WO2011141047A1

WO2011141047A1 - Helmet visor

Info

Publication number: WO2011141047A1
Application number: PCT/EP2010/056305
Authority: WO
Inventors: Derek Leslie Arnold
Original assignee: Hd Inspiration Holding B.V.
Priority date: 2010-05-09
Filing date: 2010-05-09
Publication date: 2011-11-17

Abstract

There is provided a visor for a safety helmet, the visor comprising a viewing window portion to outer a face opening of the safety helmet, a brow-edge engaging portion having an brow- edge engaging surface to engage a brow-edge of the helmet, wherein at least a portion of the brow-edge engaging surface is set back from the viewing window portion by a depth of at least 0.3 mm, preferably by at least 0.5mm, and more preferably at least 0.6mm; and a lower- edge, wherein the lower edge is not set back from the viewing window portion

Description

HELMET VISOR BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The invention relates to a visor for a safety helmet; a visor assembly for a safety helmet; a kit of parts for constructing a visor assembly, optionally with a safety helmet; and a safety helmet provided with a visor assembly.

[0002] The visor assemblies of the invention relate generally to visor assemblies of the type that comprise an inner-visor and an outer- visor attached, preferably releasably, to one another. More particularly the invention relates to visor assemblies for use with safety helmets; such as those offering face protection from small projectiles and chemical splashes, and heavy-duty face protection, for example, ballistic face outers which may be used in riot helmets and visors for use by the emergency services; and crash-helmets such as motorbike style helmets, quad-bike, snowmobile, racing car, aviation, and skiing helmets.

[0003]

2. Description of the Related Art

[0004] Visor assemblies comprising an outer- visor and an inner-visor wherein the inner- visor is attached to an inner-surface of an outer- visor and overlies a viewing window of the outer- visor are known. In a number of known visor assemblies the inner-visor is releasably attached to the outer visor by mechanical fastenings.

[0005] In such visor assemblies the outer-visor is more substantial than the inner-visor and acts as a face shield. In the case of motorbike style helmets the visor acts to protect the user's face from wind, rain, dirt and grit; and in the case of ballistic visors it acts to protect the user's face from more substantial projectiles and blows.

[0006] The inner-visor is typically utilized to provide an improved viewing window for the visor wearer. For example, the inner-visor may be adapted to have an anti-condensation function to prevent misting-up of the viewing area. The inner-visor may also be provided with tinting to give improved viewing in varying light conditions. Examples of crash-helmet visor assemblies having these advantages are known from US Patent numbers US5765235 and US6922850, the contents of which are hereby incorporated by reference in their entirety. These visor assemblies provide anti-condensation inner-visors releasably attached to outer- visors.

[0007] Outer- visors are typically movably attached to a safety helmet, so that a helmet wearer can shift the visor assembly between a closed position (the face is covered by the visor) and an open position (when the face is not covered) on the safety helmet, or various gradations therebetween. This allows a wearer to open his or her helmet visor, for example, to improve vision or communication abilities, such as a motorbike rider might when driving at slower speeds, or an emergency services personnel wearing a ballistic face shield might. This function is found in many safety helmet systems, for example those generally described above, and it is typically obtained by a pivotal attachment of the visor assembly to the helmet body. In a common pivoting system, the visor assembly is shifted from the closed position to the open position by pivoting the visor assembly upwardly over, or into, the helmet body.

[0008] When in the closed position the upper periphery of the outer-visor typically engages a brow-edge of the helmet body, preferably forming a seal therewith, to prevent ingress of material from above.

[0009] The known assemblies of inner- and outer-visors offer excellent attributes in improving the viewing window for the user, e.g. anit-fogging and tinting. However, a variety of current systems suffer from the disadvantage that the inner-visor does not provide anti- fogging and/or shading at the upper periphery of the viewing window, i.e. the area between the helmet brow-edge and the upper edge of the inner- visor, where the inner- visor does not extend. This is problematic because, in the case of fogging the upper part of the viewing window may become opaque with mist with consequent loss of full viewing capabilities, and in the case of shading, distracting light ingress can occur.

[0010] Thus, there is a need for an inner- and outer-visor assembly that improves the coverage of the inner- visor in the viewing window.

