Multiple density helmet body compositions to strengthen helmet

The method of forming a helmet having a dome-shaped body and air vent means in said body,

• said body consisting of molded, foamed, synthetic resin sections, a first said section having relatively higher density and a second said section having relatively lower density,
• said first section extending in strengthening adjacent to said second section, laterally of said vent means, and said first section having a flange penetrating into the second section, in bounding relation to the vent means, to strengthen the second section proximate the vent means, the second section forming a recess into which the first section is received during molding, said flange having a top surface,
• said first section comprising at least one insert defining walls of said vent means,
• said method including molding said second section in position to contact said insert, said insert consisting of foamed synthetic resin, wherein said step of molding said second section in a position to contact said insert comprises molding the outer surface of said second section into substantially flush relation with said flange top surface.

In a protective helmet having a dome-shaped body and air vent means in said body, communicating with the hollow interior of the helmet, the helmet comprising,

• a body consisting of molded, foamed, synthetic resin sections, a first said section having relatively higher density and a second said section having relatively lower density, said sections having the same foamed, synthetic resin composition,
• said first section extending in strengthening adjacency to said second section, laterally of said vent means, and said first section having a flange portion penetrating into the second section, in bounding relation to the vent means, to strengthen the second section proximate the vent means, the second section forming a recess into which the first section is received during molding,
• the periphery of said first section converging in a direction between the exterior of the helmet and said helmet interior to transfer impact loading laterally from the first section to said second section,
• said flange portion of said first section having a top surface which is substantially flush with the outer surface of said second section.

The method of forming a helmet having a dome-shaped body and air vent means in said body, communicating with the hollow interior of the helmet,

• said body consisting of molded, foamed, synthetic resin sections, a first said section having relatively higher density and a second said section having relatively lower density, said sections having the same foamed, synthetic resin composition,
• said first section extending in strengthening adjacency to said second section, laterally of said vent means, and said first section having a flange portion penetrating into the second section, in bounding relation to the vent means, to strengthen the second section proximate the vent means, the second section forming a recess into which the first section is received during molding,
• said method including first molding said first section to have an inner peripheral side adjacent said vent means and an outer peripheral side, and thereafter molding said second section against said first section outer peripheral side, wherein said outer peripheral side of the first section converges in a direction between said helmet exterior and the helmet interior to transfer impact loading laterally from the first section to the second section,
• said flange portion of said first section having a top surface which is substantially flush with the outer surface of said second section wherein said step of molding said second section against said first section outer peripheral side comprises molding the outer surface of said second section into substantially flush relation with said flange top surface.