Modular visor

Abstract

A visor for a helmet includes a lens sized to extend across at least a portion of a user's face when in use. The lens includes an inner surface facing the user's face when in use and an outer surface facing away from the user's face when in use. An upper frame is coupled to a top surface of the lens, and a flange is detachably coupled to the upper frame. The flange includes a stepped surface having a bottom surface and a top surface, a first end and a second end. The flange further includes a lip coupled to the second end of the stepped surface that extends upwardly from the top surface away from the bottom surface. The lip is configured to receive and abut against a front surface of the helmet when the lens extends across at least a portion of the user's face.

Description

TITLE

[0001] Modular VisorCROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 624,031 filed January 23, 2024 entitled “Modular Visor”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0003] The present disclosure generally relates to a visor and, in some embodiments, to a modular visor configured to be worn in a variety of configurations and that may be mounted onto a helmet or other head protection device.SUMMARY

[0004] In one embodiment there is a visor for a helmet, the visor including a lens sized to extend across at least a portion of the user’s face when in use, the lens having an inner surface facing the user’s face when in use and an outer surface facing away from the user’s face when in use, an upper frame coupled to a top surface of the lens, and a flange detachably coupled to the upper frame. The flange including a stepped surface having a bottom surface and a top surface opposite the bottom surface and a first end and a second end opposite the first end, and a lip coupled to the second end of the stepped surface and extending upwardly from the top surface away from the bottom surface, the lip configured to receive and abut against a front surface of the helmet when the lens extends across at least a portion of the user’s face.

[0005] In some embodiments, the lens is a powered lens configured to receive power from an external power source. In some embodiments, the powered lens includes one or more heating elements configured to heat a surface of the lens. In some embodiments, the powered lens includes at least one of an electrochromic layer and an integrated optical waveguide. In some embodiments, the visor further includes a lower frame coupled to the upper frame and extending around a remaining portion of a periphery of the lens. In some embodiments, the visor further includes a first cable duct coupled to the upper frame, a second cable duct coupled to the lower frame and spaced from the first cable duct, and a diverting duct positioned between the first and second cable ducts. In some embodiments, the first and second cable ducts define a first cable pathway and the divertingduct is positioned outside of the first cable pathway, and the diverting duct defines a second cable pathway between the first and second cable ducts that is different from the first cable pathway.

[0006] In some embodiments, the visor further includes an anchor configured to be detachably coupled to the helmet, a fastener releasably securable to the anchor, and a cable coupled to the flange, upper frame and the fastener, the cable configured to retain the flange against the front surface of the helmet when the visor is in use. In some embodiments, the cable includes a first terminal end and a second terminal end, the first terminal end being coupled to the fastener and fixed in position relative to the fastener and the second terminal end being coupled to the fastener and adjustable relative to the fastener.

[0007] In some embodiments, the flange is a first flange and the visor further includes a second flange spaced from the first flange and detachably coupled to the upper frame. In some embodiments, the visor further includes a gasket coupled to the upper frame, the gasket including a body positioned between the upper frame and the lens and forming a seal therebetween, and a flap protruding outwardly from the body and configured to abut the user’s face when in use. In some embodiments, the upper frame includes cable ducts at opposite ends of the upper frame, and the visor further includes a strap detachably coupled to the cable ducts and configured couple the visor directly to a user’s head. In some embodiments, the flange includes a buckle coupled to the stepped surface between the first end and second ends and extending downwardly from the bottom surface away from the top surface and configured to detachably couple the flange to the upper frame. In some embodiments, the flange includes a padding layer disposed on an inner surface of the lip, the padding layer configured to directly contact the front surface of the helmet. In some embodiments, the flange extends substantially along a top surface of the upper frame between opposed sides thereof.

[0008] In another embodiment there is a visor for a helmet, the visor including a powered lens sized to extend across at least a portion of the user’s face in use and having an inner surface facing the user’s face when in use and an outer surface facing away from the user’s face when in use, an upper frame coupled to a top surface of the powered lens, a lower frame coupled to the bottom surface of the powered lens and to the upper frame, a flange detachably coupled to the upper frame , the flange including a stepped surface having a bottom surface and a top surface opposite the bottom surface and a first end and a second end opposite the first end, a lip coupled to the second end of the stepped surface and extending upwardly from the top surface away from the bottom surface, the lip configured to receive and abut against a front surface of the helmet when the powered lens extends across at least a portion of the user’s face, and a padding layer disposed on an inner surface of thelip, the padding layer configured to directly contact the front surface of the helmet. The powered lens may be configured to be positioned below and behind the front surface of the helmet when the two flanges abut the front surface of the helmet.

[0009] In some embodiments, the visor further includes an anchor configured to be detachably coupled to the helmet, a fastener releasably securable to the anchor, and a cable coupled to the flange, upper frame and the fastener, the cable configured to retain the flange against the front surface of the helmet when the visor is in use. In some embodiments, the cable includes a first terminal end and a second terminal end, the first terminal end being coupled to the fastener and fixed in position relative to the fastener and the second terminal end being coupled to the fastener and adjustable relative to the fastener. In some embodiments, the visor further includes a half gasket coupled to the upper frame and extending rearwardly therefrom, the half gasket configured to abut the user’s face when the visor is in use. In some embodiments, the visor further includes a full gasket coupled to the upper and lower frames and extending rearwardly therefrom, the full gasket configured to abut the user’s face when the visor is in use.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following detailed description of embodiments of the helmet mounted visor, will be better understood when read in conjunction with the appended drawings of exemplary embodiments. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

[0011] In the drawings:

[0012] Fig. l is a perspective view of a modular visor in a first configuration and in accordance with an exemplary embodiment of the present disclosure mounted to a helmet;

[0013] Fig. 2 is a front perspective view of the visor of Fig. 1;

[0014] Fig. 3 is a rear perspective view of the visor of Fig. 1;

[0015] Fig. 4 is an exploded view of the lens included in the visor of Fig. 1;

[0016] Figs. 5A-5B are rear elevational views illustrating the removal of a flange from the visor of Fig. 1;

[0017] Fig. 6A is a front perspective view of a flange included in the visor of Fig. 1;

[0018] Fig. 6B is a rear perspective view of the flange of Fig. 6A;

[0019] Fig. 6C is a side elevational view of the flange of Fig. 6A;

[0020] Fig. 7 is a perspective view of the modular visor of Fig. 1 in a second configuration and mounted to a helmet;

[0021] Figs. 8A-8F illustrate a method of attaching a cable to the modular visor of Fig. 1;

[0022] Figs. 9A-9B are side views showing an anchor of the visor shown in Fig. 1 mounted at different positions along a rail according to an embodiment of the present disclosure;

[0023] Figs. 10A-10B are perspective views of the anchor of the visor shown in Fig. 1;

[0024] Fig. 11 is a magnified view of the anchor, fastener and cable of the visor of Fig. 1 when coupled to a helmet rail;

[0025] Figs. 12A-12B are perspective and rear elevational exploded views of the visor of Fig. 1 in a third configuration;

[0026] Fig. 13 is a perspective exploded view of the visor of Fig. 1 in a fourth configuration;

[0027] Fig. 14A is a rear perspective view of the visor of Fig. 1 with a full gasket coupled thereto;

[0028] Fig. 14B is a front perspective view of the full gasket shown in Fig. 14A.

