Patent Description:
Operatives working in potentially hazardous environments, such as construction sites and the like, are required by statute in most jurisdictions worldwide to wear a safety helmet or "hard hat" to prevent severe head trauma in the event of an accident. Numerous different types of such safety helmets are widely known and extensively used throughout various industries.

For some activities, where there is a risk of facial injury or where eye protection is required, an operative may wear a safety helmet assembly comprising a helmet shell and a transparent visor mounted on the helmet shell so as to be selectively movable between a raised/stowed position and a lowered operable position over the user's eyes and face.

Many different such visor-equipped helmet assemblies are known and widely used. For example, in its simplest form, opposing pivot pins may be mounted on respective sides of a helmet shell and engage with opposing side edges of a visor such that it can be pivoted up and down, about a horizontal axis, as required.

However, simply pivoting the visor up and down is considered undesirable because the stowed configuration disrupts the balance of the helmet, and may be uncomfortable, especially for prolonged use. In addition, it is becoming increasingly desirable to provide a removable visor carrier that can be fitted to a standard safety helmet, such that the same helmet can be used for multiple purposes.

<CIT> describes a so-called dual-pivot face shield or visor assembly. The dual-pivot assembly is configured to allow a user to adjust the visor relative to the helmet between three positions. In a first position, the visor is fully down and over a user's face. The configuration of the assembly is such that, in this position, the visor is angled inwardly from the upper brim to the lower edge. Whilst this may contribute to the facial protection provided, it can also be detrimental to the user's ability to see properly through the visor. Ideally, in the operable position, the visor should be substantially at right angles to the user's eyeline to optimise its optical performance.

In order to move the visor to the second position, they need to lift the visor relative to the helmet, causing it to pivot about a first horizontal axis, thereby moving it up and over the crown of the helmet shell. In this position, the visor can be temporarily stowed, where short periods of time between use and non-use is envisaged. However, in this position, the visor position changes the centre of gravity of the assembly, which can be detrimental to the balance of the overall helmet assembly and cause discomfort to the user. Finally, for longer term 'storage', the user can pull the visor forward (from the above-referenced second position) such that it is caused, by the double-pivot mechanism, to pivot about a second horizontal axis located rearwardly of the first horizontal axis (relative to the helmet), and in a direction opposite to the first pivoting action, so as to lower the visor closer to the crown of the helmet and, thereby reducing the centre of gravity and perceived weight, improving balance and, thereby, comfort to the user.

However, the proposed assembly is bulky, with several moving parts and potential points of wear, weakness and failure. The elasticated strap, which secures the visor assembly to the helmet for use, is unsightly and can be difficult to fit. Furthermore, the strap is susceptible to wear.

<CIT> describes a visor attachment for use in combination with a conventional safety helmet wherein the visor is pivotally mounted at the back of the helmet; when used, such helmet is thus worn front-to-back. The attachment body has two side extensions which are adapted to fit into rim slots usually provided in opposite sides of a conventional helmet. These extensions each include a manually releasable connecting member which engages the slot, allowing the visor attachment to be removed from the helmet.

<CIT> discloses a movement device for a helmet for moving a first element of the helmet with respect to a second element of the helmet. The movement device includes a pivot element for pivoting the first element of the helmet with respect to the second element of the helmet about an axis of rotation, and a pivot seat, in which the pivot element is arranged. The pivot element includes an eccentric portion or cam, and said seat includes a first seat region adapted to receive said eccentric portion and a second seat region adapted to receive said eccentric portion. The first seat region is in a position angularly offset and linearly translated with respect to said second seat region. A first position of the pivot element corresponds to said first seat region and a second position of the pivot element corresponds to a second seat region, such that, when the eccentric portion of the pivot element passes from the first seat region to the second seat region, the pivot element performs both a rotation in order to compensate for angular offsetting between the second seat region and the first seat region and a translation to compensate for linear offsetting between the second seat region and the first seat region.

