(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)

(19) World Intellectual Property

Organization
International Bureau
(10) International Publication Number
(43) International Publication Date WO 2012/097252 A2
19 July 2012 (19.07.2012) P O PCT

(51) International Patent Classification: (81) Designated States (unless otherwise indicated, for every
A42B 3/00 (2006.01) A42B 3/04 (2006.01) kind of national protection available): AE, AG, AL, AM,
AO, AT, AU, AZ, BA, BB, BG, BH, BR, BW, BY, BZ,
(21) International Application Number:
CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO,
PCT/US20 12/02 1242 DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, HN,
(22) International Filing Date: HR, HU, ID, IL, IN, IS, JP, KE, KG, KM, KN, KP, KR,
13 January 2012 (13.01 .2012) KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME,
MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ,
(25) Filing Language: English OM, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SC, SD,
(26) Publication Language: English SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, TR,
TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.
(30) Priority Data:
61/432,230 13 January 201 1 (13.01.201 1) (84) Designated States (unless otherwise indicated, for every
kind of regional protection available): ARIPO (BW, GH,
(71) Applicant (for all designated States except US): E. I. DU GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ,
PONT DE NEMOURS AND COMPANY [US/US]; UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, RU,
1007 Market Street, Wilmington, Delaware 19898 (US). TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE,
DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU,
(72) Inventors; and
LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK,
(75) Inventors/Applicants (for US only): TRENTACOSTA,
SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ,
Joseph D. [US/US]; 2021 Harwyn Road N . Graylyn Crest,
GW, ML, MR, NE, SN, TD, TG).
Wilmington, Delaware 19810 (US). WALKER, William
Charles [US/US]; 16 West 38th Street, Wilmington, Published:
Delaware 19802 (US).
without international search report and to be republished
(74) Agent: LANGWORTHY, John, A.; E . I. du Pont de upon receipt of that report (Rule 48.2(g))
Nemours and Company, Legal Patent Records Center,
4417 Lancaster Pike, Wilmington, Delaware 19805 (US).

(54) Title: METHOD OF MAKING A HELMET

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(57) Abstract: This invention relates to a method of making a helmet using a preform subassembly with arms which have an area
that matches a perimeter profile of a specified geometric shape. By use of the area matching perform with arms, the thickness of the
helmet is more uniform, seams in the preform can be minimized, and the ballistic resistance of the resulting helmet can be increased.
 METHOD OF MAKING A HELMET

This application claims priority under 3 5 U.S.C.

§119 (e) from, and claims the benefit of, U.S. Provisional
Application No. 61/432,230, filed 13 January 2011, which
i s b y this reference incorporated in its entirety as a
part hereof for all purposes.

Technical Field
This invention relates to a method of making a
helmet preform subassembly, and making a helmet using a
preform derived therefrom.

Background
Current helmet manufacturing techniques involve
using flat sheets of fabric from which a three-
dimensional shape i s formed. Numerous plies of the
fabric, or preforms, are compressed together in a matched
die mold that corresponds to the desired three-
dimensional shape of the helmet. To try to achieve
uniform thickness in a molded article that has a rounded
shape, it i s often necessary to introduce numerous cuts,
darts, folds, wrinkles or irregularly-shaped patches into
what would otherwise be a flat piece of fabric. This
reduces ballistic resistance in the product helmet.

Other efforts to manufacture a helmet have involved

rotating regions that are overlapped, a s the assembly of
preforms i s built up with each additional ply of fabric,
in order to distribute the extra thickness of the
overlapped regions evenly about the preform assembly and
theoretically achieve uniform thickness in the final
molded product. This approach i s sometimes capable of
achieving a near-net-shape preform assembly, which has
relatively good conf ormability to the final helmet shape
with minimal wrinkling, but not at a desirable level of
efficiency and consistency.

Cheese (US 7,228,571) discloses a helmet

manufactured by cutting rectangular blanks from a sheet
of fabric and making cuts in each blank to form a crown
portion. The blanks are stacked and molded to form the
helmet. Each blank has four curved cuts extending
inwardly, one from each side of the rectangle. Portions
of the preform overlap other portions around the cuts.

Medwell (US 4,656,674) discloses a helmet

manufactured by cutting a preform along a zig-zag line so
that each part has one straight edge and one edge with a
series of teeth. The cut length i s wound in several
layers around a cylindrical former, so that the teeth of
successive layers are alternating. The layers are then
compressed to bend over the teeth and give a rigid
preform.
 A need nevertheless remains for methods for making a
helmet in which the thickness of the helmet i s more
uniform, in which seams in the preform are minimized, and
in which the ballistic resistance of resulting helmet i s
increased .

