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 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.

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.

The present invention discloses a steam-formed double-layer shock-absorption sports helmet, including a helmet body. The helmet body includes a surface hard shell, an EPS material layer and an EPP material layer successively mounted together in a fitting manner. The surface hard shell is wrapped on an outer surface of the EPS material layer. The EPP material is wrapped on an inner surface of the EPS material layer. The EPS material layer is made of an EPS material and the EPP material layer is made of an EPP material. The present invention has good anti-hitting performance, water resistance, heat resistance and thermal insulation properties. Moreover, the EPP material layer with good shock resistance and energy absorption properties, high deformation recovery rate, and good heat resistance, oil resistance and thermal insulation properties is used. Furthermore, the EPP material layer has light weight, so that the article weight can be greatly reduced.

A helmet can include an upper body comprising an interior surface comprising a locking flange, and a lower body positioned at least partially inside the upper body. The lower body can comprise an edge in contact with the locking flange of the upper body. At least one joining pin can be located within, and bridge, the lower body and the upper body. An at least one basket pair can comprise an upper basket comprising a pin receiver, the upper basket being at least partially embedded within the upper body. A lower basket can comprise a pin aperture, the lower basket being at least partially embedded within the lower body and positioned such that the pin aperture is aligned with the pin receiver of the basket pair. The at least one joining pin can be positioned inside both the pin aperture and the pin receiver of the basket pair.

A bespoke protective sports helmet to be worn by a player engaged in a sporting activity is provided. The bespoke helmet includes i) systems and methods for acquiring, storing and processing a player's unique data, namely the player's anatomical features, where that player is to wear a protective sports helmet, (ii) for systems and methods of using the player's unique data to manufacture a protective sports helmet with a custom formed internal padding assembly that substantially corresponds to the player's unique data, and (iii) a protective sports helmet designed using the acquired and processed unique player's data and including the custom formed internal padding assembly that provides improved fit and comfort for the player. The system and method allows for the design and manufacture of a bespoke protective sports helmet that is purposely designed and manufactured to match the player's anatomical specifications.

A mold and a relative molding process for the manufacture of sporting helmets, in particular cycling helmets. The mold includes a frame provided with at least one molding concavity; a counter frame engageable to the frame to hermetically close the respective molding concavity and allow the execution of at least one molding cycle. The mold further includes at least one intermediate support element for supporting and positioning one or more components of the sporting helmet to be manufactured inside the respective molding concavity of the frame. The intermediate support element is kept inside the respective molding concavity during the entire molding cycle in order to keep the components of the sporting helmet to be manufactured in their assigned positions.

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 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.

Provided is a safety helmet that exhibits more than one color. Methods of manufacturing such safety helmets are also provided.