Patent ID: 6446270
Filing Date: 2002-09-10
Classification: A42B

Abstract:
A method of making a protective helmet comprising the steps of:a) forming a topvented outer mold having an interior surface that bounds a chamber sized and shaped to assimilate a protective helmet outer surface, said outer mold disposed within a split mold housing; b) forming a contoured rigid shell member, said shell member sized to fit within said outer mold; c) forming a flexible liner shaped to follow the contours of an inner surface of said shellmember, said flexible liner having spacers extending from an outer surface thereof; d) temporarily securing said liner and said shell member in a predetermined orientation within said outer mold; e) injecting a predetermined amount of polyurethane into said mold, said predetermined amount being great enough to surround said shell member; f) allowing said polyurethane to cure, forming a helmet sandwiched between said flexible liner and said outer mold interior surface; g) removing said liner and said helmet from said mold; and separating said liner and said helmet.