Summary
It has been found that the presence of a wrinkle or
any cut end in a preform assembly, despite having been
made form a high performance yarn, has a negative effect
on the ballistic resistance of a structure molded
therefrom. For example, wrinkling in a molded structure
could cause not only an increase in weight of a s much a s
9% due to the additional material incorporated into the
structure, but could also cause a drop in the V 5 0
performance of the structure of a s much a s 5%. In
another example, in a helmet using a system of 100%
Kevlar® aramid fiber, the ballistic limit, or V 5 o , of a
helmet made by conventional technology can have weak
areas that contribute to a 10% lower V 5 o at seams or cuts
in the helmet pattern.

To improve helmet products made by conventional

technology, which are frequently characterized by
weak areas where fabric cuts or seams exist;
non-uniformity in thickness due to overlapped
and non-overlapped regions in the fabric; and/or
wrinkling due to excess fabric in the preform,
there i s provided herein a method of determining the
shape and size of a preform subassembly for a helmet;
wherein the helmet i s characterized by a
hemispherical shape, and the hemispherical shape has a
center point and central axis that passes through the
center point; and
wherein the preform subassembly shape comprises m
arms arranged about a center point, each arm has at least
one width ( ), and m = 3 or 4; comprising
(a) providing a series of n reference planes (P , P2 ,
P3 . . . P ) that i s each orthogonal to the central axis
and describes a circular shape at the location of its
intersection with the hemispherical shape;

(b) measuring, for each reference plane, (1) the

perimeter length (referred to a s H for P ) of the
circular shape, and (2) the length defined by the
distance along the hemispherical shape of the arc
(referred to a s A 1 for P ) that exists between the
location of the intersection of the plane therewith and
the center point, wherein for a subassembly in which P is

the closest plane to the center point

A 1 < A 2 < A 3 < . . . < A , and H < H2 < H3 < . . . < H ;

(c) providing a series of n concentric reference

circles (C , C 2 , C 3 . . . C ) each of which has the same
center point, wherein the radius of circle C i s arc
length A ;
 (d) dividing perimeter lengths H , H , H . . . H
into m equal portions, and assigning one of the equal
portions a s an equally-spaced segment (W , 2, 3 . . . )
of each of the respective reference circles

(e) drawing a line to connect the end points of the

segments of circle length (W , 2, 3 . . . ) to
graphically represent the m arms of the preform
subassembly .

In another embodiment, the inventions hereof provide

a method of determining the shape of a preform
subassembly for a helmet wherein the helmet i s
characterized by a hemispherical shape, and the
hemispherical shape has a center point and central axis
that passes through the center point; and
wherein the prefom shape comprises m arms arranged
about a center point, each arm has a width (W) , and m >
2; comprising
(a) providing a series of n reference planes (P , P2 ,
P3 . . . P ) that i s each orthogonal to the central axis
and describes a circular shape at the location of its
intersection with the hemispherical shape;

(b) measuring, for each reference plane, (1) the

perimeter length of the circular shape (referred to a s H
for P ), and (2) the length defined by the distance along
the hemispherical shape of the arc that exists between
the location of the intersection of the plane therewith
and the center point (referred to a s A 1 for P ), wherein
A 1 < A 2 < A 3 < . . . < A , and H < H2 < H3 < . . . < H ;

(c) providing a series of n reference circles (C ,

C 2 , C 3 . . . C ) each of which has its center at the
center point of the preform shape, wherein the radius of
C is A ;

(d) dividing H , H 2 , H 3 . . . H into m equal

portions, and assigning one of the equal portions a s the
width (W , 2, 3 . . . ) of one of the m arms of the
perform shape lying at a distance of A from the center
point of the preform shape, wherein H /m gives m portions
having a width of lying a distance of A 1 away from the
center point; and

(e) drawing a line to connect the end points of the

segments of width (W , 2, 3 . . . ) in each arm to
graphically represent the shape of the perform sub
assembly.

The inventions hereof relate to methods to make a

helmet preform subassembly with arms that have an area
matching the area of a perimeter profile of a specified
three-dimensional shape, and ultimately to make a helmet
using such subassembly. By the use of an area-matching
preform subassembly, such a s a 3-armed or cruciform (4-

armed) preform shape, the thickness of a helmet

fabricated therefrom i s more uniform. Seams in a three-
armed or four-armed preform sub-assembly can be
minimized, and the ballistic resistance of a helmet
fabricated therefrom can be increased. The methods
hereof also reduce waste and produce a stronger helmet.

Brief Description of the Drawings

Figure 1 shows the a profile of a helmet of interest
in a view of the side elevation thereof.
Figure 2 shows a plan view of a helmet shape.
Figure 3 shows a four-armed preform subassembly.

Detailed Description
There i s thus described herein methods that provide
a "stitched" helmet preform. The virtue of a stitched
helmet preform i s that it involves a single component
approach wherein a flat piece of fabric i s converted into
a near-net-shape preform subassembly, and the desired
number of preform subassemblies can in turn be stacked
into a full preform assembly that i s ready to be placed
into a matched die helmet mold. The approach that the
"stitched" helmet preform provides i s a technology that
can be applied across the range of prepreg materials used
in helmet manufacturing, including laminated, woven or
unidirectional fabrics.

