GB2596531A

GB2596531A - Visor

Info

Publication number: GB2596531A
Application number: GB2009884.4A
Authority: GB
Inventors: Story John; Goodman Andrew
Original assignee: Bangor University
Current assignee: Bangor University
Priority date: 2020-06-29
Filing date: 2020-06-29
Publication date: 2022-01-05
Also published as: GB202009884D0

Abstract

An element 10 for forming into a visor is formed of a single sheet of flexible transparent plastics material. The element comprises a screen 12 for covering a wearer’s face, an inner band 14 for resting against a wearer’s face, and a cover portion 16 provided between the inner band 14 and the screen 12. The cover portion 16 is configured to space the screen 12 apart from the inner band 14 and to provide cover for the space between the inner band 14 and the screen 12. Also disclosed is a method of manufacturing a visor comprising cutting an element from a single sheet of plastic material, the element comprising a screen, a cover portion and an inner band, folding the cover portion relative to the screen, folding the inner band relative to the cover portion, connecting the inner band to the screen and connecting the cover portion to the screen. In one embodiment the inner band may be suitable to extend around the whole head (figure 4). By forming the PPE face shield from a single flat sheet it can be stored easily and manufactured cheaply.

Description

[0001] The present invention relates to a protective visor.

[0002] Visors are used in a wide variety of scenarios to protect a wearer's face. Whilst medical professionals may wear masks over their mouth and nose, visors can provide further protection to inhibit fluids from contacting the wearer's face. In addition, protective visors may be worn by workers in the food and drink industry, as well other customer-facing workplaces, to mitigate the risk of spread of disease, for example during a pandemic.

[0003] A conventional protective visor comprises a curved screen of transparent plastics material, which covers the user's face and extends to the sides of the wearer's head. An inner band is attached to an inner surface of the screen, which holds the visor to a wearer's forehead, and spaces the screen apart from the wearer's face. In some examples, the inner band may be a padded component, such as a sponge. An outer band may be affixed to the inner band, which extends around the wearer's head to hold the visor in place. In other examples, the outer band may extend from the screen.

[0004] Conventional visors may be time consuming to manufacture and may be inconvenient to store and transport. It may be advantageous to provide a visor that is quick and low-cost to manufacture and that can be distributed in mass at a low cost. It may also be advantageous to provide a visor that enhances the protection given to the wearer.

[0005] According to the present invention there is provided an apparatus and method as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

[0006] According to a first aspect of the invention, there is provided an element for forming into a visor, the element formed of a single sheet of flexible transparent plastics material and comprising a screen for covering a wearer's face, an inner band for resting against a wearer's face, and a cover portion provided between the inner band and the screen, the cover portion configured to space the screen apart from the inner band and to provide cover for the space between the inner band and the screen.

[0007] Because the element is formed from a single sheet of plastics material, the element may be easily manufactured at a low cost. Furthermore, the element being formed from a single sheet of plastics material may make it easier for a user to assemble the visor, so that the element can be distributed prior to forming into a visor. The element being formed of a single sheet of plastics material allows multiple elements to be packed flat and distributed to be assembled by the user, which may reduce the cost and space for storage of the visors and may allow more visors to be distributed at a lower cost.

[0008] Forming the element to comprise both the inner band and the screen may reduce the burden of manufacturers, because it is not necessary to affix a head band to the inside surface of the screen, to provide a band for the wearer to rest their face. The cover portion provides a first function of separating the inner band from the screen, which reduces the number of different parts making up the visor, thereby reducing the cost of manufacture and improving ease of forming the visor. The cover portion also provides a second function of covering a space at the top of the visor between the screen and the wearer's head, which may improve the protection provided by the visor.

[0009] The element may comprise left and right outer bands configured to extend around left and right sides of a wearer's head. The outer bands may project from edges of the inner band or the screen. Each outer band may comprise an anchoring element, for example one or more hooks, for receiving a securing element to connect the outer bands and extend around the back of the wearer's head in use to secure the visor on the wearer's head. The securing element may be an elastic band or other element that could be tied around the wearer's head. This may allow a user to easily fit the visor on a wearer's head without requiring further complex components.