[0011] Although upwardly extending the inner- visor to fully overlie the upper part of the viewing window of the outer-visor could at least partly address the problem of misting and/or light ingress of the upper viewing periphery it appears that this only temporarily offers any benefit. This is because upwardly extending the inner-visor to within a very close range of the brow-edge of the helmet results in the inner- visor rubbing on the brow-edge when the visor assembly is opened and closed. The result is wear on the brow-edge, and any gasket provided thereat, as well as wear on the inner- visor, possibly resulting in loss of tint, loss of any anti- misting surface, and shifting of the inner- visor in relation to the outer- visor, which also results in damage to the visors.

BRIEF SUMMARY OF THE INVENTION

[0012] According to the present invention there is provided a visor for a safety helmet, the visor comprising: a viewing window portion to shield a face opening of the safety helmet; a brow-edge engaging portion having an brow-edge engaging surface to engage a brow-edge of the helmet, wherein at least a portion of the brow-edge engaging surface is set back from the viewing window portion by a depth of at least 0.3 mm, preferably by at least 0.5mm, and more preferably at least 0.6mm; and a lower-edge, wherein the lower edge is not set back from the viewing window portion.

[0013] Advantageously, by having the brow-edge engaging surface set back from the viewing window portion, depth is created in the outer-visor to accept the depth of an inner- visor located on the inner-surface thereof. Particularly advantageously, the depth of the set back is matched to the depth of an inner- visor such that when inserted an inner-surface of the inner- visor lies substantially flush with the brow-edge engaging portion, although the brow- edge portion may sit proud of the inserted inner- visor when the depth of the set back is greater than the depth of the inner-visor.

[0014] In this manner, an advantageous clearance is created between the inner- visor and the brow-edge such that the problem of rubbing is reduced or avoided.

[0015] By the term set back is meant that the set back feature is generally rearwardly located (in relation to the helmet or visor orientation) of the feature from which it is set back. As shown in exemplary figures 1, 4, and 5 helmets and outer- visors for fitting to them have a fore and rear orientation illustrated by arrows F and R respectively. The outer- visor orientation substantially matches that of the helmet when it is in the closed position. [0016] Preferably the brow-edge engaging surface is set back from the viewing window portion by a depth of at most about 6.0mm, more preferably by at most about 4.0mm, more preferably at most about 3.0mm, even more preferably at most about 2.0mm, and most preferably about 1.5mm.

[0017] The set back of the brow-edge engaging surface can be achieved in a number of ways. In one embodiment of the invention the brow-edge engaging portion may take the form of a kinked out portion integrally formed with the outer visor window portion, for example by injection molding.

[0018] The brow-edge engaging portion can also take the form of a thickened upper part of the outer-visor. The thickened upper part of the outer-visor can be integrally formed with the viewing window portion of the outer-visor, for example by injection molding.

[0019] Preferably the viewing window portion has a first thickness Tl and the upper-gasket engaging portion has a thickness T2; wherein

T2 = T1 + T3

T3 > 0.3mm, preferably T3 > 0.5mm, and more preferably 0.6mm.

[0020] T3 thus represents the depth of set back of the brow-edge engaging surface from the inner-surface of the viewing window portion and can be varied to match the depth of an anticipated inner- visor so that the inner- visor is no deeper than flush with the brow-edge engaging surface. T3 is preferably at least 0.3 mm, more preferably at least 0.5mm, even more preferably at least 0.6mm; even more preferably at least 0.8mm, more preferably at least 1.5mm, more preferably at least 2.0mm, and can be at least 3.0mm, at least 4.0mm or even at least 5.0mm. T3 is preferably at most 10.0mm, more preferably at most 8.0mm, even more preferably at most 6.0mm, and most preferably at most 5.0mm.

[0021] The values Tl and T2 are measured as the thickest parts of the viewing window portion, and the brow-edge engaging portion respectively. Tl is typically at least 1.0mm, preferably at least 1.25mm, more preferably at least 1.5mm, even more preferably at least 2.0mm, particularly for crash-helmets such as motorbike style helmets, quad-bike,

snowmobile, racing car, aviation, and skiing helmets. For light ballistic visors, e.g. police riot visors, Tl is preferably at least 2.5mm, more preferably at least 2.75mm, even more preferably at least 3.0mm; and in the case of heavy-duty ballistic visors, e.g. military protection, Tl is preferably at least 8.0mm, more preferably at least 9.0mm, even more preferably at least 9.5mm, and most preferably at least 10mm.