In various embodiments of the methods hereof,

elements of those methods that are provided include (1)

using the length of a perimeter profile of a helmet shape

of interest to match the area of the exterior surface of
the helmet to the area of a 3 - or 4-armed shape that
serves a s a preform sub-assembly, (2) obtaining uniform
thickness in a helmet preform and in a helmet by
eliminating overlapping regions, and (3) mitigating the
effects of cuts or seam in a preform by stitching that
enhances rather that detracts from penetration
resistance .

The shape of a "stitched" helmet preform, as

provided herein, i s designed to match the perimeter
profile of the three-dimensional shape of a helmet of
interest closely enough that there i s no excess material
in the preform subassemblies to cause wrinkling. There
are only three cuts in a 3-armed subassembly, and there
are a maximum of four cuts in a cruciform (4-armed)
preform subassembly, which allows the arms of the
cruciform shape cut from flat fabric to be stitched
together to provide a subassembly of shape and size that
corresponds closely to the shape and size of a helmet of
interest. The edges of the preform subassembly are
butt-stitched together so that there are no overlapping
regions and therefore the subassembly provides uniform
thickness throughout the structure in the preform
assembly and molded structure. The presence of cuts or
seams i s mitigated by stitching the adjacent arms
together to minimize any overlap of fabric and thereby
reduce any areas that are inherently weak. The effect
on ballistic performance of the presence of seams i s
greatly reduced by having reduced the number of seams or
cuts from a s many a s eight to just three or four. The
effect of the seam i s reduced because the seams are
stitched together in a manner that reduces or eliminates
overlap, which enhances rather than reduces ballistic
resistance.

The methods hereof provide for the determination of

the shape and size of a preform subassembly for the
manufacture of a helmet, wherein the helmet i s
characterized by a hemispherical shape. A hemispherical
shape i s a shape that i s nearly but not precisely the
shape of a true hemisphere. A hemispherical shape may
have locations of slight curvature and/or inflection that
cause it to deviate from the shape of a true hemisphere
and to take on a shape that i s somewhat characteristic of
one half of an oblate spheroid.

A cross-sectional view of a side elevation of a

helmet of interest i s shown in Figure 1, and this helmet
would be described a s having a hemispherical shape. As
shown in Figure 1, the hemispherical shape has a center
point 20 located at the apex of the area defined by the
shape a s shown in the cross-sectional view, and a central
axis 1 that intersects the exterior surface of the helmet
at the location of the center point. The top of the
helmet would be described a s the portion thereof at or
near the center point 20, and the bottom of the helmet
would be described a s the open portion through the wearer
places the helmet on his or her head.
 T o prepare a subassembly for a helmet o f interest,
the dimensions and the paths o f the various arcs defined
b y the exterior surface o f the shape o f the helmet are

obtained from either a physical model o f the helmet, or

from engineering drawings o f various cross-sectional
views o f the profile defined b y the exterior surface of a
side elevation o f the helmet, and/or from a plan view of

the perimeter defined b y the external surface o f the top

o f the helmet. This data can b e entered into a computer

assisted design ("CAD") program, which enables the

program t o generate a three-dimensional model o f the

helmet and t o calculate the arc and perimeter distances
discussed below. Alternatively, those measurements can
b e made b y hand on a physical model o f the helmet.

The first step in a method o f designing a preform

subassembly, and thus a method o f determining the shape

and size o f the preform subassembly, for a helmet of
interest, i s t o provide a series o f n reference planes

(P , P 2 , P 3 . . . P ) that i s each orthogonal t o the

central axis 1. A reference plane 2 and a reference
plane 3 are shown in Figure 1. There will b e a t least

two such reference planes, and n will thus b e ≥ 2 , but

there i s otherwise n o required number o f reference
planes. In various embodiments, the number o f reference
planes can, for example, b e a t least 2 , o r a t least 4 , or

a t least 6, o r a t least 8, and yet less than 60, o r less

than 40, o r less than 30, o r less than 20. In various

embodiments, the reference plane that lies closest t o the
center point 20 can define a distance between the two
points of intersection of the plane with the exterior
surface of the helmet that i s in the range of about 0.2
inches or more, or about 0.4 inches or more, or about 0.6
inches or more, or about 0.8 inches or more, or about 1.0
inches or more, and yet about 4.0 inches or less, or
about 3.0 inches or less, or about 2.5 inches or less, or
about 2.0 inches or less, or about 1.5 inches or less.

Reference planes can, but need not necessarily, be

spaced equidistant from each other. When the reference
planes are equidistant from each other, the spacing
distance can be measured along the central axis 1 , or the
spacing distance can be measured in terms of the arc
length along the profile defined b y the exterior surface
of the helmet in a cross sectional view of the side
elevation thereof. Spacing distances for reference
planes can, for example, be selected from the following
group of selections including 0.05 inch, 0.1 inch, 0.15
inch, 0.2 inch, 0.25 inch, 0.3 inch, 0.35 inch, 0.4 inch,
0.45 inch and 0.5 inch, and mixtures thereof.