[0029] Fig. 15A is a rear perspective view of the visor of Fig. 1 with a half gasket coupled thereto;

[0030] Fig. 15B is a front perspective view of the half gasket of Fig. 15A;

[0031] Fig. 16 is a perspective view of the modular visor of Fig 1 in a third configuration and mounted to a helmet;

[0032] Fig. 17A is a side view of the modular visor of Fig. 1 in a fourth configuration according to an embodiment of the present disclosure;

[0033] Fig. 17B is a side view of the modular visor of Fig. 1 in a fifth configuration according to an embodiment of the present disclosure;

[0034] Fig. 18 is a front perspective view of a modular visor in accordance with another exemplary embodiment of the present disclosure;

[0035] Fig. 19 is a rear perspective view of the modular visor of Fig. 18;

[0036] Fig. 20 is a partial exploded view of the visor of Fig. 18;

[0037] Fig. 21 is a perspective view of the modular visor of Fig. 18 with an electrical cable connected thereto;

[0038] Fig. 22 is a side view of a helmet including a powered rail;

[0039] Fig. 23 is a partial exploded view of a detachable power node for use with the powered rail of Fig. 22 and the visor of Fig. 1 and / or of Fig. 18

[0040] Fig. 24 is a front perspective view of a visor in accordance with another exemplary embodiment of the present disclosure;

[0041] Fig. 25 is a rear perspective view of the visor of Fig. 24;

[0042] Fig. 26 is a perspective view of the visor of Fig. 24 with the flange decoupled from the frame of the visor;

[0043] Fig. 27 is a front perspective view of the flange of the visor of Fig. 24;

[0044] Fig. 28 is a rear perspective view of the flange of the visor of Fig. 24;

[0045] Fig. 29 is a rear perspective view of the visor of Fig. 24 with a prescription lens attachment decoupled from the frame;

[0046] Fig. 30 is a bottom perspective view of the visor of Fig. 24 with the gasket omitted;

[0047] Fig. 31 is a top cross-sectional view of a portion of the visor of Fig. 24;

[0048] Fig. 32 is a perspective view of a full gasket for use with the visor of Fig. 24;

[0049] Fig. 33 is a perspective view of a half gasket for use with the visor of Fig. 24;

[0050] Fig. 34 is a top perspective view of a portion of the visor of Fig. 24;

[0051] Fig. 35 is a bottom perspective view of a portion of the visor of Fig. 24;

[0052] Fig. 36 is a perspective view of the visor of Fig. 24 worn with a helmet while in a first configuration; and

[0053] Fig. 37 is a perspective view of the visor of Fig. 24 worn with a helmet while in a second configuration.DETAILED DESCRIPTION

[0054] Eye protection devices, such as visors, are often used in conjunction with other protective equipment such as head protection helmets including, for example, those used in sporting, police, or military purposes. The visors may also be used in a wide variety of environmental conditions such as, but not limited to, high humidity, low visibility, high wind, low temperatures, high temperatures, rain, and toxic or hazardous materials or gases. Additionally, in some instances it may be desirable to mount other optical devices to the helmet, such as, but not limited to, night vision goggles, or binoculars. As such, there is a need to provide a visor that is configured to transition between two or more configurations to enable a user to adjust the visor to different environmental conditions and / or provide clearance for the positioning of additional optical equipment in front of the visor.

[0055] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in Figs. 1-17B a modular visor, generally designated 100 and referred to as visor 100 for short, in accordance with an exemplary embodiment of the present invention. In some embodiments, the modular visor 100 is configured to be mounted to a helmet in one or more configurations and, in other configurations, coupled directly to a user’s head. In some embodiments, the modular visor 100 is configured to accommodate a wide range of lens typeshaving various functionality. In some embodiments, the modular visor 100 is configured to enable the use of additional optical devices simultaneously with the visor 100. In some embodiments, the visor 100 is configured to enable a user to detachably couple full gaskets, half gaskets, and / or face masks thereto as desired. In some embodiments, the visor 100 is configured to be assembled and / or disassembled without the use of tools (e.g., hand tools, hex keys, screw drivers, wrenches). In some embodiments, the visor 100 is configured to provide anti -fog capabilities. In some embodiments, the visor 100 is configured to be worn as goggles.

[0056] Referring to Fig. 1, the visor 100 may be configured to be mounted to a head protection device, such as helmet 10. Helmet 10 may be any type of head protection helmet known in the art, for example, those used for sporting, police, or military purposes. In some embodiments, the helmet 10 is a standard infantry ballistic helmet or an advanced combat helmet (ACH). In other embodiments, the helmet 10 may be a modular integrated communications helmet (MICH), a tactical ballistic helmet (TBH), a lightweight marine helmet, police general duty helmet, or a personnel armor system for ground troops (PASGT) helmet.

[0057] In some embodiments, the visor 100 includes a lens 102 that is sized and configured to extend across at least a portion of a user’s face during use (e.g., when mounted to the helmet 10). For example, lens 102 is preferably sized to at least cover a user’s eyes according to some embodiments when used in a closed position. In some embodiments, the lens 102 is sized to cover the top half of a user’s face during use. In further embodiments, lens 102 is sized to extend over at least a user’s eyes during use. In some embodiments, lens 102 is configured to protect a user’s eyes from ballistic projectiles, shrapnel, and / or other objects. In further embodiments, lens 102 may be configured to protect the user’s eyes from chemicals or environmental conditions (e.g., wind, dust, rain, etc.). While lens 102 is depicted in the appended Figures as a single lens that is sized to cover both eyes of a user, it should be understood that in some embodiments the lens 102 could include two separate lenses, one for each eye of the user.

[0058] In some embodiments, the visor 100 includes an upper frame 104 coupled to a top surface of the lens 102. The upper frame 104 may extend at least partially around a periphery of the lens 102. For example, the upper frame 104 may be extend across the entire top surface of the lens 102 and at least partially down from the top surface along the opposing side surfaces. In some embodiments, the upper frame 104 is configured to detachably couple the lens 102 to the visor 100. For example, the upper frame 104 may be detachably coupled to the lens 102 to enable a user to replace the lens 102 with another lens having a similar shape. As a further example, the upper frame 104 may be configured to receive lenses of different thicknesses and / or configurations given that thelenses have a radius of curvature corresponding to the upper frame 104. The radius of curvature, in such instances, may refer to the radius of curvature as measured between opposing side surfaces of the lens 102 and / or upper frame 104.

[0059] In some embodiments, the visor 100 includes a lower frame 106 detachably coupled to the upper frame 104. The lower frame 106 may be configured to facilitate attachment of one or more accessories to the visor 100 (e.g., gaskets), as discussed in more detail below. The lower frame 106 may be configured to extend around a remaining portion of the periphery of the lens 102. For example, the lower frame 106 may, when coupled to the upper frame 104, cover the bottom peripheral surface of the lens 102 and extend upwardly therefrom on the opposing side surfaces of the lens 102 and directly contact the upper frame 104. In some embodiments, when coupled together, the upper and lower frames 104, 106 may entirely cover the periphery of the lens 102. For example, the upper frame 104 and lower frame 106 when coupled together may completely surround the perimeter of the lens 102. In other embodiments, the upper frame 104 and lower frame 106 when coupled together may partially surround the perimeter of the lens 102. In some embodiments, the visor 100 is configured to be operable with or without the lower frame 106. For example, in some instances, the visor 100 may be mounted to the helmet 10 while the lower frame 106 is not coupled to the upper frame 104.

[0060] The upper frame 104 and / or lower frame 106 may be constructed from rigid or substantially rigid materials, such as for example a rigid plastic, metal, carbon fiber, or any other material known in the art suitable for supporting lens 102. In some embodiments, the upper frame 104 and / or lower frame 106 may be comprised of the same material or materials. In some embodiments, the upper frame 104 and / or lower frame 106 may be made by, for example, molding, machining, and / or additive manufacturing (e.g., 3-D printing). In some embodiments, the upper frame 104 and / or lower frame 106 may include one or more cavities or cutouts that are provided to lessen the weight of each respectively. In some embodiments, the upper frame 104 and / or lower frame 106 may each include a channel within which a portion of the lens 102 may be received. In some embodiments, the upper frame 104 and / or lower frame 106 are curved to match a curvature of the lens 102.

