknesses, number of layers, etc. used in forming a given fabric panel 56 used for the neck guard 50 will determine just how readily a user's breath may pass through the fabric panel. This is an important consideration because the more readily the user's breath may pass through fabric panel 56, the easier it is for the user to breathe while wearing the combined face shield and mask assembly 10, and the less likely that moisture will accumulate and cause fogging of the face shield 30.

On the other hand, if the fabric panel 56 has characteristics which make it not so easy to breathe therethrough, e.g., pores with smaller size, such fabric panel may be more effective at preventing passage of bacteria, viruses, etc. Hence, it may be desirable to balance considerations of easier breathing and better protection that can be made when preparing the fabric panel 56 of the neck guard 50 for a given user, depending on the intended use environment and/or on the user's desires. The positioning of the fabric panel 56 used in the neck guard 50 is such that much of a user's breath being discharged therethrough will be directed downward and laterally away from the user.

As will be understood, the fabric panel 56 used in the neck guard 50 is quite different from the plastic materials used to form the shield member 30, in that the fabric panel is porous and permits a user's breath to pass therethrough.

Due to the porous nature of the fabric pane 561, the combined face mask and shield 10 of this embodiment may not require any additional vents or filters, but vents and/or filters may be provided if so desired, such as the vent 45 shown in FIGS. 3-4. Further, it is possible to construct the fabric panel 56 to have a basic structure which is very porous and permits a user's breath to easily pass therethrough, and to provide additional layer(s) of fabric (not shown) together with the combined face mask and shield assembly 10, which a user may selectively attach to or detach from the fabric panel 56 for adjusting just how readily a user's breath may pass therethrough. For example, a given user may prefer to normally have a fabric panel 56 that is very porous and permits breath to easily pass therethrough for most times when the user wears the combined face shield and mask assembly 10. However, in certain situations, the user may want to add additional layer(s) of fabric to the fabric panel 56 when the user desires greater protection against airborne bacteria, viruses and the like, e.g., when the user is in a confined space with many other people, such as on an airplane, in a hospital, or in a surgery. Such additional layer(s) of fabric may be shaped to fully cover the fabric panel 56 or various parts thereof, and may include various means for being attached to the fabric panel such as an adhesive layer with a removable cover, hook-and-loop type fasteners, etc.

Optional Seal Member

Optionally, as shown in FIG. 6, the face shield and mask assembly 10 may include a flexible seal member 60 configured to be placed on top of the frame member 20 to restrict or prevent air passage therepast, and to seal the top of the assembly 10. Where used, the seal member 60 may or may not be configured to contact a user's forehead during use, depending on the wishes of the wearer. The assembly 10 may be sold with the seal member 60 packaged separately, and available for installation by the user if desired.

The seal member 60 may be curved or shaped to engage and extend along most or all of the user's forehead when the combined face shield and mask assembly 10 is worn by the user, and the seal member 60 projects inwardly from the upper edge of the frame member 20 toward the user's face, so that the inner edge portion of the seal member will engage the user's forehead when the face shield assembly 10 is worn by the user. The seal member 60 may be a single piece of flexible foam material which is very thin at side portions thereof, and which is thicker in a central portion thereof.

Where used, the seal member 60 is provided to enhance the ability of the face shield assembly 10 to prevent inhaled and exhaled breath from passing between the peripheral edge of the face shield and the user's face, thereby forcing the breath to pass through the filter provided by the neck guard 50. For example, the seal member 60 may include one or more thin strip(s) of a non-toxic, non-abrasive, plastic foam which may be bonded to the peripheral edge surface at the top of the frame member 20 using adhesive or heat, and/or may include a bead 19 of flexible, non-toxic plastic such as silicone.

