Patent ID: 8522418

Claim:
A method of limiting high-temperature deformation in a helmet, comprising: molding an outer shell of the helmet to consist essentially of thermoplastic material, the outer shell comprising a generally dome-shaped portion and a brim extending outwardly from the dome-shaped portion by at least 2.5 inches at the rear of the helmet; placing a brim support adjacent to the brim after formation of the brim such that the brim support extends along the perimeter of the brim over at least 50% of the perimeter of the brim to limit high-temperature deformation of the brim, the brim support being formed from a material that is more heat resistant than the thermoplastic material; and placing an edge trim formed of a resilient material that extends around the brim support and the perimeter of the brim over the brim support and the brim to encompass the brim support and retain the brim support in operative connection with the brim.