[0010] The element may comprise a first connecting region between the screen and the cover portion and a second connecting region between the cover portion and the inner band. The first and second connecting regions may be configured to be folded, to form the element into the visor configuration. The first and second connecting regions may each comprise a crease, to facilitate folding. This may simplify the assembly of the visor for the wearer.

[0011] The element may be configured to form a slope in the cover portion, so the surface of the cover portion increases in height from the screen to the patient's head. The configuration of the inner band may allow the cover portion to form the slope when the visor is folded. When the element is folded into the visor configuration, the second connecting region may be positioned higher than the first connecting region, thereby forming the slope in the cover portion.

[0012] The cover portion may comprise side edges configured to meet upper edges of the screen when the cover portion is folded at the first connecting region and the screen is flexed into a curved shape for curving around a wearer's face. The side edges of the cover portion may be curved to meet the upper edges of the screen. This may prevent gaps between the screen and the cover portion.

[0013] The element may comprise integrated joining fixtures for securing the visor in the folded configuration. The integrated joining fixtures may be one or more tabs and one or more slots. The tabs and slots of the element may reduce the number of components required for assembly of the visor and may allow a wearer to easily assemble the visor prior to use, thereby allowing the visors to be distributed prior to assembly.

[0014] The upper edges of the screen may comprise one or more tab and the sides of the cover portion may comprise one or more slots for receiving the one or more tabs of the screen. The upper edges of the screen may comprise a first tab and a second tab, wherein the first tab comprises a hook. The hook may provide an anchoring point for the visor and may be easy to insert into the corresponding slot of the cover portion. The second tab may be configured to fix the cover portion in place with the screen.

[0015] The inner band may be connectable to the screen. The screen may comprise slots for receiving tabs provided on the inner band. The screen may comprise two slots formed in a splay configuration, and the inner band may comprise tabs that have an increasing height in an opposing direction to the splay of the slots on the screen. This may make it easier to insert the tabs into the slots and may improves the connection between the inner band and the screen.

[0016] According to an aspect of the invention, there is provided a visor formed of a single sheet of flexible transparent plastics material, comprising a screen for covering a wearer's face, an inner band for positioning the visor against a wearer's face, and a cover portion configured to space the screen apart from the inner band and to provide cover for the space between the inner band and the screen.

[0017] The sheet of flexible transparent plastics material may comprise any or any combination of the features described above in relation to the element of the first aspect of the invention.

[0018] According to another aspect of the invention, there is provided a method of manufacturing a visor, comprising cutting an element from a single sheet of plastics material, the element comprising a screen, a cover portion and an inner band, folding the cover portion relative to the screen, folding the inner band relative to the cover portion, connecting the inner band to the screen and connecting the cover portion to the screen.

[0019] Folding the cover portion and the inner portion may form a slope in the cover portion. Folding the cover portion relative to the cover portion may comprise folding the cover portion to form an obtuse angle between the inner surfaces of the cover portion and the screen. Folding the inner band relative to the cover portion may comprise folding the inner portion to form an acute angle between inner surfaces of the cover portion and the inner band.

[0020] Connecting the cover portion to the screen may comprise flexing the screen into a curved shape and inserting tabs of the screen into slots of the cover portion.

[0021] Connecting the inner band to the screen may comprise inserting tabs of the screen into slots of the cover portion.

[0022] Although a few preferred embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

[0023] For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example only, to the accompanying diagrammatic drawings in which: [0024] Figure 1 shows a first example of a visor prior to folding; [0025] Figure 2 shows an enlarged portion of the first example; [0026] Figure 3 shows a second example of a visor prior to folding; [0027] Figure 4 shows a third example of a visor prior to folding.

