Helm

Abstract

A helmet, such as a sports helmet or a safety helmet, consists of an outer shell, an inner shell, and a helmet body. The helmet body comprises a solid foam made of expanded foam particles, which is arranged between the outer shell and the inner shell and adheres directly to both the outer shell and the inner shell.

Description

[0001] The invention relates to a helmet, in particular a sports helmet or a safety helmet.

[0002] Such a helmet is designed to protect the wearer from head injuries in the event of a fall or an impact of an object on the wearer's head. Depending on the application, the helmet can be used as a sports helmet or a work helmet, and can be designed as a bicycle helmet or riding helmet, for example. Especially when used as a bicycle helmet, the helmet can have one or more ventilation openings to support passive cooling of the wearer's head through ambient air or wind.

[0003] The helmet typically comprises a helmet body having an at least substantially concave inner side (apart from, for example, only the aforementioned ventilation openings), which faces the head of the helmet wearer when the helmet is put on, and an opposite, at least substantially convex outer side. The helmet body's shape, thickness, and material are designed to absorb, as far as possible, the kinetic energy acting on the helmet in the event of an impact (collision or collision) through inelastic and / or elastic deformation. Such shock-absorbing properties can result, in particular, from the helmet body being made of a rigid foam.

[0004] The helmet may further comprise a helmet shell arranged on a surface of the helmet body. The ventilation openings mentioned may extend (in particular in an at least substantially radial direction) through the helmet body and the helmet shell. The helmet shell may be thin compared to the helmet body and have an at least substantially constant thickness.

[0005] Typically, only a single helmet shell is provided, which is an outer shell arranged on the aforementioned outer side of the helmet body and, corresponding to the helmet body, can have an at least substantially concave inner side and an at least substantially convex outer side. The outer shell is arranged on the helmet body in such a way that its inner side rests against at least part of the outer side of the helmet body and thus covers it.

[0006] To securely attach the helmet outer shell to the helmet body, the inside of the helmet outer shell can be bonded to the outside of the helmet body, for example, by adhesive bonding. Alternatively or additionally, the helmet outer shell can also wrap around the edges of the helmet body to form a positive connection with the helmet body. The helmet outer shell can perform a supplementary protective function (e.g., shock absorption or reducing the coefficient of friction for the helmet to slide along a rough surface), or it can essentially serve a purely decorative function.

[0007] The helmet can be manufactured using the so-called in-mold technique. This involves placing the outer shell of the helmet into a mold. Casting material is then poured into the mold at at least one filling point to form the helmet body. Depending on the choice of casting material, foaming of the casting material may be required, particularly if the helmet body is to be constructed as a solid foam. By forming the helmet body directly onto the outer shell of the helmet, a reliable, permanent connection is advantageously created between the inside of the outer shell and the outside of the helmet body, eliminating the need for an additional connection between the outer shell and the helmet body, such as by gluing.

[0008] However, the provision of a helmet shell can bring advantages not only on the outside of the helmet body, but also on its inside. For example, the helmet's inside can then be easier to clean and be better protected against wear. From a decorative point of view, an inner shell arranged on the inside of the helmet body can also make it easier to design the inside of the helmet with color or graphics. Above all, however, an overall improved stability and strength of the entire helmet can be achieved if the helmet body has a helmet shell on both its outside and inside.

[0009] However, the provision of both an outer helmet shell and an inner helmet shell appears to be counteracting the helmet's construction using the aforementioned in-mold process, particularly if the helmet body is to be formed from a foamed casting material. This is because the casting material must then not only be poured into the confined space between the outer and inner helmet shells, but also foamed there. However, this typically requires the introduction of steam, which must reach as much of the casting material as possible but cannot penetrate the helmet shells, so that areas of the helmet body that are too far away from openings in the helmet shells are not foamed or are only insufficiently foamed.

[0010] It is an object of the invention to provide a helmet of the type mentioned which has very good shock-absorbing properties and at the same time offers improved stability and strength and preferably also improved possibilities for designing the inside of the helmet.

[0011] The object is achieved by a helmet having the features of claim 1. Advantageous embodiments of the invention emerge from the subclaims, the present description and the figure.

[0012] According to the invention, the helmet, which may in particular be a sports helmet or a safety helmet, comprises an outer shell, an inner shell, and a helmet body, which may be configured as described above. The helmet may, in principle, have one or more of the features and properties described above.

