U.S. patent application number 11/350963 was filed with the patent office on 2006-07-06 for method for making titanium wire face guard.
This patent application is currently assigned to MAD PARTNERS, LLC. Invention is credited to P. David Halstead, Garry W. McNabb, David E. Wright.
Application Number | 20060143765 11/350963 |
Document ID | / |
Family ID | 24048005 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060143765 |
Kind Code |
A1 |
Halstead; P. David ; et
al. |
July 6, 2006 |
Method for making titanium wire face guard
Abstract
A method of making a face mask including the steps of providing
a plurality of lengths of Grade 2, commercially pure titanium wire,
having a diameter of from about 0.21 to about 0.24 inches; forming
each length at room temperature to a desired bend angle by bending
the member at room temperature using rotary bending apparatus to a
first bend angle that is from about 1.25 to about 1.35 times
greater than the desired bend angle; and welding each of the thus
formed lengths to at least one other of the lengths in an ambient,
oxygen containing environment.
Inventors: |
Halstead; P. David;
(Knoxville, TN) ; McNabb; Garry W.; (Cookeville,
TN) ; Wright; David E.; (Livingston, TN) |
Correspondence
Address: |
LUEDEKA, NEELY & GRAHAM, P.C.
P O BOX 1871
KNOXVILLE
TN
37901
US
|
Assignee: |
MAD PARTNERS, LLC
|
Family ID: |
24048005 |
Appl. No.: |
11/350963 |
Filed: |
February 9, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09514624 |
Feb 28, 2000 |
|
|
|
11350963 |
Feb 9, 2006 |
|
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Current U.S.
Class: |
2/9 |
Current CPC
Class: |
Y10T 29/49888 20150115;
Y10S 72/702 20130101; A42B 3/20 20130101; B21F 15/08 20130101; Y10T
29/49826 20150115 |
Class at
Publication: |
002/009 |
International
Class: |
A41D 13/00 20060101
A41D013/00; A42B 1/00 20060101 A42B001/00 |
Claims
1-6. (canceled)
7. A helmet, comprising a helmet shell and a face mask attachable
to the shell, the face mask comprising: plurality of titanium wire
members positioned in a desired configuration and interconnected to
one another by a plurality of welds, each weld being a resistance
spot weld formed in an ambient, oxygen containing environment and
having suitable weld strength such that the face mask complies with
the Standard Method of Impact and Performance Requirements of the
National Operating Committee on Standards for Athletic Equipment
(Jul. 14, 1987, Revised Jul. 10, 1990).
8. The helmet of claim 7, wherein the titanium wire members
comprise Grade 2, commercially pure titanium wire.
9. The helmet of claim 7, wherein the titanium wire members have a
diameter of from about 0.21 to about 0.24 inches.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application of pending U.S. application
Ser. No. 09/514,624, entitled TITANIUM WIRE FACE GUARD AND METHOD
FOR MAKING SAME, filed Feb. 28, 2000.
FIELD OF THE INVENTION
[0002] This invention relates generally to face guards for sporting
helmets.
[0003] More particularly, this invention relates to a method for
manufacturing face guard for football helmets manufactured using
titanium wire.
BACKGROUND AND SUMMARY OF THE INVENTION
[0004] The invention further relates to a method for producing face
guards made of titanium wire in an manner that is uncomplicated and
cost effective.
[0005] The present invention is directed to a method of making a
face mask including the steps of providing a plurality of lengths
of Grade 2, commercially pure titanium wire, having a diameter of
from about 0.21 to about 0.24 inches; forming each length at room
temperature using rotary bending apparatus to a desired bend angle
by bending the member at room temperature to a first bend angle
that is from about 1.25 to about 1.35 times greater than the
desired bend angle; and welding each of the thus formed lengths to
at least one other of the lengths in an ambient, oxygen containing
environment.
[0006] The invention advantageously enables manufacture of titanium
face masks in a cost-effective and uncomplicated manner. Face masks
made in accordance with the invention are lighter in weight than
conventional steel-based face masks and offer numerous advantages
to conventional face masks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Further advantages of the invention will become apparent by
reference to the detailed description of preferred embodiments when
considered in conjunction with the figures, which are not to scale,
wherein like reference numbers, indicate like elements through the
several views, and wherein;
[0008] FIGS. 1a and 1b are front and rear perspective views,
respectively, of a face guard in accordance with a preferred
embodiment of the invention;
[0009] FIG. 2 is an exploded perspective view of the face guard of
FIGS. 1a and 1b;
[0010] FIG. 3 is a front perspective view of a football helmet
having the face guard of FIGS. 1a-b installed thereon;
[0011] FIGS. 4a-4c show steps in the manufacture of a component of
the face guard of FIGS. 1a-1b and FIG. 4d is a top plan view of the
finished component;
[0012] FIGS. 5a-5c show steps in the manufacture of another
component of the face guard of FIGS. 1a-1b and FIG. 5d is a top
plan view of the finished component;
[0013] FIGS. 6a-6c show steps in the manufacture of another
component of the face guard of FIGS. 1a-1b and FIG. 6d is a top
plan view of the finished component;
[0014] FIGS. 7a-7c show steps in the manufacture of another
component of the face guard of FIGS. 1a-1b and FIG. 7d is a top
plan view of the finished component;
[0015] FIGS. 8a and 8b show steps in the manufacture of another
component of the face guard of FIGS. 1a-1b, with FIG. 8b being a
side plan view of the finished component.