Because a helmet has a hemispherical shape, which i s

not the shape of a true hemisphere, the intersection of a
reference plane with the shape of the exterior surface of
the helmet describes a shape that can be described as
nearly circular. A nearly circular shape i s a shape
that does not form a true circle, but that deviates from
the shape of a true circle primarily because of, and at
the locations of, points of slight curvature and/or
inflection in the shape of the exterior surface of the
helmet itself. A s a result, the shape formed b y the
intersection of a reference plane with the shape of a
helmet of interest can, for example, take on a shape
approximating an elliptical shape. The shape formed b y
the intersection of a reference plane with the shape of
the helmet i s the perimeter of the helmet at the location
of that particular reference plane. Figure 2 i s a plan
view of the helmet looking down on the top of the helmet.
Nearly circular shape 8 represents the perimeter defined
b y the intersection of reference plane 2 with the profile
of the exterior surface of the helmet, and nearly
circular shape 9 represents the perimeter defined b y the
intersection of reference plane 3 with the profile of the
exterior surface of the helmet.

For each reference plane, the length of the nearly-

circular-shaped perimeter of the helmet existing at that
location i s measured. The length or linear distance of
the perimeter of the helmet at reference plane P is

referred to a s H . For each reference plane, the linear

distance of an arc formed b y the exterior surface of the
helmet between the center point 20 and a point of
intersection of the reference plane with the exterior
surface i s also measured. A s shown in Figure 1, for
reference plane 2 , arc 4 i s described b y the intersection
of the plane with the exterior surface of the helmet.
For reference plane 3 , arc 5 i s described b y such
intersection. The linear distance of an arc formed b y
the exterior surface of the helmet between the center
point 20 and a point of intersection of reference plane P
with the exterior surface i s referred to as A 1 . For the

type o f helmet shown in Figure 1 , which has a shape that

flares toward the bottom and in which each perimeter

increases in size moving from the top o f the helmet

toward the bottom, it i s typically the case that

H < H2 < H3 < . . . < H , and A1 < A2 < A3 < . . . < A .

Having determined the measurements o f the values

H , H2, H3, . . . H , and A 1, A 2, A 3, . . . A , a

diagram i s constructed that contains a series of n

concentric reference circles that each has the same

center point 22, a s shown in Figure 3. A reference

circle (C ) i s provided for each set o f H /A 1 values

obtained b y making the measurements o f linear distance

described above. A series o f n reference circles

(C , C 2 , C 3 . . . C ) i s thus provided for the series of

values sets H A , H 2 /A 2 , H /A 3 , . . . H /A .

For the H /A 1 value set, a circle i s drawn that has a

a radius o f A 1 from the center point 22 o f the circle.

Around that circle, the linear distance H is (for a 4 -

armed subassembly) apportioned in four equal parts that

are equally spaced from one another. In Figure 3, for

example, reference circle 10 has a radius 2 4 equal t o the

length o f the arc 4 between the center line o f the helmet

1 and the point o f intersection o f reference plane 2 with

the profile o f the exterior surface o f the helmet.

Around reference circle 10, the linear distance equal to

the length o f the perimeter defined b y the intersection

o f reference plane 2 with the exterior surface of the

helmet (represented b y nearly circular shape 8 ) has been

apportioned in four equal, equally spaced parts (shown by

dashed lines in Figure 3). Similarly, reference circle

11 in Figure 3 has a radius 25 equal t o the length o f the

arc 5 between the center line o f the helmet 1 and the

point o f intersection o f reference plane 3 with the

profile o f the exterior surface o f the helmet. Around

reference circle 11, the linear distance equal t o the

length o f the perimeter defined b y the intersection of

reference plane 3 with the exterior surface o f the helmet

(represented b y nearly circular shape 9 ) has been

apportioned in four equal, equally spaced parts.

The same procedure i s followed for each other

perimeter that has been generated b y the intersection of

a reference plane with the profile o f the exterior

surface o f the helmet a s shown in a view o f the side

elevation thereof. Thus reference circle C i s drawn

around center point 2 2 that has a radius o f A 1 , and the

length (H ) o f the perimeter generated b y the intersection

o f plane P with the helmet i s apportioned in four equal,

equally spaced parts ( ) around the circle C . This

continues until a series o f n reference circles (C , C 2 ,

C 3 . . . C ) , containing therwithin four equal portions of

perimeter length, has been drawn for the series o f values

sets HVA , H2 /A 2 , H /A 3 , . . . H /A . In Figure 3, for

example, the four W s provided b y apportioning the

perimeter distance generated b y the intersection of

reference plane 2 with the helmet are shown a s the four

dashed-line segments o f reference circle 10. Similarly,

the four W s provided b y apportioning the perimeter
distance generated b y the intersection of reference plane
3 with the helmet are shown a s the four dashed-line
segments of reference circle 11. Thus a series of these
one-fourth perimeter length segments of reference circle
i s provided for each reference circle, with the result
that a series of the one-fourth equal lengths
(W , W 2 , W 3 . . . W ) i s provided for the full series of
values sets HVA , H 2 /A 2 , H /A 3 , . . . H /A .