<CIT> discloses a plastic face shield that is secured to a frame of a helmet by means of a cam that is rotatably mounted on the frame. The cam projects into an elongated slot in the shield and the dimensions of the cam are such that its maximum length is slightly greater than the minor dimension of the slot.

There is an ongoing desire to improve visor carrier assemblies, and the present invention seeks to address one or more of the above-mentioned issues.

In accordance with an aspect of the present invention, there is provided a visor carrier assembly for a safety helmet, comprising: a visor; and an attachment device for attaching the visor to a safety helmet for use, the attachment device including a double-pivot mechanism attachable to each side of a safety helmet and configured to enable the visor to be selectively pivoted relative to said safety helmet, in use, between at least first, second and third visor positions, as defined in claim <NUM>.

There are numerous advantages associated with various aspects of the present invention. Firstly, because the configuration of the double-pivot mechanism allows attachment thereof to the side of the helmet, the centre of gravity is improved, compared with prior art arrangements, thereby improving balance and comfort. The double-pivot mechanism can be connected directly to the visor, eliminating the need for a separate visor carrier element and, thereby, reducing the weight (and cost) of the assembly, in comparison to prior art arrangements. The double pivot mechanism comprises a second elongate arm configured to be fixedly mounted at a respective side edge of a safety helmet for use, wherein a said coupling region is provided in or on the second elongate arm. The coupling region can be provided integrally with the second elongate arm, beneficially at an end thereof. The first pivotal coupling can be located toward the front of the safety helmet relative to the second pivotal coupling, in use.

No spring loaded struts, or other relatively complex components are required, which reduces the points of wear and potential failure, as well as reducing weight. Indeed, the configuration of the double-pivot mechanism is such that the weight and bulk of the assembly is minimised. Still further, the configuration of the double pivot mechanism enables accessories, such as ear defenders, to be used in conjunction therewith, and also stowed over the crown of the helmet shell, without interference from the visor carrier assembly.

The two pivotal couplings can be substantially horizontally aligned relative to the helmet, when oriented for use, in at least a first visor position in which said visor is fully deployed over a user's face. In prior art arrangements, the coupling between the mechanism and the visor tends to be below the brim of the helmet when in the fully lowered position, which introduces a point of weakness and can also be a hazard, especially if it protrudes significantly from the side of the visor.

These and other aspects of the present invention will be apparent from the following detailed description.

In the preceding and following description, directional descriptors such as upper, lower, inner, outer, vertical, horizontal, etc. are used to describe the invention when in the preferred orientation. It will be understood that the orientation can change during use, and therefore the corresponding descriptors will change.

Referring to <FIG> and <FIG> of the drawings, a safety helmet <NUM> is illustrated, on which a visor carrier assembly <NUM> is mounted. The safety helmet <NUM> can comprise any known configuration and can be formed of a hard outer shell 10a which is generally dome shaped so as to fit over the head of a user when worn, and the rim is generally oval in shape. The shell can be constructed of plastic materials typical of such safety helmets although it will be appreciated that the shell <NUM> can be constructed of any suitable material as will be apparent to those skilled in the art and the present invention is not necessarily intended to be limited in this regard. The safety helmet <NUM> further comprises an integral brim 10b that extends around the front edge of the shell 10a. A universal slot 10c is provided on opposing side edges of the shell 10a to receive further protective equipment, such as ear defenders <NUM>.

The visor carrier assembly <NUM> comprises a transparent visor <NUM>, in the form of a faceshield, and an attachment device <NUM> for attaching the visor <NUM> to the safety helmet <NUM> for use. The faceshield is formed of a curved piece of transparent material substantially large enough to protect the wearer from flying particulates and debris which might otherwise strike the wearer's face and cause injury or irritation. <FIG> and <FIG> illustrate the faceshield in the operable position, wherein the faceshield extends downwardly from the brim 10b of the safety helmet <NUM> and effectively covers the user's face during use. In the operable position, the faceshield <NUM> is angled or oriented so that the part of the faceshield adjacent the wearer's eyes is substantially perpendicular to the wearer's eyeline. The faceshield <NUM> is curved along its lateral axis, so that the faceshield <NUM> protects the side of the wearers face during use.

