WO2023111249A1

WO2023111249A1 - Visor assembly with improved attachments

Info

Publication number: WO2023111249A1
Application number: PCT/EP2022/086311
Authority: WO
Inventors: Bastiaan Jongsma; Jeroen Borggreve
Original assignee: Pinlock Patent B.V.
Priority date: 2021-12-16
Filing date: 2022-12-16
Publication date: 2023-06-22
Also published as: NL2030153B1

Abstract

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.

Description

VISOR ASSEMBLY WITH IMPROVED ATTACHMENTS

BACKGROUND OF THE INVENTION

1 . Field of the Invention

[0001] The invention generally relates to a visor assembly. The invention may also relate to a visor, an add-on component for a visor assembly, a method of manufacturing a visor, and a kit of parts comprising a visor and an add-on.

[0002] The visors and visor assemblies of the invention are particularly useful for personal protection equipment for facial and eye protection. Examples of preferred personal protection equipment include motorbike helmets, motorbike style helmets such as quadbike, snowmobile, racing car and skiing helmets; heavy-duty protective visors, for example, ballistic face shields which may be used in riot helmets and visors for use by the emergency services; and/or goggles such as underwater diving goggles, motorcycle goggles or skiing goggles.

2. Description of the Related Art

[0003] Visor assemblies comprising a visor with a lens releasably attached thereto by mechanical fastenings, are known.

[0004] In such visor assemblies the visor is more substantial than the lens and acts as a shield. In the case of motorbike style helmets the visor acts to protect a 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. Visors tend to extend over the eyes and that part of face adjacent the eyes. The visor may have different functions depending on usage. For example, for diving, the visor is arranged to aid underwater vision, motorcycle visors are used to protect a user’s eyes from projectiles and dirt, and ballistic visors are used to protect a user’s eyes from more substantial projectiles.

[0005] Visors may be provided in 1 -dimensional (1-D) form, that is occupying a single plane so as to be flat; 2-dimensional (2-D) form, that is curved in one direction; or 3-dimensional (3-D) form, that is curved in two directions so as to be bowled. Lenses may be provided in appropriate shapes to fit to the surfaces of these various visor forms. In this respect, lenses may also be 1-D, 2-D or 3-D. 1-D lenses are used with 1-D visors; 1-D and 2-D lenses are used with 2-D visors; and 3-D lenses are used with 3-D visors. Also, a 2-D lens may be provided to a 3-D visor. The lens may then assume the shape of the 3-D visor over time.

[0006] The lens is typically utilized to provide an improved viewing window for the visor wearer. For example, the lens may be adapted to have an anti-condensation function to prevent misting-up of the viewing area. The lens may also or alternatively be provided with tinting to give improved viewing in varying light conditions. The viewing area of the visor and/or the lens is the area through which the user looks.

[0007] To attach the lens to the visor, use is often made of separate mechanical fastening means such as rivets which are placed in and extend through premade, e.g. drilled, holes in the visor, which rivets engage with the lens lateral sides. This arrangement can be disadvantageous because it may require an extra production step of drilling holes through the visor, which may affect its structural integrity, lead to additional production flaws and have a negative effect on the tolerances of the assembly.

[0008] An example of a known helmet visor assembly is provided in WO96/16563, which discloses an anti-condensation visor which comprises an outer visor comprising a retaining means having a blind rivet, around which a plastic bush is fitted. The blind rivet is fitted on the outer visor through an opening in the outer visor. The mechanical retaining means grips the inner visor to secure it in the visor assembly.

[0009] Another example is provided in US2013/0129449A1 , which discloses a mounting structure comprising a plurality of seat parts which is rotatably fitted into a support hole in the shield. This mounting structure is provided with an eccentric shaft which may rotate through 180° between an unlock position and a lock position to allow the placement of the anti-fog sheet. A wrench or a spanner is required to rotate a retaining member such that the mounting structure provides the unlocked and locked positions.

[0010] A further example is provided in EP1095577A2, which discloses a visor for a helmet having an outer section of injection-moulded plastics. The outer shield of the visor comprises two inwardly extending projections which are injection-moulded in one piece with the outer shield of the visor. While this example does not require an additional processing step to fabricate a hole for the attachment of a separate mechanical fastening means, it diminishes the variability of different lenses that can be provided to the visor assembly.

