# US 11,540,580 B2 · Helmet comprising surface reinforcing component with embedded anchors > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,540,580 B2 - Document ID: US11540580B2 - Status: Granted - Kind: B2 - Application number: 16/422,751 - Filed: 2019-05-24 - Published: 2019-09-12 - Granted: 2023-01-03 - Earliest claimed: 2010-01-14 - Assignees: Smith Optics, Inc. - Applicants: Smith Optics, Inc. - Inventors: James A. Chilson - Web page: https://patentgrep.com/patent/US11540580B2 ## CPC - A42B 3/063: {using layered structures} - A42B 3/062: {with reinforcing means} - A42B 3/283: {Air inlets or outlets, with or without closure shutters} - B29C 44/12: Incorporating or moulding on preformed parts, e.g. inserts or reinforcements - B29C 44/1214: {Anchoring by foaming into a preformed part, e.g. by penetrating through holes (anchoring by moulding in general B29C37/0078; outsert moulding B29C45/14344, B29C70/74)} - B29C 44/5681: {Covering the foamed object with, e.g. a lining} - B29K 2025/06: {PS, i.e. polystyrene} - B29L 2031/4821: {Helmets} - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Described herein are helmets comprising at least one surface reinforcing component. In some embodiments the surface reinforcing component comprises at least one anchoring feature embedded in a structural feature of the helmet, such as a force absorbing element. In other embodiments, the surface reinforcing component comprises fasteners configured to mate with a respective fastener on a shell of the helmet. ## Claims ### Claim 1 A method of making a helmet comprising: positioning a surface reinforcing component formed of a hard plastic material into a mold along with at least a portion of a shell of a helmet, wherein the surface reinforcing component comprises an outer surface positioned against the mold, an inner surface facing an interior of the mold's cavity, and at least one anchor feature extending from a location of the inner surface toward the interior of the mold's cavity, the outer surface opposite of the location of the inner surface from which the at least one anchor feature extends; providing an expandable material into the mold; and expanding the expandable material to form a force absorbing element of the helmet, wherein the expanding causes the expandable material to surround the at least one anchor feature thereby embedding the at least one anchor feature within the force absorbing element and securing the inner surface of the surface reinforcing component to the force absorbing element while the outer surface of the surface reinforcing component remains exposed to provide an exterior surface of the helmet. ### Claim 2 (depends on 1) The method of claim 1, wherein the expandable material is expandable polystyrene. ### Claim 3 (depends on 2) The method of claim 2, wherein the expanding of the polystyrene includes injecting steam into the mold to cause the expandable polystyrene to expand. ### Claim 4 (depends on 3) The method of claim 3, wherein the surface reinforcing component comprises a plurality of anchor features, and injecting steam into the mold causes the polystyrene to surround each of the plurality of anchor features. ### Claim 5 (depends on 2) The method of claim 2, wherein the injecting steam into the mold causes the polystyrene to adhere to the portion of the shell. ### Claim 6 (depends on 5) The method of claim 5, wherein the expanding of the polystyrene further causes the polystyrene to adhere to a surface of the surface reinforcing component. ### Claim 7 (depends on 1) The method of claim 1, wherein the surface reinforcing component comprises a plurality of coupling devices and further comprising securing the shell to the surface reinforcing component by mating the plurality of coupling devices on the surface reinforcing component to a respective coupling device on the shell. ### Claim 8 A method of making a helmet comprising: positioning a surface reinforcing component formed of a hard plastic material into a mold along with at least a portion of a shell of a helmet and along a brim portion of the shell of the helmet, wherein the surface reinforcing component comprises an outer surface positioned against the mold, an inner surface facing an interior of the mold's cavity, and at least one anchor feature extending from the inner surface toward the interior of the mold's cavity; providing an expandable material into the mold; and expanding the expandable material to form a force absorbing element of the helmet, wherein the expanding causes the expandable material to surround the at least one anchor feature thereby embedding the at least one anchor feature within the force absorbing element along the brim portion of the shell of the helmet and securing the inner surface of the surface reinforcing component to the force absorbing element while the outer surface of the surface reinforcing component remains exposed to provide an exterior surface of the helmet. ### Claim 9 (depends on 1) The method of claim 1, wherein the at least one anchor feature comprises a loop shaped structure, and wherein the expandable material passes through an opening defined by the loop shaped structure when expanded to form the force absorbing element. ### Claim 10 (depends on 9) The method of claim 9, wherein the at least one anchor feature comprises a plurality of interconnected loop shaped structures, the expandable material, once expanded, passing through each of the looped shaped structures. ### Claim 11 (depends on 9) The method of claim 9, wherein the at least one anchor feature further comprises a hook. ### Claim 12 (depends on 1) The method of claim 1, wherein the positioning of the surface reinforcing component into the mold comprises positioning the surface reinforcing component to cover at least a portion of an edge of the shell. ### Claim 13 (depends on 1) The method of claim 1, forming a vent in the force absorbing element while expanding the expandable material, and wherein the at least one anchor feature is positioned to reinforce at least a portion of the vent.