Abstract:
A visor assembly for use with a helmet having at least one face mask bar comprises a visor and a mounting bracket. The visor is configured to provide a shield associated with the face mask bar. The mounting bracket is configured to secure the visor to the face mask bar. The mounting bracket includes a clip and a thumbscrew removably connected to the clip. The clip defines a channel configured to receive the face mask bar. A threaded receptacle is positioned on the clip. The thumbscrew includes a threaded post connected to a thumbwheel. The threaded post is configured to threadedly engage the receptacle of the clip and releasably retain the thumbscrew on the clip. The threaded post of the thumbscrew is configured to extend through a hole of the visor and into the receptacle. When the thumbwheel is rotated, the thumbwheel clamps the visor between the thumbwheel and the mounting bracket.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. provisional patent application No. 61/115,358, filed Nov. 17, 2008, the content of which is incorporated by reference herein in its entirety. 
     
    
     FIELD 
       [0002]    This application relates to the field of sports equipment and particularly to attachments such as visors for mounting on protective helmets. 
       BACKGROUND 
       [0003]    Football players and other athletes who use helmets sometimes attach a visor or other accessory to the helmet. Visors are typically attached to the face mask of the helmet. The visor serves as a shield to block foreign objects from passing through the face mask and injuring the athlete. For example, the visor prevents competitor hands and other body parts from passing through the face mask and poking the athlete&#39;s eyes or nose. In addition to serving as a shield, the visor may also be tinted to block sunlight from the athlete&#39;s eyes. Both tinted and clear visors may comprise a UV resistant material that serves to block harmful UV rays from the athlete&#39;s eyes. 
         [0004]    Visors are typically secured to the helmet using two clips positioned on opposite sides of the face mask. In order to mount the visor, a right side clip with two parallel arms is pressed onto a bar on the right side of the helmet until a channel in the clip fully engages the bar. A symmetric left side clip is then placed on a bar on the left side of the helmet. The visor is then positioned between the face mask and the helmet. The clips are then aligned with opposing holes in the visor. A screw is passed through each hole and clip combination and into a threaded bushing and washer seated on the outside of the clip. When the screw is tightened, the visor and clip are pinned in place upon the face mask, thus securing the face mask to the helmet. In order to remove the visor from the helmet, a screwdriver must first be located, and then the screw must be completely removed from the clip. Only after the screw is removed can the visor be released from the clip. This process of obtaining a screwdriver and unscrewing the screw from the clip is not only time consuming, but since the clip arrangement includes numerous parts, including the screw and other small parts, these parts may be easily lost when the screw is removed from the clip. Furthermore, because numerous parts and tools are required, installing and removing conventional clips is generally awkward and frustrating. Additionally, the parallel arms of conventional clips may pinch the user&#39;s fingers when the clips are slid over the bars of the face mask. 
         [0005]    There are several conditions where a visor may need to be quickly and easily removed from the athlete&#39;s helmet during a game (or during practice). As a first example, if light conditions change during a game, the athlete may wish to switch from a clear visor to a tinted visor or vice-versa. Second, if weather conditions change during a game and cause the athlete&#39;s visor to fog-up or accumulate rain droplets, the athlete&#39;s vision may be impaired and the athlete may wish to completely remove the visor. Third, if the athlete is injured on the field, it may be necessary to remove the visor to access the athlete&#39;s face. In these injury situations, the athlete&#39;s head may need to be immobilized such that the visor must be removed from the player without removing the helmet. 
         [0006]    In view of the foregoing, it would be advantageous to provide a mounting arrangement for securing a visor to a helmet that allows the visor to be quickly and easily removed from the helmet without the need for tools. It would also be advantageous if the mounting arrangement allowed the visor to be easily removed from the helmet without the need to remove the helmet from the athlete&#39;s head. Furthermore, it would be advantageous if the mechanism for securing the visor to the helmet included a relatively small number of parts compared to conventional mounting arrangements, allowing the parts of the mounting arrangement to be easily kept together and in order. It would also be advantageous if the mounting arrangement was universal such that it could be used with numerous cage sizes and could be applied to either side of a face mask. 