[0011] It is therefore desirable to provide a visor assembly with an improved attachment for a lens, such as an anti-condensation lens, that has benefits and/or overcomes one or more disadvantages in the prior art assemblies. Exemplary benefits may be achievement of an improved flexibility of the visor variability, preferably while also providing a more efficient production process and improved structural integrity and optical characteristics.

BRIEF SUMMARY OF THE INVENTION

[0012] The present invention addresses these problems by providing a visor assembly comprising: an injection moulded visor; and a lens coupled to the visor; wherein the visor comprises at least two protrusions extending from a surface of the visor, said protrusions being integrally formed with the visor; at least one add-on component attached, preferably releasably attached, to one of the at least two protrusions; said add-on component providing an outer abutment surface 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.

[0013] By virtue of providing such a visor assembly, there is no need to drill a hole through the visor after manufacturing. This can assist in simplifying the production process, potentially leading to higher efficiency and higher precision since a manual step is removed.

[0014] An alternative to the provision of drilled holes may be to provide an injection-moulded visor with injection-moulded holes in which a rivet may be housed. This may provide acceptable results in some contexts, however, injection moulding a visor with holes would require that the mould be provided with sliders to get the visor out of the mould. Such sliders could result in aesthetically unpleasing lines in the surface, which may also affect the structural integrity of the visor, and/or visibility therethrough.

[0015] A visor is often coated with an anti-scratch coating. As such, if a hole is injection- moulded, such a coating leaves a residue in the hole, which influences the hole size. As such, even if an injection-moulded hole would be viable from a production perspective, it is disadvantageous as it alters the tolerances of the hole size of the visor.

[0016] By integrally injection-moulding at least two protrusions to which the lens may be attached, no hole is necessary. This may lead to an increased structural integrity, an increased manufacturing efficiency, and an increased aesthetic appearance.

[0017] Furthermore, by providing at least one protrusion with at least one add-on component, the visor assembly may be easily adjusted to a particular lens or a particular user requirement. For example, the size of the add-on component may be adjusted over time to tighten the fit of the lens provided on a surface of the visor. It is possible that a lens partly shrinks over time, causing the engagement of the visor to loosen. In such an event, the provision of a replaceable add-on component provides the option to re-tighten the engagement of the lens with the visor. This may be done by replacing the add-on component with a larger add-on component. In other embodiments, the shape of the addon component may be adjusted so that it has a variable width with respect to the protrusion of the visor. In this manner, the variable placement of the add-on component may be adjusted to suit a particular need of the user or the lens.

[0018] In a preferred embodiment, the add-on components are releasably attached to the protrusions. In an embodiment, the protrusions are provided at an edge-region of the visor, preferably at opposing lateral edge regions of the visor. By providing the protrusions at edge regions of the visor, the protrusions may engage with the lens outside of a viewing region of a user. [0019] In an embodiment, the protrusions are provided on an inner surface of the visor. The inner surface of the visor is understood to be the surface facing the user during the use of the visor in e.g. a helmet. The outer surface of the visor is the surface facing the external environment.

[0020] In addition, by providing the inner surface of the visor with injection-moulded protrusions, the outer surface of the visor remains uninterrupted. That is, no hole or other mechanical fastening means are necessary on the outer surface of the visor to attach a lens on the inner surface of the visor. Having an uninterrupted, or continuous outer surface of the visor may provide reductions in wind noise as the visor assembly is used in e.g. motorcycle helmets. Furthermore, if a coating such as an anti-scratch coating is provided to the visor, such a coating is distributed over the entire surface of the visor. The absence of holes may improve the durability of such coatings.

[0021] In an additional or alternative embodiment, the protrusions may be provided on an outer surface of the visor, preferably at opposing lateral edge regions of the outers surface of the visor. In this case, the protrusions may be utilized to receive laminated removable lenses. In such an embodiment, the provision of at least one add-on component is preferred but not required. In this embodiment, there is provided a visor comprising at least two protrusions extending from an outer surface of the visor, said protrusions being integrally formed with the visor, said protrusions being arranged to be received in holes defined in at least one removable lens. In a preferred embodiment, the protrusions are arranged to releasably receive at least one add-on component defining an abutment surface arranged to engage with the holes in the at least one removable lens. In a preferred embodiment, said protrusions or said at least one add-on component are arranged to engage with a plurality of laminated removable lenses.

