Patent ID: 6803005
Filing Date: 2004-10-12
Classification: A42B,A42C,B29C,B29K,B29L

Abstract:
A dual spray-deposition method of making a multilayer helmet shell employing, in appropriate succession as support structures, a female cavity, and an associated male mandrel comprising:utilizing an appropriate, generally sheet-like body of a first selected material, shaping and configurationally supporting a generally helmet-shaped central structural core layer having inner and outer surfaces, and forming a first precursor helmet shell; while so supporting the core layer selectively on one of the mentioned support structures, assuring the substantially full-access exposure of at least one of such surfaces; directing toward such at least one surface a spray of a first, selected, vapor-suspension deposition material to form on, and joined to, the at least one surface a structural layer which, along with the core layer, form a second precursor helmet shell; thereafter, supporting the second precursor helmet shell on the other mentioned support structure so as to assure the substantially full-access exposure of the other one of such surfaces; and then directing toward such other surface a spray of a second, selected, vapor-suspension deposition material to form on, and suitably joined to, the other surface a third structural layer, thus completing the fabrication of the intended, finished helmet shell.