       SUMMARY 
       [0007]    A helmet attachment assembly is disclosed for use with a football helmet having a face mask comprised of a plurality of cage bars. The helmet attachment assembly comprises a visor configured to provide a shield for an upper portion of the face mask, the visor including at least one hole. The helmet attachment assembly also includes a mounting bracket configured to secure the visor to the face mask. The mounting bracket includes a clip and a removable thumbscrew, wherein the clip comprises a channel configured to receive one of the plurality of bars of the face mask, and wherein the clip further comprises a thumbscrew connector configured to engage the thumbscrew and releasably retain the thumbscrew on the clip. 
         [0008]    In at least one embodiment, the helmet attachment assembly includes a visor and a face mask bracket configured to engage a portion of the face mask. The face mask bracket includes a thumbwheel and face mask clip. The thumbwheel is in rotatable engagement with the face mask clip, wherein rotation of the thumbwheel in one direction secures the face mask clip on the face mask and rotation of the thumbwheel in an opposite direction releases the face mask clip from the face mask. 
         [0009]    In at least one embodiment, the helmet attachment assembly comprises a first material and a second co-molded material that provides a greater degree of cushioning than the first material, wherein the second material is provided in the channel of the clip. The channel is provided as a C-shaped channel that is designed and dimensioned to receive the cage bars of a football face mask. 
         [0010]    In at least one embodiment, a threaded post extends from the thumbwheel, the threaded post configured to engage a threaded receptacle in the face mask clip. The periphery of the thumbwheel is knurled with small grooves designed and dimensioned to receive a man&#39;s or a woman&#39;s fingertips. The interior surface of the thumbwheel is textured and slightly convex to facilitate engagement with the cage bars of a face mask. 
         [0011]    The above described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. However, the teachings disclosed herein extend to those embodiments which fall within the scope of any appended claims, regardless of whether such embodiments accomplish one or more of the above-mentioned advantages or include one or more of the above-mentioned features. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  shows one embodiment of a helmet attachment assembly provided in the form of a visor mounting arrangement for a football helmet; 
           [0013]      FIG. 2  shows a front view of the visor used with the mounting arrangement of  FIG. 1 ; 
           [0014]      FIG. 3  shows an elevational view of the interior surfaces of a clip and thumbscrew of the visor mounting arrangement of  FIG. 1 ; 
           [0015]      FIG. 4  shows a perspective view of the clip of  FIG. 3 ; 
           [0016]      FIG. 5  shows a side elevational view of the clip of  FIG. 3 ; 
           [0017]      FIG. 6  shows an elevational view of the outer surface of the clip of  FIG. 3 ; 
           [0018]      FIG. 7  shows a perspective view of the thumbscrew of  FIG. 3 ; 
           [0019]      FIG. 8  shows a side elevational view of the thumbscrew of  FIG. 3 ; and 
           [0020]      FIG. 9  shows an elevational view of the outer surface of the thumbscrew of  FIG. 3 . 
       
    
    
     DESCRIPTION 
       [0021]    With reference to  FIG. 1 , a helmet attachment assembly in the form of a visor assembly  20  is shown mounted on a football helmet  12  with a face mask  14 . The visor assembly  20  includes a visor  22  and a mounting bracket  24  configured to secure the visor  22  to the face mask  14 . The mounting bracket is secured to the bars  16  which make up the face mask cage. As explained in further detail below, the mounting bracket  24  is generally provided as a two-piece assembly comprising a clip  26  and a fastening member configured for use with a human hand. In at least one embodiment, the fastening member comprises a thumbscrew  28 . 
         [0022]    With reference now to  FIG. 2 , the visor  22  is made of a plastic material which allows the athlete to see through the visor. The visor  22  may be clear or tinted to block some amount of light from passing through the visor. The visor  22  includes two upper tab members  31  and  32  and two lower tab members  33  and  34  which extend outward near the corner portions of the visor. The lower tab members  33  and  34  each include a hole  36 . The visor also includes a central upper tab member  35 . The periphery of the visor  22  is slightly larger than the bars which define an upper cage portion of the face mask  14 . This allows the visor  22  to be conveniently positioned between the helmet  12  and the face mask  14  such that the bars  16  of the face mask help keep the visor in place on the helmet. Although the tab members and holes have been shown in a symmetric arrangement in  FIG. 2 , in at least one alternative embodiment, the holes  36  and/or tab members  31 - 35  may be provided in an asymmetric pattern. 
