Visor assembly having improved mountings

Abstract

The present invention generally relates to a visor assembly. In one aspect of the present invention, a visor assembly is provided, comprising an injection molded visor (2), a lens (3) coupled to the visor, the visor comprising at least two projections (5) extending from a surface of the visor, the projections being integrally formed with the visor, and at least one add-on component (4) attached, preferably releasably attached, to one of the at least two projections, the add-on component providing an outer abutment surface (41) arranged to engage a lateral side of the lens, the lens being coupled to the visor by engagement with the abutment surface of the at least one add-on component, preferably the lens being compressed between the at least two projections or held by tension by the two projections.

Description

[Technical field]

[0001] The present invention generally relates to a visor assembly. The present invention may also relate to a visor, an add-on component for the visor assembly, a method of manufacturing the visor, and a kit of parts comprising the visor and the add-on. [Background technology]

[0002] The visors and visor assemblies of the present invention are particularly useful for personal protective equipment for face and eye protection. Examples of preferred personal protective equipment include motorcycle style helmets such as motorcycle helmets, quad bikes, snowmobiles, racing cars, and ski helmets, heavy duty protective visors such as impact face shields that may be used in riot helmets and visors used by emergency services, and / or goggles such as underwater diving goggles, motorcycle goggles, or ski goggles. 2. Description of Related Art

[0003] Visor assemblies are known that include a visor, with a lens releasably attached to the visor by a mechanical fastener.

[0004] In such visor assemblies, the visor is larger than the lens and acts as a shield. In the case of motorcycle style helmets, the visor acts to protect the user's face from wind, rain, dust, and sand, and in the case of impact visors, it acts to protect the user's face from larger projectiles and blasts. The visor tends to extend over the eyes and parts of the face near the eyes. The visor may have different functions depending on the situation of use. For example, in diving, the visor is positioned to aid underwater vision, motorcycle visors are used to protect the user's eyes from projectiles and dust, and impact visors are used to protect the user's eyes from larger projectiles.

[0005] The visor may be provided in a one-dimensional (1-D) form occupying a single plane so as to be flat, in a two-dimensional (2-D) form curved in one direction, or in a three-dimensional (3-D) form curved in two directions so as to be bowl-like. The lens may be provided in an appropriate shape to fit the surface of these various visor forms. In this regard, the lens may also be 1-D, 2-D, or 3-D. A 1-D lens may be used with a 1-D visor, a 1-D and 2-D lens may be used with a 2-D visor, and a 3-D lens may be used with a 3-D visor. A 2-D lens may also be provided with a 3-D visor. The lens may then take the shape of the 3-D visor over time.

[0006] The lenses are typically utilized to provide an improved viewing window for the visor wearer. For example, the lenses may be adapted to have anti-condensation features to prevent the viewing area from fogging up. The lenses may also, or alternatively, be provided tinted to provide improved visibility in various light conditions. The viewing area of ​​the visor and / or lens is the area through which the user sees.

[0007] To attach the lens to the visor, separate mechanical fastening means, such as rivets, are often used that are installed in and extend through prefabricated, e.g. drilled, holes in the visor, and engage the lateral side of the lens. This configuration can be disadvantageous because it can require an extra production step of drilling holes through the visor, which can affect the structural integrity of the visor, lead to additional production defects, and adversely affect the tolerances of the assembly.

[0008] One example of a known helmet visor assembly is provided in WO 96 / 16563, which discloses an anti-condensation visor comprising an outer visor provided with a retaining means having a blind rivet around which a plastic bushing is fitted. The blind rivet is fitted to the outer visor through an opening in the outer visor. A mechanical retaining means grips the inner visor and secures it to the visor assembly.

[0009] Another example is provided in US Patent Publication No. 2013 / 0129449, which discloses a mounting structure comprising a plurality of seat parts rotatably fitted into a support hole in a shield. The mounting structure is provided with an eccentric shaft that can rotate through 180° between an unlocked position and a locked position to allow installation of an anti-fog seat. A wrench or spanner is required to rotate the retaining member so that the mounting structure provides the unlocked and locked positions.

[0010] A further example is provided in EP 1 095 577 A1, which discloses a helmet visor having an injection molded plastic outer section. The outer shield of the visor includes two inwardly extending projections that are injection molded integrally with the outer shield of the visor. This example does not require the additional process step of fabricating holes for attachment of a separate mechanical fastening means, but reduces the variability of different lenses that may be provided in the visor assembly.