DETAILED DESCRIPTION
[0016] With reference to the drawing figures, the invention relates
to a face guard or mask 10 that is particularly suitable for use
with a sporting helmet, such as a football helmet 12 (FIG. 3). The
mask 10 includes a plurality of interconnected members such as
members 14, 16, 18, 20 and 22 interconnected by welds W, as
discussed in more detail below.
[0017] Each of the members 14-22 is preferably provided by a length
of Grade 2, commercially pure titanium wire, having a diameter of
about 0.224 inches. FIGS. 4a, 5a, 6a, 7a and 8a show wires 24, 26,
28, 30 and 32 which are formed into the members 14-22,
respectively, and welded to provide the welds W in accordance with
the method of the invention. The formed face mask is thereafter
preferably coated with a bonded vinyl powder coating to a thickness
of from about 0.02 to about 0.09 inches and attached to the helmet
12 using conventional mounting components and techniques.
[0018] In the manufacture of the members 14-22, lengths of wire
material are provided by sharing as set forth in TABLE 1:
TABLE-US-00001 TABLE 1 Wire Shear length (inches) 24 16.25 26 17.75
28 18.06 30 18.25 32 7.50
[0019] It will be understood that the foregoing lengths are for a
preferred embodiment only and that the wires may be of various
other lengths depending on the desired configuration and size of
the mask.
[0020] The members are next formed, preferably at room temperature
(e.g., about 50 to about 80.degree. F.), to impart a desired shape
to each of the wires 24-32, the desired configuration preferably
being that shown for the members 14-22, respectively.
[0021] In this regard, and with reference to FIGS. 4b-4d, the wire
24 is preferably formed into the member 14 by first bending the
wire 24 into the configuration of FIG. 4b as by rotary bending
using a die of desired dimension to achieve a desired formed degree
of bend, represented by the angle A, of about 159 degrees and a
center-line radius (CL) of about 4.34 inches. The formed wire 24 is
substantially symmetrical and bilateral, as shown in the top plan
view of FIG. 4d.
[0022] As will be noted, ends 24a and 24b of the wire 24 are
substantially outside of the bend imparted as shown in FIG. 4b. The
ends 24a and 24b are preferably about 2 inches in length and are
formed as explained below using press brake bending equipment to
achieve the final configuration of the member 24.
[0023] Returning to the initial manipulation of the wire 24 to
achieve the desired formed degree of bend, it has been experienced
that a formed degree of bend of 159 degrees for the member 14 may
be achieved using a die having a radius of about 3.195 inches and
overbending the wire 24 to a degree of bend A', shown in phantom,
of about 206 degrees. Thus, the wire 24 must be significantly bent
past the desired formed degree of bend to impart the desired bend.
The foregoing described bend and the similar bends described below
in connection with FIGS. 5b, 6b, 7b and 8b are preferably made
using rotary bending apparatus and at room temperature. Preferred
apparatus is a rotary bending machine available from Lubow, under
Model No. ML-1025.
[0024] Next, additional bends are preferably imparted to the ends
24a and 24b in a similar manner of overbending. To provide the
preferred configuration for the member 24, the ends 24a and 24b are
each preferably bent to achieve a formed degree of bend of about 46
degrees, represented by the angle B, with an inside bend radius (R)
of about 0.75 inches. To achieve this, the ends 24a and 24b are
subjected to overbending of about 53 degrees (FIG. 4C). These bends
and the similar bends of FIGS. 5c, 6c and 7c are preferably made
using a press brake bending machine. A preferred press brake
bending machine is available from Niagra, of Buffalo, N.Y., under
Model No. MIB-15-5-6.
[0025] The members 16-22 are formed from the wires 26-32 in a
similar manner. For example, with reference to FIGS. 5a-5d, the
wire 26 is preferably formed into the member 16 by first bending
the wire 26 into the configuration of FIG. 5b as by rotary bending
using a die of desired dimension to achieve a desired formed degree
of bend, represented by the angle A, of about 164 degrees and a
center-line radius (CL) of about 3.85 inches. The formed wire 26 is
substantially symmetrical and bilateral, as shown in the top plan
view of FIG. 5d.
