A protective helmet having a cover plate over a front vision area and a cover plate knock out assembly for moving the cover plate a predetermined distance away from the helmet so that a finger of a user can get behind the cover plate to enable its removal from the front vision area of the helmet. The cover plate knock out assembly comprises a step-shaped actuator element and a light blocking cover. The upper portion of the step-shaped actuator pushes the cover plate away from the helmet when the lower portion of the step-shaped actuator is pressed. The cover plate made of clear plastic includes a spring tendency when slightly compressed when attached to the helmet thereby pushing the upper portion of the step-shaped actuator into a resting position in the helmet.

A protective helmet having a cover plate over a front vision area and a cover plate knock out assembly for moving the cover plate a predetermined distance away from the helmet so that a finger of a user can get behind the cover plate to enable its removal from the front vision area of the helmet. The cover plate knock out assembly comprises a step-shaped actuator element and a light blocking cover. The upper portion of the step-shaped actuator pushes the cover plate away from the helmet when the lower portion of the step-shaped actuator is pressed. The cover plate made of clear plastic includes a spring tendency when slightly compressed when attached to the helmet thereby pushing the upper portion of the step-shaped actuator into a resting position in the helmet.

Aspects of the present disclosure provide a helmet including customized helmet layers and corresponding methods of construction. In one aspect, a method comprises capturing a 3D image of a head corresponding to the head of an individual, and rendering a 3D headform based on the 3D image. A lining layer is formed, which includes a geometry corresponding to the 3D headform and the inner surface of the shell layer such that an inner surface of the lining layer conforms to the shape of a corresponding portion of the 3D headform. An outer surface of the lining layer further conforms to the shape of a corresponding portion of an inner surface of a shell layer. Another aspect of the method comprises forming a shell layer such that the shell layer includes a geometry corresponding to the shape of a portion of the 3D headform.

A comfort padding, configured to be attached at an innermost surface of a helmet, which is facing a wearer's head, for providing a sliding movement in the comfort padding in response to an oblique force applied to the helmet in use is provided. The comfort padding comprises a layer of membrane material provided closer to the helmet than a layer of stretchable fabric or nonwoven material, and between the two layers there is a layer of open cell polymer foam, the membrane layer has a low friction surface allowing for a sliding movement between the layer of open cell polymer foam and the membrane material. A helmet comprising the comfort padding.

A comfort padding, configured to be attached at an innermost surface of a helmet, which is facing a wearer's head, for providing a sliding movement in the comfort padding in response to an oblique force applied to the helmet in use is provided. The comfort padding comprises a layer of membrane material provided closer to the helmet than a layer of stretchable fabric or nonwoven material, and between the two layers there is a layer of open cell polymer foam, the membrane layer has a low friction surface allowing for a sliding movement between the layer of open cell polymer foam and the membrane material. A helmet comprising the comfort padding.

A press for molding expanded thermoplastic polymers, comprising at least one portion comprising a fixed plane with a first chamber and a movable plane with a chamber, the fixed plane and the movable plane comprising at least one male mold part and at least one female mold part, which form at least one cavity upon closure; the fixed plane of the at least one portion comprises, in a second chamber obtained inside the first chamber, a duct for dispensing steam inside the second chamber, adapted to superheat the at least one male mold part and/or the at least one female mold part, and a duct for dispensing water inside the second chamber, adapted to cool the at least one male mold part and/or the at least one female mold part, and a condensation discharge duct.

A helmet includes a helmet body with an outer shell and an in-molded energy management liner inside the outer shell. The in-molded energy management liner may include an inner liner of a first material and an outer liner of a second material different from the first material, with at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface. The outer liner formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface, and both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner.

Protective gear such as a helmet includes multiple shell layers connected through energy and impact transformer layers. The energy and impact transformer layers may include conical structures used to dissipate mechanical energy applied to an outer shell layer while allowing an outer shell layer the ability to rotate with respect to a middle or inner shell layer. The conical structures may be three dimensional pyramids, three dimensional parabolic structures, and may be outwardly or inwardly oriented.

A method for adjusting the comfort level of a helmet includes the steps of acquiring head shape data by measuring a three-dimensional shape of a head of a wearer of a helmet, inputting inner surface shape data showing a three-dimensional shape of a helmet inner surface, acquiring space information showing a space between the head and the helmet inner surface on the basis of the head shape data and the inner surface shape data, and displaying additional images showing the space information on a display part by superimposing the additional images on i) a shape image showing the inner surface shape data or ii) the shape image showing the head shape data and the inner surface shape data.

A method of manufacturing a protective helmet, in particular a bicycle helmet, that has a shock-absorbing helmet body having a concave inner side and a convex outer side and that has an outer shell arranged at the outer side of the helmet body. The method includes the steps: placing the outer shell into a mold; and filling a casting material into the mold at at least one filling point to form the helmet body. The casting material connects to an inner side of the outer shell. The filling point for the casting material is provided at the outer side of the formed helmet body, with the outer shell having an opening in the region of the filling point.