[0013] In particular, the helmet body has an at least substantially concave inner side, which, when the helmet is in place, faces the head of the helmet wearer, and an opposite, at least substantially convex outer side. The helmet shells (outer shell and inner shell) are thin compared to the helmet body. Preferably, they have an at least substantially constant thickness, approximately in the order of millimeters (in particular in the range of 0.5 to 15 mm).

[0014] Both helmet shells can each have an at least substantially concave inner side and an at least substantially convex outer side, corresponding to the helmet body. The helmet outer shell can be arranged on the helmet body such that its inner side rests against at least part of the outer side of the helmet body. The helmet inner shell can be arranged on the helmet body such that its outer side rests against at least part of the inner side of the helmet body. The helmet outer shell and the helmet inner shell are each preferably formed as one piece. The helmet outer shell and the helmet inner shell are preferably made of a different material than the helmet body.

[0015] According to the invention, the helmet body comprises a solid foam made of expanded foam particles. This allows the helmet body to form the central shock-absorbing element of the helmet. In principle, the solid foam can be elastically deformable (to a certain extent). Preferably, the solid foam is a rigid foam, so that the solid foam is at least essentially only plastically deformable. The helmet body can, in particular, be formed by the solid foam.

[0016] The foam is formed from expanded foam particles. These foam particles, which may be at least substantially spherical, are small particles, in particular so-called foam beads. The foam particles may be pre-foamed, i.e., already formed as foam, for example from microgranules or directly from the melt of a foamable material, in particular a polymer. The foam particles initially have a comparatively dense structure (small cells) and can be caused to expand, in particular by applying heat.

[0017] If a defined space of a certain shape (for example the casting mold for producing the helmet body) is at least largely filled with such not yet (fully) expanded foam particles and the foam particles are then caused to expand, they expand into the remaining spaces, in particular in such a way that they ultimately occupy the entire space. Typically, the expanding foam particles are pressed against one another so that they adhere to one another, stick together or even fuse. A further factor in this is that they temporarily lose their solid shape and become soft during the expansion. The foam particles can also at least partially melt, in particular if heat is supplied to them for the expansion. Preferably, the foam particles are expanded (and the resulting softening or shrinking).The expanded foam particles are bonded together in a material-to-material manner (e.g., by melting), in particular by at least partially fusing together. The expanded foam particles then form (optionally after cooling) a continuous molded body of solid foam, which has the shape of the defined space, thus acting as a mold for the formation of the solid foam.

[0018] The helmet body comprises at least one such solid foam. In principle, the helmet body can also comprise several spatially separated, optionally separately produced, solid foams. It can be provided that all of these foams are formed from expanded foam particles of the same material, or that one or more of these foams are formed from expanded foam particles of a different material than one or more of the other foams.

[0019] The fact that the solid foam is formed from expanded foam particles is not the only thing that is meant. Rather, the solid foam can consist of more than just expanded foam particles. For example, other particles, such as fibers to reinforce the foam, can be embedded in the solid foam.

[0020] According to the invention, it is further provided that the solid foam which the helmet body comprises is arranged between the helmet outer shell and the helmet inner shell and adheres directly to both the helmet outer shell and the helmet inner shell.

[0021] In particular, it can be provided that the said outer side of the helmet body adheres directly to the said inner side of the helmet outer shell, at least in some regions, and / or that the said inner side of the helmet body adheres directly to the said outer side of the helmet inner shell. Preferably, the said adhesion is a firm bond between the respective helmet shell and the helmet body, wherein the adhesion is direct in that this bond is not brought about by any additional mediator, in particular no adhesive or the like, but rather the adhesion results from the fact that the respective helmet shell and the helmet body interact directly with one another in direct contact with one another.

[0022] For example, it can be provided that the helmet body adheres directly to the outer shell and / or the inner shell of the helmet by adhesion. Said adhesion preferably comprises the helmet body being integrally bonded, at least in some areas, to the outer shell or to the inner shell of the helmet, in particular to both the outer shell and the inner shell of the helmet. This integral bond can result, in particular, from the expansion of the foam particles in direct contact with the respective helmet shell. The foam particles adjacent to a respective one of the helmet shells can fuse or adhere to the respective helmet shell during the expansion, possibly as a result of the application of heat.