[0061] In some embodiments, the visor 100 is configured to be mounted onto a helmet 10 such that lens 102 does not protrude beyond or in front of a front portion 12 of the helmet 10 during use. The front portion 12 of the helmet 10 corresponds to the portion of the helmet 10 that is configured to cover the user’s forehead during use according to some embodiments. The lens 102 may be positioned below and / or behind the front portion 12 of the helmet 10 when the visor 100 is mountedonto the helmet 10 during use, as shown for example in Fig. 1. By placing lens 102 behind the front portion 12 of the helmet 10 according to some such embodiments, clearance is provided to allow positioning of additional equipment in front of lens 102. For example, equipment such as, but not limited to, night vision goggles, cameras, and / or binoculars may be mounted onto the helmet 10 in front of the lens 102. Moreover, in some embodiments, by placing the lens 102 behind the front portion 12 of the helmet, the lens 102 may be closer to the user’s face. In some embodiments, placing the lens 102 closer to the user’s face reduces the gap through which unwanted material can get between the lens 102 and the user’s face.

[0062] In some embodiments, the upper frame 104 is configured to enable the visor 100 to be mounted onto the helmet 10 such that the lens 102 does not protrude beyond or in front of the front portion 12 of the helmet 10. The upper frame 104 may have a curvature that generally matches an exterior curvature of the front portion 12 of the helmet 10. There may one or more flanges 108 coupled to the upper frame 104 and configured to position the lens 102 behind the front portion 12 of the helmet 10 when the visor 100 is mounted to the helmet 10. Each flange 108 may extend outwardly away from and / or upwardly from a top edge of the upper frame 104. In some embodiments, there are two flanges 108 coupled to the upper frame 104 and spaced from one another. The flanges 108 may have a curvature that generally matches the exterior curvature of the front portion 12 of the helmet 10. In some embodiments, the flanges 108 are detachably coupled to the upper frame 104 to enable the visor 100 to be worn in different configurations (e.g., mounted on the helmet 10, mounted directly on the user’s face) as discussed in more detail below. In some embodiments, the flanges 108 may be constructed of a rigid or substantially rigid material (e.g., plastic, metal, carbon fiber). In some embodiments, the flanges 108 may be constructed of the same material or materials as the upper frame 104 and / or lower frame 106.

[0063] Referring to Figs. 2-3, the lens 102 includes a front surface 110 and a back surface 112. The front surface 110 may face away from the user’s face during use and may be convexly curved as shown, for example, in Figs. 2-3. The back surface 112 of the lens 102 may be opposite the front surface 110 and may be concavely curved. In other embodiments, the front surface 110 and / or back surface 112 may be planar or substantially planar. The lens 102 is preferably transparent, or at least partially transparent, and may be made from any material suitable for eye and / or face protection known in the art. Lens 102 in some embodiments is made from glass. In other embodiments, lens 102 may be made from a polymer or plastic such as polycarbonate. In yet other embodiments, lens 102 may be fabricated from a laminate or composite material. In some embodiments, the lens 102 may include nylon and / or poly(allyl diglycol carbonate) (PADC). Lens 102 may be tinted or coloredaccording to some embodiments, or configured to protect the user’s eyes from damage from specific visible and invisible wavelengths of light (e.g., UV-light or laser light). In some embodiments, the lens 102 includes one or more absorptive and / or reflective light filters for protecting a user’s eyes against any number of predetermined wavelengths of light. In some embodiments, the lens 102 includes an integrated optical waveguide.

[0064] Referring to Figs. 1 and 4, in some embodiments, the lens 102 is a powered lens configured to receive power from an external power source (e.g., power source 14 shown in Fig. 1). In some embodiments, the lens 102 may be configured to receive power from the power source 14 via a cable 114 electrically connected to the power source 14. The cable 114 may be electrically connected to a wire terminal 116 coupled to the lens 102. In some embodiments, the wire terminal 116 is mechanically and electrically coupled to the lens 102. The lens 102 may include one or more layers mechanically and / or electrically connected to one another. For example, the lens 102 may include an outer lens 102a an inner lens 102b and a conductive layer 118 sandwiched therebetween. The conductive layer 118 may be comprised of a flexible material having one or more electrical conduits (e.g., wires) or circuits connected thereto. The conductive layer 118 may be sized and shaped to extend around a periphery of the outer lens 102a and inner lens 102b while not obscuring a user’s vision through the lenses 102a, 102b. In some embodiments, there are one or more adhesive layers 120 sandwiched between the outer lens 102a, inner lens 102b and conductive layer 118. For example, there may be an adhesive layer 120 sandwiched between the outer lens 102a and the conductive layer 118 and there may be another adhesive layer 120 sandwiched between the inner lens 102b and the conductive layer 118. In this manner, the conductive layer 118 may be adhesively coupled to the outer and inner lenses 102a, 102b via the adhesive layers 120.

[0065] In some embodiments, the lens 102 is an anti-condensation lens configured to prevent or at least reduce the occurrence of condensation build-up on a surface of the lens 102. The lens 102 may include one or more heating elements configured to heat a surface of the lens 102. In some embodiments, the inner lens 102b may include a heating element configured to prevent the build-up of condensation thereon. In some embodiments, the inner lens 102b may include a conductive material that, when an electrical current is passed therethrough, causes the temperature of the inner lens 102b to increase thereby removing any condensation thereon and / or preventing further condensation. In some embodiments, the inner lens 102b is comprised of polyethylene terephthalate (PET) coated with an indium tin oxide (ITO). The inner lens 102b may be in electrical communication with the conductive layer 118 such that an electrical current may be transmitted from the conductive layer 118 to the inner lens 102b. In some embodiments, the conductive layer118 is electrically connected to the inner lens 102b by one or more through-vias electrically connected to the conductive layer 118 and inner lens 102b and extending through the adhesive layer 120 sandwiched therebetween. In this manner, an electrical current may be transmitted from the power source 14, through the cable 114 and conductive layer 118 and to the inner lens 102b to cause the temperature of the inner lens 102b to increase. In some embodiments, the lens 102 includes an electrochromic layer configured to change the light transmittance thereof in response to an electrical signal. For example, at least one of the inner lens 102b and outer lens 102c may be comprised of an electrochromic material configured to receive an electrical signal from the conductive layer 118.

[0066] In some embodiments, the visor 100 is configured to automatically transmit power to the inner lens 102b. For example, there may be a temperature sensor 122 coupled to the conductive layer 118 and in communication with a controller (e.g., application specific integrated circuit (ASIC)). The temperature sensor 122 may be configured to transmit signals to the controller indicating a measured temperature value at or proximate the lens 102. The controller may be configured to, in response to receiving the signal from the temperature sensor 122 cause the power source 14 to transmit or cease transmitting power to the inner lens 102b via the cable 114 and conductive layer 118. In this manner, the controller may be configured to automatically activate and deactivate the inner lens 102b based on an observed temperature at and / or proximate to the inner lens 102b.

[0067] In some embodiments, there may be a humidity sensor coupled to the lens 102 and in communication with the controller. The humidity sensor may be configured to transmit signals to the controller indicated a measured amount of humidity proximate the lens 102. In some embodiments, the humidity sensor is coupled to the conductive layer 118. In some embodiments, the humidity sensor is configured to measure the amount of humidity between the lens 102 and a wearer’s face. For example, in some embodiments the humidity sensor is coupled to the inner lens 102 such that when worn the humidity sensor is positioned between the inner lens 102b and the wearer’s face. In some embodiments, the lens 102 includes both the temperature sensor and humidity sensor.

[0068] In some embodiments, the lens 102 is configured to receive data from a data source and automatically control operation of one or more powered components included therewith based on the received data. For example, the lens 102 may receive data from one or more of the temperature sensor and / or humidity sensor and automatically control operation of the heating elements for providing anti-condensation functionality to the lens 102. In some embodiments, the datatransmitted to the lens 102 may be used to automatically control operation of an electrochromic layer and / or optical waveguide included therewith.