[0022] In an embodiment, the protrusions extend substantially orthogonal to the surface of the visor. By having the protrusions extend substantially orthogonal to the surface of the visor, their angle with the lens in the assembly is sufficiently acute to maintain a tight position of the lens with respect to the visor. In other embodiments, the protrusions may define an angle of between about 30° and 90°, preferably of between about 50° and 90°, more preferably of between about 70° and 90°. In an embodiment, the protrusions on either side of the visor may extend substantially parallel. In this embodiment, the angle of the protrusion with the surface of the visor is dependent on the curvature of the visor itself. Having two protrusions extend substantially parallel from the surface of the visor assembly is advantageous during manufacturing as there is no requirement of deforming the visor to retrieve the visor, and in particular the protrusions, from the mould.

[0023] In an embodiment, a lateral cross-section of the protrusions defines an oval shape, preferably a circular shape. [0024] In an embodiment, a lateral cross-section of the protrusions defines a non-circular shape, preferably wherein the lateral cross-section of the protrusions defines a shape which is rectangular, square, star-shaped, or triangular.

[0025] In an embodiment, the add-on component comprises an opening arranged to receive the protrusion, preferably wherein the opening has a shape corresponding to a cross- sectional shape of the protrusion.

[0026] The provision of such a lateral cross-section of the protrusions defining a non-circular shape may allow various positioning options of the add-on component having a correspondingly shaped opening. In particular, having e.g. a square cross-sectional shape, allows for four distinct positioning options of the add-on component. The add-on component may have a shape defined such that the distance from the opening to its periphery is not constant. In such an embodiment, different positioning of the add-on component may be used to adjust the distance from the abutment surface to the opening of the add-on component. If a lens is not engaged with the abutment surface tightly enough, the add-on component may be provided in a different position to increase the pressure between the abutment surface and the lens. An advantage of having an opening defining a non-circular shape is that e.g. pressure of the lens or vibrations cannot alter the positioning of the add-on component. In the embodiment where the opening of the add-on component defines a circular shape, the add-on component may be pushed back into a less tensioned position due to e.g. the pressure of the lens or vibrations during use.

[0027] In an embodiment, an add-on component is releasably attached to each of the at least two protrusions.

[0028] In an embodiment, the abutment surface extends at least partly around a periphery of the add-on component, said periphery defining a shape which is non-circular, preferably wherein the shape is oval, rectangular, square, star-shaped, or triangular.

[0029] By providing an abutment surface extending at least partly around a non-circular periphery of the add-on component, the distance from the opening defined in the add-on component is made variable. This allows for re-positioning of the add-on component and thus adjusting the tension on the lens. In an embodiment where the opening of the addon component is circular, such adjustment is gradual. In an embodiment where the opening of the add-on component is non-circular, such adjustment is incremental. In an alternative embodiment, wherein such adjustment of the distance between the periphery and the opening is not necessary, the periphery may be circular.

[0030] In an embodiment, the opening of the add-on component is provided away from a centre of the periphery so that the periphery defines an eccentric shape in relation to the opening. [0031 ] The provision of an eccentric add-on component is another way in which the distance between the lens and the protrusion may be adjusted. If the rotational position of the addon component is changed with respect to the protrusion, the distance between the lens and the protrusion is also adjusted, thereby providing the possibility of adjusting the tension on the lens. This may be achieved by providing an eccentric shape of the add-on component. In such an embodiment, the periphery may define any desirable shape such as e.g. circular, oval, rectangular, square, triangular, or star-shaped. The centre of the periphery is defined as the geometrical centre-point of the shape defined by the periphery.

[0032] In an embodiment, the material of the add-on component is one of polycarbonate, nylon, or an elastic material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, most preferably of about 70.

[0033] In an embodiment, the abutment surface comprises an elastically deformable material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, most preferably of about 70.

[0034] The Shore A scale is used to measure the hardness of elastomers, rubber-like materials, and elastomer materials like polyurethane. The method of Shore A hardness measurement is one using a durometer as described in standard ISO 7619-1 :2010.

[0035] A visor assembly wherein the abutment surface comprises an elastically deformable material provides increased stability of the lens and limits the detrimental effects of vibrations of the lens in the visor assembly. The possibility of changing the add-on component allows for flexibility in providing different degrees of elasticity to meet the requirements of particular usages of the visor assembly. In an embodiment, an engagement member is provided on the inner side of the opening in the add-on component. Such an engagement member may comprise an elastic material, such as a rubber ring.

[0036] In an embodiment, the protrusions comprise attachments arranged to engage with the add-on component, wherein preferably the attachments comprise hooks, barbs, a roughened surface, a local thickening, or an elastic surface.