[0011] It would therefore be desirable to provide a visor assembly having an improved mounting for a lens, such as an anti-condensation lens, that has benefits and / or overcomes one or more disadvantages of prior art assemblies. Exemplary benefits may achieve improved flexibility in visor variations, while preferably also providing a more efficient production process as well as improved structural integrity and optical properties. [Prior art documents] [Patent documents]

[0012] [Patent Document 1] International Publication No. 96 / 16563 [Patent Document 2] US Patent Application Publication No. 2013 / 0129449 [Patent Document 3] European Patent No. 1095577 Summary of the Invention

[0013] The present invention addresses these problems by providing a visor assembly comprising: an injection molded visor; a lens coupled to the visor, the visor comprising at least two protrusions extending from a surface of the visor, the protrusions being integrally formed with the visor; and at least one add-on component attached, preferably releasably attached, to one of the at least two protrusions, the add-on component providing an outer abutment surface arranged to engage a lateral side of the lens, the lens being coupled to the visor by engagement with the abutment surface of the at least one add-on component, preferably the lens is compressed between the at least two protrusions or held by tension by the two protrusions.

[0014] By providing such a visor with an assembly, there is no need to drill holes through the visor after manufacture, which helps to simplify the production process as a manual step is removed, potentially leading to greater efficiency and greater accuracy.

[0015] An alternative to providing drilled holes could be to provide an injection molded visor with injection molded holes into which rivets can be accommodated. While this may provide somewhat acceptable results, injection molding a visor with holes requires that the mold be provided with a slider for removing the visor from the mold. Such a slider may result in aesthetically unpleasing lines in the surface, which may also affect the structural integrity of the visor and / or visibility through the visor.

[0016] Visors are often coated with a scratch resistant coating. Therefore, if the holes are injection molded, such coating remains in the holes and affects the size of the holes. Therefore, even if injection molded holes are feasible from a production standpoint, this is disadvantageous as it changes the tolerances of the hole size of the visor.

[0017] By integrally injection molding at least two projections to which a lens may be attached, the need for holes is eliminated, which may lead to improved structural integrity, improved manufacturing efficiency, and improved aesthetic appearance.

[0018] Furthermore, by providing at least one protrusion with at least one add-on component, the visor assembly can be easily adjusted to a specific lens or specific user requirements. For example, the size of the add-on component can be adjusted over time to enhance the fit of the lens provided on the surface of the visor. Over time, the lens may partially shrink, loosening the engagement of the visor. In such cases, the provision of an exchangeable add-on component provides an option to re-enhance the engagement of the lens with the visor. This can be done by replacing the add-on component with a larger add-on component. In other embodiments, the shape of the add-on component can be adjusted to have a variable width relative to the protrusion of the visor. In this way, the variable placement of the add-on component can be adjusted to suit the specific needs of the user or lens.

[0019] In a preferred embodiment, the add-on component is releasably attached to the protrusion. In one embodiment, the protrusion is provided in an edge region of the visor, preferably in opposing lateral edge regions of the visor. By providing the protrusion in an edge region of the visor, the protrusion can engage the lens outside the user's viewing area.

[0020] In one embodiment, the projections are provided on an inner surface of the visor, which is understood to be the surface that faces the user during use of the visor, for example in a helmet, and the outer surface of the visor is the surface that faces the external environment.

[0021] Additionally, by providing the inner surface of the visor with injection molded protrusions, the outer surface of the visor remains uninterrupted; that is, no holes or other mechanical fastening means are required on the outer surface of the visor to attach a lens to the inner surface of the visor. Having an uninterrupted or continuous outer surface of the visor may provide reduced wind noise when the visor assembly is used, for example, in a motorcycle helmet. Furthermore, if a coating is provided on the visor, such as a scratch resistant coating, such coating is applied to the entire surface of the visor. The absence of holes may improve the durability of such coating.

[0022] In an additional or alternative embodiment, the protrusions may be provided on the outer surface of the visor, preferably on opposing lateral edge regions of the outer surface of the visor. In this case, the protrusions may be utilized to receive a laminated removable lens. In such an embodiment, the provision of at least one add-on component is preferred, but not essential. In this embodiment, a visor is provided, comprising at least two protrusions extending from the outer surface of the visor, the protrusions being integrally formed with the visor, the protrusions being adapted to be received in holes defined in the at least one removable lens. In a preferred embodiment, the protrusions are arranged to engage holes in the at least one removable lens, which is arranged to releasably receive the at least one add-on component defining the abutment surface. In a preferred embodiment, the protrusions or the at least one add-on component are arranged to engage a plurality of laminated removable lenses.

