A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

A method for fabricating a strengthened plastic shell of a safety helmet and a helmet structure fabricated using the method are disclosed. The method includes providing at least one fiber layer and at least one shell that has a thin, flat structure; binding the fiber layer to the shell to form a preform; heating and pressing the preform with a first forming module, so that at least some local, surface texture of the shell is fused with or interlaced with the fiber layer to form an assembly that has a helmet-like shape (or contour); and arranging a foam material at an inner surface of the assembly and attaching the foam material over the inner surface of the assembly using a second forming module, thereby forming a helmet structure. The method makes the overall fabrication less complicated and less time-consuming as compared to the prior art.

The present invention relates to a method for preparing a three-dimensional shaped article, comprising the following steps: a) unfolding the three-dimensional profile of the three-dimensional shaped article with a curved surface via a computer-aided design software; b) dividing the unfolded three-dimensional profile obtained in step a) into several elemental layers via the computer-aided design software; c) cutting a continuous fiber reinforced thermoplastic resin based composite sheet to have the same or similar shape and size with the elemental layers; d) stacking the cut composite sheets in order of size to obtain a stack; and g) forming the stack obtained in step d), followed by demoulding and optionally trimming to obtain the three-dimensional shaped article. With the method of the present invention, a continuous fiber reinforced thermoplastic resin based composite sheet can be processed into a three-dimensional shaped article with uneven thickness and a high degree of curvature. The resulting three-dimensional shaped article features a light weight, good impact resistance and compression resistance.

A bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the bespoke protective equipment with a custom formed internal padding assembly that substantially corresponds to the player's unique data. The system and method allows for the design and manufacture of bespoke protective sports equipment that is purposely designed and manufactured to match the anatomical specifications of the player's body part.

Partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.

A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

A partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck comprising an interface surface and at least one side is formed. The interface surface of the puck is placed in direct contact with a receiving surface of a cap located in an impact liner mold. Next, the interface surface of the puck is thermally fused directly to the receiving surface of the cap while contemporaneously an impact liner body is formed inside the mold. The impact liner body is fused to the at least one side of the puck, and to a majority of the receiving surface of the cap. The density of the puck may be greater than the density of the impact liner body. The puck and the impact liner body may be expanded polystyrene (EPS), and the cap may be polycarbonate (PC).

A bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the bespoke protective equipment with a custom formed internal padding assembly that substantially corresponds to the player's unique data. The system and method allows for the design and manufacture of bespoke protective sports equipment that is purposely designed and manufactured to match the anatomical specifications of the player's body part.

The present invention relates to a new headgear for protecting the head of a person, the new headgear comprising: a base body; a plurality of high frequency impact absorbing elements embedded or adhered to the base body; a cover element that surrounds the base body and the plurality of high frequency impact absorbing elements; a pair of adjustment pieces partially embedded or adhered to the low portion of the base body; and an adjustment band or strap that joins both adjustment pieces; wherein the base body is made of a material capable of absorbing low frequency impacts and the plurality of high frequency impact absorbing elements are made of a material capable of absorbing high frequency impacts. The present invention further relates to a method for producing a new headgear.