Reinforced expanded plastic helmet construction

Claim 2

In a helmet, the combination comprising: a) a helmet body consisting of gas expanded synthetic resin, and having dome shaped extent and defining a lower edge extending generally in a loop, said body subject to cracking under high impact loading, b) a separate and first elongated reinforcement member encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement member having lower ends connected to said first member and arching upwardly and encapsulated within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body.

Claim 3

The combination of claim 1 wherein said first elongated reinforcement member has band shape, the first elongated reinforcement member oriented to have a lower edge projecting toward the helmet lower edge.

Claim 4

The combination of claim 1 including a fabric cover fitting over the body and retained to the body proximate the lower edge thereof.

Claim 5

The combination of claim 1, wherein said helmet body has a front end and a rear end, and wherein said at least one additional elongated reinforcement member arches upwardly and rearwardly with respect to said helmet body from said first member so as to be disposed at an angle of less than about 90° relative to a plane of said first member.

Claim 6

In a helmet, the combination comprising: a) a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, b) an elongated reinforcement member embedded in the helmet body to extend above said lower edge, c) said body having an air vent opening therethrough, the said reinforcement member projecting partly into said opening, edgewise of the member.

Claim 7

In a helmet, the combination comprising: a) a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, b) an elongated reinforcement member embedded in the helmet body to extend above said lower edge, c) said body having an air vent opening therethrough, the said reinforcement member projecting partly into said opening, edgewise of the member.

Claim 8

In a helmet, the combination comprising: a) a molded helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, said body subject to cracking under high impact loading, b) a separate and first elongated reinforcement member molded into and thereby encapsulated in the helmet body to extend above said lower edge, and at least one additional elongated reinforcement member having lower ends connected to said first member at opposite sides thereof and arching upwardly and embedding within said dome-shaped extent of the helmet, said member being formed from a material having a composition different from that of said body to reinforce said body, c) said first member having band shape, said first member oriented to have a lower edge projecting toward the helmet lower edge, d) the first member being a ring which consists of high strength synthetic resin.

Claim 9

In a helmet, the combination comprising: a) a molded helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, said body subject to cracking under high impact loading, b) a separate and first elongated reinforcement member molded into and thereby encapsulated in the helmet body to extend above said lower edge, and at least one additional elongated reinforcement member having lower ends connected to said first member at opposite sides thereof and arching upwardly and embedding within said dome-shaped extent of the helmet, said member being formed from a material having a composition different from that of said body to reinforce said body, c) said first member having band shape, said first member oriented to have a lower edge projecting toward the helmet lower edge, d) the first member being a ring which consists of high strength synthetic resin.

Claim 10

In a helmet, the combination comprising: a) a molded helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, said body subject to cracking under high impact loading, b) a separate elongated reinforcement member molded into and thereby encapsulated in the helmet body to extend above said lower edge, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member at opposite sides thereof and arching upwardly and encapsulated within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, c) and locator means projecting on the member to locate it in the body of the helmet at the time of molding thereof.

Claim 11

In a helmet, the combination comprising: a) a molded helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, said body subject to cracking under high impact loading, b) a separate elongated reinforcement member molded into and thereby encapsulated in the helmet body to extend above said lower edge, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member at opposite sides thereof and arching upwardly and encapsulated within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, c) and locator means projecting on the member to locate it in the body of the helmet at the time of molding thereof.

Claim 12

In a method of constructing a helmet, the steps including: a) forming a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending in a loop, b) embedding a separate reinforcement member in the body, to project throughout its length proximate and above said lower edge, substantially entirely around the helmet body and between inner and outer walls defined by said body, and also embedding in said body at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member at opposite sides thereof and arching upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, said embedding including molding said body about said separate member and about the entirety of said additional member.

Claim 13

In a method of constructing a helmet, the steps including: a) forming a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending in a loop, b) embedding a separate reinforcement member in the body, to project throughout its length proximate and above said lower edge, substantially entirely around the helmet body and between inner and outer walls defined by said body, and also embedding in said body at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member at opposite sides thereof and arching upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, said embedding including molding said body about said separate member and about the entirety of said additional member.

Claim 14

The method of claim 8 including providing said separate reinforcement member to have band shape, and effecting said embedding to locate the separate reinforcement member width substantially parallel to the outer side for the helmet near its lower edge.

Claim 15

The method of claim 8 including employing lugs on said member to position it in a mold in which the body is molded.