[0023] According to a particularly advantageous embodiment, the helmet body is foamed onto the outer shell and the inner shell. In other words, the described expansion of the foam particles for producing the helmet body takes place between the two helmet shells, so that the solid foam comprising the helmet body comes into direct, close, surface-to-surface, and particularly adhesive, contact with the helmet shells during its formation. For this purpose, the helmet shells can be arranged on the walls of the mold for the helmet body or can themselves form the mold into which the foam particles are poured and in which the foam particles are caused to expand.During expansion, those foam particles which are adjacent to the helmet shells are pressed against the helmet shells so that they form a surface-adhering connection with the respective helmet shell, in particular they at least partially fuse or bond with the respective helmet shell, preferably at least partially form a material connection with it.

[0024] The application of heat, which is optionally provided anyway for expanding the foam particles, can contribute in particular to the surface-adhering connection of the helmet body to the outer and inner shells. In particular, during manufacture of the helmet according to the invention, provision can be made for infrared radiation to be used to expand the foam particles in the manufacture of the helmet body - in contrast to conventional processes for producing a solid foam (in particular a rigid foam), in which the expansion of foam particles occurs using steam. Advantageously, the infrared radiation can also heat the foam particles through the helmet shells, so that the foam particles can be caused to expand even when they are located between the helmet shells and are largely enclosed by them.For example, in this case and in the process described below, the solid foam can be produced according to one of the methods described in WO 2017 / 109079 A1.

[0025] A method for producing the helmet can comprise: providing a helmet outer shell (said helmet outer shell) and a helmet inner shell (said helmet inner shell) and, unless they are already stably connected to one another (for example, because they are formed together as a single component), stably arranging them relative to one another, in particular stably connected to one another, for example by arranging them on the walls of a casting mold for the helmet body; filling foam particles between the helmet outer shell and the helmet inner shell, preferably into a space formed by the helmet shells, in particular delimited on the one hand by the helmet outer shell and on the other hand by the helmet inner shell (in particular through one or more filling openings formed in the helmet outer shell and / or in the helmet inner shell), preferably in such a way that the space is at least largely filled;that the foam particles are made to expand, in particular by heating by means of infrared radiation, so that the foam particles, optionally after they have been cooled, bond together to form a solid foam, in particular in a material-to-material manner, which forms a helmet body (the said helmet body) of the helmet, which is arranged between the helmet outer shell and the helmet inner shell and adheres directly to both the helmet outer shell and the helmet inner shell, in particular at least partially forming a material-to-material connection with the helmet outer shell and / or with the helmet inner shell;

[0026] The invention therefore also relates to a helmet obtainable by carrying out this method, whereby the method need not be limited to the aforementioned method steps, but may include further method steps for producing the helmet, in particular further parts of the helmet. The possible embodiments of the helmet according to the invention described above and below also apply equally to the helmet obtainable by the aforementioned method.

[0027] According to an advantageous embodiment, the helmet outer shell and the helmet inner shell are designed as separate components and are stably connected to one another independently of the helmet body, in particular such that they are arranged in a defined manner relative to one another. The two helmet shells are therefore not only connected to one another via the helmet body, but also have a connection to one another that is independent of the helmet body.

[0028] In particular, the helmet outer shell and the helmet inner shell can already be securely connected to one another before the helmet body is formed between the helmet outer shell and the helmet inner shell. In principle, the helmet outer shell and the helmet inner shell can be connected to one another via one or more additional components. Preferably, however, the helmet outer shell and the helmet inner shell are directly connected to one another. It is further preferred that the helmet outer shell and the helmet inner shell be firmly bonded to one another.

[0029] The design of the helmet outer shell and the helmet inner shell as separate components makes it possible to use different materials for the helmet outer shell and the helmet inner shell. Alternatively, according to another embodiment, the helmet outer shell and the helmet inner shell can be formed as a single piece, i.e., together as a single component. A single-piece design has the advantage that the helmet outer shell and the helmet inner shell can be manufactured together, for example, by injection molding.

[0030] Regardless of whether the helmet outer shell and the helmet inner shell are formed in one piece or as separate components, it is further advantageous if the helmet has at least substantially the shape of a spherical shell section and is delimited in the tangential direction by a circumferential edge of the helmet with respect to a center point of the shape, wherein the helmet outer shell and the helmet inner shell are connected to one another along the entire circumferential edge of the helmet.