[0023] In one embodiment, the protrusion extends substantially perpendicular to the surface of the visor. By having a protrusion extending substantially perpendicular to the surface of the visor, the angle between the protrusion and the lens in the assembly is acute enough to maintain a tight position of the lens relative to the visor. In other embodiments, the protrusion may define an angle of about 30° to 90°, preferably about 50° to 90°, more preferably about 70° to 90°. In one embodiment, the protrusions on both sides of the visor may extend substantially parallel. In this embodiment, the angle between the protrusion and the surface of the visor depends on the curvature of the visor itself. Having two protrusions extending substantially parallel from the surface of the visor assembly is advantageous during manufacturing since it is not necessary to deform the visor to remove the visor, specifically the protrusions, from the mold.

[0024] In one embodiment, the cross-section of the projection defines an oval shape, preferably a circular shape.

[0025] In one embodiment, the cross-section of the protrusions defines a non-circular shape, preferably the cross-section of the protrusions defines a shape that is rectangular, square, star, or triangular.

[0026] In one embodiment, the add-on component comprises an opening arranged to receive the protrusion, and preferably the opening has a shape corresponding to the cross-sectional shape of the protrusion.

[0027] Providing such a cross section of the protrusion defining a non-circular shape may allow various positioning options for the add-on component with a correspondingly shaped opening. In particular, having a square cross-sectional shape, for example, allows four separate positioning options for the add-on component. The add-on component may have a shape defined such that the distance from the opening to its circumference is not constant. In such an embodiment, the different positioning of the add-on component may be used to adjust the distance from the abutment surface to the opening of the add-on component. If the lens is not tightly engaged with the abutment surface sufficiently, the add-on component may be provided in different positions to increase the pressure between the abutment surface and the lens. The advantage of having an opening defining a non-circular shape is that, for example, pressure or vibration of the lens cannot change the positioning of the add-on component. In an embodiment in which the opening of the add-on component defines a circular shape, the add-on component may be pushed back to a less tensioned position, for example due to pressure or vibration of the lens during use.

[0028] In one embodiment, the add-on component is releasably attached to each of the at least two protrusions.

[0029] In one embodiment, the abutment surface extends at least partially around a periphery of the add-on component, the periphery defining a shape that is non-circular, preferably the shape is oval, rectangular, square, star-shaped or triangular.

[0030] By providing an abutment surface that extends at least partially around the non-circular perimeter of the add-on component, the distance from the opening defined in the add-on component can be altered. This allows for repositioning of the add-on component and therefore adjustment of the tension of the lens. In an embodiment where the add-on component opening is circular, such adjustment is stepwise. In an embodiment where the add-on component opening is non-circular, such adjustment is incremental. In an alternative embodiment where such adjustment of the distance between the perimeter and the opening is not required, the perimeter may be circular.

[0031] In one embodiment, the opening in the add-on component is provided away from the center of the periphery such that the periphery defines an eccentric shape relative to the opening.

[0032] Providing an eccentric add-on component is another way in which the distance between the lens and the protrusion can be adjusted. If the rotational position of the add-on component is changed relative to the protrusion, the distance between the lens and the protrusion is also adjusted, thereby providing the possibility to adjust the tension of the lens. This can be achieved by providing an eccentric shape of the add-on component. In such an embodiment, the perimeter can define any desired shape, such as, for example, a circle, an oval, a rectangle, a square, a triangle, or a star. The center of the perimeter is defined as the geometric center point of the shape defined by the perimeter.

[0033] In one embodiment, the material of the add-on component is one of polycarbonate, nylon, or an elastomeric material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, and most preferably about 70.

[0034] In one embodiment, the abutment surface comprises an elastically deformable material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, and most preferably about 70.

[0035] The Shore A scale is used to measure the hardness of elastomers, rubber-like materials, and elastomeric materials, such as polyurethane. The method for measuring Shore A hardness is using a durometer as described in ISO standard 7619-1:2010.

[0036] A visor assembly in which the abutment surface comprises an elastically deformable material enhances the stability of the lens and limits the adverse effects of lens vibration in the visor assembly. The possibility of varying the add-on component allows the flexibility to provide different degrees of elasticity to meet the requirements of a particular use of the visor assembly. In one embodiment, an engagement member is provided inside the opening of the add-on component. Such an engagement member may comprise an elastic material such as a rubber ring.