[0022] In an alternative embodiment of the invention, the benefit of easy adaptation of current outer- visor designs either during manufacture or post-manufacture is considered. For example, the redesigning of injection molds to create new and more complex outer visor shapes requires considerable effort and investment for manufacturers. For consumers, the need to purchase a new visor or a whole safety helmet system in order to obtain the benefit of improved inner- visor coverage is also disadvantageous.

[0023] In this respect a preferred embodiment of the invention provides a retro-fit embodiment for adaptation of existing outer-visors, and a visor as discussed above is provided wherein the brow-edge engaging portion comprises a spacer attached to an upper periphery of the viewing window portion.

[0024] The spacer may take the form a bead or line of material attached to the upper periphery of the viewing window portion. It may also take the form of substantially U-shaped gasket the channel of which receives the upper edge of the viewing window portion.

[0025] The spacer may be mechanically or chemically (adhered) attached to the viewing window portion by any known means. A preferred form of mechanical attachment is provided wherein the spacer comprises a channel receiving an upper edge of the viewing window portion, one or both of the channel and the upper edge or periphery of the viewing window having raised areas mating with opposed recessed areas in the channel, or upper edge or periphery. Preferably in such an embodiment the spacer comprises a thermoplastic material that can be softened by warming to a temperature from 40°C to 100°C, preferably from 50°C and 100°C, so that the gasket can be located in the soft state and then cooled such that it becomes fixed.

[0026] The invention thus also relates to a method of adapting a pre-formed outer- visor having a relatively planar inner surface for receiving a releasably attached inner- visor, comprising fixing an edge region to the inner surface of the visor at least along an upper periphery, the edge region having a thickness about greater than or equal to a depth of the inner-visor.

[0027] When retro-fitting a brow-edge spacer to a pre-existing visor as discussed above, the reorientation of the visor in relation to the helmet body must be taken into account. To provide adequate clearance for the visor to close into the open face portion of the safety helmet the visor must be fixed more forwardly than allowed by its original design. It is the case that with some safety helmets the elements for the pivotable attachment of the outer- visor to the helmet body (commonly referred to as the baseplates) can be adjusted to allow the visor to be placed more forward on the helmet. Alternatively to, or in combination with, adjustment of the baseplates, the outer-visor can be attached to the helmet pivot attachment point by a replacement attachment washer. The typically provided attachment washer for outer-visors and helmets is centric, by replacing this centric washer with an eccentric washer (one in which attachment hole is non-centric) the attachment point of the outer-visor can be moved forward to make space for the added brow-edge spacer element.

[0028] A lack of set back in the lower-edge is advantageous since variations in thickness and shape of the lower edge can lead to visibility problems when a visor is only part way open or closed. The lower edge of the outer-visor is preferably continuous with the general line of the viewing window portion.

[0029] As is common with safety helmets having visors, the brow-edge preferably comprises a brow-edge gasket to engage with the outer- visor in the closed position. The gasket is typically a rubbery material which abuts and seals against the visor when closed. In the current invention, the brow-edge engaging portion and surface preferably engage such a brow- edge gasket, and can thus be referred to as the brow-edge gasket engaging portion and brow- edge gasket engaging surface.

[0030] Preferably the visor is for a safety helmet having a chin portion (also known as a chin-bar) and the visor has a chin-edge engaging surface to engage a chin-edge of the helmet, wherein the chin-edge engaging portion is not set back from the viewing window portion. The chin edge is the edge located at the lower periphery of the face opening of the helmet. Safety helmets having chin portions are referred to in the art as full- face helmets, and in the current application this term includes modular or flip-up helmets that have a chin-bar that can be pivoted from a closed to an open position. Full face and modular constructions are common to motorbike style helmets.

[0031] According to a further aspect of the invention there is provided a visor assembly for a safety helmet, the visor assembly comprising: an outer- visor comprising a viewing window portion to shield a face opening of the safety helmet; a brow-edge engaging portion having a brow-edge engaging surface to engage a brow-edge of the helmet, wherein at least a portion of the brow-edge engaging surface is set back from the viewing window portion; and a lower-edge, wherein the lower edge is not set back from the viewing window portion; and an inner- visor having a depth of T4 and being attached to an inner-surface of the outer- visor and at least partially overlying the viewing window portion; wherein the depth of set back of the brow-edge engaging surface is > T4.

