A helmet body includes an outer shell having an inner surface, an outer surface, and an outer shell lower edge extending between the inner surface and the outer surface, the outer shell further comprising at least two shoulder pad recesses positioned at a lower edge of the outer shell on a respective left and right sides of the helmet; and an energy management liner adjacent to the inner surface of the outer shell and comprising at least two shoulder pads formed of a foamed energy management material, each of the at least two shoulder pads received into one of the at least two shoulder pad recesses on the respective left or right side of the helmet.

A method is providing for manufacturing an integrally formed cap, the method comprising: in step 1, providing a shell fabric B and a thermoplastic lining fabric C, superposing the shell fabric on a surface of the lining fabric and tightly attaching the shell fabric to the lining fabric, to obtain the fabric A needed, and providing the shaping mold matched with the shape of a cap; in step 2, cutting the fabric A obtained in Step 1 into set dimensions; and in step 3, tightly attaching the fabric A cut in Step 2 onto the shaping mold obtained in Step 1, thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap. With the method of the invention, the production speed and quality stability can be increased, the production cost reduced, and the production process is energy-saving and environment-friendly.

Impact-dissipating liners, helmets having an impact-dissipating liner, and methods of fabricating impact-dissipating liners are provided. The liners include a fluid impermeable enclosure having cavities with sidewalls, re-enforcing fabric sheets, and a fluid contained in the enclosure. The enclosure may have a central portion and lobes extending from the central portion, wherein the central portion and the lobes are adapted to conform to the shape of an internal surface of a helmet. The re-enforcing sheets may be made from a broad range of materials and may enhance the structural support, structural integrity, and/or durability to the liner. Aspects of the invention are particularly adapted for use as head protection, such as, helmets; however, aspects of the invention are also adaptable to provide impact-dissipation for any body or surface that would benefit from such protection.

The invention relates to an outer shell for a safety helmet (1), in particular for a motorcycle safety helmet, for distributing impact forces, said outer shell having an outer shell material (2). The outer shell is characterized in that, on a side (3) having the outer shell material (2) of the outer shell, the outer shell has a cover (4) having the outer shell material (2) in order to hold an antenna (5) between the cover (4) and the side (3). The invention further relates to a safety helmet (1) having such an outer shell and to a method for producing such an outer shell.

The present invention provides a head protective gear comprising a plurality of three-dimensional inserts configured into hollow members made of an energy absorbing material, formulations forming the energy absorbing material, method of preparing the energy absorbing material. The present invention is designed to protect against or at least mitigate both linear and angular impacts exerted on a head section of a wearer of the head protective gear incorporated with the hollow three-dimensional structure made of the energy absorbing material.

The present disclosure is for a luminous helmet, comprising an outer shell configured to fit over a human head, an inner shell, a light-emitting band arranged along an elongated slit opening on the outer shell, and a light transmitting groove enclosing the light emitting band. In the manufacturing process, the outer shell was formed first, with a slit cut to match the light transmitting groove. The light-transmitting groove, comprising fixing grooves, engage fixing strips extending from edges of the outer shell along the slit opening. This structure then serves as a base to house the light-emitting band, and to receive pressure injection of the inner shell material.

A helmet manufacturing method involves: producing a shell and a protector, the shell having two opposing cheek-protecting portions, the protector having a jaw-protecting portion and a neck-protecting portion connected to the jaw-protecting portion; putting the shell and the protector in a die such that bottom edges of the cheek-protecting portions of the shell connect to a top edge of the neck-protecting portion of the protector; introducing a foam material into the die, apply heat and pressure to the foam material such that the foam material expands and binds to an inner side of the shell and an inner side of the protector; and taking a helmet finished product out of the die. Therefore, both the jaw-protecting portion of the integrally-formed protector and the helmet finished product are reinforced.

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 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.