[0037] The attachments may be advantageous to keep the add-on component engaged with the protrusions, even under e.g. vibrating conditions. This is particularly advantageous in embodiments wherein the protrusions are provided under a less acute angle with respect to the visor, such that the lens may provide a force leading to potential disengagement of the add-on component from the protrusion. The provision of an additional attachment to the protrusions may increase the stability of the add-on component. In an alternative or additional embodiment, the attachments may be provided in the opening of the add-on component. [0038] In an embodiment, the lens comprises two notches, arranged to laterally receive the addon component and/or the protrusion. In an embodiment, the notches are elongated such that they allow for movement of the add-on component in the notches such that the lens may be moved in an upward or downward direction once it is coupled to the visor.

[0039] According to another aspect of the invention, there is provided an injection moulded visor, comprising at least two protrusions extending from a surface of the visor, said protrusions being integrally formed with the visor, and wherein the at least two protrusions are arranged to receive at least one add-on component, said add-on component defining an abutment surface arranged to engage with a lateral side of a lens, preferably wherein at least one of said two protrusions is provided with said add-on.

[0040] In an embodiment, the protrusions are provided at an edge-region of the visor, preferably at opposing lateral edge regions of the visor.

[0041] In an embodiment, the protrusions are provided on an inner surface of the visor. In an embodiment, the protrusions extend substantially orthogonal to the surface of the visor.

[0042] In an embodiment, a lateral cross-section of the protrusions defines a circular shape.

[0043] In an embodiment, a lateral cross-section of the protrusions defines a non-circular shape, preferably wherein the lateral cross-section of the protrusions defines a shape which is oval, rectangular, square, star-shaped, or triangular.

[0044] In an embodiment, the protrusions comprise attachments arranged to engage with the add-on component, wherein preferably the attachments comprise hooks, barbs, a roughened surface, a local thickening, or an elastic surface.

[0045] According to another aspect of the invention, there is provided an add-on component comprising an opening arranged to receive a protrusion of a visor, said add-on component defining an abutment surface extending at least partly around a periphery of the add-on component, said abutment surface being arranged to engage with a lateral side of a lens.

[0046] In an embodiment, said periphery defines a shape which is circular, oval, rectangular, square, star-shaped, or triangular. In an embodiment, the opening is provided away from a centre of the periphery so that the periphery defines an eccentric shape in relation to the opening. In an embodiment, the opening defines a circular shape.

[0047] In an embodiment, the opening defines a non-circular shape, preferably wherein the opening defines a shape which is oval, rectangular, square, star-shaped, or triangular.

[0048] According to another aspect of the invention, there is provided a method of manufacturing a visor according to any of the embodiments described hereinbefore, comprising the steps of: providing a mould defining the shape of a visor having two protrusions being integrally formed with the visor; injecting pressurized liquid material at a first temperature into the mould; cooling the mould to a temperature lower than the first temperature; and extracting the visor from the mould.

[0049] According to another aspect of the invention, there is provided a kit of parts comprising: a visor according to any of the embodiments described hereinbefore; and at least one addon component according to any of the embodiments described hereinbefore.

[0050] According to another aspect of the invention, there is provided a helmet, the helmet comprising a visor assembly according to any of the embodiments described herein. In an embodiment, the helmet comprises a visor assembly comprising: an injection moulded visor; and a lens coupled to the visor; wherein the visor comprises at least two protrusions extending from a surface of the visor, said protrusions being integrally formed with the visor; at least one add-on component attached, preferably releasably attached, to one of the at least two protrusions; said add-on component providing an outer abutment surface 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.

[0051] BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The features and advantages of the invention will be appreciated upon reference to the following drawings, in which:

[0053] FIG. 1 is a perspective view of one embodiment of the invention showing a cut-off visor assembly comprising a visor having a protrusion, an add-on component releasably attached to the protrusion, and a lens coupled to the visor;

[0054] FIG. 1A is a blow-out view of one embodiment of the invention, showing an add-on component, a protrusion, and a lens comprising a notch arranged to laterally receive the add-on component

[0055] FIG. 2 is a cross-sectional view of an embodiment of the invention showing a cut-off visor assembly comprising a visor having a protrusion, an add-on component releasably attached to the protrusion, and a lens coupled to the visor;

[0056] FIG. 3A-3G are top views of example embodiments of the invention showing add-on components having different peripheral shapes and different openings; and