[0032] T4 is preferably at least 0.3 mm, more preferably at least 0.5mm, even more preferably at least 0.6mm; even more preferably at least 0.8mm. T4 is preferably at most 10.0mm, more preferably at most 8.0mm, even more preferably at most 6.0mm, and most preferably at most 5.0mm.

[0033] T4 is measured as the thickest part of the inner- visor (including any spacer or seal attached thereto) along the upper edge thereof, i.e. the edge of the inner-visor closest to the brow-edge engaging portion of the outer-visor.

[0034] As discussed above, by adapting the visor assembly in a manner so that the inner- visor is at most flush with the brow-edge engaging surface, the problems of rubbing between the inner- visor and the brow-edge can be reduced or avoided even the inner- visor extends to within a close range of the top of the viewing window. Thus, preferably in the visor assembly of the present invention an upper edge of the inner-visor is within 5mm, preferably within 3mm, preferably within less than 3mm, even more preferably within 1mm of the brow-edge engaging portion. Most preferably at least a portion of the upper edge of the inner-visor abuts the brow-edge engaging portion. [0035] In this manner the inner-visor can more fully fill the viewing window. Preferably the inner-visor overlies at least 50% of the area of the viewing window portion; preferably at least 70 %, preferably at least 80%>, more preferably at least 90%>, and most preferably at least 95%; and most preferably at least 99%.

[0036] According to a preferred embodiment of the invention the inner-visor is spaced from the inner-surface of the outer- visor by a spacer extending around at least a part of a periphery of the inner-visor. Most preferably the spacer acts as a seal to form a sealed compartment between the inner-visor and outer-visor. This sealed compartment acts as an insulator reducing the possibility of condensation formation in the viewing area of the visor. In an advantageous embodiment, where the inner-visor is removable, the spacer is adhered to the inner-visor and releasably abuts the inner-surface of the outer-visor.

[0037] The seal comprises an elastomer resin. Examples of suitable elastomer resins for use in forming the spacer or seal include resins selected from the group consisting of silicone resins, epoxy resins and polyurethane resins. These may be thermoplastic resins. The seal may be applied to the inner-visor as an extruded bead, or may be injection molded onto the inner- visor, as described in WO09040581, the content of which is hereby incorporated by reference in its entirety.

[0038] The spacing between the inner-visor and outer- visor can be adjusted as desired to optimise the anti-misting properties of the assembly. The set back depth of the brow-edge engaging surface is adjusted accordingly to ensure that the inner-visor is at most flush with the brow-edge engaging surface.

[0039] In the visor assembly of the present invention the spacer preferably spaces the inner- visor from the outer- visor at an upper periphery, by no more than the set back depth, preferably no more than 3.0mm, more preferably no more than 2.0mm, and most preferably no more than 1.0mm.

[0040] As discussed above, the visor assembly of the present invention maintains a wearer's vision through the visor assembly. In relation to this the inner-visor is preferably provided with an anti-misting surface, for example, in the form of a surface having hydrophilic properties. The surface may be applied as a coating of a hydrophilic material. The coating is preferably a silicone based material which is applied by dip-coating.

[0041] The inner-visor may also be provided with a colouring agent in the form of a permanent colouring or a photo-chromic UV reactive dye. This acts to reduce the ingress of excess light during, for example, sunny conditions, or to filter particular wavelengths of light.

[0042] The inner-visor may be provided with an anti-scratch coating, separately or in combination with an anti-misting surface, on either or both of its major surfaces.

[0043] The inner-visor is preferably comprised of a cured/tempered cellulose acetate or cellulose propionate, which material advantageously has a good light transmission.

[0044] It is preferred that the inner-visor is releasably attached to the outer-visor by one or more mechanical retaining elements, although in its broadest sense the invention also relates visor assemblies having an inner-visor that is permanently or semi-permanently adhered to the outer-visor. The one or more mechanical retaining elements can be of any known type fit for purpose. The retaining elements can, for example, be raised abutments such as pin-shaped elements (e.g. a blind rivet), a raised post, or a wall or ridge.