         [0023]      FIG. 3  shows at least one embodiment of the mounting bracket  24  provided as a two-piece arrangement comprised of a clip  26  and a thumbscrew  28 . The clip is shown in further detail in  FIGS. 4-6  and the thumbscrew is shown in further detail in  FIGS. 7-9 . 
         [0024]    With particular reference now to  FIGS. 3-6 , the clip  26  of the mounting bracket  24  is comprised of a relatively hard and rigid polymer material. For example, the clip  24  may be comprised of polyethylene, PVC, or another polymer material. The clip  26  is a substantially flat and smooth outer surface  40  and a contoured inner surface  42 . The outer surface  40  of the clip  26  is generally trapezoidal in shape with a longer upper portion  44 , a shorter lower portion  46 , and slanted sides  41 ,  43 . The outer surface  40  of the clip  26  is designed to face outward from the helmet  12  when the clip is mounted on the helmet. 
         [0025]    The contoured inner surface  42  of the clip  26  includes chamfered edges  45  along the longer upper portion  44 . A C-shaped channel  48  runs laterally from side-to-side across the upper portion  44  of the clip  26  beneath the chamfered edges  45 . The upper wall  47  of the channel  48  is longer than the lower wall  49  of the channel, making the openings at the ends of the channel slightly slanted relative to the walls  47  and  49 . This slant defined at the channel openings is the same slant defined along the sides  41 ,  43  of the trapezoidal shaped clip  26 . The slanted sides  41 ,  43  of the clip  26  generally matches the slant of the vertical bars found on most face mask cages and the vertical edge of the visor, thus allowing the side edge of the clip  26  to be substantially aligned with the face mask bars and visor when mounted on the helmet  12 , as shown in  FIG. 1 . Furthermore, because the slant is provided on both sides  41  and  43  of the clip  26 , the clip may be used on either the left or right side of the helmet  12  and still be aligned with the slanted vertical bars of the face mask cage  14 . 
         [0026]    The C-shaped channel  48  is designed and dimensioned to at least partially receive one of the cage bars of a typical football face mask. Depending on the diameter and depth of the channel  48 , the cage bar may be only partially engaging the channel  48  or may be fully seated in the channel  48 . The channel  48  includes a plurality of surface irregularities, such as vertical ribs  50 , which provide additional gripping ability of the clip  26  against the face mask bar. In at least one embodiment, the surface irregularities are provided by a resilient plastic insert  52  that provides a rubber cushion effect in the C-channel  48 . Accordingly, the insert  52  may be comprised of, for example, a polyurethane material or other elastomer material. The resilient quality of the insert  52  allows for compression of the material when various sized face mask cages are secured in the C-channel, and also prevents the cage from slipping in the channel  48 . This accommodates varying amounts of vinyl dip coating that manufacturers use on the face mask bars. In at least one embodiment, the insert  54  extends through the lower portion  46  of the clip and provides a lower cushion surface  54  on the bottom of the clip  26 . 
         [0027]    The lower portion  46  of the clip  26  also includes a threaded receptacle  56 . The threaded receptacle  56  may be comprised of a corrosion resistant material to inhibit and prevent rust. In at least one embodiment, the threaded receptacle may be comprised of a metal material, such as steel or a steel alloy. The opening to the threaded receptacle is located adjacent to the lower edge of the C-channel  48 . The receptacle  56  is configured to receive a threaded post of the thumbscrew  28 , as described in further detail below. 
         [0028]    The clip  26  may be formed by any of various methods, including injection molding. The cushion insert  52  may be co-molded with the rest of the clip such that the clip  26  is provided as a single integral component. In this embodiment, the color of the cushion insert may be customized to match that of various teams or school colors. The plastic material of the clip  26  is molded around the receptacle  56  when the clip is formed, thus securing the receptacle in place on the clip  26 . The co-molded materials allow for a unified part that is stronger than would be achievable if the different materials were joined with glue or other solvents. In particular, the co-injection molded materials form a stable bond under the heat and pressure of the co-molding process. 
         [0029]    With reference now to FIGS.  3  and  7 - 9 , the thumbscrew  28  includes a threaded post  60  extending outward from the center of a hand adjustment member provided in the form of a disc shaped thumbwheel  62 . The threaded post  60  may be comprised of a corrosion resistant material. In at least one embodiment, the threaded post is comprised of a metal material, such as steel, similar to the receptacle  56 . The thumbwheel may be comprised of a relatively hard polymer material such as, for example, a polyethylene or a poly-vinyl chloride, similar to the clip  26 . 
