# US 2023/0404202 A1 · In-molded helmet chinbar > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0404202 A1 - Document ID: US20230404202A1 - Status: Published application - Kind: A1 - Application number: 18/460,871 - Filed: 2023-09-05 - Published: 2023-12-21 - Earliest claimed: 2016-05-05 - Assignees: Fox Head, Inc. - Applicants: Fox Head, Inc. - Inventors: David L. DURHAM; Dennis TAN - Web page: https://patentgrep.com/patent/US20230404202A1 ## CPC - A42B 3/205: {Chin protectors} - A42B 3/326: {Helmets with movable or separable chin or jaw guard} - A42B 3/062: {with reinforcing means} - A42B 3/125: {with a padded structure, e.g. foam} - A42B 3/222: {in an articulated manner, e.g. hinge devices} - A42B 3/32: Collapsible helmets; Helmets made of separable parts {; Helmets with movable parts, e.g. adjustable} - A42C 2/002: {In-mould forming} - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) - A42C: MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS ## Abstract A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding. ## Claims ### Claim at position 1 1-20. (canceled) ### Claim 21 A helmet, comprising: a shell having a front opening; a padding coupled to an interior surface of the shell, the padding having a first lateral side portion and a second lateral side portion; and a chinbar extending around the front opening, the chinbar comprising a first flange extending from a first interface and a second flange extending from a second interface, the first and second flanges having flange apertures extending therethrough, wherein the first flange is encased within the first lateral side portion of the padding and the second flange is encased within the second lateral side portion of the padding and the padding extends through the flange apertures; and wherein a continuous bottom edge of the helmet defined by a portion of the chinbar, and wherein the chinbar extends around a lower portion of a wearer's head when the helmet is worn. ### Claim 22 (depends on 21) The helmet of claim 21, wherein the padding comprises (i) an outer layer coupled to the interior surface of the shell and molds over the first flange and the second flange, and (ii) an inner layer configured to conform to the head of the wearer. ### Claim 23 (depends on 22) The helmet of claim 22, wherein the outer layer includes a first material having a first density, and the inner layer includes a second material different from the first material. ### Claim 24 (depends on 21) The helmet of claim 21, wherein the chinbar includes an chinbar exterior surface, wherein the first and second flange each includes a flange exterior surface, and wherein the flange exterior surface is offset toward an interior of the helmet from the chinbar exterior surface. ### Claim 25 (depends on 21) The helmet of claim 21, further comprising a fastener extending through coaxially aligned holes in the shell and the chinbar to secure the chinbar to the shell. ### Claim 26 (depends on 21) The helmet of claim 21, wherein the first interface extends from a first end of the chinbar, and wherein the second interface extends from a second end of the chinbar. ### Claim 27 A helmet, comprising: a shell having a front opening; a padding coupled to an interior surface of the shell, the padding having a first lateral side portion and a second lateral side portion; and a chinbar extending around the front opening, the chinbar comprising a first flange extending from a first interface and a second flange extending from a second interface, the first and second flanges having flange apertures extending therethrough, wherein the first flange is encased within the first lateral side portion of the padding and the second flange is encased within the second lateral side portion of the padding; and wherein a continuous bottom edge of the helmet defined by a portion of the shell and a portion of the chinbar, and wherein the chinbar extends around a lower portion of a wearer's head when the helmet is worn. ### Claim 28 (depends on 27) The helmet of claim 27, wherein the padding includes (i) an outer layer attached to the shell and molds over the first flange and the second flange, and (ii) an inner layer adjacent to the outer layer and configured to conform to the head of a wearer. ### Claim 30 (depends on 27) The helmet of claim 27, wherein the first and second flanges extend rearwardly from the first and second interfaces. ### Claim 31 (depends on 27) The helmet of claim 27, further comprising a fastener extending through coaxially aligned holes in the shell and the chinbar to secure the chinbar to the shell. ### Claim 32 (depends on 27) The helmet of claim 27, wherein the chinbar comprises a cage. ### Claim 33 (depends on 27) The helmet of claim 27, wherein the first flange and the second flange each define a plurality of apertures, and wherein a portion of the padding extends through the apertures. ### Claim 34 (depends on 27) The helmet of claim 27, wherein the first flange and the second flange each define a plurality of fingers that fan out within the padding. ### Claim 35 A helmet, comprising: a shell; a padding coupled to an interior surface of the shell, the padding including a side portion configured to be positioned adjacent to a side of a head of a wearer and defining a chinbar engagement surface, and a chinbar comprising a cage coupled to the shell and the padding, and defining a padding engagement surface conforming with the chinbar engagement surface, the chinbar including a flange extending through the chinbar engagement surface and with a flange aperture extending therethrough, wherein the flange is encased within the side portion of the padding, wherein a continuous bottom edge of the helmet defined by a portion of the shell and a portion of the chinbar, and wherein the chinbar extends around a lower portion of a wearer's head when the helmet is worn. ### Claim 36 (depends on 35) The helmet of claim 35, wherein the padding includes (i) an outer layer attached to the shell and molds over the flange, and (ii) an inner layer adjacent to the outer layer and configured to conform to the head of a wearer. ### Claim 37 (depends on 36) The helmet of claim 36, wherein the outer layer includes a first material having a first density, and the inner layer includes a second material different from the first material. ### Claim 38 (depends on 35) The helmet of claim 35, wherein the flange defines a plurality of apertures, and wherein a portion of the padding extends through the apertures. ### Claim 39 (depends on 27) The helmet of claim 27, wherein the outer layer includes a first material having a first density, and the inner layer includes a second material different from the first material. ### Claim 39 (depends on 35) The helmet of claim 35, wherein the first defines a plurality of fingers that fan out within the padding. ### Claim 40 (depends on 35) The helmet of claim 35, further comprising a fastener extending through coaxially aligned holes in the shell and the chinbar to secure the chinbar to the shell.