[0057] FIG. 4 is a perspective view of a helmet according to an embodiment of the invention, the helmet comprising a visor assembly having two protrusions, two add-on components releasably attached to the protrusions, and a lens coupled to the visor.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0058] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the drawings. Referring to FIG. 1 , a perspective view of one embodiment of the invention showing a cut-off visor assembly comprising a visor 2 having a protrusion 5, an add-on component 4 releasably attached to the protrusion 5, and a lens 3 coupled to the visor 2 is shown. The visor 2 is generally arranged to be attached to a helmet 1 to prevent the ingress of dust, grit or rain. The lens 3 is attached to the visor 2 to prevent the visor 2 misting up during use. To provide a seal between the space defined between the visor 2 and the lens 3, a peripheral gasket 7 is provided.

[0059] The visor 2 comprises a concave surface and comprises two protrusions 5. In Fig. 1 , only one protrusion 5 is shown. The protrusion 5 is integrally formed with the visor 2. The visor 2 may be produced by injection moulding. To the protrusion 5, an add-on component 4 is provided. As can be more clearly seen in Fig. 1 A, the protrusion 5 has a triangular cross- sectional shape. The add-on component 4 has an opening 6 having a corresponding triangular shape. As neither the protrusion 5 nor the opening 6 are circular, the add-on component 4 cannot rotate with respect to the visor 2 in this embodiment.

[0060] In the shown embodiment, the height of the add-on component 4 is low, relative to e.g. the embodiment of FIG. 2. The height of the add-on component 4 may be chosen dependent on, for example, the thickness of the lens 3 and the thickness of the gasket 7. In a preferred embodiment, the height of the add-on component 4 is between 1 mm and 20 mm, preferably between 3 mm and 15 mm, more preferably of between 5 mm and 12 mm.

[0061] Furthermore, the opening 6 and the protrusion 5 may be of different shapes to the triangular shapes shown in the FIG. 1 A embodiment. For example, to attain more possible positions, the opening 6 and the protrusion 5 may both have a hexagonal shape, leading to six positions of the add-on component 4 on the protrusion 5.

[0062] The opening 6 and the protrusion 5 may also define a round shape, which leads to a analogue, non-discrete positioning of the add-on component 4 on the protrusion 5. That is, the add-on component 4 may be rotated about the protrusion 5 and take any position, dependent on the user requirements. In this embodiment, the add-on component 4 does not need to be lifted from the protrusion 5 but may rather be turned while remaining attached to the protrusion 5.

[0063] The lens 3 is kept in place by the tension provided to a lateral side 31 of the lens by the add-on component 4. On the other side, not shown, the lens 3 may be kept in place by tension provided by the protrusion 5 or an add-on component 4, attached to the protrusion 5.

[0064] In the shown embodiment, the lens 3 comprises a notch 8, which is arranged to laterally receive the add-on component 4. The notch 8 in Fig. 1 has a shape corresponding to the shape of the add-on component 4. As such, when the add-on component 4 is received in the notch 8, the movement of the lens with respect to the visor 2 is restricted. That is, the lens 3 cannot slide up and down with respect to the visor 2 due to the engagement between the notch 8 and the add-on component 4. That is, the lens 3 is restricted in a direction parallel to the surface of the visor 2. In an alternative embodiment, the notch 8 is elongated such that it allows for movement of the add-on component 4 in the notch 8. As such, the lens 3 may be moved in an upward or downward direction once it is coupled to the visor 2.

[0065] If the lens 3 changes in size by e.g. shrinking or expanding, the add-on component 4 may be replaced or rotated to attain a different distance between the protrusion 5 and the lens 3. As a result, the tension on the lens 3 may be maintained, even if the lens 3 is changed in size. Furthermore, if a different lens 3 is provided to the visor 2 altogether, the different lens 3 having a different shape than the previous lens, the add-on components 4 may be similarly interchanged or rotated to adjust the distance between the protrusions 5 and the lens 3. As such, the lenses 3 do not need to be exactly the same shape to be fitted into the visor 2 and the same visor 2 may be used, even if the lenses 3 differ in size. As such, the visor 2 may be maintained coupled to the helmet 1 if the user wishes to use a different lens 3.

[0066] As shown in FIG. 1A, the add-on components 4 are releasably attached to the protrusions 5. As such, if a different distance between the protrusion 5 and the lens 3 is required, the add-on component 4 may be removed and replaced by a different add-on component 4, having a different distance between its opening 6 and its periphery, said distance corresponding to the distance between the protrusion 5 and the lens 3 in assembled state.