Alternatively or additionally, thin strip(s) of a peel-and-stick type sealing material (not shown) may be provided with the face shield assembly 10, which a person may use to customize the face shield assembly 10 to more comfortably, closely and snugly fit against the person's face and/or forehead. For example, the thin strip(s) may include a plastic or plastic foam material which is 1/16 to ¼ inch thick, ¼ to ½ inch wide and any desired length, with adhesive provided on one surface of the strip(s) and a removable “peel-off” covering over the adhesive. The user may cut the thin strip(s) to a desired length and/or width, remove the covering from the adhesive, and engage the adhesive surface to a desired portion of the periphery of the shield member 30 or the spacer 40. Such peel-and-stick type sealing material would be useful for closing any gaps between the periphery of the shield member 30 and the person's face, or for achieving a more comfortable, snug fit of the face shield assembly 10.

FIGS. 9, 10, and 11 show the combined face shield and mask assembly 10 according to the first embodiment being worn by a user, and FIG. 11 illustrates that the combined face shield and mask assembly may be worn in conjunction with and along with traditional glasses, which may be prescription glasses or sunglasses.

Second Embodiment

Referring to FIGS. 12A-12B and 13-15, an adjustable face shield and mask assembly 200 according to an second exemplary illustrative embodiment of the present invention. The adjustable face shield and mask assembly 200 generally comprises a flexible face shield 230 which is at least partially transparent and partially concave such that it will cover much of a user's face including mouth, nose and eyes, a neck guard 250 which is attached to a lower edge and side portions of the face shield and through which a person wearing the adjustable face mask and shield can inhale and exhale breath, and straps 208, 210 which are secured to a periphery of the flexible face shield, which may be made of elastic material and which may be adjustable for fitting the periphery of the flexible face shield in engagement with at least one of the user's face and head.

The combined face shield and mask assembly 200 according to the second embodiment omits the frame member 210 of the first embodiment, and instead, uses an upper strap 208 to removably and adjustably attach the top portion of the assembly to a user's head, as shown in FIG. 13. The upper strap 208 provides attachment structure for the mask assembly 200 in this embodiment.

The mask assembly 200 according to the second embodiment also includes a padded spacer 212 which is attached to an upper portion of the flexible face shield, projects inwardly away from an inner surface of the flexible face shield and is configured to face toward the user's face and keep the flexible face shield from engaging the user's face except at the peripheral side and lower portions of the flexible face shield.

As best shown in FIGS. 13-15, the flexible face shield 230 may correspond to and define the overall shape of the adjustable face shield and mask assembly 200 which covers much of a user's face. The face shield 230 is at least partially curved or concave, and shaped such that when the adjustable face shield and mask assembly 200 is worn by a user, the flexible face shield 230 may extend along the user's forehead, downward along both sides of the user's face slightly forward of the user's ears, and adjacent part of the user's throat rearward of the user's chin. Also, a portion of the face shield 230 which covers the user's chin may be disposed at a lowest level when the face shield and mask assembly 200 is worn by a user, e.g., as shown in FIG. 13, the face shield 230 may extend downward to an area at or below the user's chin, and then extend rearwardly and upwardly. The lower edge of the neck guard 250 engages the user's neck or throat, as shown in FIG. 13.

The flexible face shield 230 may be formed of any appropriate flexible, non-porous, lightweight materials such as plastics and plastic sheet material, and is at least partially transparent such that a user may see through the face shield with little or no obstruction, and such that the user's face may be clearly visible to others through the face shield. In the depicted embodiment essentially the entire face shield is transparent other than at the periphery of the face shield where the straps 208, 210 are attached. For example, the face shield 230 may be made from clear polyvinyl chloride (PVC) sheet material which is 1-12 mils thick, although any other clear, flexible plastic sheet material may be used with any desired thickness.

Also, because the adjustable face shield and mask assembly 200 will substantially cover the user's entire face, such that moist exhaled breath from the user will be contained between the non-porous face shield 230 and the user's face, the surface of the face shield which faces toward the user may have a coating or treatment of fog-suppressing material applied thereto so as to prevent or minimize fogging of the face shield 230 by the user's exhaled breath. Such a coating or treatment of a fog-suppressing material is not shown in the drawing as this would be very thin and transparent, but there are many commercially available agents and coatings which provide such anti-fogging effect and any of these may be used which are compatible with the plastic material of the face shield.