[0026] It has been experienced that a formed degree of bend of 164
degrees for the member 16 may be achieved using a die having a
radius of about 2.977 inches and overbending the wire 26 to a
degree of bend A', shown in phantom, of about 214 degrees.
[0027] Ends 26a and 26b (FIG. 5b) each preferably have a length of
about 2.125 inches. A first portion of each end 26a, 26b having a
length of about 0.875 inches is preferably bent to achieve a formed
degree of bend of about 74 degrees, represented by the angle B,
with an inside bend radius (R) of about 0.25 inches. To achieve
this, the first portion is subjected to overbending of about 79
degrees (FIG. 5C).
[0028] A second portion of the ends 26a and 26b having a length of
about 1.25 inches is similarly formed to achieve a formed degree of
bend of about 74 degrees, represented by the angle B', with an
inside bend radius (R') of about 0.25 inches. To achieve this, the
first portion is subjected to overbending of about 79 degrees (FIG.
5C).
[0029] As shown in FIGS. 6a-6d, the wire 28 is preferably formed
into the member 18 by first bending the wire 28 into the
configuration of FIG. 6b as by rotary bending using a die of
desired dimension to achieve a desired formed degree of bend,
represented by the angle A, of about 164 degrees and a center-line
radius (CL) of about 3.81 inches. The formed wire 28 is
substantially symmetrical and bilateral, as shown in the top plan
view of FIG. 6d.
[0030] It has been experienced that a formed degree of bend of 164
degrees for the member 18 may be achieved using a die having a
radius of about 2.977 inches and overbending the wire 28 to a
degree of bend A', shown in phantom, of about 213 degrees.
[0031] Ends 28a and 28b (FIG. 6b) each preferably have a length of
about 1.9 inches and are bent to achieve a formed degree of bend of
about 33 degrees, represented by the angle B, with an inside bend
radius (R) of about 0.25 inches. To achieve this, the first portion
is subjected to overbending of about 38 degrees (FIG. 6C).
[0032] As shown in FIGS. 7a-7d, the wire 30 is preferably formed
into the member 20 by first bending the wire 30 into the
configuration of FIG. 7b as by rotary bending using a die of
desired dimension to achieve a desired formed degree of bend,
represented by the angle A, of about 157 degrees and a center-line
radius (CL) of about 3.55 inches. The formed wire 30 is
substantially symmetrical and bilateral, as shown in the top plan
view of FIG. 7d.
[0033] It has been experienced that a formed degree of bend of 164
degrees for the member 20 may be achieved using a die having a
radius of about 2.857 inches and overbending the wire 28 to a
degree of bend A', shown in phantom, of about 200 degrees.
[0034] Ends 30a and 30b (FIG. 7b) each preferably have a length of
about 4.9 inches and are bent to achieve a formed degree of bend of
about 67 degrees, represented by the angle B, with an inside bend
radius (R) of about 0.75 degrees. To achieve this, the first
portion is subjected to overbending of about 72 degrees (FIG.
7C).
[0035] Wire 32 (FIG. 8a) is preferably formed into the member 22 by
bending the wire 32 into the configuration of FIG. 8b as by rotary
bending using a die having a radius of about 3.195 inches to
achieve a continuous bend, as shown in FIG. 8b, with a center-line
radius (CL) of about 4.81 inches. To achieve this, the bend applied
is approximately 1.29 times that of the final bend, such that the
wire 32 is bend to have a center-line radius (CL') (shown in
phantom) of about 2.476 inches so that when the bending force is
removed, the set or formed bend has a radius of about 3.195
inches.
[0036] The foregoing information concerning the formation of the
members 14-22 from the wires 24-32 is provided below in Tables 2
and 3. Table 2 relates to the primary bends in the members (FIGS.
4b, 5b, 6b, 7b and 8b) and Table 3 relates to the subsequent bends
(FIGS. 4c, 5c, 6c and 7c). TABLE-US-00002 TABLE 2 Die (A') (A)
Radius Degree of Formed Degree Center Line (CL) Member (in) Bend
Applied of Bend Radius (in) 14 3.195 206 159 4.34 16 2.977 214 164
3.85 18 2.977 213 164 3.81 20 2.857 200 157 3.55 22 3.195
continuous continuous 4.81
[0037] As will be noted from Table 2, for bends formed using the
described rotary bending apparatus, the ratio of the degree of bend
applied to that of the formed bend is generally between about 1.25
and 1.35 and, is most preferably between about 1.28 and 1.30.