Referring additionally to <FIG> and <FIG> of the drawings, the attachment device comprises a double pivot mechanism <NUM>, attached or otherwise provided on each side of the visor <NUM>, at its upper edge when oriented for use. The term, 'double pivot mechanism' refers to a mechanism that allows the visor to be pivoted about two separate but parallel horizontal axes. More specifically, it enables the visor <NUM> to be pivoted about a first axis, upward, away from the user's face and over the top of the safety helmet <NUM> (see <FIG>), and then about a second axis, downward and toward the helmet shell 10a so that it can be stowed close to the top of the helmet (as illustrated in <FIG>), without significantly affecting the centre of gravity and balance of the helmet/visor carrier assembly.

Referring now to <FIG>, each double pivot mechanism <NUM> comprises a first elongate arm <NUM> and a second elongate arm <NUM>. The first elongate arm <NUM> is generally linear along its length and has a rounded first end <NUM>. The longitudinally opposing second end terminates in a wider coupling region <NUM> defining a profiled aperture <NUM>.

The second elongate arm <NUM> is generally arcuate along its length having a concave recess or 'cap' <NUM> at one end. The longitudinally opposing other end terminates in a coupling region <NUM> defining a profiled aperture <NUM>. The first and second elongate arms <NUM>, <NUM> can be formed of any suitable material, such as hard plastic or rubber, and the present invention is not intended to be in any way limited in this regard.

The inner edge of each coupling region <NUM>, <NUM> of a double pivot mechanism <NUM> (i.e. the profiled edge of the respective aperture <NUM>, <NUM> nearest the main body of the respective elongate arm <NUM>, <NUM>) defines a respective notch <NUM>, <NUM>. Referring to the coupling region <NUM> of the first elongate arm <NUM>, the profiled edge of the aperture <NUM> opposite the notch <NUM>, defines two laterally spaced apart rounded notches 39a, 39b and a generally arcuate wall therebetween. Referring to the coupling region <NUM> of the second elongate arm <NUM>, the profiled edge of the aperture <NUM> has two spaced-apart ridges 42a, 42b and rounded wall sections between the notch <NUM> and the ridges 42a, 42b and a generally arcuate wall section between the ridges 42a, 42b.

Referring to <FIG> of the drawings, the visor <NUM> is pivotally coupled to the second elongate arm <NUM> by a coupling peg <NUM> which is received within the aperture <NUM> of the coupling region <NUM> of the second elongate arm <NUM> (see <FIG>). The coupling peg <NUM> is generally elongate and of a length substantially equal to the distance between the notch <NUM> and the opposing profiled wall of the aperture. The coupling peg <NUM> comprises two generally circular locating members 52a, 52b with an integral short, narrower linear portion <NUM> therebetween. One of the locating members 52a of the coupling peg <NUM> is received within the notch <NUM> and defines a first fixed pivot point (i.e. the 'front' pivot point) of the mechanism. The other locating member 52b sits against the opposing profiled wall so that, as the mechanism is pivoted about the first fixed pivot point defined by the first locating member 52a, the second locating member 52b can slide along the profiled wall.

The second elongate arm <NUM> is pivotally coupled, at the end including the cap <NUM>, to the first elongate arm <NUM> by a coupling peg <NUM> which is received in the aperture <NUM> of the coupling region <NUM> of the first elongate arm (see <FIG>). Once again, the coupling peg <NUM> is generally elongate and of a length substantially equal to the distance between the notch <NUM> and the opposing profiled wall of the aperture <NUM>. The coupling peg <NUM> comprises two generally circular locating members 58a, 58b with an integral narrower linear portion <NUM> therebetween. One of the locating members 58a is received within the notch <NUM> and defines a second fixed pivot point of the mechanism. The other locating member 58b sits against the opposing profiled wall so that, as the mechanism is pivoted about the second fixed pivot point (i.e. the 'rear' pivot point) defined by the first locating member 58a, the second locating member 58b can slide along the profiled wall.