[0037] In one embodiment, the protrusion comprises a fitting arranged to engage the add-on component, preferably the fitting comprises a hook, a barb, a roughened surface, a localised thickening or a resilient surface.

[0038] The attachment may be advantageous to keep the add-on component engaged with the protrusion, for example under vibration conditions. This is particularly advantageous in embodiments where the protrusion is provided at a less acute angle to the visor, such that the lens may provide forces that could potentially lead to disengagement of the add-on component from the protrusion. Providing additional attachments to the protrusion may increase the stability of the add-on component. In alternative or additional embodiments, the attachment may be provided at an opening in the add-on component.

[0039] In one embodiment, the lens comprises two notches arranged to laterally receive the add-on components and / or protrusions, in one embodiment, the notches are elongated to allow movement of the add-on components within the notches and thus the lens may move upwards or downwards when coupled to the visor.

[0040] According to another aspect of the invention, there is provided an injection molded visor comprising at least two protrusions extending from a surface of the visor, the protrusions being integrally formed with the visor, the at least two protrusions being arranged to receive at least one add-on component, the add-on component defining an abutment surface arranged to engage a lateral side of a lens, preferably at least one of the two protrusions being provided with the add-on.

[0041] In one embodiment, the projections are provided in edge regions of the visor, preferably in opposite lateral edge regions of the visor.

[0042] In one embodiment, the protrusion is provided on an inner surface of the visor, hi one embodiment, the protrusion extends substantially perpendicular to the surface of the visor.

[0043] In one embodiment, the cross-section of the protrusion defines a circular shape.

[0044] In one embodiment, the cross-section of the protrusions defines a non-circular shape, preferably the cross-section of the protrusions defines a shape that is oval, rectangular, square, star, or triangular.

[0045] In one embodiment, the protrusion comprises a fitting arranged to engage the add-on component, preferably the fitting comprises a hook, a barb, a roughened surface, a localised thickening or a resilient surface.

[0046] According to another aspect of the invention, there is provided an add-on component having an opening arranged to receive a protrusion of a visor, the add-on component defining an abutment surface extending at least partially around a circumference of the add-on component, the abutment surface being arranged to engage a lateral side of a lens.

[0047] In one embodiment, the perimeter defines a shape that is circular, oval, rectangular, square, star, or triangular. In one embodiment, the opening is provided away from a center of the perimeter such that the perimeter defines an eccentric shape relative to the opening. In one embodiment, the opening defines a circular shape.

[0048] In one embodiment, the opening defines a non-circular shape, and preferably the opening defines a shape that is oval, rectangular, square, star, or triangular.

[0049] According to another aspect of the invention, there is provided a method of manufacturing a visor according to any of the above described embodiments, comprising the steps of providing a mould defining the shape of the visor having two protrusions integrally formed with the visor, injecting a pressurised liquid material into the mould at a first temperature, cooling the mould to a temperature below the first temperature, and extracting the visor from the mould.

[0050] According to another aspect of the present invention, there is provided a kit of parts comprising a visor according to any of the above described embodiments and at least one add-on component according to any of the above described embodiments.

[0051] According to another aspect of the present invention, there is provided a helmet comprising a visor assembly according to any of the embodiments described herein. In one embodiment, the helmet comprises a visor assembly comprising an injection molded visor, a lens coupled to the visor, the visor comprising at least two protrusions extending from a surface of the visor, the protrusions being integrally formed with the visor, and at least one add-on component attached, preferably releasably attached, to one of the at least two protrusions, the add-on component providing an outer abutment surface arranged to engage a lateral side of the lens, the lens being coupled to the visor by engagement with the abutment surface of the at least one add-on component, preferably the lens being compressed between the at least two protrusions or held by tension by the two protrusions. [Brief description of the drawings]

[0052] The features and advantages of the present invention may be understood upon reference to the following drawings.

