Outer shell for a safety helmet

A safety helmet comprising:

• an outer shell comprising an outer shell material and defining an inner surface of the outer shell comprising the outer shell material and an outer surface of the outer shell;
• a cover adjacent said inner surface, the cover comprising the outer shell material, wherein the cover and the outer surface are located on opposite sides of the inner surface;
• an antenna between the cover and the inner surface;
• an inner layer held by the outer shell and configured to dampen impact forces;
• and
• an antenna feed line coupled with the antenna, wherein at least part of the antenna feed line is located between the inner surface of the outer shell and the inner layer;
• wherein, at at least a portion of the inner layer, there is no outer shell material between at least a portion of the inner surface and said at least a portion of the inner layer.

A method comprising:

• producing an outer shell for a safety helmet, wherein
• the outer shell comprises an outer shell material and defines an inner surface of the outer shell comprising the outer shell material, an outer surface of the outer shell, and a cover adjacent said inner surface, the cover comprising the outer shell material,
• the cover and the outer surface are located on opposite sides of the inner surface;
• the outer shell is configured to hold an antenna between the cover and the inner surface;
• an inner layer is held by the outer shell and configured to dampen impact forces,
• wherein at at least a portion of the inner layer, there is no outer shell material between at least a portion of the inner surface and said at least a portion of the inner layer;
• and
• the outer shell includes an antenna feed line at least in part located between the inner surface and the inner layer and wherein the antenna feed line is coupleable with said antenna when said antenna is located between the cover and the inner surface,
• the method further including:
• on a side of a preform comprising a fibrous material, locating a cover layer comprising the fibrous material,
• locating a mold core between the side of the preform and the cover layer, and
• curing a matrix material surrounding the fibrous material of the cover layer and thereby forming the outer shell and the cover,
• wherein the cover defines a pocket, which is open in said opening direction configured to receive an antenna therethrough and is closed in a direction opposite the opening direction.