[0028] As shown in figure 1, a first example of an element 10 to be formed into a visor is formed of a single sheet of flexible transparent plastics material and comprises a screen 12, an inner band 14 and a cover portion 16.

[0029] The flexible transparent plastics material may be PETG. The flexible transparent plastics material may be less than 1mm thick, for example 0.5mm thick, or 0.75mm thick.

[0030] The screen 12 is configured to cover a wearer's face in use and the inner band 12 is configured to be positioned against a wearer's forehead. The screen forms the main protective surface curved around the wearer's face. The screen 12 and the inner band 14 are connected by the cover portion 16.

[0031] The screen 12 is configured to bend when the element is formed into the folded visor configuration, to curve over a wearer's face. The inner band 14 is configured to lie across a wearer's forehead and the cover portion 16 is configured to separate the inner band 14 from the screen 12, so that in use, the screen 12 is spaced apart from a wearer's face.

[0032] The cover portion 16 provides a surface which covers the space between the inner band 14 and the upper edges 18, 20 of the screen 12, thereby providing further protection to the wearer.

[0033] The visor comprises two outer band portions 22, 24, wherein each outer band portion is configured to extend around opposing sides of a wearer's head. The first outer band portion 22 extends from a left side of the screen 12 and the second outer band portion 24 extends from a right side of the screen 12. Each outer band portion 22, 24 comprises a plurality of hooks 26, 28 for receiving a securing element such as an elastic band or tying component that connects the outer band portions 22, 24 and extends around the back of the wearer's head in use to secure the visor on the wearer's head. The outer band portions 22, 24 comprise ear relievers 29, for when the visor is used in conjunction with masks with ear elastics.

[0034] The visor element 10 comprises a plurality of tabs and slots, to enable easy forming into a visor. The visor may be formed by folding and inserting tabs into slots.

[0035] The left and right upper edges 18, 20 of the screen 12 are substantially straight.

Towards a centre of the upper end of the screen 12, between the left and right upper edges18, 20, there is provided a first join 30, where the cover portion 16 connects to the screen 12. The first join 30 comprises a crease. The cover portion 16 can be folded relative to the screen 12 along the crease, to form the sloping cover of the visor.

[0036] The left and right side edges 32, 34 of the cover portion 16 extend from the first join 30 and are curved. The curvature of the left and right side edges 32, 34 of the cover portion 16 are configured to match the curvature of the upper edges 18, 20 of the screen 12 when the screen 12 is bent into its curved shaped. This allows the left and right upper edges 18, 20 of the screen 12 to meet the respective left and right edges 32, 34 of the cover portion 16, thereby preventing gaps between the screen 12 and the cover portion 16 and so improving the protection provided by the visor.

[0037] The left and right upper edges 18, 20 of the screen each comprise first and second tabs 36, 38 for connecting to the cover portion 16. The cover portion 16 comprises corresponding first and second slots 40, 42 for receiving the first and second tabs 36, 38. When the cover portion 16 is folded at the first join 30, the screen 12 can be bent to the curved shape so that the first and second tabs 36, 38 on the left upper edge 18 can be inserted into the respective first and second slots 40, 42 on the left side of the cover portion 16 and the first and second tabs 36, 38 on the right upper edge 20 can be inserted in the respective first and second slots 40,42 on the right side of the cover portion 16.

[0038] Figure 2 shows an enlarged view of the first and second tabs 36, 38 on the right upper edge 20 of the screen 12. As shown in figure 2, the inner first tab 36 comprises a hook 44.

The hook 44 is configured to provide an anchor point for the visor and is easy to insert into the first slot 40 of the connecting portion. The second, outer tab 38 is shaped differently to the first tab 36 and does not comprise a hooked region. The second tab 38 is configured to click into place in the second slot 42, to fix the cover portion 16 in place with the screen 20.