[0053] [Figure 1] FIG. 1 is a perspective view of one embodiment of the present invention showing a cut-away visor assembly including a visor having a protrusion, an add-on component releasably attached to the protrusion, and a lens coupled to the visor. [Figure 1A] FIG. 1 is a blow-up view of one embodiment of the present invention showing a lens with an add-on component, a protrusion, and a notch positioned to laterally receive the add-on component. [Diagram 2] FIG. 2 is a cross-sectional view of one embodiment of the present invention showing a cut-away visor assembly including a visor having a protrusion, an add-on component releasably attached to the protrusion, and a lens coupled to the visor. [Figure 3A] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3B]1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3C] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3D] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3E] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3F] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 3G] 1A-1C are top views of an exemplary embodiment of the present invention showing add-on components having different perimeter shapes and different openings. [Figure 4] FIG. 1 is a perspective view of a helmet according to an embodiment of the present invention, the helmet including a visor assembly having two protrusions, two add-on components releasably attached to the protrusions, and a lens coupled to the visor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] The following is a description of specific embodiments of the invention, given by way of example only, and with reference to the drawings. Referring to Figure 1, there is shown a perspective view of one embodiment of the invention showing a cut away visor assembly comprising a visor 2 having a protrusion 5, an add-on component 4 releasably attached to the protrusion 5, and a lens 3 coupled to the visor 2. The visor 2 is generally mounted to the helmet 1 and positioned to prevent ingress of debris, sand, or rain. The lens 3 is attached to the visor 2 to prevent fogging of the visor 2 during use. A peripheral gasket 7 is provided to provide a seal between the space defined between the visor 2 and the lens 3.

[0055] The visor 2 comprises a concave surface and two protrusions 5. In FIG. 1 only one protrusion 5 is shown. The protrusions 5 are integrally formed with the visor 2. The visor 2 may be produced by injection molding. The protrusions 5 are provided with an add-on component 4. As can be seen more clearly in FIG. 1A, the protrusions 5 have a triangular cross-sectional shape. The add-on component 4 has an opening 6 with a corresponding triangular shape. In this embodiment, the add-on component 4 cannot rotate relative to the visor 2, as neither the protrusions 5 nor the openings 6 are circular.

[0056] In the embodiment shown, the height of the add-on component 4 is reduced with respect to, for example, the embodiment of Fig. 2. The height of the add-on component 4 can be selected depending, for example, on the thickness of the lens 3 and the thickness of the gasket 7. In a preferred embodiment, the height of the add-on component 4 is between 1 mm and 20 mm, preferably between 3 mm and 15 mm, more preferably between 5 mm and 12 mm.

[0057] Additionally, the opening 6 and the protrusion 5 may be of a different shape than the triangular shape shown in the embodiment of Figure 1 A. For example, to achieve more possible positions, both the opening 6 and the protrusion 5 may have a hexagonal shape, leading to six positions of the add-on component 4 relative to the protrusion 5.

[0058] The opening 6 and the protrusion 5 may also define a rounded shape, which leads to an analog and continuous positioning of the add-on component 4 relative to the protrusion 5. That is, the add-on component 4 may be rotated around the protrusion 5 to assume any position depending on the user's requirements. In this embodiment, the add-on component 4 does not need to be lifted off the protrusion 5, but rather may be rotated while still attached to the protrusion 5.

[0059] The lens 3 is held in place by tension provided to the lateral side 31 of the lens by the add-on component 4. Alternatively, not shown, the lens 3 can be held in place by tension provided by the protrusion 5 or an add-on component 4 attached to the protrusion 5.

[0060] In the embodiment shown, the lens 3 comprises a notch 8 arranged to laterally receive the add-on component 4. The notch 8 in FIG. 1 has a shape corresponding to the shape of the add-on component 4. Thus, when the add-on component 4 is received in the notch 8, the movement of the lens relative to the visor 2 is restricted. That is, the lens 3 cannot slide up or down relative to the visor 2 due to the engagement between the notch 8 and the add-on component 4. That is, the lens 3 is constrained in a direction parallel to the surface of the visor 2. In an alternative embodiment, the notch 8 is elongated to allow the movement of the add-on component 4 within the notch 8. Thus, the lens 3 can move upwards or downwards when coupled to the visor 2.

[0061] If the size of the lens 3 is changed, for example by shrinking or enlarging, the add-on component 4 can be replaced or rotated to achieve a different distance between the protrusion 5 and the lens 3. As a result, the tension of the lens 3 can be maintained even if the size of the lens 3 is changed. Furthermore, if a different lens 3 is provided together with the visor 2, and the different lens 3 has a different shape than the previous lens, the add-on component 4 can be replaced or rotated in the same way to adjust a different distance between the protrusion 5 and the lens 3. In this way, the lens 3 does not necessarily have to be of the same shape to fit the visor 2, and the same visor 2 can be used even if the size of the lens 3 is different. In this way, the visor 2 can remain coupled to the helmet 1 if the user wants to use a different lens 3.

[0062] 1A, the add-on component 4 is releasably attached to the protrusion 5. Thus, if a different distance between the protrusion 5 and the lens 3 is required, the add-on component 4 can be removed and replaced with a different add-on component 4 having a different distance between its opening 6 and its periphery, which distance corresponds to the distance between the protrusion 5 and the lens 3 in the assembled state.