Alternatively, the chemical compounds used to make the plastic shield material may contain additives which provide anti-fogging qualities to the plastic making up the shield member. Further, additional amounts of anti-fogging treatments may be provided with the face shield and mask, e.g., in a spray bottle or moistened towelette, which the user may selectively apply to the face shield when desired.

The spacer 212 may be curved or shaped to engage and extend along most or all of the user's forehead when the combined face shield and mask assembly 200 is worn by the user, and projects away from the flexible face shield 230 toward the user's face, so that the spacer 212 will engage the user's forehead when the face shield and mask assembly 200 is worn by the user.

According to an aspect of the present invention, the spacer 212 projects away from the face shield 230 by a sufficient distance, or in other words the spacer 212 has a sufficient thickness, to assure that the face shield will be spaced away from the user's face, except at the periphery of the face shield when the face shield and mask assembly 200 is worn by the user, and so that most of the face shield 230 will not contact the user's face or any eyeglasses or the like worn by a user when the shield and mask assembly 200 is being worn by the user. This is important for minimizing any discomfort and distraction caused by the face shield and mask assembly 200 to the user. Also, as best shown in FIGS. 15, 16A and 16B, the spacer 212 may have a varying thickness, and possibly a varying height as well, as it extends along and around the user's forehead so as to assure proper spacing from the user's face. For example, at a lateral center of the spacer 212, the thickness of the spacer 212 may be 0.5-2.0 inches thick and 0.5-2.0 inches high, and then taper so as to be smaller in thickness and/or height as the spacer extends to the lateral edges of the face shield and mask assembly 200 so that the peripheral sides and lower portions of the face shield 230 may engage the user's face, e.g., the thickness at the lateral edges of the spacer may be 0.1-0.25 inches.

The spacer 212 may be made of any appropriate lightweight, non-toxic material that would not cause any abrasion or particular discomfort to the user's forehead when the face shield and mask assembly 200 is worn by a user, even for extended periods of time. For example, foam plastic materials, cloth fabrics and combinations of these may be used. Cloth fabrics would also desirably absorb sweat from the user's forehead. The spacer 212 may be attached to an upper portion or edge of the flexible face shield 230 by any appropriate means. For example, the spacer 212 may adhesively bonded to the upper portion or upper edge of the flexible face shield with any appropriate adhesive or melt bonded with heat. The spacer 212 provides additional strength and mass to the upper portion of the face shield and mask assembly 200, noting that other components such as the face shield 230 and straps 208, 210 may be made of flexible, lightweight materials, e.g., the face shield may be made of flexible plastic sheeting as discussed above, while the straps 208, 210 may be made of elastic, stretchable material.

An adjustable upper strap 208 may be provided at the upper portion of the face shield and mask assembly 200, e.g., by having ends of the strap attached to or near lateral ends of the spacer 212, and is configured to extend substantially horizontally around to the back of the user's head just above the user's ears. The upper strap 208 may include a locking mechanism 214 which may be easily manipulated by a user for adjusting the length of the strap. Between the elastic nature of the upper strap 208 and the adjustability of the strap length through the locking mechanism 214, the upper strap 208 may be readily manipulated by the user such that the strap snugly engages the user's head and maintains the spacer 212 in engagement with the user's forehead, without being so tight that it becomes uncomfortable to the user.

For example, the locking mechanism 214 may be a so-called cord lock which has an opening defined therein through which the upper strap 208 may be extended, and a spring-biased locking member which normally will clamp against the portions of the strap extending therethrough so as to lock the mechanism to such portions of the strap. A user may depress the spring-biased locking member to unclamp it from the strap portion, adjust the length of the strap by moving the strap and/or locking mechanism relative to the other, and then stop depressing the locking member to again clamp the mechanism to different portions of the strap.

