Thermoformed protective face shield

Abstract

A unitary thermoformed protective face shield includes a curved top member adapted to conform to a user's forehead. The curved top member includes a plurality of exhaust channels formed therein for allowing ventilation. The face shield further includes a visor portion extending outward from a lower end of the curved top member, thereby creating a space between the user's face and a face cover portion. The face cover portion extends downward from the visor portion and covers and provides protection for the face of a user. A side shield portion extends inwardly from the face cover portion for shielding the sides of a user's face. Further, a perimeter flange may extend perpendicular to the perimeter of the face shield for providing structural support to the face shield.

1 . A thermoformed protective face shield comprising:
 a curved top member having a bottom end and a top end and being longitudinally curved to conform to a user's forehead, said curved top member including a plurality, of exhaust channels, each one of said plurality of exhaust channels having a first end positioned adjacent to the bottom end of the curved top member and a second end positioned adjacent to the top end of the curved top member for allowing moisture and/or heat to escape;   a visor portion extending outwardly from a lower end of the curved top member;   a face cover portion extending downward from the visor portion for shielding the face of a user;   a side shield portion extending inwardly from the face cover portion for shielding the sides of a user's face; and   a perimeter flange extending perpendicular to the perimeter of the face shield for providing structural support to the face shield.   
     
     
         2 . The thermoformed protective face shield of  claim 1 , further comprising a positioning wedge extending outwardly from a center portion of said curved top member. 
     
     
         3 . The thermoformed protective face shield of  claim 1 , wherein said curved top member comprises an outwardly extending step configured to provide a space between a user's forehead and said curved top member. 
     
     
         4 . The thermoformed protective face shield of  claim 3 , further comprising a foam pad positioned in said outwardly extending step. 
     
     
         5 . The thermoformed protective face shield of  claim 4 , wherein said foam pad has a thickness of 0.25 inches to 0.75 inches. 
     
     
         6 . The thermoformed protective face shield of  claim 5 , wherein said foam pad has a length of about 9.0 inches. 
     
     
         7 . The thermoformed protective face shield of  claim 4 , wherein said foam pad is comprised of a closed cell adhesive backed foam. 
     
     
         8 . The thermoformed protective face shield of  claim 1 , further comprising a strap for securing said thermoformed protective face shield to a user. 
     
     
         9 . The thermoformed protective face shield of  claim 8 , wherein said curved top member comprises:
 a) a positioning wedge extending outwardly from a center portion of said curved top member, and   b) an outwardly extending step configured to provide a space between a user's forehead and said curved top member,
 further wherein said strap is located under said positioning wedge and adjacent to said outwardly extending step. 
   
     
     
         10 . The thermoformed protective face shield of  claim 8 , wherein said perimeter flange comprises slots for positioning said strap. 
     
     
         11 . The thermoformed protective face shield of  claim 8 , wherein said strap is formed of an elastic material. 
     
     
         12 . The thermoformed protective face shield of  claim 8 , wherein said strap is formed of a non-elastic material, said strap further comprising a releasable closure that can be tightened and loosened. 
     
     
         13 . The thermoformed protective face shield of  claim 12 , wherein said strap is a hook-and-loop strap. 
     
     
         14 . The thermoformed protective face shield of  claim 1 , wherein said side shield portion comprises a plurality of side segments extending rearwardly from said face cover portion. 
     
     
         15 . The thermoformed protective face shield of  claim 14 , wherein said side segments are planar and come together at an angle to provide a shield that is adapted to surround the sides and bottom of a user's face. 
     
     
         16 . The thermoformed protective face shield of  claim 14 , further comprising intermediate side segments positioned between said side shield portion and said face cover portion. 
     
     
         17 . The thermoformed protective face shield of  claim 1 , wherein said perimeter flange is present around the entire perimeter of said thermoformed protective face shield. 
     
     
         18 . The thermoformed protective face shield of  claim 1 , wherein at least said visor portion, said face cover portion, and said side shield portion are formed from an optically clear material. 
     
     
         19 . The thermoformed protective face shield of  claim 1 , formed as a one-piece unit from an optically clear thermoplastic material. 
     
     
         20 . The thermoformed protective face shield of  claim 19 , wherein said optically clear thermoplastic material is polyethylene terephthalate glycol, polyvinyl chloride, polycarbonate, or polyethylene terephthalate. 
     
     
         21 . The thermoformed protective face shield of  claim 20  wherein said optically clear thermoplastic material has a thickness of from about 0.025 inches to about 0.156 inches.