[0067] In one embodiment, the add-on component 4 may be replaced, but with a different orientation. As shown in FIG. 1A, the add-on component 4 comprises a triangular opening 6, which may receive the protrusion 5 having a similar shape in three different ways. In the shown embodiment of FIG. 1 A, the angles of the corners of the triangle are substantially equal so that the opening 6 and the protrusion 5 have matching shapes, regardless of their orientation with respect to one another. As shown in FIG 1 , the orientation of the add-on component 4 is provided such that the smallest distance available is provided between the protrusion 5 and the lens 3. If the add-on component 4 is released from the protrusion 5, turned 120° and replaced onto the protrusion 5, the distance between the protrusion and the lens is increased. This is because the periphery of the add-on component 4 defines an eccentric shape with respect to the opening 6 of the add-on component 4. As a result, turning the add-on component 4 to a different orientation will adjust the distance between the protrusion 5 and the lens 3, and thereby the tension provided to the lens 3 when coupled to the visor 2.

[0068] Referring now to FIG. 2, a cross-sectional view of an embodiment of the invention is shown. FIG. 2 shows a cut-off visor assembly comprising a visor 2 having a protrusion 5, an add-on component 4 releasably attached to the protrusion 5, and a lens 3 coupled to the visor 2. As shown, the add-on component 4 comprises an opening 6, which corresponds to the shape of the protrusion 5. The protrusion 5 is integrally formed with the visor 2. The add-on component 4 is attached to the protrusion 5 in a releasable fashion. In the shown embodiment, the protrusion 5 comprises a local thickening 51 , provided on an upper region of the protrusion 5. This local thickening 51 engages with a corresponding shape in the opening 6 of the add-on component 4. This arrangement allows the add-on component 4 to be releasably attached to the protrusion 5 without it falling off due to e.g. gravity or forces exerted on the add-on component 4 by the lens 3.

[0069] The add-on component 4 comprises an outer abutment surface 41 , which is arranged to engage with a lateral side 31 of the lens 3. The pressure between the outer abutment surface 41 and the lens 3 provides the tension on the lens 3 to keep it under tension and coupled to the visor 2. In a preferred embodiment, the abutment surface 41 is concave, limiting the movement of the lens 3 along the height of the add-on component 4. That is, by providing the abutment surface with a concave surface, the lens 3 has a balanced position in the middle of the height of the add-on component 4. This limits the possibilities of the lens 3 vibrating upwards, and thus limits the possibility of the lens 3 disengaging with the visor 2. In the shown embodiment of FIG. 2, the abutment surface 41 is slightly concave.

[0070] The lens 3 further comprises a peripheral gasket 7, provided around a peripheral region of the lens 3. The gasket 7 provides a seal between the lens 3 and the visor 2 to prevent the ingress of moisture and/or dirt. The height of the gasket 7, in part, determines the required height of the add-on component 4 on the protrusion 5.

[0071] As shown in FIG. 2, the tension on the lens 3 is determined by the distance between the protrusion 5 and the lens 3, which is dependent on the distance between the opening 6 and the outer abutment surface 41 of the add-on component 4. In the shown embodiment, the add-on component 4 may be released from the protrusion 5 and rotated about 180° to reduce the distance between the protrusion 5 and the lens 3. If, for example, the tension on the lens 3 must be reduced, the add-on component 4 may be rotated. As a result, the tension on the lens 3 may be adjusted without the need for replacing components, let alone replacing the entire lens 3 and/or visor 2.

[0072] Referring now to FIG. 3A-3G, top views of example embodiments of the invention are shown, where add-on components 4 have different peripheral shapes and different openings 6. As shown in FIG. 3A, the add-on component 4 comprises a circular shape, and an opening 6 having a five-pointed star shape. The opening 6 is provided in an eccentric position with respect to the peripheral circular shape of the add-on component 4. The opening 6 is arrange to be provided on a protrusion having the same cross- sectional shape. As such, five distinct positions may be attained by the add-on component 4, allowing for a stepwise increase or decrease of the distance between the protrusion 5 and the lens 3 in an assembled state. [0073] FIG. 3B shows a similar embodiment to FIG. 3A, wherein the shape of the opening 6 of the add-on component 4 is square. As such, it may be attached to a similarly square protrusion 5 which allows four distinct positions of the add-on component 4 on the protrusion 5, thus varying the distance between the lens 3 and the protrusion 5, thereby allowing the tension on the lens 3 to be adjusted.