When the ends of these segments of the reference

circles that each represents one-fourth of a perimeter
length (H ) are connected b y a straight line, the arms of
a cruciform shaped pattern for a preform subassembly are
provided, with the end of each arm of the cruciform being
provided along the track of the reference circle further
from the center point 22. The arms of the subassembly
are joined to the area around the center point 22 b y the
track of the reference circle closest to center point 1 .
The longest distance from the center point 22 of a
preform subassembly to a point on the exterior end of an
arm can, in various embodiments, be between about 5 and
about 2 0 inches.

If it desired to have a preform subassembly with

three arms rather than four, the same procedure as
described above i s followed except that the perimeter
distance H i s divided into three equal segments that are
equally spaced around corresponding reference circle, and
W i i s thus one-third of H rather than one fourth. In
either case, the graphical representation of the preform
subassembly obtained b y connecting the end points of the
W i segments with a straight line can be used to prepare a
pattern from which a preform subassembly can be cut from
a flat sheet of ballistic resistant fabric. When the
adjacent edges of the arms of the preform subassembly are
butt stitched together, the preform subassembly is
provided in a shape that quite closely matches the shape
of the helmet of interest with a minimum, if any, of
wrinkles, folds or darts. This i s possible because the
preform subassembly has been cut wholly from just one
piece of fabric.

A further embodiment of this invention i s a method

to fabricate a helmet. The first step in such a

fabrication or manufacturing method i s providing a
plurality of helmet preform subassemblies designed b y the
methods described above. The preform comprises at least
two of the preform subassemblies nested together wherein
the fabric of the preform subassemblies i s impregnated
with a polymer resin. Adjacent arms of the preform
subassemblly are stitched together at the side edges of
the arms to form a stitched preform. Next, the stitched
preform subassemblies are stacked to provide a preform,
and the preform i s compression molded.

The fabric of the preform subassembly may be made of

high performance fibers having a tenacity greater than
about 8 g/den such a s para-aramid (e.g. DuPont Kevlar®
fiber) , ultra high molecular weight polyethylene
(UHMWPE) , high tenacity nylon, carbon fiber, or
p-phelnyl-2-6-benzobisoxazole (PBO) fibers. Fabrics
made from such fibers can, a s desired, b e made a s plain,
twill, harness or satin weave. The impregnating polymer
resin may b e a thermoplastic or thermoset polymer such a s
a urethane or functionalized ethylene copolymer. Once
the shape of the preform subassembly has been matched to
the helmet design, preform subassemblies may b e cut from
larger sheets of fabric b y conventional means such a s
scissors or knives.

The adjacent side edges of a preform subassembly may

b e butt stitched together such that there i s essentially
no overlap of the side edges of the subassembly arms.
The stitching of side edges of the arms that are adjacent
to each other may have a density between about 5 ends per
inch to about 2 0 ends per inch. The thread used for
stitching may b e made of high performance fibers having a
tenacity greater than about 8 g/den such a s fibers made
from carbon, para-armid, fiberglass, ultra high molecular
weight polyethylene and PBO.

The adherence together of the side edges of the

adjacent arms of the subassembly may also b e accomplished
b y adhesively bonding a unidirectional (UD) tape to each
edge of the adjacent arms such that there i s essentially
no overlap of the adjacent side edges. The
unidirectional U D tape may b e made of high performance
fibers having a tenacity greater than about 8 g/den such
a s fibers made from para-aramid (e.g. DuPont Kevlar®
fiber) , ultra high molecular weight polyethylene
(UHMWPE) , high tenacity nylon, carbon, or p-phelnyl-2-6-
benzobisoxazole (PBO) .

A stack of preforms to b e compression molded may

have 1 0 to 75, or 4 0 to 50, stitched preforms. The
number of preforms that are compressed together will b e
determined b y the basis weight of the ultimate helmet
product, which i s often in the range of about 1.8 to
about 2.2 lbs/square foot. The compression molding may
b e conducted at a temperature between about 120 °C to
about 180°C using between about 200 to about 500 tons of
force .
 Examples
The operation and effects of certain embodiments of
the inventions hereof may be more fully appreciated from
a series of examples (Examples 1 and 2), a s described
below. The embodiments on which these examples are
based are representative only, and the selection of those
embodiments to illustrate the inventions does not
indicate that materials, designs, conditions, techniques
or protocols not described in the examples are not
suitable for use herein, or that subject matter not
described in the examples i s excluded from the scope of
the appended claims and equivalents thereof. The
significance of the examples i s better understood by
comparing the results obtained therefrom with the results
obtained from certain trials that are designed to serve
a s controlled experiments (Controls A and B ) and provide
a basis for such comparison since the distinguishing
features of the inventions hereof were not used therein.