[0045] In the preferred embodiment the mechanical retaining means comprises two blind rivets which are fitted respectively through two holes in the outer visor.

[0046] In order to obtain an initial tension for the purpose of pressing the inner-visor against the inner-surface of the outer-visor, the inner-visor preferably has a radius of curvature which is greater than the radius of curvature of the outer-visor. When the inner- visor is fitted and gripped by the mechanical retaining elements it is pressed against the inside surface of the outer visor. When the inner-visor is provided with a spacer or seal spacer or seal is pressed into contact with the inner-surface of the inner-visor. In the case that inner-visor has no spacer , for a 2-D outer-visor (i.e. curved in one plane) substantially the whole of the inner- visor contacts the inner-surface of the outer-visor; for a 3-D outer-visor (i.e. curved so as to be bowled) only the periphery of the inner-visor contacts the inner-surface of the outer-visor.

[0047] Preferably the inner-visor is provided with at least one recess to mate with the mechanical retaining elements. In the preferred embodiment the inner visor has two recesses, one on two opposite edges of the inner visor, each to mate with a mechanical retaining element respectively.

[0048] In a preferred embodiment the mechanical retaining elements comprise two blind rivets in the outer- visor, the blind rivets being placed at a distance from each other which is no greater, and preferably slightly less to give a compressive effect, than the distance between the recesses provided in the inner-visor.

[0049] Suitable mechanical retaining elements of this type are described in US5,765,235 and US6,922,850, which pins are preferably eccentric for rotation to allow tightening onto the inner-visor.

[0050] Alternative mechanical retaining elements include interlocking projection fasteners as described in US patent publication 2009-0293165-A1, the contents of which is hereby incorporated by reference in its entirety. Particularly such releasable fastening elements include interlocking arrays of mushroom shaped projections adapted to inter-engage with one another

[0051] The visor assembly of the present invention can conveniently be provided as a kit of parts comprising an outer visor as discussed above; and an inner- visor suitable to be attached to an inner-surface of the outer- visor in a manner to at least partially overlie the viewing window portion. Optionally the kit of parts may also comprise a safety helmet on which the visor assembly can be fitted.

[0052] According to another aspect of the invention there is provided a safety helmet assembly comprising a safety helmet, and a visor assembly as discussed above fitted, or suitable to be fitted to the safety helmet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The features and advantages of the invention will be appreciated upon reference to the following drawings, in which:

[0054] Figure 1 shows a motorcycle style helmet provided with a visor assembly; [0055] Figures 2, 2a and 2b show details of the visor assembly of FIG. 1; [0056] Figure 3 shows a partial visor assembly cut-away in its height; [0057] Figure 4 shows a schematic section along line I of figure 3;

[0058] Figure 5 shows a schematic section of an alternative visor assembly similarly to figure 4;

[0059] Figure 6 shows a schematic section of an alternative visor assembly similarly to figures 4 and 5;

[0060] Figure 7 shows a schematic section of an alternative visor assembly similarly to figures 4, 5 and 6;

[0061] Figure 8 shows a partial visor assembly 1; and

[0062] Figures 9a and 9b show cross-sections of two alternative embodiments along the line II-II of figure 8

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0063] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the drawings.

[0064] Figure 1 shows a safety helmet in the form of a motorcycle full- face helmet oriented with its foreside facing in the direction of arrow F, its rear side facing in the direction of arrow R, and extending upwardly with height in the direction of arrow U. The helmet has an opaque skull protecting body 3; a face opening 4; that is the forward facing opening in the helmet body having a brow-edge 8 at its upper periphery; and a chin portion 5. A visor assembly 1 is attached to the helmet body 3 in a pivotable manner so that the visor assembly 1 can be raised from the shown closed position to an open position. In the closed position the visor assembly covers the face opening 4 (shown) and in the open position the visor assembly 1 lies above the helmet body 3 so as to leave the face opening 4 uncovered.

[0065] The visor assembly 1 is provided with an outer-visor 2 having releasably attached to its inner-surface (i.e. attached to the rearside of the outer visor 2) an inner-visor 6.