Claim 16

The method of claim 8 including twisting said separate reinforcement member during molding of the body to position the separate reinforcement member in the body during molding thereof.

Claim 17

In a helmet, the combination comprising: a) a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, b) an elongated reinforcement member embedded in the helmet body to extend above said lower edge, c) said member having band shape, the member oriented to have a lower edge projecting toward the helmet lower edge, d) the band shaped member having vertical edge portions projecting below the helmet body lower edge at opposite sides of the helmet.

Claim 18

In a helmet, the combination comprising: a) a helmet body consisting of gas expanded synthetic resin, and having dome shape defining a lower edge extending generally in a loop, b) an elongated reinforcement member embedded in the helmet body to extend above said lower edge, c) said member having band shape, the member oriented to have a lower edge projecting toward the helmet lower edge, d) the band shaped member having vertical edge portions projecting below the helmet body lower edge at opposite sides of the helmet.

Claim 19

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member and arching upwardly and encapsulated within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body.

Claim 20

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member and arching upwardly and encapsulated within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body.

Claim 21

The combination of claim 13 including attachment means positively attaching the holder to the helmet at said outer upper side thereof, said separate reinforcement member located generally below the level of said openings, said separate reinforcement member having band shape, the separate reinforcement member being oriented to have a lower edge projecting toward the helmet lower edge.

Claim 22

The combination of claim 13 wherein the holder defines slot means through which the strap passes for adjustable retention by the holder proximate said one opening.

Claim 23

The combination of claim 15 wherein said strap includes a first portion extending upwardly through the one opening for passing through the slot means, and a second portion extending back down into the one opening adjacent said first portion to terminate at or proximate said one opening.

Claim 24

The combination of claim 13 wherein said holder comprises solid material having band shape, the helmet having a re-entrant recess at said upper surface receiving said holder, above the level of said reinforcement member.

Claim 25

The combination of claim 17 wherein said band-shaped holder and said recess have arc shape, cross-wise of the helmet outer side.

Claim 26

The combination of claim 13 wherein said helmet body consists of air expanded synthetic resin.

Claim 27

The combination of claim 15 including a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet.

Claim 28

The combination of claim 20 including a net fabric cover fitting over the body and holders, and retained to the body proximate the lower edge thereof.

Claim 29

The combination of claim 20 wherein said two strap holders are interconnected.

Claim 30

The combination of claim 22 wherein said two interconnected strap holders form an arch adapted to conform to curvature of the helmet body.

Claim 31

The combination of claim 15 wherein the holder is carried at a forward portion of the helmet, and including another holder configured to be supported by the outer side of the helmet at a rearward portion thereof, the other holder attached to a strap that extends through another of said openings.

Claim 32

In a helmet, the combination comprising: a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by at the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement, member having lower ends connected to said separate reinforcement member and arching upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, e) attachment means positively attaching the holder to the helmet at said outer upper side thereof, said member located generally below the level of said openings, said member having band shape, the member oriented to have a lower projecting toward the helmet lower edge, f) said attachment means comprising hook and pile elements one of which is carried by the holder and the other of which is carried by the helmet body, above the level of said member.

Claim 33

In a helmet, the combination comprising: a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by at the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement, member having lower ends connected to said separate reinforcement member and arching upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, e) attachment means positively attaching the holder to the helmet at said outer upper side thereof, said member located generally below the level of said openings, said member having band shape, the member oriented to have a lower projecting toward the helmet lower edge, f) said attachment means comprising hook and pile elements one of which is carried by the holder and the other of which is carried by the helmet body, above the level of said member.

Claim 34

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) said holder comprising solid material having band shape, the helmet having a re-entrant recess at said upper surface receiving said holder, above the level of said reinforcement member, f) the helmet defining a notch proximate a side of the recess for finger reception to lift the holder from the recess, the holder being releasably retained in the recess.

Claim 35

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) said holder comprising solid material having band shape, the helmet having a re-entrant recess at said upper surface receiving said holder, above the level of said reinforcement member, f) the helmet defining a notch proximate a side of the recess for finger reception to lift the holder from the recess, the holder being releasably retained in the recess.

Claim 36

The combination of claim 26 including attachment means positively attaching the holder to the helmet at said outer side.

Claim 37

The combination of claim 26 wherein the helmet body consists of an expanded polystyrene.

Claim 38

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) the holders consisting of solid material and have adjustable connections to said straps, the holders releasably attached to the helmet body to be lifted for effecting strap adjustment, and to be re-attached to the body.