[0063] In one embodiment, the add-on component 4 may be displaced but have a different orientation. As shown in FIG. 1A, the add-on component 4 comprises a triangular opening 6 that can receive a protrusion 5 having a similar shape in three different orientations. In the embodiment shown in FIG. 1A, the angles of the corners of the triangle are substantially equal to each other so that the opening 6 and the protrusion 5 have a matching shape regardless of their orientation. As shown in FIG. 1, the orientation of the add-on component 4 is provided such that the shortest distance available is provided between the protrusion 5 and the lens 3. If the add-on component 4 is released from the protrusion 5, rotated 120°, and placed back on the protrusion 5, the distance between the protrusion and the lens increases. This is because the periphery of the add-on component 4 defines an eccentric shape relative to the opening 6 of the add-on component 4. As a result, rotating the add-on component 4 to a different orientation adjusts the distance between the protrusion 5 and the lens 3 when coupled to the visor 2, and thereby the tension provided to the lens 3.

[0064] Referring now to FIG. 2, a cross-sectional view of one embodiment of the present invention is shown. FIG. 2 shows a cut-away visor assembly comprising a visor 2 having a protrusion 5, an add-on component 4 releasably attached to the protrusion 5, and a lens 3 coupled to the visor 2. As shown, the add-on component 4 comprises an opening 6 corresponding to the shape of the protrusion 5. The protrusion 5 is integrally formed with the visor 2. The add-on component 4 is attached to the protrusion 5 in a releasable manner. In the embodiment shown, the protrusion 5 comprises a local thickening 51 provided in an upper region of the protrusion 5. This local thickening 51 engages with a corresponding shape of the opening 6 of the add-on component 4. This arrangement allows the add-on component 4 to be releasably attached to the protrusion 5 without falling due to forces exerted on the add-on component 4, for example, by gravity or the lens 3.

[0065] The add-on component 4 comprises an outer abutment surface 41 arranged to engage the lateral side 31 of the lens 3. The pressure between the outer abutment surface 41 and the lens 3 provides tension to the lens 3 to keep the visor 2 attached under tension. In a preferred embodiment, the abutment surface 41 is concave and limits the movement of the lens 3 along the height of the add-on component 4. That is, by providing an abutment surface with a concave surface, the lens 3 has a balanced position in the middle of the height of the add-on component 4. This limits the possibility of the lens 3 vibrating upwards and therefore of the lens 3 moving away from the visor 2. In the embodiment shown in FIG. 2, the abutment surface 41 is slightly concave.

[0066] The lens 3 further comprises a peripheral gasket 7 provided around a peripheral region of the lens 3. The gasket 7 provides a seal between the lens 3 and the visor 2 to prevent the ingress of moisture and / or dust. The height of the gasket 7 partially determines the required height of the add-on component 4 over the protrusion 5.

[0067] As shown in Fig. 2, the tension of the lens 3 is determined by the distance between the protrusion 5 and the lens 3, which depends on the distance between the opening 6 and the outer abutment surface 41 of the add-on component 4. In the embodiment shown, the add-on component 4 can be released from the protrusion 5 and rotated by about 180° to reduce the distance between the protrusion 5 and the lens 3. For example, the add-on component 4 can be rotated when the tension of the lens 3 has to be reduced. As a result, the tension of the lens 3 can be adjusted without having to replace the components, much less the entire lens 3 and / or visor 2.

[0068] 3A-3G, top views of an exemplary embodiment of the present invention are shown, in which the add-on component 4 has different circumferential shapes and different openings 6. As shown in FIG. 3A, the add-on component 4 has a circular shape and the openings 6 have a pentagram shape. The openings 6 are provided in the add-on component 4 at eccentric positions relative to the circumferential circular shape. The openings 6 are arranged to be provided in protrusions having the same cross-sectional shape. In this way, five distinct positions can be achieved by the add-on component 4, allowing a gradual increase or decrease in the distance between the protrusion 5 and the lens 3 in the assembled state.

[0069] 3B shows an embodiment similar to that of FIG. 3A, in which the shape of the opening 6 of the add-on component 4 is square. Thus, the add-on component can be attached to the square projection 5 in the same way, which allows four distinct positions of the add-on component 4 on the projection 5, thus varying the distance between the lens 3 and the projection 5, and thereby adjusting the tension of the lens 3.