[0066] The outer- visor 2 is provided with pivot attachment 14 for pivotally attaching it to the helmet body 3. It is also provided with a viewing window portion, generally indicated in its height by 15 in figure 2. The viewing window portion is that part of the outer visor 2 through which a wearer is able to look when the visor 2 is in the closed position on the helmet body 3. In the illustrated embodiment it is considered to be defined by the periphery of the open face portion 4 of the helmet body 3. The outer- visor 2 is further provided with a brow edge engaging portion 9 carrying a brow-edge engaging surface 10 set back from the viewing window portion 15. When closed the brow-edge engaging surface 10 abuts a rubber gasket provided on the brow-edge 8.

[0067] The inner-visor 6 is releasably attached to the outer-visor 2 by mechanical fastenings 11 at opposed ends of the outer- visor 2.

[0068] One of the mechanical fastenings 11 can be seen more clearly in figures 2, 2a and 2b. It is comprised of an eccentric pin 11 fitted to the outer- visor 2. The inner- visor 6 is provided with a recess 12 which mates with the eccentric pin 11. The mechanical fastenings 11 hold the inner- visor 6 under tension within the inner curve of the outer- visor 2. The eccentric pins 11 of this embodiment are rotatable into and out of engagement with the recesses 12 of the inner- visor 6 in order to ensure a secure retention thereof. In the event that the inner- visor 6 should shrink in relation to the outer-visor 2, the eccentric pins 11 can be tightened to re-secure the inner- visor 6.

[0069] Also illustrated in figures 1 and 2 is a seal member 7 provided around the periphery of the inner-visor 6. As a result of the presence of this seal the inner-visor 6 is rearwardly spaced from the outer-visor 2 and a chamber, sealed as far as possible with respect to the environment, is formed between the inner- visor 6 and the outer- visor 2. This sealed chamber acts as an insulator reducing the possibility of condensation formation in the viewing area of the outer- visor 2.

[0070] The seal member 7 is adhered to the inner- visor 6 and is held in non-adhesive relation to the outer- visor 2 by the mechanical fastening 11 so that it forms an airtight seal but does not adhere to the outer- visor 2. In this manner the inner- visor 6 is removable from the outer- visor 2 so that it can be replaced if damaged, or removed or replaced depending upon weather conditions.

[0071] An alternative visor assembly is shown in figures 3 and 4, wherein the brow-edge engaging portion 9 is rearwardly kinked from the viewing window portion 15 to set back the brow-edge engaging surface by a distance T3. The viewing window portion has a thickness Tl, and the brow-edge engaging portion has a thickness T2. The inner- visor 6, provided with seal 7, has a thickness T4 adjacent the brow-edge engagement portion, which in the illustrated embodiment is equal to T3 so that the inner-visor 6 is flush with the brow-edge engagement surface 10. The lower periphery 16 of the outer- visor 2 substantially follows the line of the viewing window portion 15 so that it is not set back therefrom.

[0072] Also shown in figure 4, the upper edge of inner visor 6 extends to within a distance T5 of the brow-edge engaging portion 9, along the height line of the outer- visor 2.

[0073] A schematic section of a further alternative visor assembly 1 is shown in figure 5, in similar manner to that shown in figure 4. This illustrated embodiment differs from figure 4 in that the brow-edge engaging portion 9 is formed as thicker upper periphery of outer- visor 2.

[0074] A schematic section of a further alternative visor assembly 1 is shown in figure 6, in similar manner to that shown in figures 4 and 5. This illustrated embodiment differs from figure 4 in that the brow-edge engaging portion 9 is formed as a retro-fitted spacer 18 chemically adhered to the upper periphery of a preformed outer- visor 2.

[0075] A schematic section of a further alternative visor assembly 1 is shown in figure 7, in similar manner to that shown in figures 4, 5 and 6. This illustrated embodiment differs from figure 4 in that the brow-edge engaging portion 9 is formed as a retro-fitted U-shaped gasket 19 chemically adhered to the upper periphery of a preformed outer- visor 2.

[0076] Figure 8 shows a partial visor assembly 1. The outer visor 2 is not provided with a set back brow-edge engagement surface 10. Instead the outer- visor 2 is pre-formed visor which has had a number of recesses 22 made along its upper periphery, for example by grinding or drilling. A retrofitting U-gasket 19 (figure 9) having protrusions 24 spaced and shaped to mate with the recesses 22 can be brought into engagement with the upper periphery such that the U-gasket 19 is mechanically held in place. The U-gasket 19 comprises a thermoplastic material such that it can be made flexible by heating prior to placing on the outer- visor 2.