Together, the two pivot mechanisms, that define two separate but substantially parallel horizontal pivotal axes, provide a visor carrier assembly with five defined visor positions, as will now be described with reference to <FIG> and <FIG> of the drawings. When the visor carrier assembly is mounted on the safety helmet for use, the first elongate arm <NUM> is fixedly attached on the safety helmet, the second elongate arm <NUM> is configured to be selectively pivoted relative to the first elongate arm <NUM> about the rear pivot point, and the visor <NUM> can be selectively pivoted relative to the second elongate arm <NUM> (at the opposite end) about the front pivot point, relative thereto in order to move the visor into a selected one of the five defined visor positions.

Referring to <FIG> of the drawings, a first visor position is defined when the coupling peg <NUM> (coupling the visor <NUM> to the second elongate arm <NUM> at one end) is in Position A (the locating member 52b of the coupling peg <NUM> is located in the ridge 42b) abutting a first side edge (i.e. horizontal / uppermost edge) of the aperture <NUM> defining the coupling region <NUM> of the second elongate arm <NUM>, and the second coupling peg <NUM> (coupling the second elongate arm <NUM> at the other end - i.e. the end opposing the end of the second elongate arm <NUM> with the coupling region <NUM> - to the fixed first elongate arm <NUM>) is in Position <NUM> (the locating member 58b of the coupling peg <NUM> is located in the notch 39a) abutting a first side edge (i.e. uppermost edge) of the aperture <NUM> of the coupling region <NUM> of the first elongate arm <NUM>. As shown in <FIG>, when the double pivot mechanism is in this configuration, in use, the visor <NUM> is fully down and locked for use. In other words, the visor <NUM> is in the operable position, described above, when the visor <NUM> extends downwardly from the brim 10b of the safety helmet <NUM> and effectively covers the user's face during use. In the operable position, the visor <NUM> is angled or oriented so that the part of the visor <NUM> adjacent the wearer's eyes is substantially perpendicular to the wearer's eyeline. In this configuration, the coupling peg <NUM> and the visor <NUM> can be described as being at an angle of <NUM>° from horizontal.

From this configuration, if the visor <NUM> is pushed upward, away from the user's face, it can pivot about the second (rear) fixed pivot point until the respective coupling peg <NUM> reaches Position <NUM> (the locating member 58b of the coupling peg <NUM> is located in the notch 39b), having respectively passed Positions <NUM> and <NUM> (the locating member 58b of the coupling peg <NUM> is located at the generally arcuate wall section between notches 39a and 39b), abutting the opposing side wall/edge (i.e. lowermost edge) of the aperture <NUM> defining the coupling region <NUM> of the first elongate arm <NUM>. During this process, the other pivotal coupling (i.e. the coupling peg <NUM>) remains stationary in Position A and, when the rear pivot reaches Position <NUM>, the visor <NUM> is fully up, over the user's head and over the top of the safety helmet <NUM>, as illustrated in <FIG> and <FIG>. In this configuration, the coupling peg <NUM> and the visor <NUM> can be described as being at about an angle of <NUM>° from the operable position, when the visor is fully down and locked for use.

From this configuration, the visor <NUM> can be pivoted (relative to the second elongate arm <NUM>) about the front pivot (with the rear pivot remaining stationary in Position <NUM>), through Position B of the front pivot (the second locating member 52b of the coupling peg <NUM> is located in the generally arcuate wall section between the ridges 42a, 42b) - see <FIG> and <FIG>; to position C (the second locating member 52b of the coupling peg <NUM> is located in ridge 42a) with the coupling peg <NUM> abutting the opposing side wall/edge (i.e. lowermost edge) of the aperture <NUM> (see <FIG>), thereby moving the visor <NUM> to a fully stowed and locked configuration, as shown in <FIG>.