[0069] Referring to Figs. 5A-5B, and as discussed above, the flange 108 may be detachably coupled to the upper frame 104. For example, the upper frame 104 may include a flange receiving aperture 124 configured to receive the flange 108. In some embodiments, the upper frame 104 includes two flange receiving apertures 124 spaced from one another. The flange receiving apertures 124 may be positioned proximate the left and right-side surfaces of the upper frame 104. In some embodiments, each flange receiving aperture 124 protrudes outwardly away from a front surface of the upper frame 104. In some embodiments, the flanges 108 are configured to be coupled to and decoupled from the flange receiving apertures 124 without the use of hand tools. For example, each flange 108 may include a buckle 126, as discussed in more detail below, configured to be snap-fit to the corresponding flange receiving aperture 124. In this manner, the buckle 126 and corresponding flange receiving aperture 124 may form a side release buckle connection to enable a user to easily couple and decouple the flanges 108 from the upper frame 104 without the use of hand tools.

[0070] Referring to Figs. 6A-6C, each flange 108 may include a stepped surface 128 and a lip 130 coupled to the stepped surface 128. The stepped surface 128 may be configured to abut a bottom surface of the helmet 10 and the lip 130 may be configured to abut against a front surface 12 of the helmet 10 when the lens 102 extends across at least a portion of the user’s face (as shown in Fig. 1). For example, when the visor 100 is mounted to the helmet 10, the lip 130 may abut against the front surface 12 of the helmet 10 and the stepped surface 128 may abut against the bottom surface thereof. In some embodiments, the lip 130 extends upwardly from the stepped surface 128. The stepped surface 128 may include a bottom surface 132 and a top surface 134 opposite the bottom surface 132. When the visor 100 is mounted to the helmet 10, the top surface 134 of the stepped surface 128 may abut against the bottom surface of the helmet 10. The stepped surface 128 may include a first end 136 and a second end 138 opposite the first end 136. In some embodiments, the first end 136 may be a proximal end and the second end 138 may be a distal end of the stepped surface 128.

[0071] The lip 130 may be coupled to the second end 138 of the stepped surface 128 and extend upwardly from the top surface 134 thereof away from the bottom surface 132. In some embodiments, the lip 130 is curved to match the contour of the front surface 12 of the helmet 10 (shown in Fig. 1). The buckle 126 may be coupled to the bottom surface 132 of the stepped surface 128 and extend downwardly therefrom away from the top surface 134. In some embodiments, the buckle 126 is positioned between the first end 136 and the second end 138. In some embodiments, the buckle 126 is generally equidistant between the first end 136 and the second end 138. In otherembodiments, the buckle 126 is closer to the first end 136 than the second end 138. In some embodiments, each flange 108 is a unitary construct. For example, the lip 130, stepped surface 128 and buckle 126 may be integrally formed with one another. In some embodiments, each flange 108 include a cable track 140 configured to route a cable used to securely mount the visor 100 to the helmet 10 as discussed in more detail below. The cable track 140 may be coupled to the lip 130. In some embodiments, the cable track 140 and lip 130 are integrally formed.

[0072] Referring to Fig. 7, in some embodiments, the visor 100 is configured to be adjustably coupled to the helmet 10. The visor 100 may include an anchor 142 configured to be detachably coupled to the helmet 10, a fastener 144 releasably securable to the anchor 142 and a cable 146. The cable 146 may be coupled to the flange 108, upper frame 104 and the fastener 144 and configured to retain the flange 108 against the front surface 12 of the helmet 10 when the visor 100 is in use. Although not shown, there may be first and second fasteners 144 each being generally the same as one another and configured to engage with respective first and second anchors 142 that are secured at different locations on the helmet 10 (e.g., left and right sides of the helmet 10). Furthermore, there may be first and second cables 146 each being generally the same as one another and each coupled to a respective flange 108, fastener 144 and upper frame 104 in generally the same manner as will be described further herein. In some embodiments, each cable 146 is elastic and may include, for example, an elastic cord (e.g., a bungee cord), elastic band, or elastic strap. In some embodiments, the anchor 142 is configured to be detachably coupled to a rail 300 coupled to the helmet 10. The rail 300 may be configured to couple one or more accessories (e.g., visor 100, ear protection, communications devices, power source 14, light sources) to the helmet 10. Although not shown, there may be a rail 300 coupled to the right side of the helmet 10.

[0073] Referring to Figs. 8A-8F there is illustrated a method of securing a cable 146 to the visor 100. The cable 146 may be inserted into the cable track 140 of the flange 108, as shown in Fig. 8A, and looped through the cable track 140, as shown in Fig. 8B, to secure the cable 146 to the flange 108. The flange 108 and cable 146 secured thereto may be coupled to the upper frame 104. For example, and as illustrated in Figs. 8C-8D, the buckle 126 of the flange 108 may be inserted into the flange receiving aperture 124 of the upper frame 104 thereby coupling the flange 108 to the upper frame 104. In some embodiments, the cable 146 may be inserted into a cable duct 148 of the upper frame 104 and a cable duct 150 of the lower frame 106, as shown in Fig. 8E. Each of the upper frame 104 and lower frame 106 may include cable ducts 148, 150 configured to be aligned with one another when the upper frame 104 and lower frame 106 are coupled to one another. The cable ducts 148, 150 may be sized to receive the cable 146. In some instances, only the upper frame 104 may becoupled to the lens 102 and as such, the cable 146 may be inserted into the cable duct 148 of the upper frame 104 and not the cable duct 150 of the lower frame 106, as illustrated in Fig. 7. In some embodiments, the cable 146 is routed through the cable ducts 148, 150 while the flange 108 is coupled to the upper frame 104. In some embodiments, the upper frame 104 and lower frame 106 each include cable ducts 148, 150 at opposite ends of the upper and lower frames 104, 106 respectively. In some embodiments, once the cable 146 has been routed through the cable track 140 and respective cable ducts 148, 150, (e g., as shown in Fig. 8F) the fastener 144 may be secured to the anchor 142 to thereby secure the visor 100 to the helmet 10.

[0074] Referring to Figs. 9A-9B, the anchor 142 may be configured to be detachably coupled to the rail 300 at different positions along the rail 300. The rail 300, which may represent either the first and / or second rail 300 coupled to the helmet 10, may define a groove or channel 302 in which the anchor 142 may be positioned. In some embodiments, the anchor 142 may be secured to different locations within the groove or channel 302. For example, in Fig. 9A the anchor 142 is at a first position along the rail 300 and in Fig. 9B the anchor 142 is at a second position. In some embodiments, the anchor 142 may have a dovetail fit with groove or channel 302. In some embodiments, rail 300 includes one or more indents 304 that are configured to receive a portion of anchor 142. For example, and as shown in Figs. 10A-10B, in some embodiments, the anchor 142 may include a protrusion 152 that may be received in one of the one or more indents 304 of the rail 300. As further shown in Figs. 10A-10B, in some embodiments, the anchor 142 may include a hook 154 that is sized and configured to hook onto fastener 144. The hook 154 may define a groove that is sized and configured to receive at least a portion of the fastener 144. For example, and as shown in Fig. 1 1, the fastener 144 may include an indent 156 configured to receive and abut a portion of the hook 154.

[0075] Referring to Fig. 11 fastener 144 may be constructed of, for example, plastic, metal, carbon fiber, composites, or other suitable materials. In some embodiments the fastener 144 may be constructed as a single component or, in other embodiments, may be made from two or more components that are fitted together. In some embodiments, the fastener 144 includes a first opening 158a and a second opening 158b configured to receive opposing ends of the cable 146. In some embodiments, at least one of the first and second openings 158a, 158b may include a series of teeth (not shown) arranged within the respective opening 158a, 158b. In some embodiments, the teeth are configured to clamp onto the cable 146 in order to secure the cable 146 to the fastener 144. In some embodiments, the first opening 158a includes a series of teeth configured to clamp onto the cable 146 and the second opening 158b does not include a series of teeth to permit the cable 146 to beadjustable relative to the second opening 158b. In some embodiments, the first opening 158a includes a series of teeth for clamping onto the cable 146 and the second opening includes a single pair of teeth for retaining the cable 146 in a desired position. For example, a user may pull the cable 146 through the second opening 158b to a desired position and clamp the teeth positioned therein on the cable 146 thereby retaining the position of the cable 146.