[0031] According to a further advantageous embodiment, at least parts of the helmet outer shell and the helmet inner shell together form a hollow body within which the helmet body is arranged. Preferably, the entire helmet outer shell and the entire helmet inner shell together form the hollow body.

[0032] In particular, the interior of the hollow body can correspond to the aforementioned space formed by the helmet shells, within which the helmet body can be formed by filling and expanding the aforementioned foam particles. In this case, it can advantageously be provided that the hollow body is largely closed, in particular only with the exception of one or more filling openings for the foam particles formed in the helmet outer shell and / or the helmet inner shell. The maximum diameter of these filling openings can, for example, be at most 3 cm, preferably at most 1 cm, in particular at most 0.5 cm. Several separate hollow bodies of this type can be formed by the helmet outer shell and the helmet inner shell. In this case, the helmet body can comprise several separate sections, each of which is arranged within one of the hollow bodies, in particular has been formed within the respective hollow body.Preferably, however, the helmet body is formed in one piece, i.e. as a single continuous component.

[0033] According to an advantageous embodiment, the helmet outer shell and the helmet inner shell have a different hardness than the helmet body. Preferably, the helmet outer shell and the helmet inner shell have a greater hardness than the helmet body. In this way, the helmet outer shell and the helmet inner shell can protect the helmet body from minor external damage, such as scratches and minor impacts, while the helmet body can still reliably absorb the energy of larger impacts.

[0034] Furthermore, a comparatively hard helmet shell construction can help distribute the energy of an impact that strikes a relatively small area of the respective helmet shell over a larger area before it is transferred to the helmet body. This advantageously contributes to shock absorption. Since the helmet shells define the outer boundary of the helmet, the hardness of the helmet shells also advantageously contributes to a corresponding strength of the helmet as a whole.

[0035] According to a further advantageous embodiment, the helmet outer shell and the helmet inner shell are formed as injection-molded parts. This allows for a comparatively simple and cost-effective construction of the helmet shells. Furthermore, it is conceivable that at least some of the same mold parts are used for injection molding (at least one) of the helmet shells as for producing the helmet body by expanding foam particles. During the production of the helmet body, the helmet shells are inserted into the mold, and the foam particles are expanded between the helmet shells.

[0036] According to a further advantageous embodiment, the helmet outer shell and the helmet inner shell each comprise an injection-molded and / or deep-drawn plastic as a material. In principle, any plastic that can be used to form an injection-molded part and / or to form a deep-drawn part is suitable. Depending on the area of application of the helmet, the plastic can in particular be an acrylonitrile-butadiene-styrene copolymer (ABS), a polycarbonate (PC), a polyethylene terephthalate (PET) or a polyamide (PA). The helmet outer shell and the helmet inner shell do not necessarily have to be made of the same material, but preferably they are.

[0037] For the solid foam made of expanded foam particles that the helmet body comprises, in principle, any plastic from which expandable foam particles and then molded parts can be produced is suitable. According to an advantageous embodiment, the helmet body comprises in particular a solid foam made of expanded polystyrene (EPS), expanded polypropylene (EPP), expanded acrylonitrile-butadiene-styrene copolymer (EABS), expanded polycarbonate (EPC), expanded polyamide (EPA), expanded polybutylene terephthalate (EPBT), expanded polyethylene terephthalate (EPET), expanded modified polyphenylene ether (EmPPE), expanded thermoplastic polyurethane (ETPU), expanded polyoxymethylene (EPOM), expanded polymethyl methacrylate (EPPMA) and / or expanded polyether ketone (EPEK). The solid foam can in particular also be formed from a mixture of foam particles of two or more of the aforementioned substances.

[0038] The invention is further explained below merely by way of example with reference to the figure, which shows an embodiment of the helmet according to the invention in a sectional view.

[0039] The helmet 11 in Fig. The embodiment shown in Figure 1 is a bicycle helmet, illustrated in a highly simplified sectional view. The helmet 11 comprises an outer helmet shell 19, an inner helmet shell 25, and a helmet body 13 arranged between the outer helmet shell 19 and the inner helmet shell 25. Overall, the helmet 11 has the shape of a spherical shell section and therefore a concave inner side and a convex outer side. The helmet 11 is designed to be placed on the head of a wearer, with the inner side of the helmet 11 facing toward or resting against the head, and the outer side of the helmet 11 facing away from the head.