The lower strap 210 may be provided with, and attached to the peripheral side and lower portions of the neck guard 250, e.g., it may have ends which are also attached to or near the lateral ends of the spacer 212, extend along sides of the neck guard at an area slightly forward of the user's ears and down to the user's neck or throat rearward of the user's chin when the face shield and mask assembly 200 is being worn by the user. The lower strap 210 may be movably attached to the periphery of the neck guard 250 such that the strap 210 can be moved relative to the outer peripheral edge of the neck guard for selectively drawing or cinching the periphery in close engagement with the user's face and for loosening the periphery when desired. The lower strap 210 may also include a locking mechanism 214 so that the strap 210 may be readily manipulated by the user such that the periphery of the neck guard 250 snugly engages the user's face.

For movably attaching the lower strap 10 to the neck guard 250, a peripheral edge of the neck guard may be folded over and bonded to an adjacent portion of the neck guard periphery with adhesive or sewing so as to form a generally tubular channel through which portions of the strap may be movably extended. Also, grommets 216, made of a rigid material such as metal or plastic, may be provided at openings defined in the folded peripheral edge of the neck guard 250 where portions of the strap are extended into the tubular channel, such as shown in FIG. 17. The grommets 216, where used, are helpful to prevent the lower strap 210 from ripping or otherwise damaging the openings of the folded peripheral edge of the neck guard.

For enhancing the ability of the face shield and mask assembly 200 to prevent inhaled and exhaled breath from passing between the peripheral edge of the face shield and the user's face, and thus forcing the breath to pass through the neck guard 250, a seal may be provided with the surface of the face shield periphery that will engage the user's face, similar to the seal described herein in connection with the first embodiment.

Third Embodiment

Referring to FIGS. 18A-18B, there is shown an adjustable face shield and mask assembly 400 according to a third illustrative exemplary embodiment according to the present invention. The face shield and mask assembly 400 has features which are similar to features of the second embodiment, unless specifically described as different herein.

The face shield and mask assembly 400 generally includes a transparent face shield 402, a neck guard 450 formed from a fabric panel 56 which has one peripheral edge thereof connected to peripheral side and lower portions of the transparent face shield 402 by adhesive bonding or other appropriate means.

The face shield and mask assembly 400 of this embodiment also includes a forehead-engaging bumper 412, and adjustable bands or straps 70, 71 respectively associated with the neck guard 450 and the forehead-engaging bumper 412.

Other Optional Features

The combined face shield and mask assembly 10 or 400 may be provided with a QR barcode or other barcode (not shown) for quality control and inventory tracking.

In addition, as shown in FIGS. 18A-18B, the combined face shield and mask assembly 10 or 400 may further include an internal voice-activated microphone and one or more speakers to encourage clear communications between the wearer and other people. A first speaker 82 may be attached to the outside of the shield member 20 for outgoing communications, and a second speaker (not shown) may be provided on one of the temple-contacting arms 26, 28 of the frame member 20, or in other suitable location configured to be disposed near a user's ear when the assembly 10 is worn, for incoming communications. Optionally, if desired, a second microphone (not shown) may be provided on the exterior of the assembly 10 such as, for example, on the shield member 20 to pick up external audio for the wearer to receive. Other suitable accessories such as a battery, microprocessor and memory module may be provided as needed to make the microphone(s) and speakers functional.

Further optional features which may be provided as part of the face shield and mask assembly 10, 200 or 400 include a small electric cooling fan (not shown) and/or a camera 85, which may be used for taking still pictures, video recording or both. The face shield and mask assembly 10, 200 or 400 may also be equipped with Bluetooth wireless communication capability to be a hands free voice activated extension of a user's smart phone, tablet, or computer.

Kit of Components

According to another aspect of the present invention provides a kit of components which may be assembled by the user as needed to form the face shield and mask assembly 10. The components may include the frame member 20, and will necessarily include the shield member 30 with the neck guard 50 attached thereto, and the spacer 40, all as previously described herein. Optionally, the kit may include the spacer 40 attached to the front upper surface of the frame member 20.