[0076] In some embodiments, the cable 146 includes a first terminal end 146a and a second terminal end 146b opposite the first terminal end 146a. The first terminal end 146a may be coupled to the fastener 144 and fixed in position relative to the fastener 144. For example, the first terminal end 146a may be received within the first opening 158a of the fastener 144 and secured therein such that the first terminal end 146a is fixed in position relative to the fastener 144. The second terminal end 146b may be adjustable relative to the fastener 144. For example, when the cable 146 is received within the second opening 158b of the fastener 144, the second terminal end 146b may pass therethrough and be adjustable in position relative to the fastener 144. By providing a second terminal end 146b that is movable relative to the fastener 144, the visor 100 may enable the user to selectively tighten and / or loosen the fit of the visor 100 to the helmet 10.

[0077] In some embodiments, the fastener 144 includes a first pull strap 160 and the cable 146 may include a second pull strap 162 each of which may be sized and configured to be grasped by a user. In some embodiments, the second pull strap 162 is coupled to and extends outwardly from the second terminal end 146b of the cable 146. The pull straps 160, 162 may be made from a flexible material such as, for example, nylon webbing, ripstop fabric, or another textile. The second pull strap 162 may be configured to be detachably coupled to the first pull strap 160. For example, the second pull strap 162 and first pull strap 160 may each include respective halves of a hook and loop fastener such that the second pull strap 162 may be detachably coupled to the first pull strap 160. In some embodiments, at least one side of the first pull strap 160 includes a hook or loop patch. In some embodiments, the first pull strap 160 is configured to be grasped by a user to help engage or disengage the fastener 144 from the anchor 142. In some embodiments, the helmet 10 may be provided with one or more hook or loop patches to which the first and / or second pull straps 160, 162 may be fastened.

[0078] Referring to Figs. 12A-12B, in some embodiments, the upper frame 104 and / or lower frame 106 may be configured to be coupled to and decoupled from the lens 102 without the use of hand tools. For example, the lower frame 106 is configured to be snap fit to the upper frame 104 thereby securing the upper frame 104 and lower frame 106 to the lens 102. The upper frame 104 may define a channel 105 configured to receive the upper surface 103a of the lens 102 as well as aportion of the left-side surface 103 c and right-side surface 103 d thereof. In some embodiments, the channel 105 has a width that is generally equal to the thickness of the lens 102 such that the front surface 110 and back surface 112 of the lens 102 directly contact the channel 105. In other embodiments, the channel 105 has a width that is greater than the thickness of the lens 102 such that a spacer (not shown) may be positioned within the channel 105 and the front and back surfaces 110, 112 of the lens 102 may abut the spacer. The lower frame 106 may define a channel 107 that is similar to the channel 105 of the upper frame 104. The channel 107 may be configured to receive the bottom surface 103b of the lens 102 as well as a remaining portion of the left-side surface 103c and right-side surface 103d thereof. In some embodiments, the channel 107 has a width that is generally equal to the width of the channel 105 of the upper frame 104.

[0079] The lower frame 106 may include one or more mating features configured to engage corresponding mating features of the upper frame 104. In some embodiments, the mating features of the lower frame 106 and upper frame 104 form a snap-fit joint. For example, the lower frame 106 may include a first hook 164a, a second hook 164b and a third hook 164c. Each hook 164a- 164c may be coupled to the distal end of an upwardly extending beam that is configured to bend or deflect as the corresponding hook 164a- 164c is moved into engagement with the upper frame 104. In some embodiments, the upper frame 104 includes a first slot 166a for receiving the first hook 164a. The slot 166a and first hook 164a may form a first snap-fit joint configured to detachably couple the upper and lower frames 104, 106. In some embodiments, the upper frame 104 may second and third slots 166b, 166c positioned opposite one another and configured to receive the second and third hooks 164b and 164c respectively. The second and third slots 166b, 166c and second and third hooks 164b, 164c may form second and third snap-fit joints. In some embodiments, the upper frame 104 and lower frame 106 are detachably coupled to one another solely by the hooks 164a- 164c and corresponding slots 166a- 166c. In this manner, the upper and lower frames 104, 106 may be detachably coupled to one another without the use of any hand-tools.

[0080] Referring to Figs. 7 and 13, and as discussed above, the visor 100 may be configured to be mounted to the helmet 10 without the lower frame 106 coupled to the upper frame 104. In such instances, the upper frame 104 may be coupled to the lens 102 by a mounting frame 168 that is similar to the lower frame 106 except that it covers a lesser portion of the lens 102. The mounting frame 168 may define a channel 169 having a width that is generally the same as the width of the channel 105 of the upper frame 104. In some embodiments, the mounting frame 168 is configured to abut directly against a portion of the bottom surface 103b of the lens 102. For example, the nasal bridge region of the lens 102 may be positioned within the channel 169 when the mounting frame168 is coupled to the lens 102. The mounting frame 168 may include a hook 170 generally the same as hook 164a of the lower frame 106 and configured to be received within the first slot 166a in generally the same manner. As such, the mounting frame 168 may be detachably coupled to the upper frame 104 and configured to couple the upper frame 104 to the lens 102. In some embodiments, the mounting frame 168 is detachable from the upper frame 104 and lens 102 without the use of hand tools.

[0081] Referring to Figs. 14A-14B, in some embodiments, the visor 100 may include a full gasket 172 configured to abut the user’s face when the visor 100 is in use (e.g., as illustrated in Fig. 1). The full gasket 172 may be coupled to the upper and lower frames 104, 106 and extend rearwardly therefrom. The full gasket 172 may define a channel 173 within which the lens 102 may be positioned. When the full gasket 172 is coupled to the visor 100, the lens 102 may be positioned within the channel 173 and the upper and lower frames 104, 106 may be coupled directly to the full gasket 172. The full gasket 172 in some embodiments, encompasses the entire periphery of the lens 102. In some embodiments, the lens 102 is frictionally secured to the channel 173 to form a seal between the channel 173 and lens 102. In some embodiments, the full gasket 172 is configured to form a seal with the user’ s face during use in order to prevent or reduce the chance of unwanted material from entering the space between the lens 102 and the user’s face. In some embodiments the full gasket 172, or at least a portion thereof, may be made from a soft or resilient material such as, for example, foam, elastomer, silicone, rubber, gel, etc.

[0082] Referring to Figs. 15A-15B, in some embodiments, the visor 100 may include a half gasket 174 configured to abut the user’s face when the visor 100 is in use (e.g., as illustrated in Fig. 7). The half gasket 174 may be configured to form at least a partial seal between the user’s face and the lens 102 in generally the same manner as the full gasket 172. The half gasket 174 may be coupled to the upper frame 104 and extend rearwardly therefrom. The half gasket 174 may be similar to the full gasket 172 except that it extends around a portion of the lens 102. For example, the half gasket 174 may extend along a bottom surface of the lens 102 an upwardly therefrom along a portion of both side surfaces of the lens 102. In some embodiments, the half gasket 174 defines a channel 175 within which a portion of the lens 102 is received. In some embodiments, the channel 175 may form a seal between the lens 102 and the half gasket 174.