Claim 39

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) the holders consisting of solid material and have adjustable connections to said straps, the holders releasably attached to the helmet body to be lifted for effecting strap adjustment, and to be re-attached to the body.

Claim 40

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) said two strap holders being interconnected and forming an arch adapted to conform to curvature of the helmet body, h) the two holders forming slots and cross-pieces for strap reception and connection, there being attachment mean on a region of the arch between the slots defined by the two holders, for attachment to the helmet at an outer side thereof, the attachment means allowing lifting of the arch for adjustment of the straps relative to the holders.

Claim 41

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings, and the holder operable to transmit strap tension to the helmet, d) and an elongated reinforcement member embedded in the helmet body to extend above said lower edge, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) said two strap holders being interconnected and forming an arch adapted to conform to curvature of the helmet body, h) the two holders forming slots and cross-pieces for strap reception and connection, there being attachment mean on a region of the arch between the slots defined by the two holders, for attachment to the helmet at an outer side thereof, the attachment means allowing lifting of the arch for adjustment of the straps relative to the holders.

Claim 42

In a helmet, the combination comprising: a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) said two strap holders being interconnected, and said two interconnected strap holders forming an arch adapted to conform to curvature of the helmet body, h) the two holders forming slots and cross-pieces for strap reception and connection, there being attachment means on a region of the arch between the slots defined by the two holders, for attachment to the helmet at an outer side thereof, the attachment means allowing lifting of the arch for adjustment of the straps relative to the holders, i) said two holders being carried at a forward portion of the helmet, and including another holder configured to be supported by the outer side of the helmet at a rearward portion thereof, the other holder attached to a third strap that extends through another of said openings.

Claim 43

In a helmet, the combination comprising: a generally dome shaped helmet body having inner and outer sides, and a lower edge extending generally in a loop, b) openings through the body to pass retention straps, c) a first strap holder configured to be supported at and by the outer side of the helmet, the holder attached to at least one strap that extends through one of said openings and the holder operable to transmit strap tension to the helmet, d) an elongated separate reinforcement member molded into and thereby encapsulated in the helmet body to extend throughout its length above said lower edge and substantially entirely around the helmet body and between inner and outer walls defined by said body, and at least one additional elongated reinforcement member having lower ends connected to said separate reinforcement member upwardly within said dome-shaped extent of the helmet, said members being formed from a material having a composition different from that of said body to reinforce said body, e) the holder defining slot means through which the strap passes for adjustable retention by the holder proximate said one opening, f) a second strap holder configured to be supported at and by the outer side of the helmet, the second holder attached to a second strap that extends through another of said openings, and the second holder operable to transmit second strap tension to the helmet, g) said two strap holders being interconnected, and said two interconnected strap holders forming an arch adapted to conform to curvature of the helmet body, h) the two holders forming slots and cross-pieces for strap reception and connection, there being attachment means on a region of the arch between the slots defined by the two holders, for attachment to the helmet at an outer side thereof, the attachment means allowing lifting of the arch for adjustment of the straps relative to the holders, i) said two holders being carried at a forward portion of the helmet, and including another holder configured to be supported by the outer side of the helmet at a rearward portion thereof, the other holder attached to a third strap that extends through another of said openings.

Claim 44

The combination of claim 31 wherein the straps have interconnection to form a harness.

Claim 45

The combination of claim 31 wherein said third strap includes two strap sections extending through spaced openings in the helmet body, said strap sections adjustably attached to said other holder at spaced portions thereof, located at the upper side of the helmet body.

Claim 46

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, b) two strap holders at the outer side of the helmet body, c) and strap means passing through the helmet body between the inner and outer sides thereof, and adjustably attached to the holder, d) the holder being elevatable away from the outer sides of the body to permit strap means adjustment, e) and band shaped, reinforcement means embedded in said body, in spaced relation to said strap means.

Claim 47

In a helmet, the combination comprising a) a generally dome shaped helmet body having inner and outer sides, b) two strap holders at the outer side of the helmet body, c) and strap means passing through the helmet body between the inner and outer sides thereof, and adjustably attached to the holder, d) the holder being elevatable away from the outer sides of the body to permit strap means adjustment, e) and band shaped, reinforcement means embedded in said body, in spaced relation to said strap means.

Claim 48

The combination of claim 34 wherein the strap holders are located at the front and rear of the helmet body.