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.

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 light-emitting helmet is provided. The helmet includes a main body, a number of fixing members, and a number of light-emitting lamp strips. The main body includes a shell and inner layer. The shell includes an outer surface and a number of grooves defining in the outer surface. The fixing members are secured in the inner layer. The lamp strips are detachably mounted in the grooves by the fixing frames respectively. In addition, a light-emitting helmet manufacturing method is also provided.

A method for manufacturing a helmet with hidden light sources includes: fixing a helmet housing with at least one light transmitting portion to a base mold; providing a light source protector and a light source belt, and fixing the light source protector to the light source belt, wherein the light source belt comprises a circuit board and a plurality of light sources mounted on, wherein the light source protector comprises a plurality of accommodating holes corresponding to the light sources one by one, and the light sources each are received in a corresponding accommodating hole and enclosed by the light source protector and the circuit board; aligning the light sources to the light transmitting portion and fixing the light source protector to an inner surface of the helmet housing; and injecting a buffer material into the base mold to form a base.

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 EPS, and the cap may be PC.

The present invention is applicable to the field of bicycle motion protection and safeguard equipment. The present invention discloses a light emitting helmet, including a helmet main body and a light emitting lamp band, a fixing groove is formed in the surface of the helmet main body, a through hole is formed in the fixing groove, the light emitting lamp band is provided with a control line, the light emitting lamp band is fixed in the fixing groove through a fixing mechanism, and when the light emitting lamp band is fixed, the control line is in signal connection with a controller by penetrating through the through hole. As the light emitting lamp band is fixed in the fixing groove, the control line of the light emitting lamp band forms the signal connection with the controller by penetrating through the through hole. Even if damage occurs, the light emitting lamp band can be singly repaired in the production process, thereby avoiding the problems that the light emitting lamp band arranged in the helmet main body cannot be repaired when a fault occurs, and that arrangement of the lead of the light emitting lamp band is complex in the forming process, and reducing the production cost and the forming difficulty of the light emitting helmet.

A helmet body includes an outer shell and an energy management liner with an outer shell lower edge extending between the inner surface and the outer surface of the outer shell. At least two shoulder pad recesses are positioned at a lower edge of the outer shell on a respective left and right sides of the helmet. The energy management liner is adjacent to the inner surface of the outer shell and includes at least two shoulder pads formed of a foamed energy management material. Each of the at least two shoulder pads is received into one of the at least two shoulder pad recesses on the respective left or right side of the helmet, each shoulder pad extending from inside of the outer shell to across at least a majority of a width of the lower edge of the outer shell.

The present invention is applicable to the field of bicycle motion protection and safeguard equipment. The present invention discloses a luminous helmet, including an outer shell and an inner shell in joint connection with the outer shell, a light emitting band is arranged between the inner shell and the outer shell, the outer shell is provided with a strip-shaped fixing hole at the position of the light emitting band, a light transmission groove for accommodating the light emitting band is formed in the fixing hole, and an extension part extending toward the outer side is arranged at the opening of the light transmission groove. During blister forming of the outer shell, the blister forming is carried out after the whole PC sheet is colored, the area requiring light transmission is cut to form the fixing hole, and the light transmission groove and the fixing hole are fixed to form a light transmission structure. No light transmission blank area needs to be arranged on the PC sheet, thereby preventing the deviation between an uncolored blank area of a light transmission position and a light emission position of the formed outer shell from affecting the beautiful appearance and quality of a product in a production process, improving the production efficiency of the luminous helmet and reducing the production cost.

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.

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck with an interface surface and at least one side. 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 EPS, and the cap may be PC.