A cruciform design for a single component (single

piece) preform was developed. By empirically varying
the parameters of the design, it was possible to match
the perimeter profile of the exterior of a simplified
hemispherical helmet. Table 1 gives the dimensions of
the arms of the subassembly a s prepared in Control B and
Example 1 for a hemispherical shaped helmet where the
diameter of the corresponding true hemisphere equals 10",
which models a size medium helmet. In Table I , Al, A2,
A 3 and A 4 are the distances from the center point o f the
subassembly to the edge o f four reference circles (i.e.

the radii o f the respective circles) in a layout of a

subassembly that corresponds to the subassembly shown in
Figure 3. For example, A l and A 2 could b e considered to
correspond to radii 2 4 and 25 in Figure 3, and A 3 and A 4
would correspond to the respective radii o f reference
circles not shown in Figure 3. The widths o f the
preform arms are listed in Table 1 a s Wl, W2, 3 and W4,
and those widths correspond, respectively, to segments of
the reference circles determined b y the respective radii
Al, A2, A 3 and A 4 . W l and W 2 could b e considered to
correspond to the dashed-line segments o f reference
circles 10 and 11, respectively, a s shown in Figure 3.

W 3 and W 4 would correspond to the dashed-line segments of

reference circles not shown in Figure 3. The dimensions
in Table 1 are given in inches.

Control A
In Control A , a lightweight [1.6-1.8 pounds per
square foot aerial density (where the aerial density
given in Table I I i s the weight per unit area o f the
preform given in pounds per square foot) ] Personnel Armor
System for Ground Troops (PASGT )style helmet was molded
from 42 plies (or layers o f fabric, counted in ply count)
o f 5.1 ounces per square yard, 2 9 ends x 2 9 ends, plain
weave fabric (Style 751, JPS Inc., Spartanburg SC) made
with 600 denier Kevlar® KM2 fiber. Each ply or layer of
fabric was coated with a film o f a thermoplastic polymer
(Mark VI, DuPont, Wilmington DE) such that the resin
content level was greater than 1 0 wt% but less than 2 0
wt%. The preform was a multiple component preform
consisting of a 21" diameter circle with 7.5" cuts at 0,

90, 180 & 360 degrees, and a four legged cross where the
width of each leg was 4.25", and the length of each leg
was 10.5" from the center point. B y overlapping the
circle in the cut areas, the circle-cross preform was
formed into a bucket shape such that the wall thickness
in all areas was 2 plies thick. This technique was
repeated for each circle-cross pair until 2 1 preform
buckets were nested together.

The subassembly of preform buckets was placed into a

matched die PASGT helmet mold with a 0.080" metal shim,
and processed at a molding temperature of 160°C and a
molding pressure of 200 tons total force for 13 minutes.
The material was cooled to below 70°C while being held at
mold pressure. The molded helmet was removed from the
matched die helmet mold and the excess material removed.
The molded weight of the helmet i s given in pounds in
Table II. The helmet was ballistically tested to
determine its V 5 o in terms of a 1 7 grain fragment
simulated projectile (fsp) (listed a s the Threat in Table
II) . V 5 o i s the strike velocity of the projectile at
which 50% of the projectiles at that velocity will b e
stopped, and 50% will completely penetrate the helmet.
The V 5 o value i s shown in Table I I below in feet per
second. Control A i s made b y conventional technology in
which portions of the same or adjacent plies are
overlapped, and i s thus not made b y any of the methods of
this invention.

Control B
In Control B , a lightweight (1.6-1.8 pounds per
square foot aerial density) PASGT style helmet was molded
from 42 plies of 5.1 ounces per square yard, 2 9 x 2 9
plain weave, fabric made with 600 denier Kevlar® KM2
fiber. Each ply or layer of fabric was coated with a
film of a thermoplastic polymer such that the resin
content level was greater than 1 0 wt% but less than 2 0
wt%. Each ply was cut into a single component cruciform
shaped preform subassembly where the width of each spoke
of the cruciform i s shown in Table I below. The four
arms of each subassembly were stitched together such that
there was no overlap at the seams. The stitched
subassemblies were nested together into a moldable
preform. Although the preform of Control B was
fabricated using a four arm preform subassembly, the
widths of the subassembly arms were not determined b y
equal apportionment of the linear distance of a perimeter
generated b y the intersection of a reference plane with
the profile of the desires helmet shape, that i s those
dimensions were not determined b y the methods of this
invention a s described above.

