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Abstract

A method for fabricating a strengthened plastic shell of a safety helmet and a helmet structure fabricated using the method are disclosed. The method includes providing at least one fiber layer and at least one shell that has a thin, flat structure; binding the fiber layer to the shell to form a preform; heating and pressing the preform with a first forming module, so that at least some local, surface texture of the shell is fused with or interlaced with the fiber layer to form an assembly that has a helmet-like shape (or contour); and arranging a foam material at an inner surface of the assembly and attaching the foam material over the inner surface of the assembly using a second forming module, thereby forming a helmet structure. The method makes the overall fabrication less complicated and less time-consuming as compared to the prior art.

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First Claim