A system for manufacturing a shell for a batting helmet includes interchangeable mold-core portions configured to form a cavity for receiving molding material. The mold-core portions include a first base mold-core portion and a plurality of inner side mold-core portions configured to form an interior contour of the shell. The mold-core portions further include a second base mold-core portion and a plurality of outer mold-core portions configured to form an exterior contour of the shell. Mold-core portions are interchangeable, removable, and replaceable from an interlocked position relative to other mold-core portions. A method of manufacturing batting helmet shells includes selecting mold-core portions corresponding to various helmet shell configurations having various protective features, assembling the mold-core portions into a mold assembly, and providing molding material into a cavity in the mold assembly. A kit of parts for making a shell for a batting helmet includes a variety of interchangeable mold-core portions.

A support template for moulds for sports helmets, in particular cycling helmets, provided with at least one frame includes: at least one support portion, placed on a first side of the frame, for the support of at least one component of a helmet to be obtained by a moulding or co-moulding process, the support portion being configured to keep the respective component of the helmet to be obtained according to a predetermined position inside a respective mould; at least one centring portion placed on the first side of the frame and arranged to engage a respective centring seat made on the respective mould so as to ensure the alignment of the latter with the support template and keep the centred positioning of the component of the helmet according to a predetermined configuration; and at least one grip portion to allow manual engagement of the support template by an operator.

A method of designing an impact mitigating structure. The method determines the force exerted by an object on the structure (11) as a function of the distance by which the object displaces a surface of the structure during impact. The method calculates a ratio of the integral of the force exerted by the object on the structure with respect to the distance by which the object displaces the surface of the structure during impact to the product of the maximum force exerted by the object on the structure during the impact and the total distance by which the object displaces the surface of the structure during the impact. The method also determines the respective values of characteristic variables of the structure that maximise the ratio for use in designing the structure.

Methods of making a foamed article include: (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

A method of manufacturing an article of sport gear, the method comprising: providing a first component; making a second component by: (i) applying heat to expand polymeric microspheres each comprising a polymeric shell and a fluid encapsulated in the polymeric shell to produce a core of polymeric cellular material that comprises a first side and a second side opposite one another and a body of expanded polymeric microspheres; (ii) molding a covering onto the core of polymeric cellular material such that the covering covers at least part of the first side and at least part of the second side of the core of polymeric cellular material; and mounting the second component to the first component.

A method of making a foamed article comprises (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

A helmet has inner and outer shells separated by a plurality of interconnected relatively soft columns or posts. The columns each have a middle post or pillar section, a capital that is of larger diameter than the post, and a base also of larger transverse dimension than the post. When an impact above a design threshold occurs on the outer shell, the columns, particularly the post sections thereof, near the impact location compress and buckle, dissipating impact kinetic energy, while columns spaced from the impact zone stretch and support more of the impact force. The applied force is therefore reduced and spread out over a relatively large area, and a resultant wave created within the column manifold disperses additional heat, further reducing the force and torque applied on the outer shell and transmitted to the inner shell and onto the skull of a helmet user. A method and mold for fabricating the column manifold are also disclosed.

In some embodiments, a method of forming a bonded assembly includes: providing a first object comprising a first surface having a plurality of locking orifices formed therein, each of the plurality of locking orifices including an opening on the surface of the object and a cavity extending in the first object; positioning an adhesive on at least one of the first surface of the first object and a second surface on a second object; positioning the first surface of the first object on the second surface of the second object with the adhesive between the first and second surfaces; and curing the adhesive to form the bonded assembly.

A sport helmet for protecting a head of a wearer, such as a hockey, lacrosse or football player. The sport helmet includes an outer shell with an internal side and an external side and an inner pad mounted to the internal side of the outer shell for absorbing shocks when the sport helmet is impacted. The inner pad includes a core of polymeric cellular material with a body of expanded polymeric microspheres and a molded covering being molded onto the core of polymeric cellular material.

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).