The preform of stitched subassemblies was placed

into a matched die PASGT helmet mold with a 0.080" metal
shim, and processed at a molding temperature of 160°C and
a molding pressure of 200 tons total force for 13
minutes. The material was cooled to below 70°C while
being held at mold pressure. The molded helmet was
removed from the matched die helmet mold, and the excess
material removed. The helmet was tested to determine
its ballistic limit for a 1 7 grain fsp, and its value i s
shown in Table I I below.

Example 1
In Example 1, an example of the invention, a
lightweight (1.6-1.8 pounds per square foot aerial
density) PASGT style helmet was molded from 42 plies of
5.1 ounces per square yard, 2 9 x 2 9 plain weave, fabric
made with 600 denier Kevlar® KM2 yarn. Each ply or
layer of fabric was coated with a film of a thermoplastic
polymer such that the resin content level was greater
than 10% but less than 20%. Each ply was cut into a
single component cruciform shaped preform where the width
of each spoke or arm of the cruciform matched the
perimeter profile of the hemispherical shape that
approximated a medium size PASGT helmet. The dimensions
of the preform are shown in Table I below. The arms of
each preform were stitched together such that there was
no overlap at the seam. The stitched preforms were
nested together into a subassembly.

The subassembly of stitched preforms were placed

into a matched die PASGT helmet mold with a 0.080" metal
shim, and processed at a molding temperature of 160C and
a molding pressure of 200 tons total force for 13
minutes. The material was cooled to below 70C while
being held at mold pressure. The molded helmet was
removed from the matched die helmet mold, and the excess
material removed. The helmet was tested to determine
its ballistic limit for a 1 7 grain fsp, and its value i s
shown in Table I I below. Example 1, made b y a method of
this invention, exhibits the highest ballistic limit
observed .

Table I
Dimensions of
Control B and Example 1 Preform Designs.
 Table I I
Ballistic Limits (V50 values) of
Controls A and B and Example 1

Example 2
In a flat panel study, it was shown that butt
stitching a seam with a zig-zag or satin stitch with a
high performance fiber thread can provide equivalent
ballistic performance in a flat panel of uncut fabric
plies .

Panels A & F were twelve inch square molded flat

panels each consisting of 2 1 plies of 12" x 12" 600
denier KM2 S751 woven fabric coated with a thermoplastic
resin containing polyethylene and Kraton®
styrene/ethylene-butadiene/styrene copolymer (designated
a s Mark IV) . The plies were heated to 320°F under
pressure for 1 0 minutes and cooled under pressure to
below 100°F. These panels, A & F were the flat panel
controls to provide the ballistic limit that would
provide the target for the stitched panels.

Panels B , C , D, and E were twelve inch square molded

flat panels consisting of 2 1 plies of the same material
system butt stitched together with stitching a s specified
in Table III. Each panel had seven plies that consisted
of three sections, 4" wide b y 12" long, that were butt
stitched along the 12" side so that the stitched ply was
12" x 12". Each panel also had seven plies that
consisted of one section 3" wide b y 12" long, and a
second section that was 4" wide b y 12" long, and a third
section that was 5" wide b y 12" long. The three
sections were butt stitched along the 12" side so that
the stitched ply was 12" x 12". Each panel also had
seven plies that consisted of one section 5" wide b y 12"
long, and a second section that was 4" wide b y 12" long,
and a third section that was 3" wide b y 12" long. The
three sections were butt stitched along the 12" side so
that the stitched ply was 12" x 12". The stitched plies
were assembled b y alternating each ply so that the
stitched seams did not align with the underlying ply.

The six panels were ballisticly tested to determine

the ballistic limit for each configuration and i s shown
in Table III. Panel C , with its stitching arrangement,
showed that its ballistic limit was statistically
equivalent to the unstitched controls of the same
material system, and basis weight.
 Table III
Stitched Flat Panel Study

In this specification, unless explicitly stated

otherwise or indicated to the contrary by the context of
usage, where an embodiment of the subject matter hereof
i s stated or described a s comprising, including,
containing, having, being composed of or being
constituted by or of certain features or elements, one or
more features or elements in addition to those explicitly
stated or described may be present in the embodiment.
An alternative embodiment of the subject matter hereof,
however, may be stated or described a s consisting
essentially of certain features or elements, in which
embodiment features or elements that would materially
alter the principle of operation or the distinguishing
characteristics of the embodiment are not present
therein. A further alternative embodiment of the
subject matter hereof may be stated or described a s
consisting of certain features or elements, in which
embodiment, or in insubstantial variations thereof, only
the features or elements specifically stated or described
are present.
 Claims

What i s claimed is:

1. A method of determining the shape and size of a

preform subassembly for a helmet;
wherein the helmet i s characterized by a
hemispherical shape, and the hemispherical shape has a
center point and central axis that passes through the
center point; and
wherein the preform subassembly shape comprises m
arms arranged about a center point, each arm has at least
one width (W ), and m = 3 or 4; comprising
(a) providing a series of n reference planes (P , P2 ,
P3 . . . P ) that i s each orthogonal to the central axis
and describes a circular shape at the location of its
intersection with the hemispherical shape;