[0039] When the first and second tabs 36, 38 are inserted into the respective first and second slots 40, 42 of the cover portion 16, the upper edges 18, 20 of the screen 12 and side edge 32, 34 of the cover portion 16 will remain together and will not flex open if the visor is flexed. Despite these edges not being fixed together, they will remain together due to the geometry of the screen portion 12 and cover portion 16. The visor may thereby be configured to accommodate different wearers with heads of different shapes and sizes.

[0040] The inner band 14 is connected to the cover portion 16 at a second join 46 provided at an upper end of the cover portion 16. The second join 46 comprises a crease. The inner band 14 can be folded relative to the cover portion 16 along the crease, to form the band where the visor rests against the wearer's forehead.

[0041] The right and left inner edges of the cover portion 16 are shaped to rest against a wearer's head in use. The inner band 14 folds down so that it is provided behind the screen 12. A central region of the inner band 14 is separated from the screen 12 by a depth provided by the cover portion 16. At the sides of the visor, left and right ends 48, 50 of the inner band connect to the screen 12, to hold the inner band 14 in position.

[0042] The screen 12 comprises third and fourth slots 52, 54 to receive respective third and fourth tabs 56, 58 provided at the left and right ends 48, 50 of the inner band. As shown in figures 1 and 2, the third and fourth slots 52, 54 are provided in a splay configuration, wherein the separation between the slots 52, 54 decreases in a direction towards the centre of the screen. The third and fourth tabs 56, 58 are shaped such that a height of the tab 56, 58 increases in a direction towards the centre of the inner band 14. The opposing shapes of the third and fourth slots 52, 54 and third and fourth tabs 56, 58 makes it easier to insert the tabs 56, 58 into the slots 52, 54 and improves the retention of the tabs 56, 58 in the slots 52, 54. The shapes of the cover portion 16, upper edges 18, 20 of the screen 12 and the inner band 14 have the effect of reducing a load introduced by the inner band 14 and the screen 12 drawing away from each other.

[0043] The shape of the inner band 14 allows the cover portion 16 to form a slope. That is, the length of the inner band 14 is such that a lower end of the inner band 14 rests against a wearer's forehead, whilst the upper end of the inner band 14, at the second join 46, is raised relative to the upper edges 18, 20 of the screen 12, so that the cover portion 16 slopes between the screen 12 and the upper end of the inner band 14.

[0044] At a lower end 60 of the screen 12, there are provided cut-out portions that can be folded out to form two projections 62, 64 that extend in opposing directions from each other. In use, a retaining element such as an elastic band can be connected to the two projections 62, 64, which draws the two projections 62, 64 towards each other. This may help to retain the screen 12 in the curved configuration and may allow the visor to better accommodate a mask [0045] Figure 3 shows a second example of an element 100 to be folded into a visor. The element 100 is formed of a single piece of flexible transparent plastics material and comprises a screen 112, an inner band 114 and a cover portion 116 that connects the inner band 114 and the screen 116.

[0046] As shown in figure 3, the shape of the element 100 corresponds substantially to the shape of the element 10 of figure 1, but differs in the connecting tabs and slots that hold the folded element 100 together into the form of the visor.

[0047] The screen 112 comprises first and second tabs 136, 138 on left and right upper edges 118, 120 of the screen 112, wherein the second tabs 138 have the same shape as the first tabs 136 and are configured to be inserted into the first and second slots 140, 142 in the cover portion 116.

[0048] The screen comprises two rectangular openings 152 positioned towards an upper end of the screen 112 for receiving tabs 156, 158 of the inner band 114. First tabs 156 are provided at opposing ends of the inner band 114, and second tabs 158 are formed by cut-outs in the inner band 114, and extend in a direction opposite to the direction of the first tabs 156. The first and second tabs 156, 158 each have a curved surface which slot through the rectangular openings 152 in the screen 112, to hold the inner band 114 to the screen 112.

[0049] Figure 4 shows a third example of an element 200 to be folded to form a visor. The element 200 is formed of a single piece of flexible transparent plastics material.