Use of the Face Shield and Mask Assembly

The face shield assembly 10 according to the exemplary embodiment shown in FIGS. 1-7 is convenient to wear and use, and provides several advantages over conventional face masks and conventional face shields. For use, a user may place the face shield assembly 10 on the user's head by sliding the shield and mask assembly on rearwardly, while placing the temple-contacting arms 26, 28 of the frame member 20 past the user's temples and above the ears.

When the shield assembly 10 is thus placed on the user's face and head most of the shield member 30 excluding its peripheral side edges are spaced away from the person's face, including the mouth, nose, eyes, eyeglasses and the like (if any), so as to avoid any discomfort or inconvenience that would otherwise be caused if these components engaged against the person's face. Also, if the person is wearing eyeglasses or makeup, these would not be engaged or smeared by the spaced portions of the shield member 30.

FIG. 11 is a front plan view of a user wearing the combined face shield and mask assembly along with their own traditional glasses, which may be prescription or non-prescription including sunglasses.

Further, because the shield member 30 is transparent, it is possible for others to see and recognize the person's face through the face shield, and the anti-fogging treatment or coating applied to the inner surface of the shield member 30 prevents or resists it from being fogged up by the user's exhaled breath. Still further, because the neck guard 50 is spaced forwardly away from the user's mouth and nose, it will not interfere with the person's breathing to any significant extent.

Also, because the seal member 60 may be provided along the top periphery of the face shield assembly, this can help to prevent or minimize passage of the person's breath around the periphery of the shield member 30.

Additionally, the face shield assembly 10 is generally lightweight, and compact so that it can be stored and transported easily, unlike conventional face shields. Further, the face shield assembly 10 may be easily cleaned or disinfected with soap and water, typical cleaning and disinfecting agents or sprays, etc. so that the face shield assembly 10 may be reused, lowering the effective cost of same.

The foregoing description involving present exemplary embodiments of the face shield and mask according to the exemplary embodiments of the face shield and mask according to the exemplary embodiments discussed above is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom. Modifications within the scope of the claimed invention will be apparent to those having ordinary skill in the art and are encompassed within the scope of the invention.

For example, while two elastic and adjustable straps or bands are described as used with some of the exemplary embodiments of the invention, it is possible to use one strap or more than two straps, and the straps need not be both elastic and adjustable, but may be one or the other. As another example, the face shield portions in the above exemplary embodiments of a face shield and mask according to the present invention are transparent/clear for assuring good visibility by the person wearing same as well as for assuring that the face of the person wearing the face shield and mask is clearly visible to other persons through the face shield portion. It is also possible within the scope of the present invention to have face shield portions which are not strictly transparent/clear, but which are translucent with various colors material. This would give the face shield and masks a fashionable element as a matching accessory to the rest of the attire of the person wearing the mask. Any such color of translucent hue would not be so deep or dark as to interfere with visibility through the face shield portions.

Further, it is possible to provide an optional electric fan (not shown) which may be operated to continuously draw air into the face mask and shield according to any of the exemplary embodiments of the present invention, so that a person wearing the face mask and shield will not have to strain to breathe in air through the filter. This would be helpful for people that have difficulty breathing with a face mask on, people who are exercising, etc. Such a fan may be relatively small, e.g., the diameter of a US quarter the same thickness or somewhat larger as a quarter, self-contained with no exposed wiring, a power source such as a coin battery, an on-off switch and an adhesive surface that may be attached to a lower portion of the face mask and shield near the filter or at any other portion of the face mask and shield. Alternatively, the power source and on/off switch for the fan may be disposed with the padding or bumper of the face mask and shield and connected to the fan with wiring extending inconspicuously along the periphery of the face shield.

Although the present invention has been described herein with respect to a number of specific illustrative embodiments, the foregoing description is intended to illustrate, rather than to limit the invention. Those skilled in the art will realize that many modifications of the illustrative embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.