[0074] FIG. 3C shows an embodiment of an add-on component 4 wherein the peripheral shape of the add-on component 4 is triangular, while the shape of the opening 6 is square. As such, the add-on component 4 can be attached in four ways to a similarly square protrusion 5 to adjust the tension on the lens 3.

[0075] FIG. 3D shows an embodiment of an add-on component 4 wherein the peripheral shape of the add-on component 4 is hexagonal, the add-on component 4 having a square opening 6. As such, the add-on component 4 can be attached in four ways to a similarly square protrusion 5 to adjust the tension on the lens 3.

[0076] FIG. 3E shows an embodiment of an add-on component 4 wherein the peripheral shape of the add-on component 4 is circular. The opening 6 of the add-on component 4 has a triangular shape, having three corners which do not all have the same angles. As such, there is only one way to provide the add-on component 4 to the protrusion 5 without flipping the add-on component 4 around. A different distance between the protrusion 5 and the lens 3 may be provided by flipping the add-on component 4 around, such that the opening 6 is provided to the protrusion 5 with the other side of the add-on component 4 facing downwards.

[0077] FIG. 3F shows an embodiment of an add-on component 4 wherein the peripheral shape of the add-on component 4 is circular. The opening 6 of the add-on component 4 has a hexagonal shape, thus allowing for six positions of the add-on component 4 on a protrusion 5 having a similar cross-sectional hexagonal shape. The opening 6 is provided in an eccentric relation to the periphery of the add-on component 4 to alter the tension to the lens 3 between the positions of the add-on component 4 on the protrusion 5.

[0078] FIG. 3G shows an embodiment of an add-on component 4 wherein the peripheral shape of the add-on component 4 is square with rounded corners and having an opening 6 having a square shape. The add-on component 4 may attain four positions with respect to a similarly square protrusion 5 on the visor 2 to adjust the tension on the lens 3.

[0079] Referring now to FIG. 4, a perspective view of a helmet 1 according to an embodiment of the invention is shown. The helmet 1 comprises a visor assembly having two protrusions 5, two add-on components 4 releasably attached to the protrusions 5, and a lens 3 coupled to the visor 2.

[0080] Thus, the invention has been described by reference to certain embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternative forms well known to those of skill in the art. For example, the openings 6 of the add-on components 4 may be varied to attain certain positions of the add-on component relative to the visor 2, thus adjusting the tension to the lens 3 in different manners. Further, the peripheral shape of the add-on components 4 may be varied such that the combination of the peripheral shape of the add-on components 4 and the shape and location of the opening 6 tension the lens 3 in different manners.

[0081] According to an aspect of the invention, there is provided a kit of parts comprising: a visor 2 according to any of the embodiments described hereinbefore and at least one add-on component 4 according to any of the embodiments described hereinbefore. In particular, the kit of parts may comprise any of the add-on components 4 as provided in the example embodiments of FIG. 3A-3G, and a visor 2 having at least two protrusions 5 having a corresponding shape to the opening 6 of the add-on component 4.

[0082] 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

1. A visor assembly comprising: an injection moulded visor (2); and a lens (3) coupled to the visor (2); wherein the visor (2) comprises at least two protrusions (5) extending from a surface of the visor (2), said protrusions (5) being integrally formed with the visor (2); at least one add-on component (4) attached, preferably releasably attached, to one of the at least two protrusions (5); said add-on component (4) providing an outer abutment surface (41) arranged to engage with a lateral side (31) of the lens (3); and the lens (3) is coupled to the visor (2) by engagement with the abutment surface (41) of the at least one add-on component (4), preferably wherein the lens (3) is compressed between the at least two protrusions (5) or is held is tension by the two protrusions (5).

2. The visor assembly of claim 1 , wherein the protrusions (5) are provided at an edge-region of the visor (2), preferably at opposing lateral edge regions of the visor (2).

3. The visor assembly of any of the preceding claims, wherein the protrusions (5) are provided on an inner surface of the visor (2).

4. The visor assembly of any of the preceding claims, wherein the protrusions (5) extend substantially orthogonal to the surface of the visor (2).

5. The visor assembly of any of the preceding claims, wherein a lateral cross-section of the protrusions (5) defines an oval shape, preferably a circular shape.