[0070] 3C shows an embodiment of the add-on component 4 where the perimeter shape of the add-on component 4 is triangular, but the shape of the opening 6 is square. In this way, the add-on component 4 can be attached to the square protrusion 5 in the same four directions to adjust the tension of the lens 3.

[0071] 3D shows an embodiment of the add-on component 4 where the peripheral shape of the add-on component 4 is hexagonal and the add-on component 4 has a square opening 6. In this manner, the add-on component 4 can be attached to the square protrusion 5 in the same four directions to adjust the tension of the lens 3.

[0072] 3E shows an embodiment of the add-on component 4, where the perimeter shape of the add-on component 4 is circular. The opening 6 of the add-on component 4 has a triangular shape, with three corners that do not all have the same angle. In this way, there is only one orientation in which the add-on component 4 is presented to the protrusion 5 without flipping the add-on component 4. Different distances between the protrusion 5 and the lens 3 can be provided by flipping the add-on component 4 such that the opening 6 is presented to the protrusion 5 with the other side of the add-on component 4 facing downwards.

[0073] 3F illustrates an embodiment of the add-on component 4, where the periphery of the add-on component 4 is circular. The opening 6 in the add-on component 4 has a hexagonal shape, thus allowing six positions of the add-on component 4 on the protrusion 5 having a similar cross-sectional hexagonal shape. The opening 6 is provided in an eccentric relationship with respect to the periphery of the add-on component 4 to vary the tension of the lens 3 between the positions of the add-on component 4 on the protrusion 5.

[0074] 3G shows an embodiment of the add-on component 4 where the peripheral shape of the add-on component 4 is a square with rounded corners and the opening 6 has a square shape. The add-on component 4 can achieve four positions of the visor 2 relative to the square protrusion 5 in the same way to adjust the tension of the lens 3.

[0075] 4, there is shown a perspective view of a helmet 1 according to an embodiment of the present invention. The helmet 1 comprises a visor assembly having two protrusions 5, two add-on components 4 releasably attached to the protrusions 5, and a lens 3 coupled to a visor 2.

[0076] Thus, the present invention has been described with reference to the specific embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternatives known to those skilled in the art. For example, the opening 6 of the add-on component 4 can be altered to achieve a particular position of the add-on component relative to the visor 2 in a different manner and thus adjust the tension of the lens 3. Furthermore, the peripheral shape of the add-on component 4 can be altered such that the combination of the peripheral shape of the add-on component 4 and the shape and location of the opening 6 tensions the lens 3 in a different manner.

[0077] According to one aspect of the invention, a kit of parts is provided, comprising a visor 2 according to any of the above described embodiments and at least one add-on component 4 according to any of the above described embodiments. In particular, the kit of parts may comprise any of the add-on components 4 provided in the exemplary embodiments of Figures 3A-3G and a visor 2 having at least two protrusions 5 having a shape corresponding to the openings 6 of the add-on component 4.

[0078] Further modifications to the structures and techniques described herein in addition to those described above may be made without departing from the spirit and scope of the present invention. Thus, although specific embodiments have been described, these are examples only and are not intended to limit the scope of the present invention.

Claims

1. 1. A visor assembly comprising: - an injection moulded visor (2), - a lens (3) attached to said visor (2), - a lens (3) comprising at least two projections (5) extending from a surface of the visor (2), the projections (5) being integrally formed with the visor (2); Equipped with at least one add-on component (4) is attached, preferably removably attached, to one of said at least two projections (5), said add-on component (4) presenting an outer abutment surface (41) arranged to engage a lateral side (31) of said lens (3); - said lens (3) is coupled to said visor (2) by engagement with said abutment surface (41) of said at least one add-on component (4), preferably said lens (3) being compressed between said at least two protrusions (5) or held by tension by said two protrusions (5), a visor assembly.

2. A visor assembly according to claim 1, wherein said projections (5) are provided in edge regions of said visor (2), preferably in opposing lateral edge regions of said visor (2).

3. A visor assembly according to claim 1 or 2, wherein said projection (5) is provided on an inner surface of said visor (2).

4. A visor assembly according to any one of the preceding claims, wherein said projection (5) extends substantially perpendicular to said surface of said visor (2).

5. A visor assembly according to any one of the preceding claims, wherein the transverse cross-section of said projection (5) defines an oval shape, preferably a circular shape.

6. A visor assembly according to any one of claims 1 to 4, wherein a transverse cross-section of the projection (5) defines a non-circular shape, preferably, the transverse cross-section of the projection (5) defines a shape that is rectangular, square, star-shaped or triangular.

