Visor Assembly Protrusion Lens Attachment
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Solution Overview
Problem
Existing visor assemblies require additional production steps and can compromise structural integrity due to the need for drilling holes for mechanical fastenings, which also limits lens variability and affects optical characteristics.
Innovation Solution
A visor assembly with injection-moulded protrusions on the visor surface, where a lens is coupled by engagement with an add-on component providing an outer abutment surface, eliminating the need for drilled holes and allowing for adjustable lens fit and user requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fastenings with drilled holes are used to attach the lens to the visor, then the lens can be securely attached, but the structural integrity of the visor is compromised and production complexity increases
Solution Approach 1:
An add-on component serves as an intermediary element between the protrusion and the lens. This component provides an abutment surface that engages with the lens lateral side, while the protrusion engages with the add-on component. This intermediary structure allows secure lens attachment without requiring holes through the visor, thus maintaining visor integrity while achieving reliable lens attachment.
2Ease of manufacture
If drilled holes are created in the visor for mechanical fastenings, then lens attachment is enabled, but additional production steps are required and manufacturing precision is reduced
Solution Approach 1:
The protrusions are pre-formed as integral features of the visor during the injection molding process, before the lens attachment step. This preliminary action eliminates the need for subsequent drilling operations and hole creation, simplifying the production process and maintaining manufacturing precision by avoiding additional machining steps that would affect tolerances.
3Adaptability or versatility
If the visor design is fixed with integral fastening features, then production is simplified, but lens variability and adaptability are limited
Solution Approach 1:
The attachment system is segmented into three distinct components: the visor with integral protrusions, the separate add-on component with the abutment surface, and the lens. This segmentation allows the add-on component to serve as an adaptable interface that can accommodate different lens types and configurations, thereby increasing lens variability without significantly increasing overall device complexity.
4Shape
If drilled holes are made in the visor, then lens attachment is achieved, but aesthetic appearance and optical characteristics are negatively affected
Solution Approach 1:
The attachment mechanism extracts the fastening function from the visor body itself by using protrusions that engage with a separate add-on component. This extraction eliminates the need for holes in the visor, preserving its aesthetic appearance and optical characteristics, while the attachment capability is maintained through the external add-on component that provides the necessary engagement surfaces.
Data Source
AI summary
The invention generally relates to a visor assembly. In an aspect of the invention, there is provided a visor assembly comprising: an injection moulded visor (2); and a lens (3) coupled to the visor; wherein the visor comprises at least two protrusions (5) extending from a surface of the visor, said protrusions being integrally formed with the visor; at least one add-on component (4) attached, preferably releasably attached, to one of the at least two protrusions; said add-on component providing an outer abutment surface (41) arranged to engage with a lateral side of the lens; and the lens is coupled to the visor by engagement with the abutment surface of the at least one add-on component, preferably wherein the lens is compressed between the at least two protrusions or is held is tension by the two protrusions.