         [0030]    The length of the post  60  of the thumbwheel allows for proper engagement and tightening of the thumbscrew  28  in the threaded receptacle  56 . In particular, the post  60  is not too long such that it bottoms out in the receptacle  56  before properly tightening the visor on the helmet, as described in further detail below. In addition, the post  60  is not too short such that the threads of the post do not reach or have insufficient holding strength because only a few turns of the thumbscrew is possible before the visor is tightened on the helmet. Accordingly, in at least one embodiment, the post  60  is between 8 mm and 12 mm in length, and the receptacle  56  is a similar depth. In any event, the length of the post and receptacle should generally provide a good post/receptacle combination that allows for face masks of various sizes to be placed in the channel  48  of the clip  26  without allowing the post to bottom out in the receptacle and still allowing for sufficient tightening engagement between the threads on the post  60  and the receptacle  56 . 
         [0031]    When making a determination for the length of the post, the designer will generally consider the helmet/cage/face mask set-up. In at least one common embodiment, the visor is approximately 2.5 mm thick, offsetting the thumbwheel from the clip by 2.5 mm. As long as the face mask bar fits well within the “c” channel, then a sandwich of parts is created forming a median/baseline measurement. Contributing factors such as the diameter of the vinyl dip coat and obstructions like cage bars will ultimately effect the median measurement plus or minus a few millimeters. A post having a length of 10 mm post + or −2 mm provides a good length when used with a 2.5 mm visor and an 8 mm diameter cage bar. However, in other embodiments the post may be longer, especially if the post must pass through additional elements in addition to the visor, such as a washer or additional clip members before engaging with the receptacle. 
         [0032]    The thumbwheel disc  62  includes a knurled perimeter  64  which includes a plurality of concave grooves  66  designed and dimensioned to receive the tips of a human finger or thumb. To facilitate easy rotation of the thumbwheel  62  by the user, the thumbwheel disc  62  is typically between 10 mm and 30 mm in diameter, although it will be recognized that thumbwheels of other diameters are also possible. In at least one embodiment, the thumbwheel  62  is about 20 mm in diameter. The thumbwheel disc  62  also includes a plurality of voids  65  formed in the disc. These voids generally reduce the overall weight of the thumbscrew  28 . 
         [0033]    As best shown in  FIG. 8 , the outer wall  68  of the thumbwheel disc  62  is convex and substantially smooth. The opposite inner wall  70  of the thumbwheel disc  62  is also convex and includes a plurality of small surface irregularities. The surface irregularities may take the form of a plurality of small bumps  72  provided in numerous rows on the convex surface of the inner wall. The threaded post  60  extends outward from the inner wall  70  of the thumbwheel disc  62 . 
         [0034]    The small bumps  72  on the inner surface of the thumbwheel  62  are configured to closely engage the visor surface and prevent the threaded post  60  from backing out of the receptacle when the thumbscrew  28  is fastened to the clip  26  and tightened against the visor  22 . Advantageously, the convex shape of the thumbwheel inner wall  70  generally compliments the concave inner surface of the visor and prevents the visor from interfering with the visor when the thumbwheel  62  is tightened. In particular, in certain embodiments where the thumbwheel has a generally flat inner wall, the thumbwheel may tend to engage the surface of the visor before the thumbscrew is completely tightened, thus making it difficult to further rotate and completely tighten the thumbscrew. Accordingly, in the embodiment of  FIG. 8 , the convex shape of the inner wall  70  facilitates rotation and complete tightening of the thumbwheel  62 . 