[0083] In some embodiments, the half gasket 174 includes two fastening arms 176 positioned opposite one another and configured to couple the half gasket 174 to the upper frame 104. For example, the two fastening arms 176 may detachably engage the second and third slots 166b- 166c of the upper frame 104 (as shown in Fig. 15 A) to couple the half gasket 174 to the upper frame 104. Insome embodiments, the half gasket 174 includes a deflectable clip 178 positioned at the front of the half gasket 174 and extending outwardly therefrom. The deflectable clip 178 may be configured to engage with the mounting frame 168 when the visor 100 is worn in a configuration in which the lower frame 106 is not coupled thereto. For example, and as shown in Fig. 7, the deflectable clip 178 may be sandwiched between the half gasket 174 and the mounting frame 168 and obscured from sight. Although not shown, in some embodiments, the half gasket 174 may be mounted to the lens 102 while the upper frame 104 and lower frame 106 are coupled thereto. In some embodiments, the deflectable clip 178 is configured to engage with the lower frame 106 when the lower frame 106 is coupled to the lens 102. For example, the deflectable clip 178 may be engage with the first hook 164 (shown in Fig. 12a) when the lower frame 106 and half gasket 174 are coupled to the lens 102.

[0084] Referring to Fig. 16, the visor 100 may be configured to be worn by a user without the full gasket 172 or half gasket 174 coupled to the lens 102. For example, and as shown in Fig. 16, the visor 100 is shown in a configuration in which the upper frame 104 and mounting frame 168 are coupled to the lens 102. The flanges 108 are coupled to the upper frame 104 and the visor 100 is mounted directly to the helmet 10. Although not shown, visor 100 may be worn in a configuration in which the lower frame 106 is coupled to the upper frame 104 and neither the full or half gasket 172, 174 is coupled thereto.

[0085] Referring to Figs. 17A-17B, in some embodiments, the visor 100 may be worn in a configuration in which the visor 100 does not abut against the front surface 12 of the helmet 10. In such configurations, the flanges 108 may be decoupled from the upper frame 104 thereby allowing the visor 100 to not directly contact the helmet 10 when worn by the user. In some embodiments, there may be a strap 180 coupled to the visor 100 and configured to couple the visor 100 directly to the user’s head (e.g., as shown in Fig. 17B) or to the user’s head and helmet 10 (e.g., as shown in Fig. 17A). The strap 180 may include a looped cable 182 at each end of the strap 180 and configured to be received within the cable ducts 148, 150 of the upper and lower frames 104, 106. For example, the looped cable 182 may extend through the cable ducts 148, 150 at respective ends of the upper and lower frames 104, 106 thereby detachably coupling the strap 180 to the visor 100. In some embodiments, the strap 180 is configured to receive one or more accessories for use with the visor 100. For example, and as shown in Fig. 17B, the strap 180 may be configured to couple the power source 14 thereto such that the visor 100 may receive power from the power source 14. In some embodiments, the power source 14 may include a clip or any other suitable mounting feature for coupling the power source 14 to the strap 180.

[0086] Referring to Figs. 18-20 there is shown a modular visor, generally designated 200, in accordance with another exemplary embodiment of the present disclosure. The visor 200 may be similar to the visor 100 except that it may include a half gasket 274 configured to at least partially surround the lower frame 206 of the visor 200. The visor 200 may include a lens 202, an upper frame 204 and a lower frame 206 that are generally the same as the lens 102 and upper and lower frames 104, 106 except that they may be shaped and / or sized differently. The upper and lower frames 204, 206 may be detachably coupled to the lens 202 in generally the same manner as the upper and lower frames 104, 106 discussed above. In some embodiments, the upper frame 204 is configured to detachably receive flanges 208 in generally the same manner as the upper frame 104. The flanges 208 may be generally the same as the flanges 108 discussed above. The half gasket 274 may be generally the same as the half gasket 174 discussed above except that it is configured to couple to the lower frame 206 such that the half gasket 274 is external to the lower frame 206. The half gasket 274 may include a channel 255 (shown in Fig. 20) configured to receive the lower frame 206. For example, the channel 255 is sized such that when the half gasket 274 is coupled to the frame 206, the channel 255 at least partially surrounds and abuts the bottom surface of the lower frame 206. As such, when coupled to the lower frame 206, the half gasket 274 is external to and partially surrounds the lower frame 206. The half gasket 274 may include a deflectable latch 277 configured to engage with the first hook 264a of the lower frame 206. The latch 277 may enable a user to securely fasten the half gasket 274 to the lower frame 206 and / or easily decouple the half gasket 274 therefrom. Although not shown, it should be understood that the visor 200 may be configured to couple a full gasket and / or mounting frame thereto in generally the same manner as the full gasket 172 and mounting frame 168 described above.

[0087] Referring to Fig. 21-23, in some embodiments, the visor 200 may be configured to transmit power and / or data to lens 202 in generally the same manner as the lens 102 discussed above. The visor 200 may include a cable 214, generally the same as cable 114 discussed above, that is electrically coupled to the lens 202. The cable 214 may be configured to transmit power and / or data from an external source to the lens 202. In some embodiments, the cable 214 is configured to connect to a powered rail 300 coupled to a helmet 10 (shown in Fig. 22). The powered rail 300 may include a recessed groove 302 for receiving accessories at one or more powered nodes 303 positioned along the groove 302. The powered rail 300 may include one or more power and / or data lines embedded therein and configured to transmit data and / or power to accessories coupled thereto. For example, an accessory coupled to one of the powered nodes 303 of the rail may receive power from the power source 14 via the rail 300.

[0088] In some embodiments, the rail 300 includes one or more powered nodes 303 positioned above the groove 302 along a top surface of the rail 300 such that one or more detachable power nodes 310 may be electrically and mechanically connected to the rail 300. The detachable power nodes 310 may be detachably coupled to the rail 300 and configured to couple to the cable 214 of the visor 200. For example, the detachable node 310 may include a bulkhead connector 314 configured to mate with a connector 215 of the cable 214. The detachable node 310 may further include a dust cover configured to cover the bulkhead connector 314 when not in use such that dust and debris is prevented from entering into the connector 314. In some embodiments, the detachable node 310 includes a power switch 316 configured to allow a user to selectively provide power to accessories coupled thereto. For example, when the visor is electrically connected to the detachable node 310 via the cable 214, a user may activate or deactivate the power switch 316 to control whether power is transmitted from the power source 14 to the visor 200.

[0089] Referring to Figs. 24-37 there is shown a visor, generally designated 400, in accordance with another exemplary embodiment of the present disclosure. The visor 400 may be generally similar to the visor 100 and / or visor 200 except as discussed below. The visor 400 may include a lens 402, an upper frame 404 and a lower frame 406 generally similar to the lens 102, upper frame 104 and lower frame 106 discussed above. In some embodiments, the lens 402 is a powered lens generally similar to lens 102 as discussed above. The visor 400 may include a cable 414 coupled to the upper and / or lower frame 404, 406 and configured to transmit data and / or power to the lens 402, in generally the same manner as cable 114 discussed above.

[0090] Referring to Fig. 24, a humidity sensor 409 may be coupled to the lens 402 and in electrical communication with the cable 114. In some embodiments, the humidity sensor 409 is positioned relative to the lens to minimize obstruction of a wearer’s view. For example, and as illustrated in Fig. 24, the humidity sensor is positioned at a lower left-hand comer of the lens 402 such that it has little to no impact on a wearer’s field of vision. In some embodiments the lens 402 includes an inner lens and outer lens similar to the lens 102 and the humidity sensor 409 may be positioned between the inner and outer lenses. In some embodiments, the humidity sensor 409 is positioned interior to the lens 402. For example, the humidity sensor 409 may be positioned between the lens 402 and a wearer’s face when the visor 400 is in use.

