Tool-less Visor System for Protective Sports Helmet
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Solution Overview
Problem
Conventional sports helmets face challenges in securely attaching aftermarket visors without deforming the optics and requiring tools, which complicates installation and may compromise the helmet's structural integrity.
Innovation Solution
A protective sports helmet design featuring a shell with an impact attenuation system, a tool-less visor system that securely attaches to the helmet without distorting the optics, and a lower chin bar assembly that enhances energy management and field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to attach aftermarket visors to sports helmets, then the visor can be secured to the helmet, but the optics of the visor are deformed and tool-based installation is required
Solution Approach 1:
The visor attachment system is divided into separate components: a visor cap with attachment features and a helmet shell with corresponding receptacles. This segmentation allows the visor to be attached without deforming its optics while enabling tool-less installation through snap-fit or friction-based connection mechanisms.
Solution Approach 2:
The patent introduces an intermediary attachment mechanism (such as a visor cap, retention clips, or friction-fit interface) between the visor and the helmet shell. This intermediary component enables secure attachment without requiring tools or deforming the visor optics, resolving the contradiction between secure attachment and optical quality.
2Adaptability or versatility
If traditional helmet designs are used, then structural integrity is maintained, but player field of view and awareness are limited
Solution Approach 1:
The helmet shell incorporates localized features such as strategically positioned openings, contours, or integrated visor mounting structures that enhance field of view in specific directions while maintaining overall structural integrity. The design optimizes specific regions for visibility without compromising the global strength of the helmet.
3Reliability
If complex attachment systems are used for visors, then secure attachment is achieved, but device complexity increases
Solution Approach 1:
The visor attachment system is designed to be self-aligning and self-securing through features such as friction-fit interfaces, snap-fit mechanisms, or elastic retention clips. The system automatically secures the visor without requiring external tools or complex adjustment procedures, achieving reliable attachment while minimizing system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a secure, tool-less attachment of the visor, improved impact response due to the energy attenuation system, and increased player awareness through enhanced field of view, while maintaining the helmet's structural integrity.
Implementation Method 1
a shell having an impact attenuation system purposely engineered to adjust a specific portion of the helmet's behavior in response to an impact or series of impacts received by the helmet
Data Source
AI summary
An innovative protective football helmet includes a durable shell having an impact attenuation system, a visor system with a visor, a lower chin bar assembly, and internal impact attenuation assembly. The connection of the visor to the shell is “tool-less,” meaning that no unique tool is required for coupling or removing the visor system. The visor system is not coupled to the lower chin bar assembly, which allows the visor to independently flex and independently elastically deform relative to the chin bar assembly. The visor is configured to match a substantial extent of the frontal shell region, thus the visor does not need to be substantially deformed during the installation process, which eliminates the introduction of additional stresses on the visor during the installation process. The visor also replaces a significant upper extent of a conventional facemask that is both heavy and costly to manufacture. Due to the design of the helmet and visor system, there is a significant increase in the player's field of view through the frontal helmet opening and the visor. This increase in the field of view provides greater situational awareness for the player and allows the player to reduce the amount of head rotation necessary to see objects or other players when the player is engaged in playing the sport.