[0050] The element 200 comprises a screen 212, a cover portion 216 and an inner band 214, and differs from the first and second example elements 10, 100 in that the outer bands 222, 224 that extend around the sides of the wearer's head and comprise hooks 226, 228 for receiving an elastic band are provided at the ends of the inner band 214.

[0051] Each of the left and right upper edges 218, 220 of the screen comprise only one tab 238 and each side of the cover portion 216 comprises only one slot 242 for receiving the respective tab 238 of the screen 212.

[0052] The left and right sides of the screen, towards the upper edges 218, 220, comprise two parallel slots 252, 254 for receiving semi-circular tabs 256, 258 provided in the inner band 214. The two semi-circular tabs 26, 258 extend in opposite directions, for retaining the screen 212 and the inner band 214 together when the visor is formed.

[0053] To manufacture a visor, the first second and/or third example elements can be cut out of a sheet of plastics material. The cover portion is then folded down relative to the screen, the screen is flexed to a curved shape so that the tabs of the screen can be inserted into the slots of the cover portion. The inner band is then folded down, and the tabs of the inner band are inserted into the slots or opening of the screen. A securing element such as an elastic band can then be connected to the outer bands, to form a band around a wearer's head, and a second elastic band can be attached at the bottom of the screen to hold the screen in the curved formation.

[0054] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0055] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0056] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0057] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. An element for forming into a visor, the element formed of a single sheet of flexible transparent plastics material and comprising a screen for covering a wearer's face, an inner band for resting against a wearer's face, and a cover portion provided between the inner band and the screen, the cover portion configured to space the screen apart from the inner band and to provide cover for the space between the inner band and the screen.
2. The element according to claim 1, comprising a first connecting region between the screen and the cover portion and a second connecting region between the cover portion and the inner band, wherein the first and second connecting regions are configured to be folded, to form the element into the visor configuration.
3. The element according to claim 2, wherein the element is configured to form a slope in the cover portion, so that the height of the cover portion increases from the first connecting region to the second connecting region.
4. The element according to claim 2 or claim 3, wherein the cover portion comprises side edges configured to meet upper edges of the screen when the cover portion is folded at the first connecting region and the screen is flexed into a curved shape for curving around a wearer's face.
5. The element according to any preceding claim, comprising integrated joining fixtures for securing the element in the visor configuration.
6. The element according to claim 5, wherein the integrated joining fixtures comprise one or more tabs on upper edges of the screen and one or more slots in the cover portion, wherein the one or more slots are configured to receive the one or more tabs, and wherein at least one of the one or more tabs comprises a hook.
7. The element according to claim 5 or claim 6, wherein the inner band comprises one or more tabs at opposing ends of the inner band, and the screen comprises slots for receiving the tabs provided on the inner band, wherein the slots in the screen are formed in a splay configuration, and the tabs on the inner band have an increasing height in an opposing direction to the splay of the slots on the screen.
8. A visor formed of a single sheet of flexible transparent plastics material, comprising a screen for covering a wearer's face, an inner band for positioning the visor against a wearer's face, and a cover portion configured to space the screen apart from the inner band and to provide cover for the space between the inner band and the screen
9. A method of manufacturing a visor, comprising cutting an element from a single sheet of plastics material, the element comprising a screen, a cover portion and an inner band, folding the cover portion relative to the screen, folding the inner band relative to the cover portion, connecting the inner band to the screen and connecting the cover portion to the screen.
10. The method according to claim 9, wherein folding the cover portion and the inner band forms a space between the screen and the inner portion, and wherein the cover portion covers the space between the screen and the inner band, and wherein the cover portion slopes upwards from the screen to the inner band.
11. The method according to claim 9 or claim 10, wherein connecting the cover portion to the screen comprises flexing the screen into a curved shape and inserting tabs of the screen into slots of the cover portion.
12. The method according to any of claims 9 to 11, wherein the connecting the inner band to the screen comprises inserting tabs of the screen into slots of the cover portion.