Method for producing a body protection item and resulting body protection item

Manufacturing method of a body protection comprising:

• producing a structural shell (10) with a maximum thickness of 5 mm, made of thermoplastic material, and defining a concave interior (11) and a convex exterior (12);
• over-moulding an expanded polystyrene layer (20) overlapping the concave interior (11) of the structural shell (10), producing its adhesion by close contact to the structural shell (10);
• wherein the structural shell (10) is produced by means of the distributed placement, in a mould, of a mixture of thermoplastic material and reinforcing fibres stable at temperatures equal to or lower than the melting temperature of the thermoplastic material, the closure and heating of the mould above the melting temperature of the thermoplastic material, causing the melting of the thermoplastic material without damaging the reinforcing fibres, and the subsequent cooling of the mould, hardening the thermoplastic material with the reinforcing fibres embedded therein forming a composite material;
• and
• wherein:
• the thermoplastic material (10) and the reinforcing fibres are brought into the mould integrated in a woven fabric or in a non-woven fabric;
• overlapping layers of woven fabric and/or of non-woven fabric are brought into the mould;
• and
• at least the layers constituting the extrados of the structural shell (10) are constituted only by thermoplastic material strands, producing a structural shell (10) with greater density of reinforcing fibres in its concave interior (11) than in its convex exterior (12).