Claims

1. A protective face shield assembly, comprising:

a shield member which is configured to cover a user's face including mouth, nose and eyes, the shield member attached to the frame member and formed of a transparent plastic material;

attachment structure for removably attaching the shield member to a user's face;

a spacer disposed inside an upper portion of the shield member, the spacer formed of a flexible foam material and having a convexly curved front surface; and

a neck guard attached to an outer edge portion of the shield member, the neck guard formed of a flexible fabric material configured to permit passage of air therethrough and having an elastic band attached to a free edge portion thereof.

2. The face shield assembly according to claim 1, wherein the shield member is formed in a shape resembling a half moon having a flattened edge portion which is disposed at a top portion of the assembly

3. The face shield assembly according to claim 1, wherein the shield member is at least partially curved, and wherein the assembly is configured to enclose an area of the user's face extending from the user's forehead along sides of the face and down to a portion of the user's neck below the user's chin.

4. The face shield assembly according to claim 3, wherein the neck guard is attached to the edge of the shield at peripheral side and lower portions thereof.

5. The face shield assembly according to claim 1, wherein the assembly is configured to fit over and accommodate eyeglasses worn by a user.

6. The face shield assembly according to claim 1, further comprising a flexible seal member configured to be placed on top of the frame member to seal the top of the assembly and to restrict or prevent air passage therepast.

7. The face shield assembly according to claim 1, further comprising a microphone and a speaker.

8. The face shield assembly according to claim 2, wherein the shield member has indicia thereon.

9. The face shield assembly according to claim 1, further comprising a vent separate from the neck guard and through which exhaled breath of the user may also be discharged from the face shield assembly, the vent including a check valve which prevents air from passing inwardly through the vent during use.

10. A protective face shield assembly, comprising:

a frame member including a brow-contacting central section having a nose bridge, and a pair of temple-contacting arms attached to opposite side portions of the central section;

a shield member which is configured to cover a user's face including mouth, nose and eyes, the shield member attached to the frame member and formed of a transparent plastic material;

a spacer disposed between the frame member and the shield member, the spacer formed of a flexible foam material and having a convexly curved front surface; and

a neck guard attached to an outer edge portion of the shield member at peripheral side and lower portions thereof, the neck guard formed of a flexible fabric material configured to permit passage of air therethrough and having an elastic band attached to a free edge portion thereof,

wherein the assembly is configured to fit over and accommodate eyeglasses worn by a user.

11. The face shield assembly according to claim 10, wherein the shield member is formed in a shape resembling a half moon having a flattened edge portion which is disposed at a top portion of the assembly

12. The face shield assembly according to claim 10, wherein the shield member is at least partially curved, and wherein the assembly is configured to enclose an area of the user's face extending from the user's forehead along sides of the face and down to a portion of the user's neck below the user's chin.

13. The face shield assembly according to claim 10, further comprising a flexible seal member configured to be placed on top of the frame member to seal the top of the assembly and to restrict or prevent air passage therepast.

14. The face shield assembly according to claim 10, wherein the shield member has a pair of holes formed therein which receive rear portions of the temple-contacting arms therethrough.

15. The face shield assembly according to claim 10, further comprising a vent separate from the neck guard and through which exhaled breath of the user may also be discharged from the face shield assembly, the vent including a check valve which prevents air from passing inwardly through the vent during use.

16. A kit of components which may be used to construct a protective face shield assembly, said kit comprising:

a frame member including a brow-contacting central section having a nose bridge, and a pair of temple-contacting arms attached to opposite side portions of the central section;

a shield member for covering a user's face including mouth, nose and eyes in the finished assembly, the shield member formed of a transparent plastic material and configured to be attached to the frame member;

a spacer for placement between the frame member and the shield member, the spacer formed of a flexible foam material and having a convexly curved front surface; and

a neck guard attached to an outer edge portion of the shield member, the neck guard formed of a flexible fabric material configured to permit passage of air therethrough and having an elastic band attached to a free edge portion thereof.

17. The kit of claim 16, wherein the spacer has a vent therein including a check valve which only permits air to flow therethrough in a single direction.