# US 11,304,469 B2 · Helmets including spray on materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,304,469 B2 - Document ID: US11304469B2 - Status: Granted - Kind: B2 - Application number: 15/676,802 - Filed: 2017-08-14 - Published: 2018-01-25 - Granted: 2022-04-19 - Earliest claimed: 2013-06-28 - Assignees: Galvion Ltd. - Applicants: Galvion Ltd. - Inventors: David Redpath; Marie-Pierre Gendron; Curtis Herman - Web page: https://patentgrep.com/patent/US11304469B2 ## CPC - A42B 3/04: Parts, details or accessories of helmets - A42B 3/061: {External coatings, e.g. with light reflective material (helmet covers A42B3/003)} - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) ## Abstract Various embodiments of helmets and methods of their manufacture are disclosed. In some embodiments, the helmet includes a helmet shell having a helmet shell edge and/or a mounting location for mounting an accessory to the helmet shell. A material that is adherent to the helmet shell may be sprayed onto the helmet shell edge of the helmet shell to form a trim. Alternatively, the material may be sprayed onto a portion of the helmet shell associated with either a mounting location for mounting an accessory or a position for a mounted accessory. ## Claims ### Claim 1 A method of manufacturing a helmet, the method comprising: spraying a material onto a helmet shell edge of a helmet shell to form a trim along the helmet shell edge, wherein the trim formed along the helmet shell edge covers the helmet shell edge and a portion of each of an exterior surface of the helmet shell and an interior surface of the helmet shell adjacent to the helmet shell edge, and wherein an adjacent portion of the interior surface and an adjacent portion of the exterior surface is free of the material. ### Claim 2 (depends on 1) The method of claim 1, wherein the material comprises a polymeric material. ### Claim 3 (depends on 2) The method of claim 2, wherein the polymeric material comprises at least one of polyurethane and polyurea. ### Claim 4 (depends on 2) The method of claim 2, wherein the polymeric material cures after it is sprayed on the helmet shell. ### Claim 5 (depends on 1) The method of claim 1, wherein spraying the material further comprises spraying a mixture of a polymeric resin and an activator. ### Claim 6 (depends on 5) The method of claim 5, further comprising mixing the mixture of the polymeric resin and the activator during spraying. ### Claim 7 (depends on 1) The method of claim 1, further comprising masking a portion of the helmet shell prior to spraying the material to limit application of the material to only form the trim along the helmet shell edge. ### Claim 8 (depends on 7) The method of claim 7, wherein masking the portion of the helmet shell includes masking an interior portion of the helmet shell and masking an exterior portion of the helmet shell at the same time. ### Claim 9 (depends on 7) The method of claim 7, wherein masking the portion of the helmet shell includes masking the portion of the helmet shell with a collapsible mask. ### Claim 10 (depends on 1) The method of claim 1, further comprising applying an intermediate non-adhesive layer to an underlying base material of the helmet shell prior to spraying the material onto the helmet shell. ### Claim 11 (depends on 1) The method of claim 1, further comprising: spraying a material onto a portion of an exterior surface of a helmet shell associated with either a mounting location for mounting an accessory or a position for a mounted accessory, wherein a coefficient of friction of the material is greater than a coefficient of friction of an adjacent portion of the exterior surface of the helmet shell free of the material, wherein the material comprises a polymeric material, and wherein the polymeric material cures after it is sprayed on the helmet shell. ### Claim 12 (depends on 11) The method of claim 11, wherein the polymeric material comprises at least one of polyurethane and polyurea. ### Claim 13 (depends on 11) The method of claim 11, further comprising applying an intermediate non-adhesive layer to an underlying base material of the helmet shell prior to spraying the material onto the helmet shell. ### Claim 14 (depends on 1) The method of claim 1, wherein spraying the material onto the helmet shell includes spraying a continuous layer of material onto the helmet shell edge, the portion of the interior surface of the helmet shell, and the portion of the exterior surface of the helmet shell. ### Claim 15 (depends on 14) The method of claim 14 wherein spraying the continuous layer onto the helmet shell conforms the material to a shape of the helmet shell without a seam line. ### Claim 16 (depends on 1) The method of claim 1, wherein the helmet shell includes a mounting location for mounting an accessory separate from the trim, and further comprising spraying the material onto the exterior surface of the helmet shell at the mounting location, and wherein an adjacent portion of the exterior surface of the helmet shell surrounding the mounting location is free of the material. ### Claim 17 A method of manufacturing a helmet, the method comprising: assembling an inner mask to an interior surface of a helmet shell; assembling an outer mask to an exterior surface of the helmet shell; and spraying a material onto a helmet shell edge, an unmasked portion of the interior surface, and an unmasked portion of the exterior surface of the helmet shell while the inner mask and the outer mask are assembled with the helmet shell at the same time to form a trim along the helmet shell edge. ### Claim 18 (depends on 17) The method of claim 17, wherein the trim formed along the helmet shell edge covers the helmet shell edge and a portion of each of an exterior surface of the helmet shell and an interior surface of the helmet shell adjacent to the helmet shell edge without a seam line. ### Claim 19 (depends on 18) The method of claim 18, wherein an adjacent portion of the interior surface and an adjacent portion of the exterior surface is free of the material. ### Claim 20 (depends on 17) The method of claim 17, wherein the material comprises a polymeric material. ### Claim 21 (depends on 20) The method of claim 20, wherein the polymeric material cures after it is sprayed on the helmet shell. ### Claim 22 (depends on 17) The method of claim 17, wherein spraying the material onto the helmet shell includes spraying a continuous layer of material onto the helmet shell edge, the unmasked portion of the interior surface of the helmet shell, and the unmasked portion of the exterior surface of the helmet shell. ### Claim 23 (depends on 17) The method of claim 17, wherein the helmet shell includes a mounting location for mounting an accessory separate from the trim, and further comprising spraying the material onto the exterior surface of the helmet shell at the mounting location, and wherein an adjacent portion of the exterior surface of the helmet shell surrounding the mounting location is free of the material.