Gentex Corporation

Michael R Lavender

Leonard P Frieder, Jr

An individually fitted helmet liner includes a plurality of layers, each of which consists of a thermoplastic sheet formed with an array of pockets receiving the major portions of energy-absorbing spheres, the spheres of one layer being in register with the spaces between the spheres of an adjacent layer. The liner is fitted to an individual wearer's head by heating the sheets to a plastic state, placing the liner between an outer shell and the wearer's head, and applying tension to the layers around their periphery to deform the sheets to a degree determined by the relative position of the spheres. A mold member for use in making the individual resin-sphere layers and a method employing the mold member to make such layers are also disclosed.

Individually fitted helmet liner and method of making same

A custom-fitted helmet in which a preformed elastomer sack containing a resin-bead composite adapted to rigidify in response to mechanical deformation accommodates a single rigid outer shell to various individual head sizes. The underside of the sack is formed with circular channels concentric about the top of wearer's head which lockingly receive resilient strips that are part of a preformed inner helmet assembly. The resilient strips are carried on the inner assembly by intermediary energy-absorbing strips which are in turn adhered to a flexible leather liner fitting over the wearer's head.

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Vandling, PA, United States of America

Michael R Lavender