6. The visor assembly of any of claims 1-4, wherein a lateral cross-section of the protrusions (5) defines a non-circular shape, preferably wherein the lateral cross-section of the protrusions (5) defines a shape which is rectangular, square, star-shaped, or triangular.

7. The visor assembly of any of the preceding claims, wherein the add-on component (4) comprises an opening (6) arranged to receive the protrusion (5), preferably wherein the opening (6) has a shape corresponding to a cross-sectional shape of the protrusion (5).

8. The visor assembly of any of the preceding claims, wherein an add-on component (4) is releasably attached to each of the at least two protrusions (5).

9. The visor assembly of any of the preceding claims, wherein the abutment surface (41) extends at least partly around a periphery of the add-on component (4), said periphery defining a shape which is non-circular, preferably wherein the shape is oval, rectangular, square, star-shaped, or triangular. The visor assembly of any of the preceding claims, wherein the opening (6) of the add-on component (4) is provided away from a centre of the periphery so that the periphery defines an eccentric shape in relation to the opening (6). The visor assembly of any of the preceding claims, wherein the material of the add-on component (4) is one of polycarbonate, nylon, or an elastic material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, most preferably of about 70. The visor assembly of any of the preceding claims, wherein the abutment surface (41) comprises an elastically deformable material having a Shore A hardness of 50-95, preferably 60-90, more preferably 65-80, most preferably of about 70. The visor assembly of any of the preceding claims, wherein the protrusions (5) comprise attachments arranged to engage with the add-on component (4), wherein preferably the attachments comprise hooks, barbs, a roughened surface, a local thickening, or an elastic surface. The visor assembly of any of the preceding claims, wherein the lens (3) comprises two notches, arranged to laterally receive the add-on component (4) and/or the protrusion (5). An injection moulded visor (2), comprising at least two protrusions (5) extending from a surface of the visor (2), said protrusions (5) being integrally formed with the visor (2), and wherein the at least two protrusions (5) are arranged to receive at least one add-on component (4), said add-on component (4) defining an abutment surface (41) arranged to engage with a lateral side (31) of the lens (3), preferably wherein at least one of said two protrusions (5) is provided with said add-on. The visor of claim 15, wherein the protrusions (5) are provided at an edge-region of the visor (2), preferably at opposing lateral edge regions of the visor (2). The visor assembly of any of claims 15 or 16, wherein the protrusions (5) are provided on an inner surface of the visor (2). The visor assembly of any of claims 15 to 17, wherein the protrusions (5) extend substantially orthogonal to the surface of the visor (2). -16-

19. The visor assembly of any of claims 15 to 18, wherein a lateral cross-section of the protrusions (5) defines a circular shape.

20. The visor assembly of any of claims 15 to 18, wherein a lateral cross-section of the protrusions (5) defines a non-circular shape, preferably wherein the lateral cross-section of the protrusions (5) defines a shape which is oval, rectangular, square, star-shaped, or triangular.

21. The visor assembly of any of claims 15 to 20, wherein the protrusions (5) comprise attachments arranged to engage with the add-on component (4), wherein preferably the attachments comprise hooks, barbs, a roughened surface, a local thickening, or an elastic surface.

22. An add-on component (4) comprising an opening (6) arranged to receive a protrusion (5) of a visor (2), said add-on component (4) defining an abutment surface (41) extending at least partly around a periphery of the add-on component (4), said abutment surface (41) being arranged to engage with a lateral side (31) of a lens (3).

23. The add-on component (4) of claim 22, wherein said periphery defines a shape which is circular, oval, rectangular, square, star-shaped, or triangular.

24. The add-on component (4) of any of claims 22 or 23, wherein the opening (6) is provided away from a centre of the periphery so that the periphery defines an eccentric shape in relation to the opening (6).

25. The add-on component (4) of any of claims 22 to 24, wherein the opening (6) defines a circular shape.

26. The add-on component (4) of any of claims 22 to 25, wherein the opening (6) defines a non-circular shape, preferably wherein the opening (6) defines a shape which is oval, rectangular, square, star-shaped, or triangular.

27. Method of manufacturing a visor according to any of claims 15 to 21 , comprising the steps of: providing a mould defining the shape of a visor (2) having two protrusions (5) being integrally formed with the visor (2); injecting pressurized liquid material at a first temperature into the mould; cooling the mould to a temperature lower than the first temperature; and extracting the visor (2) from the mould. -17- Kit of parts comprising: a visor (2) according to any of claims 15 to 21 ; and at least one add-on component (4) according to any of claims 22-26.