The present invention relates to a method of manufacturing a body made of composite material such as a shell of a helmet. Said body constitutes a multilayer structure where each layer is formed by superposed strata comprising portions of fabrics preimpregnated with thermoplastic resin in which at least some of said layers are formed by woven or non-woven LFRTP-type preimpregnated fabrics. The outer layer is formed by strata of portions of “veil” type or “felt” type fabrics, with non-woven and non-oriented fibers of lengths comprised between 5 and 20 mm. In the method, the multilayer structure arranged in a mold is subjected to the action exerted by a bag that is inflated due to pressure occupying the cavity of the mold.

Various embodiments of helmets and methods of their manufacture are disclosed. In some embodiments, the helmet includes a helmet shell having a helmet shell edge and/or a mounting location for mounting an accessory to the helmet shell. A material that is adherent to the helmet shell may be sprayed onto the helmet shell edge of the helmet shell to form a trim. Alternatively, the material may be sprayed onto a portion of the helmet shell associated with either a mounting location for mounting an accessory or a position for a mounted accessory.

A video recording system for a head safety device includes a microcontroller and an accelerometer mounted in the head safety device. The accelerometer is coupled to the microcontroller. A plurality of camera modules are mounted on the head safety device and coupled to the microcontroller. The camera modules are positioned facing outward to obtain images at different angles of an environment surrounding the head safety device. The microcontroller receives data from the accelerometer and automatically initiates video recording with the camera modules when movement of the head safety device, as sensed using the accelerometer, reaches or exceeds a selected movement threshold.

The invention relates to a protective sports helmet purposely designed for a selected group of helmet wearers from amongst a larger population of helmet wearers. A multi-step method for helmet design starts by collecting information from a population of players that may include information about the shape of a player's head and the impacts the player has sustained. This information is then processed to create player population information that is sorted to create categories. Advanced mathematical techniques are utilized to further sort these categories into player groups or data sets based on player attributes. Once the player groups are identified, another multi-step process is utilized to design optimized helmet prototype models for each player group. These optimized helmet prototype models are then further processed into complete helmet models by determining a structural design and chemical composition that is manufacturable and has mechanical properties that are substantially similar to the optimized helmet prototype model. Physical helmet prototypes are then created and tested using a unique helmet standard derived from information associated with each player group. Once the prototypes pass testing, the complete helmet models can be manufactured to create actual stock helmets or stock helmet components for future players whose characteristics and attributes place them within the selected player group.

The invention relates to a protective sports helmet purposely designed for a selected group of helmet wearers from amongst a larger population of helmet wearers. A multi-step method for helmet design starts by collecting information from a population of players that may include information about the shape of a player's head and the impacts the player has sustained. This information is then processed to create player population information that is sorted to create categories. Advanced mathematical techniques are utilized to further sort these categories into player groups or data sets based on player attributes. Once the player groups are identified, another multi-step process is utilized to design optimized helmet prototype models for each player group. These optimized helmet prototype models are then further processed into complete helmet models by determining a structural design and chemical composition that is manufacturable and has mechanical properties that are substantially similar to the optimized helmet prototype model. Physical helmet prototypes are then created and tested using a unique helmet standard derived from information associated with each player group. Once the prototypes pass testing, the complete helmet models can be manufactured to create actual stock helmets or stock helmet components for future players whose characteristics and attributes place them within the selected player group.

A hinge mechanism for attaching ear accessories to a helmet allows an accessory to be attached at a point outside the helmet shell utilizing, for example, a slidable mounting rail, and to reach under the edge of the helmet shell so that the accessory is supported in contact with the wearer's head. The hinge mechanism is well suited for use in connection with military helmets that have a “bulge” or protrusion over the ear.

A hinge mechanism for attaching ear accessories to a helmet allows an accessory to be attached at a point outside the helmet shell utilizing, for example, a slidable mounting rail, and to reach under the edge of the helmet shell so that the accessory is supported in contact with the wearer's head. The hinge mechanism is well suited for use in connection with military helmets that have a “bulge” or protrusion over the ear.

A helmet may include a helmet body, a fit system, a bezel, and a hardware retainer. The helmet body may have an outer shell and an energy management layer. The bezel may be separate from the outer shell and coupled to the helmet body at the vent opening of the helmet, encircle the vent opening, and have a hardware opening extending through the bezel and an anchor opening in the bezel adjacent the hardware opening. The hardware retainer may be positioned behind and coupled to the bezel. The hardware retainer may include a hardware receiving aperture aligned with the hardware opening and a hardware retainer cover coupled to a rear side of the hardware retainer. The hardware retainer may further include an anchor recess aligned with the anchor opening. The bezel may be in-molded into the energy management layer.

A helmet may include a helmet body, a fit system, a bezel, and a hardware retainer. The helmet body may have an outer shell and an energy management layer. The bezel may be separate from the outer shell and coupled to the helmet body at the vent opening of the helmet, encircle the vent opening, and have a hardware opening extending through the bezel and an anchor opening in the bezel adjacent the hardware opening. The hardware retainer may be positioned behind and coupled to the bezel. The hardware retainer may include a hardware receiving aperture aligned with the hardware opening and a hardware retainer cover coupled to a rear side of the hardware retainer. The hardware retainer may further include an anchor recess aligned with the anchor opening. The bezel may be in-molded into the energy management layer.

A helmet includes a helmet body and a clip coupled to the helmet body, for retaining a helmet accessory such as a face cage. The clip comprises a first clip section partly defining an aperture into which a part of the helmet accessory can be received and a second clip section located opposite the first clip section. The second clip section has a first end and a second end, the first end partly defining the aperture into which the part of the helmet accessory can be received, and the second end being coupled to the helmet body. The second clip section further includes a ramped surface that can be depressed to provide access to or from the aperture by the part of the helmet accessory. Also disclosed is a clip for retaining a helmet accessory.