[0040] Corresponding to the overall shape of the helmet 11, the helmet body 13, the helmet outer shell 19 and the helmet inner shell 25 each have an inner side 15, 21, 27 and an outer side 17, 23, 29. For a clear graphical differentiation of the helmet body 13, the helmet outer shell 19 and the helmet inner shell 25 from each other, the helmet body 13 is Fig. 1 with a distance from the helmet shells 19, 25. However, the resulting visible free space between the helmet body 13 and the helmet shells 19, 25 does not actually exist. Rather, the inner side 15 and the outer side 17 of the helmet body 13 lie directly and tightly against the outer side 29 of the helmet inner shell 25 and the inner side 21 of the helmet outer shell 19, respectively, with the helmet body 13 also adhering flatly to both the helmet outer shell 19 and the helmet inner shell 25.

[0041] The helmet 11 has a circumferential edge 31 that defines the helmet 11 in a tangential direction (relative to a center point of the aforementioned spherical shell shape of the helmet 11). Along the edge 31, the helmet outer shell 19 and the helmet inner shell 25 meet and are stably connected to each other, in particular by a material bond.

[0042] The helmet 11 has several ventilation openings 33, each of which extends in a substantially radial direction (relative to the said center point) through the helmet body 13 and the two helmet shells 19, 25. The outer helmet shell 19 and the inner helmet shell 25 also meet in the middle of these ventilation openings 33, namely along a line which Fig. 1 is shown interrupted.

[0043] A type of seam can be formed along this line, at which the helmet outer shell 19 and the helmet inner shell 25 can be connected to one another, for example, welded or glued. However, the line does not have to correspond to any recognizable structure. In particular, the helmet outer shell 19 and the helmet inner shell 25 can merge seamlessly along the line and / or along the edge 31, for example, if they are formed as a single component.

[0044] Due to the described connection of the helmet outer shell 19 and the helmet inner shell 25 along the edge 31 and within the ventilation openings 33, the helmet outer shell 19 and the helmet inner shell 25 together form a hollow body 35, within which the helmet body 13 is arranged. In the present example, the hollow body 35 extends around the ventilation openings 33, so that the helmet outer shell 19 and the helmet inner shell 25 form only a single hollow body 35 despite the ventilation openings 33. The helmet body 13 completely fills the hollow body 35 and is therefore formed as a single piece.

[0045] The hollow body 35 is largely sealed off from the outside. In particular, it can be completely sealed except for one or more filling openings 37. Fig.In the embodiment shown in Figure 1, such a filling opening 37 is located within one of the ventilation openings 33. This may be the only filling opening 37. However, additional filling openings may also be provided, in particular at the edge 31 and / or in the region of additional ventilation openings 33. The filling openings 37 serve to enable the helmet body 13 to be manufactured within the hollow body 35. After the helmet body 13 has been manufactured, the filling openings 37 can also be closed.

[0046] The helmet body 13 comprises a solid foam made of expanded foam particles. In particular, the helmet 13 can be formed from this solid foam. In the embodiment shown, this can, for example, be a solid foam made of expanded polystyrene (EPS) or expanded polypropylene (EPP).

[0047] The helmet outer shell 19 and the helmet inner shell 25, on the other hand, are injection-molded parts made of an injection-moldable plastic. In the embodiment shown, the plastic can be, for example, acrylonitrile butadiene styrene copolymer (ABS) or polycarbonate (PC). The helmet outer shell 19 and the helmet inner shell 25 are harder than the helmet body 13, thereby protecting the helmet body 13 from external damage.

[0048] To manufacture the helmet body 13, the helmet outer shell 19 and the helmet inner shell 25 can first be manufactured, in particular injection-molded, and, unless they are formed as a single piece, for example as a single injection-molded part, can be stably connected to one another. Subsequently, unexpanded foam particles can be poured into the hollow body 35 formed by the (optionally interconnected) helmet shells 19, 25 through one or more filling openings 37 until the hollow body 35 is largely filled with foam particles. The foam particles are then caused to expand, whereby the expanded foam particles form a continuous foam that is foamed onto the helmet outer shell 19 and the helmet inner shell 25 and ultimately forms the helmet body 13 as a solid foam.