As illustrated by <FIG>, the visor <NUM>, when being pivoted down for use, from the fully up position illustrated in <FIG>, the front pivot remains stationary at Position A and the rear pivot moves through Position <NUM> (at which the angle of the visor <NUM> and the coupling peg <NUM> is around <NUM>° from the operable position; and the locating member 58b is located at the end of the generally arcuate wall section , between notches 39a and 39b, that is closest to notch 39b) to Position <NUM> (at which the angle of the visor <NUM> and the coupling peg <NUM> is around <NUM>° from the operable position; and the locating member 58b is located at the end of the generally arcuate wall section, between notches 39a and 39b, that is closest to notch 39a), see <FIG>, and, from there, can be moved to Position <NUM> for use (<FIG> and <FIG>).

The 'cap' <NUM> of the second elongate arm <NUM> arcs over the existing universal slot 10c of the safety helmet <NUM>, thus enabling both the visor assembly and other mountable components to be attached to the safety helmet <NUM> and function independently without compromising the function of the visor assembly and the mountable component. For example, ear defenders <NUM> can be attached to the safety helmet <NUM> with the visor assembly, and both can function independently without compromising either element of face and/or ear protection. The ear defenders <NUM>, with their standard universal attachment means, are not interfered with, either in use or, indeed, when not in use, because the pivot mechanism enables ear defenders <NUM> and the visor <NUM> to be stored together above the helmet <NUM>.

The lightweight and streamlined arrangement, together with the fact that both pivots remain above the brim of the safety helmet <NUM> at all times, irrespective of the visor position, results in significantly reduced weight and improved balance and comfort.

The double pivot design enables the visor <NUM> to be stowed close to the crown of the helmet <NUM>, thus reducing the centre of gravity, perceived weight and improving balance, thus increasing comfort. All of these benefits are provided whilst still providing a useful range of 'locked' visor positions.

Claim 1:
A visor carrier assembly (<NUM>) for a safety helmet (<NUM>), comprising:
a visor (<NUM>); and
an attachment device (<NUM>) for attaching the visor (<NUM>) to the safety helmet (<NUM>), the attachment device (<NUM>) including double-pivot mechanisms (<NUM>) for attachment to each side of the safety helmet (<NUM>) to enable the visor (<NUM>) to be selectively pivoted relative to the safety helmet (<NUM>), between first, second and third visor positions;
characterised in that:
each double pivot mechanism (<NUM>) comprises first and second elongate arms (<NUM>, <NUM>);
the first elongate arm (<NUM>) is to be fixedly mounted at a respective side edge of the safety helmet (<NUM>) and a coupling region (<NUM>) is provided in or on the first elongate arm (<NUM>);
the second elongate arm (<NUM>) is:
coupled at one end to a respective side region of the visor (<NUM>) by a first pivotal coupling comprising a coupling member (<NUM>) and a coupling region (<NUM>), and
coupled at a second end to the coupling region (<NUM>) of the first elongate arm (<NUM>) by a second pivotal coupling comprising a coupling member (<NUM>) and a coupling region (<NUM>);
each coupling member comprises a fixed elongate pin (<NUM>, <NUM>) having a rounded portion (52a, 52b, 58a, 58b) at each end;
each coupling region (<NUM>, <NUM>) comprises an aperture (<NUM>, <NUM>) defining a first notch or aperture (<NUM>, <NUM>) along its inner edge within which one of the rounded portions (52a, 58a) of a respective coupling member is received to define a fixed pivot point, and an arcuate guide wall with which the opposite rounded portion (52b, 58b) of said respective coupling member engages and having ridges defining grooves or notches (39a, 39b, 42a, 42b) for receiving the opposite rounded portion (52b, 58b) as a respective pivotal coupling is pivoted about the fixed pivot point; and
each groove or notch (39a, 39b, 42a, 42b) defines a respective visor position.