         [0035]    Returning again to  FIG. 1 , the football helmet  12  is shown having the visor  22  secured to the face mask using the mounting bracket  24  described herein. In order to secure the visor  22  to the mounting bracket  24 , the user first places the visor  22  between the upper cage bars of the face mask  14  and the helmet  12 . Next, the user places the clip  26  on the cage bars  16  located below the eye area by inserting the C-channel  48  of the clip over the outer portion of the cage bar. The user then aligns the receptacle  56  of the clip  26  with the hole  36  in the visor  22 . After this, the threaded post  60  of the thumbscrew  28  is inserted through the opposite side of the hole  36  in the visor and into the receptacle  56  of the clip  26 . The thumbwheel  62  is then rotated such that the threads of the post  60  engage the threads of the receptacle  56 . The user continues to tighten the thumbscrew until the inner convex wall  70  of the thumbwheel  62  is tightly pressed against the visor  22 . The convex inner surface  70  of the thumbwheel  62  allows the thumbwheel to continue to turn against the inner surface of the visor even as the thumbwheel  62  is tightened. Furthermore, the gripping bumps  72  on the inner surface  70  of the thumbwheel  62  help prevent the thumbwheel  62  from slipping on the visor and backing out when the thumbscrew is tightened. The process is then repeated with a second clip and thumbscrew on the opposite side of the visor. When the clips  26  and thumbscrews  28  are securely mounted on both the left and right sides of the cage bars, the visor is secured in pace on the helmet. 
         [0036]    The size and shape of the thumbwheel  62 , including with the fingertip grooves  66 , allows the thumbwheel to be easily manipulated by a human hand. Thus, a user may tighten and loosen the thumbscrew  28  when attaching the visor assembly to the helmet without the need for tools. Of course, if desired, tools such as pliers may also be utilized to provide additional tightening or loosening force. In addition, in at least one embodiment, the thumbwheel may include a bit-shaped slot, groove or other tightening feature for use in combination with a screwdriver, wrench or other tool to provide the user with the option of tightening the thumbscrew with additional force. 
         [0037]    Advantageously, because both side portions of the clip  26  are slanted as described above, a clip may be used on either the left or right side of the helmet and still align with the slant on the face mask and visor. This configuration allows the mounting brackets  24  to be sold in a kit that includes a visor and two or more identical mounting brackets. With such a kit, the purchaser may conveniently use either clip  26  on the left or right side of the helmet  12  without concern that a clip  26  has been improperly placed on either the left or right side of the helmet. In addition, when used with a double-bar face mask cage, the clip  26  can be positioned on either of the lower bars. The ability to place the clip on different bars allows the user to raise or lower the visor on the helmet to better align the edge of the visor with the edge of the face mask bar and reduce the potential for the edges to interfere with the wearer&#39;s line of sight. This is generally in contrast to conventional slip-on type clips that are configured only for use on the top bar of a double bar cage. With such conventional clips, the clip cannot be properly installed between the top bar and the lower bar, and therefore such conventional clips are not designed with the level of adjustment contemplated by the clip  26  described herein. 
         [0038]    In addition to the foregoing, it will be recognized that each clip  26  is relatively simple and includes only two distinct parts that are used together to provide the mounting bracket. Accordingly, there are fewer parts that may be lost than in past arrangements. In addition, because the parts are universal, they may be used interchangeably on either side of the helmet. 
         [0039]    As set forth in the preceding paragraph, the mounting bracket  24  allows a person to quickly and easily secure the visor  22  to the helmet  12  without necessarily requiring the use of a screwdriver, pliers, or other tools. In addition, the mounting bracket  24  and visor  22  may be conveniently removed from the helmet  12  without the use of tools. In order to remove the mounting bracket  24  and visor  22  from the helmet  12 , the user simply rotates the thumbwheel  62  in a counter-clockwise direction until the threads of the thumbscrew post  60  are released from the threads of the receptacle  56  on the clip  26 . Once the thumbscrew  28  is released from the clip  26 , the thumbscrew post  60  is pulled out of the hole  36  in the visor  22 , releasing the visor  22  from the mounting bracket  24  and face mask  14 . 
         [0040]    Although the helmet attachment assembly has been described with respect to the embodiment shown in  FIGS. 1-9 , it will be appreciated by those of skill in the art that other implementations and adaptations are possible. For example, instead of the fastening member comprising a threaded post, the fastening member could comprise a threaded receptacle that receives a threaded post on the clip. As another example, the fastening member could include a locking post with a spring bearing or cotter pin that is used to secure the fastening member to the clip in lieu of a threaded post. As yet another example, a Clevis pin or a click-lock style clip similar to those found on lanyards, quick release key chains and backpack straps could be used to attach the clip to the face mask. Moreover, there are advantages to individual advancements described herein that may be obtained without incorporating other aspects described above. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.