[0077] Figures 9a and 9b show cross-sections of two alternative embodiments along the line II-II of figure 8, with a U-gasket 19 in place. [0078] Thus, the invention has been described by reference to certain embodiments discussed above. Further modifications in addition to those described above may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A visor for a safety helmet, the visor comprising: a viewing window portion to cover a face opening of the safety helmet; a brow-edge engaging portion having an brow-edge engaging surface to engage a brow-edge of the helmet, wherein at least a portion of the brow-edge engaging surface is set back from an inner surface of the viewing window portion by a distance T3, wherein T3 is at least 0.3 mm, preferably by at least 0.5mm, and more preferably at least 0.6mm; and a lower-edge, wherein the lower edge is not set back from the viewing window portion.

2. A visor according to claim 1 wherein the viewing window portion has a first thickness Tl and the brow-edge engaging portion has a thickness of at least T2; wherein

T2 = T1 + T3

T3 > 0.3mm, preferably T3 > 0.5mm, and more preferably > 0.6mm.

3. A visor according to any of the preceding claims wherein the brow-edge engaging portion comprises a spacer attached to at least an upper periphery of the viewing window portion.

4. A visor according to claim 3 wherein the spacer comprises a channel receiving an upper edge of the viewing window portion, the channel being adhered to the upper edge of the viewing window.

5. A visor according to claim 3 wherein the spacer comprises a channel receiving an upper edge of the viewing window portion, one or both of the channel and the upper edge or periphery of the viewing window having raised areas mating with opposed recessed areas in the channel, or upper edge or periphery.

6. A visor assembly for a safety helmet, the visor assembly comprising: an outer- visor comprising a viewing window portion to shield a face opening of the safety helmet; a brow-edge engaging portion having a brow-edge engaging surface to engage a brow-edge of the helmet, wherein at least a portion of the brow-edge engaging surface is set back from an inner surface of the viewing window portion; and a lower-edge, wherein the lower edge is not set back from the viewing window portion; and an inner- visor having a depth of T4 and being attached to an inner-surface of the outer- visor and at least partially overlying the viewing window portion wherein the brow-edge engaging surface is set back from the inner surface of the viewing window portion by a depth > T4.

7. A visor assembly according to claim 6 wherein the inner- visor is releasably attached to the outer- visor by one or more mechanical retaining elements.

8. A visor assembly according to any of claims 6 to 7 wherein at least a portion of an upper edge of the inner-visor is within a distance T5 of the gasket upper-engaging portion; wherein T5 is 5mm, preferably 3mm, preferably less than 3mm, and more preferably 1mm; and more preferably wherein at least a portion of the upper edge of the inner-visor abuts the upper-gasket engaging portion.

9. A visor assembly according to any of claims 6 to 8 wherein the inner- visor fills at least 50% of the viewing window portion area; at least 70 %, preferably at least 80%, more preferably at least 90%, and most preferably at least 95% ; more preferably at least 99%.

10. A visor assembly according to any of claims 6 to 9 wherein the inner- visor is spaced from the inner-surface of the outer-visor by a spacer extending around at least a part of a periphery of the inner- visor, the spacer being adhered to the inner- visor and releasably abutting the inner-surface of the outer-visor.

11. A visor assembly according to claim 10 wherein the spacer acts as a seal to provide an air chamber between the inner- visor and the out-visor.

12. A visor assembly according to any of claims 10 or 11 wherein the spacer spaces the inner- visor from the outer-visor at an upper periphery, by no more than the set back depth, preferably no more than about 6.0mm, more preferably nor than about 4.0mm, more preferably no more than about 2.0mm, and most preferably no more than about 1.0mm.

13. A visor assembly according to claim 7 or any later claim depending therefrom, wherein the mechanical retaining elements comprise raised portions on the outer-visor abutting the inner-visor to hold it against the outer-visor under compression.

14. A kit of parts comprising: an outer visor, wherein the outer visor is a visor in accordance with any of claims 1 to 5; an inner-visor suitable to be attached to an inner-surface of the outer-visor in a manner to at least partially overlie the viewing window portion; and optionally a safety helmet.

15. A safety helmet assembly comprising: a safety helmet; and a visor assembly according to any of claims 6 to 13.