7. A visor assembly according to any one of claims 1 to 6, wherein the add-on component (4) comprises an opening (6) arranged to receive the projection (5), preferably said opening (6) having a shape corresponding to the cross-sectional shape of the projection (5).

8. A visor assembly according to any one of the preceding claims, wherein an add-on component (4) is releasably attached to each of said at least two protrusions (5).

9. A visor assembly according to any one of the preceding claims, wherein the abutment surface (41) extends at least partially around an outer periphery of the add-on component (4), said periphery defining a shape that is non-circular, preferably said shape being oval, rectangular, square, star-shaped or triangular.

10. A visor assembly according to any one of the preceding claims, wherein the opening (6) of the add-on component (4) is provided away from a centre of its periphery such that the periphery defines an eccentric shape relative to the opening (6).

11. A visor assembly according to any one of the preceding claims, wherein the material of the add-on component (4) is one of polycarbonate, nylon or an elastic material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80 and most preferably about 70.

12. A visor assembly according to any one of the preceding claims, wherein said abutment surface (41) comprises an elastically deformable material having a Shore A hardness of 50 to 95, preferably 60 to 90, more preferably 65 to 80 and most preferably about 70.

13. A visor assembly according to any one of claims 1 to 12, wherein the protrusion (5) comprises a fitting arranged to engage with the add-on component (4), preferably the fitting comprising a hook, a barb, a roughened surface, a localised thickening or a resilient surface.

14. A visor assembly according to any one of the preceding claims, wherein said lens (3) comprises two notches arranged to laterally receive said add-on component (4) and / or said protrusion (5).

15. 1. An injection molded visor (2), comprising at least two protrusions (5) extending from a surface of the visor (2), said protrusions (5) being integrally formed with the visor (2), said at least two protrusions (5) being arranged to receive at least one add-on component (4), said add-on component (4) defining an abutment surface (41) arranged to engage a lateral side (31) of a lens (3), preferably at least one of said two protrusions (5) being provided together with said add-on.

16. Visor according to claim 15, wherein said projections (5) are provided in edge regions of the visor (2), preferably in opposite lateral edge regions of the visor (2).

17. A visor assembly according to claim 15 or 16, wherein the projection (5) is provided on an inner surface of the visor (2).

18. A visor assembly according to any one of claims 15 to 17, wherein the projection (5) extends substantially perpendicular to a surface of the visor (2).

19. A visor assembly according to any one of claims 15 to 18, wherein the transverse cross-section of the projection (5) defines a circular shape.

20. A visor assembly according to any one of claims 15 to 18, wherein a transverse cross-section of the projection (5) defines a non-circular shape, preferably said transverse cross-section of the projection (5) defines a shape that is oval, rectangular, square, star-shaped or triangular.

21. A visor assembly according to any one of claims 15 to 20, wherein the protrusion (5) comprises a fitting arranged to engage with said add-on component (4), preferably the fitting comprising a hook, a barb, a roughened surface, a localised thickening or a resilient surface.

22. An add-on component (4) comprising an opening (6) arranged to receive a projection (5) of a visor (2), The add-on component (4) defines an abutment surface (41) extending at least partially around a circumference of the add-on component (4); The add-on component (4), wherein said abutment surface (41) is arranged to engage a lateral side (31) of the lens (3).

23. The add-on component (4) according to claim 22, wherein the perimeter defines a shape that is circular, oval, rectangular, square, star-shaped, or triangular.

24. An add-on component (4) according to claim 22 or 23, wherein the opening (6) is provided away from the centre of the periphery such that the periphery defines an eccentric shape relative to the opening (6).

25. The add-on component (4) according to any one of claims 22 to 24, wherein the opening (6) defines a circular shape.

26. The add-on component (4) according to any one of claims 22 to 25, wherein the opening (6) defines a non-circular shape, preferably the opening (6) defines a shape that is oval, rectangular, square, star-shaped or triangular.

27. A method for manufacturing a visor according to any one of claims 15 to 21, comprising the steps of: - providing a mould defining the shape of the visor (2) having two projections (5) integrally formed with the visor (2); - injecting a pressurized liquid material into said mould at a first temperature; - cooling the mould to a temperature below the first temperature; - extracting the visor (2) from the mould.

28. 1. A kit of parts comprising: - a visor (2) according to any one of claims 15 to 21, - at least one add-on component (4) according to any one of claims 22 to 26.

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