[0049] The foam particles can be caused to expand, in particular, by heating them using infrared radiation. In this way, despite the confined space within the hollow body 35 and the small number of (small) filling openings 37, heat can be reliably supplied to all of the foam particles filled into the hollow body 35. As a result of the expansion, the foam particles not only bond to one another, preferably in a material-to-material bond, but the solid foam formed from the foam particles also adheres flatly to both the helmet outer shell 19 and the helmet inner shell 25, with this adhesive bond also preferably being a material bond. The adhesive bond is so strong that the helmet outer shell 19 and the helmet inner shell 25 would still hold reliably to the helmet body 13 even if they were not connected to one another.

[0050] Due to the described design, the helmet 11 according to the invention not only has very good shock-absorbing properties due to the helmet body 13 being designed as a solid foam, but also has particularly high stability and strength due to the fact that a respective helmet shell 19 or 25 is arranged on the outer side 17 of the helmet body 13 as well as on the inner side 15 of the helmet body 13 in a manner that adheres flatly to the helmet body 13. Reference symbol 11 Helmet 13 Helmet body 15 Inside of the helmet body 17 Outside of the helmet body 19 Helmet outer shell 21 Inside of the helmet outer shell 23 Outside of the helmet outer shell 25 helmet inner shell 27 Inside of the helmet inner shell 29 Outside of the helmet inner shell 31 rand 33 Ventilation opening 35 hollow bodies 37 Filling opening QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] WO 2017 / 109079 A1

[0024]

Claims

[1] Helmet (11), in particular a sports helmet or work safety helmet, with a helmet outer shell (19), a helmet inner shell (25) and a helmet body (13), wherein the helmet body (13) comprises a solid foam made of expanded foam particles, which is arranged between the helmet outer shell (19) and the helmet inner shell (25) and adheres directly to both the helmet outer shell (19) and the helmet inner shell (25). [2] Helmet according to claim 1, wherein the helmet body (13) is foamed onto the helmet outer shell (19) and the helmet inner shell (25). [3] Helmet according to claim 1 or 2, wherein the helmet outer shell (19) and the helmet inner shell (25) are designed as separate components and are stably connected to one another, in particular by a material bond, independently of the helmet body (13). [4] Helmet according to claim 1 or 2, wherein the helmet outer shell (19) and the helmet inner shell (25) are formed in one piece. [5] Helmet according to one of the preceding claims, wherein at least parts of the helmet outer shell (19) and the helmet inner shell (25) together form a hollow body (35) within which the helmet body (13) is arranged. [6] Helmet according to one of the preceding claims, wherein the helmet outer shell (19) and the helmet inner shell (25) have a different, in particular greater, hardness than the helmet body (13). [7] Helmet according to one of the preceding claims, wherein the helmet outer shell (19) and the helmet inner shell (25) are formed as injection-molded parts. [8] Helmet according to one of the preceding claims, wherein the helmet outer shell (19) and the helmet inner shell (25) each comprise an injection-moldable and / or deep-drawable plastic, in particular an acrylonitrile-butadiene-styrene copolymer (ABS), a polycarbonate (PC), a polyethylene terephthalate (PET) or a polyamide (PA) as material. [9] Helmet according to one of the preceding claims, wherein the helmet body (13) comprises a solid foam made of expanded foam particles, in particular of expanded polystyrene (EPS), expanded polypropylene (EPP), expanded acrylonitrile-butadiene-styrene copolymer (EABS), expanded polycarbonate (EPC), expanded polyamide (EPA), expanded polybutylene terephthalate (EPBT), expanded polyethylene terephthalate (EPET), expanded modified polyphenylene ether (EmPPE), expanded thermoplastic polyurethane (ETPU), expanded polyoxymethylene (EPOM), expanded polymethyl methacrylate (EPPMA) and / or expanded polyether ketone (EPEK). [10] Helmet, in particular sports helmet or safety helmet, obtainable by carrying out a process which comprises: - that a helmet outer shell and a helmet inner shell are provided and, if they are not stably connected to one another, are arranged stably relative to one another, in particular are stably connected to one another; - that foam particles are filled between the outer shell of the helmet and the inner shell of the helmet; - that the foam particles are caused to expand so that the foam particles combine with one another to form a solid foam which forms a helmet body of the helmet, which is arranged between the outer helmet shell and the inner helmet shell and adheres directly to both the outer helmet shell and the inner helmet shell.

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