Abstract: A helmet shell assembly wherein a helmet shell is provided with a covering of normally flat thermoplastic material which is disposed on the shell in such a manner as to have a minimum number of seams. The assembly is made by inserting a support member (44) into a helmet shell (12), positioning the shell and support into a cavity (50) of a forming fixture (46), then draping a sheet of softened thermoplastic material (16) [which is supported by a frame (48)] over one side of the shell, vacuum forming the sheet (16) about the side of the shell, and then trimming the sheet after it has set. The other side of the helmet shell is then covered by repeating the above steps, and then a tape is applied over the length of the helmet to cover the exposed seams. A protective coating and an edge roll may then be applied. The shell may initially be covered with a surface finish.

Abstract: A shock attenuation system useful in protective headgear is disclosed wherein shock is attenuated by the axial compression and lateral deflection of elastomeric columns. Cushioning material occupies the spaces between the columns.

Abstract: A ballistic resistant armor panel and a method of constructing the same utilizes a first layer of resin-impregnated fabric, a second layer of flexible woven fabric, a border layer of resin-impregnated fabric bordering the second layer, and a third layer of resin-impregnated fabric. The percentage by weight of resin in the first layer is such that the first layer distributes the impact of a projectile which strikes its surface over a large area of the panel and effectively contributes to the ability of the panel to stop and/or slow the projectile. Furthermore, the second layer of flexible woven fabric is encapsulated by the first, border and third layers. Such a construction minimizes blunt trauma in body armor in which the panel is utilized and preserves the dry ballistic resistance of the woven fabric comprising the second layer. The panel of the invention is particularly well-suited for utilization in a helmet, and a helmet which includes such a panel possesses very good ballistic resistance.

Abstract: A shock attenuation system comprising a plurality of shock attenuating columns of a substantially resilient elastomeric material. The columns are so dimensioned and configured that, when subjected to an axial impact force of predetermined magnitude, they resiliently deform for attenuating the shock resulting from the impact force. The columns then spring back substantially to their undeformed shape.