Patent ID: 9700095
Date: 2017-07-11
CPC Classifications: A42B,A42C

Claim:
1. A method for forming a protective headgear, comprising: providing a first mold portion defining a cavity generally approximating a portion of a person's head; providing a second mold portion defining a protrusion that generally corresponds to the cavity of the first mold portion; providing a fabric sheet beneath the second mold portion; laminating a face of the fabric sheet that faces the first mold portion; providing a film on the cavity of the first mold portion; applying a gel onto the film into the cavity of the first mold portion; placing the first and second mold portions into closely-spaced arrangement until the laminated face of the fabric sheet contacts the gel and the gel has cured to form the protective headgear, wherein the gel does not contact the first mold portion after the gel is applied; and stitching a band around a periphery of the headgear; wherein one of the first and second mold portions further defines one or more punches for forming ventilation apertures in the headgear, wherein the ventilation apertures extend through each of the fabric sheet, laminated face, and gel, wherein, in use, the headgear is positioned on a wearer's head beneath a helmet.