(b) measuring, for each reference plane, (1) the

perimeter length (referred to a s H for P ) of the
circular shape, and (2) the length defined by the
distance along the hemispherical shape of the arc
(referred to a s A 1 for P ) that exists between the
location of the intersection of the plane therewith and
the center point, wherein for a subassembly in which P is

the closest plane to the center point

A 1 < A 2 < A 3 < . . . < A , and H < H2 < H3 < . . . < H ;
 (c) providing a series of n concentric reference
circles (C , C2 , C3 . . . C ) each of which has the same
center point, wherein the radius of circle C i s arc

length A ;

(d) dividing perimeter lengths H , H2 , H3 . . . H

into m equal portions, and assigning one of the equal
portions a s an equally-spaced segment (W , 2, 3 . . . )
of each of the respective reference circles

(e) drawing a line to connect the end points of the

segments of circle length (W , 2, 3 . . . ) to
graphically represent the m arms of the preform
subassembly .

2. A method of fabricating a helmet, comprising:

(a) providing a helmet preform designed according to
the method of Claim 1 that comprises at least two layers
of fabric wherein the at least two layers of fabric are
impregnated with a polymer resin;
(b) stitching together side edges of the arms of the
perform which are adjacent to each other to form a
stitched perform;
(c) stacking a plurality of stitched preforms to
form a stack; and
(d) compression molding the stack.
 3. A method according to Claim 2 wherein the fabric
comprises a fiber prepared from para-aramid, ultra high
molecular weight polyethylene, high tenacity nylon,
carbon, or p-phelnyl-2-6-benzobisoxazole .

. A method according to Claim 2 wherein the

polymer resin i s a thermoplastic or thermoset polymer.

5. A method according to Claim 2 wherein the

stitching together of adjacent side edges comprises butt
stitching such that there i s essentially no overlap of
the side edges of the preform arms which are adjacent to
each other.

6. A method according to Claim 2 wherein the

stitching together of side edges of the preform arms
which are adjacent to each other has a density between 5
ends per inch to 2 0 ends per inch.

7. A method according to Claim 2 wherein the stack

comprises between fifteen and seventy five stitched
preforms .

8. A method according to Claim 2 wherein the

compression molding i s conducted at a temperature between
120°C to 180°C.

9. A method according to Claim 2 wherein the

compression molding i s conducted at a pressure of between
200 to 500 tons of force.

10. A method according to Claim 2 wherein the

distance from the center to an exterior end of an arm
along the central axis i s between 5 and 2 0 inches.

11. A method according to Claim 2 wherein the

stitching together of side edges of the arms of the
perform which are adjacent to each other i s done with
thread made of high performance fibers having a tenacity
greater than 8 g/den prepared from a material selected
from carbon, para-aramid, fiberglass, ultra high
molecular weight polyethylene and p-phelnyl-2-6-
benzobisoxazole.

12. A method according to Claim 5 wherein the

stitching together of side edges of the arms of the
preform which are adjacent to each other comprises a step
of adhesively bonding a unidirectional (UD) tape such
that there i s essentially no overlap of the adjacent side
edges .

13. A method according to Claim 12 where the

unidirectional UD tape i s made of high performance fibers
having a tenacity greater than 8 g/den prepared from a
material selected from para-aramid, ultra high molecular
weight polyethylene, high tenacity nylon, carbon and p -
phelnyl-2-6-benzobisoxazole .
 14. A method of determining the shape of a preform
sub-assembly for a helmet;
wherein the helmet i s characterized by a
hemispherical shape, and the hemispherical shape has a
center point and central axis that passes through the
center point; and
wherein the preform shape comprises m arms arranged
about a center point, each arm has a width (W) , and m >
2; comprising
(a) providing a series of n reference planes (P , P2 ,
P3 . . . P ) that i s each orthogonal to the central axis
and describes a circular shape at the location of its
intersection with the hemispherical shape;

(b) measuring, for each reference plane, (1) the

perimeter length of the circular shape (referred to a s H
for P ), and (2) the length defined by the distance along
the hemispherical shape of the arc that exists between
the location of the intersection of the plane therewith
and the center point (referred to a s A 1 for P ), wherein
A 1 < A 2 < A 3 < . . . < A , and H < H2 < H3 < . . . < H ;

(c) providing a series of n reference circles (C ,

C 2 , C 3 . . . C ) each of which has its center at the
center point of the helmet design shape, wherein the
radius of C is A ;

(d) dividing H , H 2 , H 3 . . . H into m equal

portions, and assigning one of the equal portions a s the
width (W , W , W . . . ) of one of the arms of the
perform shape lying at a distance of A from the center
point of the preform shape, wherein H /m gives m portions
having a width of lying a distance of A 1 away from the
center point; and

(f) drawing a line to connect the end points of the

segments of width (W , 2, 3 . . . ) in each arm to
graphically represent the shape of the perform sub
assembly.