Protective helmet and method of manufacture thereof

Abstract

A protective helmet according to the invention includes an outer shell and a shock-absorbing cap arranged within the shell, the shell being formed by a thin shell. The shell is covered, at least locally, by a panel made of a flexible material, the panel being stretched against the shell and connected thereto at least one seam line along one of its edges. According to the manufacturing method, the outer shell is made, a panel of flexible material is prepared, the outer shell is then covered with the panel by at least one seam between an edge of the panel and the shell, and the inside of the shell is then fitted with the cap.

1 . A protective helmet comprising: 
 a thin outer shell;    a shock-absorbing cap arranged within the shell;    the shell being at least partially covered by a panel of flexible material;    the panel being stretched against the shell and assembled to the shell by means of at least one seam along at least one edge of the panel.    
     
     
         2 . A protective helmet according to  claim 1 , wherein: 
 the seam is visible from outside the helmet.    
     
     
         3 . A protective helmet according  claim 2 , wherein: 
 the panel is formed from a plurality of pieces.    
     
     
         4 . A protective helmet according to  claim 3 , wherein: 
 at a junction of two of said plurality of pieces a seam line connects the panel to the shell.    
     
     
         5 . A protective helmet according to  claim 3 , wherein: 
 at least two of the pieces of the panel have different textures and/or different colors.    
     
     
         6 . A protective helmet according to  claim 1 , wherein: 
 at least a second edge of the panel is assembled to the shell by means of at least at least one seam.    
     
     
         7 . A protective helmet according to  claim 1 , wherein: 
 at least a second edge of the panel is assembled to the shell by means of at least a strip of glue.    
     
     
         8 . A protective helmet according to  claim 1 , wherein: 
 the shell has ventilation openings; and    the panel has cutouts coinciding with said openings.    
     
     
         9 . A protective helmet according to  claim 1 , wherein: 
 the flexible material of the panel is a textile fabric.    
     
     
         10 . A protective helmet comprising: 
 an outer shell formed from a flat sheet having a thickness between 0.7 mm and 1.5 mm, or between about 0.7 mm and about 1.5 mm;    a shock-absorbing cap arranged within the shell;    the shell being at least partially covered by a panel of flexible material;    the panel being stretched against the shell and assembled to the shell by means of at least one seam along at least one edge of the panel.    
     
     
         11 . A protective helmet according to  claim 10 , wherein: 
 the seam is visible from outside the helmet.    
     
     
         12 . A protective helmet according to  claim 10 , wherein: 
 the panel is formed from a plurality of pieces.    
     
     
         13 . A protective helmet according to  claim 12 , wherein: 
 at a junction of two of said plurality of pieces a seam line connects the panel to the shell.    
     
     
         14 . A protective helmet according to  claim 12 , wherein: 
 at least two of the pieces of the panel have different textures and/or different colors.    
     
     
         15 . A protective helmet according to  claim 10 , wherein: 
 at least a second edge of the panel is assembled to the shell by means of at least at least one seam.    
     
     
         16 . A protective helmet according to  claim 10 , wherein: 
 at least a second edge of the panel is assembled to the shell by means of at least a strip of glue.    
     
     
         17 . A protective helmet according to  claim 10 , wherein: 
 the shell has ventilation openings; and    the panel has cutouts coinciding with said openings.    
     
     
         18 . A protective helmet according to  claim 10 , wherein: 
 the flexible material of the panel is a textile fabric.    
     
     
         19 . A method for manufacturing a helmet having a thin outer shell and an inner shock-absorbing cap, said method comprising: 
 making the outer shell;    making a panel of flexible material;    connecting the outer shell with the panel by means of at least one seam along at least one edge of the panel;    fitting an inside of the shell with the cap.    
     
     
         20 . A method according to  claim 19 , further comprising: 
 making the cap by injection of material inside the shell, the shell having been covered by the panel prior to making the cap.