[0091] Referring to Figs. 24-25, the flange 408 may be generally the same as flange 108 except that it may be sized to extend substantially along a top surface of the upper frame 404. The flange 408 may extend substantially along the width of the upper frame 404 at the top surface thereof. In some embodiments, the flange 408 is configured to abut against an outer surface of a helmet ingenerally the same manner as flange 108. For example, the flange 408 includes a lip 430 contoured to generally match the contour at the outer surface of a helmet shell. When the visor 400 is worn with a helmet shell, the lip 430 of the flange 408 may abut against the outer surface of the helmet shell. In some embodiments, providing a flange 108 that extends substantially along the width of the upper frame 404 improves the fit of the visor 400 when worn with a helmet shell. For example, the upper frame 404 may contact more surface area of the helmet shell when worn as compared to flanges 108 described above.

[0092] In some embodiments, the flange 408 includes a padding layer 411 configured to abut against a helmet shell. The padding layer 411 may be coupled to an inner surface of the lip 430 such that when the visor 400 is worn with a helmet the padding layer 411 is sandwiched between the helmet and the lip 430. In some embodiments, the padding layer 411 is comprised of an elastic material. For example, the padding layer 411 may be comprised of a rubber or foam material that deforms when compressed (e.g., against a helmet shell) and generally returns to its original shape when no longer compressed. In some embodiments, the padding layer 411 is comprised of a foam like or rubber like material. In some embodiments, the padding layer 411 improves the fit of the flange 408 against a helmet shell when compared to flange 108. For example, the padding layer 411 may compress against and conform to the contour of a helmet shell when the visor 400 is coupled to the helmet shell.

[0093] Referring to Figs. 26-28, the flange 408 may be configured to couple to the upper frame 404 in generally the same manner as flange 108 as discussed above. The flange 408 may include a stepped surface 428 similar to stepped surface 128 discussed above and buckles 426 protruding downwardly therefrom that are generally similar to buckles 126. The buckles 426 may protrude from the stepped surface 428 in a direction opposite lip 430. In some embodiments, the upper frame 404 includes receiving apertures 424 generally similar to receiving apertures 124 as discussed above. The buckles 426 may be received within apertures 424 such that the flange 408 is detachably coupled to the upper frame 404 in generally the same manner as flange 108 as discussed above.

[0094] Referring to Figs. 25 and 29, the visor 400 may be configured to receive a prescription lens attachment 413. The visor 400 may include an anchor 415 configured to detachably coupled the lens attachment 413 to the visor 400. The anchor 415 may be positioned at an interior surface of the visor 400 proximate the nasal bridge region. For example, the anchor 415 is positioned above the nasal bridge formed by the lower frame 406. The anchor 415 may be fixed in position relative to the upper and / or lower frame 404, 406. The prescription lens attachment 413 may be include prescription lenses specific to a wearer of the visor 400. For example, the prescription lensattachment 413 may include a frame 417 and two prescription lenses coupled thereto that are specific to a wearer of the visor 400. In some embodiments, the frame 417 is configured to detachably couple to the anchor 415 such that the attachment 413 is positioned between the lens 402 and a wearer’s face when the visor 400 is worn.

[0095] Referring to Fig. 30, the visor 400 may include one or more indents 419 along a bottom surface of the lower frame 406 and configured to aid a user in gripping the visor 400. The indents 419 may be a series of indents 419 along the bottom surface of the lower frame 406. In some embodiments, there are two series of indents 419 each positioned along the bottom surface of the lower frame 406. In some embodiments, the series of indents 419 terminate proximate to the nasal bridge region formed by the lower frame 406.

[0096] Referring to Figs. 25 and 31-32, the visor 400 may be configured to receive a gasket 472 generally similar to gasket 172 discussed above. The gasket 472 may be coupled to the visor 400 via the upper and / or lower frame 404, 406. The gasket 472 may include a base 479 and flaps 481 protruding outwardly from the base 479. The base 479 may be configured to couple to the upper and / or lower frame 406 and the flaps 481 may be configured to contact a wearer’s face when in use. In some embodiments, the base 479 is configured to form a seal between the lens 402 and the upper and / or lower frames 404, 406. For example, and as illustrated in Fig. 31, the base 479 is sandwiched between the lens 102 and the upper frame 404. In some embodiments, the seal formed by the gasket 479 with lens 402 and the upper and / or lower frames 406 may protect electronics of the visor 400 from water and / or debris that may damage the electronics.

[0097] What is shown in Fig. 31 is a cross-sectional view of one half of the visor 400 with gasket 472 coupled thereto when viewed from the top. The corresponding view of the remaining half of the visor 400 with gasket 472 may be a mirror image of what is shown in Fig. 31. In some embodiments, the gasket 472 includes an aperture 483 configured to permit the cable 414 from passing therethrough and establishing an electrical connection with the lens 402. In some embodiments, the visor 400 is configured to receive gaskets other than gasket 472. For example, and referring briefly to Fig. 32, a half gasket 474 may be coupled to the visor 400 in generally the same manner as gasket 472. The gasket 474 may be substantially the same as the gasket 472 except that the flaps 487 thereof may extend only partially along the base 485. The base 485 may be substantially the same as base 479 and may include an aperture 489 to permit the cable 414 access to the powered lens 402. The flaps 487 may extend partially along the periphery of the base 485.

[0098] Referring to Figs. 34-37, the visor 400 may include one or more cable ducts configured to route a cable for coupling the visor 400 to a helmet 10. The cable ducts of the visor 400 may besimilar to the cable ducts of visors 100 and / or 200 as described above except that they may be configured to enable a cable 446 to be retained against the visor 400 in two or more configurations. The cable 446 may be generally the same as cable 146 described above. The cable 446 may be configured to be coupled to a helmet 10 via a fastener 444 generally the same as fastener 144 described above.

[0099] The upper frame 404 may include a first cable duct 448 and the lower frame 406 may include a second cable duct 450 generally similar to cable ducts 148, 150 discussed above, except that the cable ducts 448 and 450 may be spaced from one another. The first cable duct 448 and second cable ducts 450 may not directly contact one another when the upper and lower frames 404, 406 are coupled together. In some embodiments, the visor 400 includes a diverting duct 449 configured to divert the path of the cable 446 between the first and second cable ducts 448, 450. The diverting duct 449 may be positioned between the cable ducts 448, 450. For example, the diverting duct 449 may be positioned along the upper frame 404 or lower frame 406 between the cable ducts 448, 450.

[0100] In some embodiments, the diverting duct 449 is positioned outside the first cable pathway defined by the first and second cable ducts 448, 450 such that the cable 446 may pass between the ducts 448, 450 in a first configuration without interference from the diverting duct 449. For example, and as illustrated in Fig. 36, the cable 446 extends along a first cable pathway between duct 448 and duct 450 without interference from the diverting duct 449. In some embodiments, the first cable pathway is generally linear. The diverting duct 449 may define a second cable pathway between the first and second ducts 448, 450 that is different from the first cable pathway. In some embodiments, the cable 446 may pass between the ducts 448, 450 in a second configuration in which the cable wraps around the diverting duct 449. For example, and as illustrated in Fig. 37, the cable 446 diverts from the first cable pathway (illustrated in Fig. 36) and follows the second cable pathway between ducts 448, 450 and wraps around the diverting duct 449. In such instances the cable 446 is engaged with the diverting duct 449 thereby increasing the friction between the cable 446 and ducts 448, 449, and 450. Accordingly, in the second configuration (shown in Fig. 37) the cable 446 may be more securely retained against the visor 400 than when compared to the first configuration.

[0101] In some embodiments, the visor 400 includes a third cable duct 451 configured to prevent the cable 446 from obscuring the lens 102 when in use. The third cable duct 451 may be positioned between the first cable duct 448 and the flange 408. In some embodiments, the third cable duct 451 is coupled to the upper frame 404. The third cable duct 451 may be integrally formed withthe upper frame 404. In some embodiments, the third cable duct 451 is positioned at a comer of the upper frame 404. For example, the third cable duct 451 is positioned proximate the edge between the top surface and side surface of the upper frame 404. In some embodiments, the cable 446 may pass through the third cable duct 451 and to the first cable duct 448 in the upper frame 404. For example, and as illustrated in Figs. 36 and 37, the cable 446 passes through the cable duct 451 and to cable duct 448 in both the first and second configurations discussed above with regards to Figs. 36 and 37. The cable duct 451 may engage the cable 446 between the flange 408 and the cable duct 448 such that the cable 446 does not accidentally or unintentionally pass over the front surface of the upper frame 404. Accordingly, the cable duct 451 may substantially prevent the risk of the cable 446 from passing in front of the lens 402 and obscuring the vision of the wearer.