TABLE-US-00003 TABLE 3 Degree of (B) Formed Inside Bend Member Bend
Applied Degree of Bend Radius (in) 14 46 41 0.75 16 79 74 0.25 79
74 (B') 0.25 18 38 33 0.25 20 72 67 0.75
[0038] As will be noted frown Table 3, for bends formed using the
described press bending apparatus, the ratio of the degree of bend
applied to that of the formed bend is generally between about 1.05
and 1.16 and, is most preferably between about 1.07 and 1.15.
[0039] The formed members 14-22 are thereafter arranged in the
desired configuration and held in position and squeezed against one
another, as by a clamp fixture, for welding. Welding is
accomplished as by spot welding at each weld location W using a
press-type projection welder of the type available from Standard
Resistance Welding Company of Winston, Ga. A preferred welder is A
50 KVA, 460 Volt, single phase welder available from Standard
Resistance Welder Company.
[0040] The transformer setting or TAP setting for the welder is
preferably set at about 7, with the welder control settings set
forth in TABLE 4: TABLE-US-00004 TABLE 4 Welder Control Preferred
Value Range Squeeze 10 1-100 Weld/heat 24 15-28 Percent current 28
23-29 Hold 01 .gtoreq.01
[0041] It is surprising that welds of suitable strength to achieve
a face mask compliant with the relevant standards of the National
Operating Committee on Standards for Athletic Equipment (NOCSAE)
such as the NOCSAE Standard Method of Impact and Performance
Requirements for Football Faceguards were achievable. It is known
that titanium is highly reactive and would not be expected to
provide suitable weld strength when welded in a reactive
environment, such as in the presence of oxygen. As will be
appreciated, the ability to achieve suitable weld strength in this
manner achieves considerable cost savings as compared to welding in
a non-reactive environment.
[0042] For the purposes of the invention, it was observed that the
settings set forth in Table 3 were important to achieving suitable
weld strength.
[0043] After welding, the guard is removed from the fixture and all
wire terminations ground using silicon carbide sandpaper to a full
radius to avoid sharp ends. The face guard is thereafter cleaned,
primed with a bonding agent, such as a lacquer basic phenolic
bonding agent, and coated with vinyl to a thickness of from about
0.02 to about 0.09 inches.
[0044] When used for football helmets, face guards in accordance
with the invention should be tested for compliance with the
afore-mentioned NOCSAE standard. Likewise, compliance with any
other relevant standards or criteria should be determined dependent
upon the intended use of the face guard.
[0045] A face guard constructed as described herein was observed to
have a weight less than that of conventional steel wire and steel
tubing face guards. For example, a similarly configured face guard
made from steel wire of the same diameter (0.225 inches) would have
a weight of over about 16 ounces, uncoated, and one made from steel
tubing having an outside diameter of about 0.25 inches (i.d. 0.160
inches) would have a weight of at least about 11 ounces, uncoated.
The foregoing described face guard of the invention has a weight of
about 9 ounces, uncoated.
[0046] It has also been observed that face guards made in
accordance with the invention are more resistant to corrosion than
conventional steel and steel tubing face guards.
[0047] The invention advances the art by enabling the production of
face guards made of titanium wire which have desirable qualities
and which may be produced in an economical and uncomplicated
manner. It has been stated in the prior art that face guards could
be made using titanium containing materials. For example, U.S. Pat.
No. 5,713,082 states that the face mask thereof "is usually cast
with thin cross sections as a single piece and hardened using high
strength alloys (e.g. titanium, 4140 steel, 4140 stainless steel,
etc.)." Col. 5, lines 2-4. U.S. Pat. No. 5,806,088 describes a face
guard of metal tubes construction, with a metal tube 22 thereof
made of steel, or of other metals or metal alloys (metal mixtures)
such as aluminum, carbon, cobalt, chromium, iron, nickel, tin
titanium and zinc. Co, 4, lines 7-11. It is believed that prior
attempts to manufacture face guards using titanium containing
materials have resulted in face guards that are unsuitable for
their intended purpose and/or of such expense so at to be
commercially unfeasible.
[0048] It has unexpectedly been discovered that face guards of
desirable characteristics may be economically produced in
accordance with the invention. For example, in accordance with the
invention, it has been discovered that face guards having desirable
characteristics may be manufactured using Grade 2, commercially
pure titanium wire, having a diameter of from about 0.21 to about
0.24 inches, most preferably from about 0.224 to about 0.225
inches. For the purposes of the invention, it was observed that the
selection of this particular material in the afore-mentioned
diameter range was important to achieving the purposes of the
invention.
[0049] The foregoing description of certain exemplary embodiments
of the present invention has been provided for purposes of
illustration only, and it is understood that numerous modifications
or alterations may be made in and to the illustrated embodiments
without departing from the spirit and scope of the invention as
defined in the following claims.
* * * * *