[0102] In some embodiments, the flange 408 includes a cable track 440 similar to the track 140 discussed above except the track 440 is configured to reduce bending of the cable 446. The cable track 440 may be positioned along a side edge of the flange 408 such that the cable 446 passes from the track 440 to the third cable duct 451. For example, and as illustrated in Figs. 36 and 37 the cable 446 passes from the track 440 to the cable duct 451 and to the cable duct 448. In some embodiments, the track 440 is integrally formed with the flange 408. In Figs. 34-37 the ducts 448- 451 and track 440 are shown in relation to one side (e.g., the right side) of the visor 400, however it should be understood that the opposite side (e.g., the left side) of the visor 400 may include a mirror configuration of ducts and a track respectively. The visor 400 may be configured to receive two cables 446 at opposite sides thereof in generally the same manner as visors 100 and 200 discussed above.

[0103] Referring to Figs. 1-35, the visors 100,200 and 300 have been shown and described in relation to a variety of configurations. For example, the visor 100 in Fig. 1 is shown in a first configuration in which the visor 100 is mounted to the helmet 10, the upper and lower frames 104, 106 are coupled to the lens 102 and the full gasket 172 is coupled to the lens 102. Furthermore, in Fig. 7, the visor 100 is shown in a second configuration in which the visor 100 is mounted to the helmet 10 and the upper frame 104 and half gasket 174 are coupled to the lens 102. In Fig. 16 the visor 100 is shown in a third configuration in which the visor 100 is mounted to the helmet 10 and the upper frame 104 is coupled to the lens 102 while neither the full or half gasket 172, 174 is coupled thereto. Additionally, the visor 100 is shown in fourth and fifth configurations in Figs. 17A and 17B respectively in which the visor 100 is not mounted to the helmet 10 and instead is coupled directly to a user’s head via the strap 180. Each of visor 200 and 400 may be coupled to a helmet 10 via a strap generally the same as strap 180 and in generally the same manner as visor 100. It shouldbe understood though that the visors 100, 200 and 400 of the present disclosure may be worn in a variety of other configurations, not shown in Figs. 1-35. For example, the upper and lower frames 104, 106, mounting frame 168, full gasket 172, half gasket 174, and strap 180 may enable the visor 100 to be worn in a number of combinations in which one or more of those elements is included. In some embodiments, the visors 100, 200 and / or 400 may be configured to enable a user to easily transition between such configurations without the need for any hand tools.

[0104] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways.

[0105] Specific features of the exemplary embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may be combined. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. Finally, unless specifically set forth herein, a disclosed or claimed method should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the steps may be performed in any practical order.

Claims

CLAIMSWhat is claimed is:

1. A visor for a helmet, the visor comprising: a lens sized to extend across at least a portion of the user’s face when in use, the lens having an inner surface facing the user’s face when in use and an outer surface facing away from the user’s face when in use; an upper frame coupled to a top surface of the lens; and a flange detachably coupled to the upper frame, the flange comprising: a stepped surface having a bottom surface and a top surface opposite the bottom surface and a first end and a second end opposite the first end; and a lip coupled to the second end of the stepped surface and extending upwardly from the top surface away from the bottom surface, the lip configured to receive and abut against a front surface of the helmet when the lens extends across at least a portion of the user’s face.

2. The visor of claim 1, wherein the lens is a powered lens configured to receive power from an external power source.

3. The visor of claim 2, wherein the powered lens includes one or more heating elements configured to heat a surface of the lens.

4. The visor of claim 2, wherein the powered lens includes at least one of: an electrochromic layer and an integrated optical waveguide.

5. The visor of claim 1 further comprising: a lower frame coupled to the upper frame and extending around a remaining portion of a periphery of the lens.

256. The visor of claim 5 further comprising: a first cable duct coupled to the upper frame; a second cable duct coupled to the lower frame and spaced from the first cable duct; and a diverting duct positioned between the first and second cable ducts.

7. The visor of claim 6, wherein the first and second cable ducts define a first cable pathway and the diverting duct is positioned outside of the first cable pathway, and wherein the diverting duct defines a second cable pathway between the first and second cable ducts that is different from the first cable pathway.

8. The visor of claim 1 further comprising: an anchor configured to be detachably coupled to the helmet; a fastener releasably securable to the anchor; and a cable coupled to the flange, upper frame and the fastener, the cable configured to retain the flange against the front surface of the helmet when the visor is in use.

9. The visor of claim 7, wherein the cable includes a first terminal end and a second terminal end, the first terminal end being coupled to the fastener and fixed in position relative to the fastener and the second terminal end being coupled to the fastener and adjustable relative to the fastener.

10. The visor of claim 1, wherein the flange is a first flange and the visor further includes a second flange spaced from the first flange and detachably coupled to the upper frame.

11. The visor of claim 1 further comprising: a gasket coupled to the upper frame, the gasket comprising: a body positioned between the upper frame and the lens and forming a seal therebetween; anda flap protruding outwardly from the body and configured to abut the user’s face when in use.

12. The visor of claim 1, wherein the upper frame includes cable ducts at opposite ends of the upper frame, and the visor further includes a strap detachably coupled to the cable ducts and configured couple the visor directly to a user’s head.

13. The visor of claim 1, wherein the flange includes a buckle coupled to the stepped surface between the first end and second ends and extending downwardly from the bottom surface away from the top surface and configured to detachably couple the flange to the upper frame.

14. The visor of claim 1, wherein the flange includes a padding layer disposed on an inner surface of the lip, the padding layer configured to directly contact the front surface of the helmet.

15. The visor of claim 1, wherein the flange extends substantially along a top surface of the upper frame between opposed sides thereof.

16. A visor for a helmet, the visor comprising: a powered lens sized to extend across at least a portion of the user’s face in use and having an inner surface facing the user’s face when in use and an outer surface facing away from the user’s face when in use; an upper frame coupled to a top surface of the powered lens; a lower frame coupled to the bottom surface of the powered lens and to the upper frame; a flange detachably coupled to the upper frame, the flange comprising: a stepped surface having a bottom surface and a top surface opposite the bottom surface and a first end and a second end opposite the first end;a lip coupled to the second end of the stepped surface and extending upwardly from the top surface away from the bottom surface, the lip configured to receive and abut against a front surface of the helmet when the powered lens extends across at least a portion of the user’s face; and a padding layer disposed on an inner surface of the lip, the padding layer configured to directly contact the front surface of the helmet, wherein the powered lens is configured to be positioned below and behind the front surface of the helmet when the two flanges abut the front surface of the helmet.

17. The visor of claim 16 further comprising: an anchor configured to be detachably coupled to the helmet; a fastener releasably securable to the anchor; and a cable coupled to the flange, upper frame and the fastener, the cable configured to retain the flange against the front surface of the helmet when the visor is in use.

18. The visor of claim 17, wherein the cable includes a first terminal end and a second terminal end, the first terminal end being coupled to the fastener and fixed in position relative to the fastener and the second terminal end being coupled to the fastener and adjustable relative to the fastener.

19. The visor of claim 16 further comprising: a half gasket coupled to the upper frame and extending rearwardly therefrom, the half gasket configured to abut the user’s face when the visor is in use.

20. The visor of claim 16 further comprising: a full gasket coupled to the upper and lower frames and extending rearwardly therefrom, the full gasket configured to abut the user’s face when the visor is in use.28

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