Title:
Article with 3-dimensional secondary element
Document Type and Number:
United States Patent 7398562

Abstract:
An article having a generally domed-shaped crown and an exterior surface. A secondary element extending from the exterior surface at an intersection area between the crown and the secondary element. A portion of the exterior surface of the crown typically being raised above the intersection area to give the appearance that the secondary element has torn, morphed, splashed, cracked or phase changed, such as by melting, through the crown. The secondary element is typically indicative of a particular sporting club and the article is typically a helmet. The secondary element is also typically integrally molded with the crown.

Inventors:
Mollo, Richard (Bridgewater, NJ, US)
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Sponsored by:
Flash of Genius
Application Number:
10/797347
Publication Date:
07/15/2008
Filing Date:
03/10/2004
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Assignee:
Easy Rhino Designs, Inc. (Bound Brook, NJ, US)
Primary Class:
Other Classes:
2/425
International Classes:
A42B1/24
Field of Search:
2/410, 2/171, 40/586, D29/103, 2/422, D2/891, D2/878, 40/329, 446/27, D29/106, 2/209.13, D2/866, D2/895, 2/424, D2/870, D29/102, 2/411, 2/425
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5621922Sports helmet capable of sensing linear and rotational forcesApril, 1997Rush, III
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5628071Collapsible helmetMay, 1997Nezer
5636383Head mounted apparatus for supporting and raising ceiling materialsJune, 1997Cwiakala
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5926848Sports enthusiast headbandJuly, 1999Bartholomae
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5983400Headwear piece with improved ornamentationNovember, 1999Kronenberger
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6292952Insert-molded helmetSeptember, 2001Watters et al.
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6308343Full-face type helmetOctober, 2001Arai
6314586Supplemental protective pad for a sports helmetNovember, 2001Duguid
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6349416Headguard-protective sports headbandFebruary, 2002Lampe et al.
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6352383Mounting adapter for mounting a protector to a helmet or likeMarch, 2002Ristola
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6360376Protective hatMarch, 2002Carrington
D455869Safety helmetApril, 2002Ho
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D459555Sport helmetJune, 2002Gatellet
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6401262Protection implement, particularly for use in sports practiceJune, 2002Bacchiega
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6405382HelmetJune, 2002Shida
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Foreign References:
DE4421110December, 1995
Primary Examiner:
Worrell, Danny
Attorney, Agent or Firm:
Lerner, David, Littenberg, Krumholz & Mentlik, LLP
Claims:
The invention claimed is:

1. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; wherein said secondary element and said crown are integrally molded to one another.

2. The headgear of claim 1, wherein said secondary element is indicia suggesting or identifying one of a particular sporting club, a business name and a corporate logo.

3. The headgear of claim 1, wherein said secondary element is indicia identifying one of a mascot and a team name.

4. The headgear of claim 1, wherein said secondary element is only partially formed.

5. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; further comprising a facemask connected to said crown.

6. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown gives the appearance of said secondary element tearing through said crown.

7. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown gives the appearance of said secondary element morphing out of said crown.

8. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown gives the appearance of said secondary element splashing through said crown in a liquefied state.

9. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown gives the appearance of said secondary element cracking said crown.

10. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown gives the appearance of said secondary element altering the phase of said crown.

11. The headgear of claim 10, wherein said phase altering is melting.

12. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; wherein said intersection area is non-geometric.

13. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; wherein said raised portion of said exterior surface of said crown is jagged.

14. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; further comprising crown particles in said raised portion, said crown particles having the appearance of having been separated from said crown.

15. The headgear of claim 14, wherein the appearance of separation is by cracking.

16. The headgear of claim 1, wherein said raised portion of said exterior surface of said crown completely circumscribes said intersection area.

17. The headgear of claim 1, wherein said secondary element is non-elastomeric.

18. The headgear of claim 1, wherein said crown further includes an interior surface, said headgear further comprising padding attached to said interior surface.

19. Headgear comprising: a generally domed-shaped crown having an exterior surface; and a decorative secondary element extending from said exterior surface at an intersection area between said crown and said secondary element; wherein a portion of said exterior surface of said crown is raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown; wherein said crown and said secondary element are monolithic.

20. The headgear of claim 1, wherein said secondary element is horns to identify or suggest the Los Angeles Rams of the National Football League.

21. The headgear of claim 1, wherein said secondary element is a block of cheese to identify or suggest the Green Bay Packers of the National Football League.

22. The headgear of claim 1, wherein said secondary element is a dolphin fin to identify or suggest the Miami Dolphins of the National Football League.

23. The headgear of claim 1, wherein said secondary element is a rivet to identify or suggest the Pittsburgh Steelers of the National Football League.

24. The headgear of claim 1, further comprising artwork adorning said crown, wherein said secondary element is associated with said artwork.

25. A helmet comprising: a crown having a generally domed-shaped first portion and a second portion raised from said first portion; and a secondary element attached to said first portion at an attachment area wherein said second portion extends above said attachment area.

26. The helmet of claim 25, wherein said crown and said secondary element are integrally molded to one another.

27. The helmet of claim 25, wherein said secondary element is indicative of a sporting club.

28. The helmet of claim 25, wherein said secondary element is non-elastomeric.

29. The helmet of claim 25, wherein said crown and said secondary element are monolithic.

30. A helmet comprising: a crown having a generally domed-shaped first portion and a second portion raised from said first portion; and a secondary element attached to said second portion at an attachment area wherein said second portion extends above said attachment area.

31. The helmet of claim 30, wherein said crown and said secondary element are integrally molded to one another.

32. The helmet of claim 30, wherein said secondary element is indicative of a sporting club.

33. The helmet of claim 30, wherein said secondary element is non-elastomeric.

34. The helmet of claim 30, wherein said crown and said secondary element are monolithic.

Description:

BACKGROUND OF THE INVENTION

My invention relates broadly to articles, novelties, paraphernalia and the like having three-dimensional secondary elements connected thereto or integrally molded therewith, and configured in a manner so as to be indicative of a sporting team. It is well known that professional and amateur sporting clubs have specific insignias, logos or mascots to distinctly identify each club. In order to show their loyalty to the sporting club, fans of the clubs often wear articles of apparel or display objects adorned with images emblematic of such insignias, logos or mascots. For sporting events requiring use of a helmet, such as football, one of the most popular apparel or display items is a football helmet that may be associated with a specific team. Such helmets are frequently worn or displayed by fans.

The prior art abounds with helmets incorporating a particular team's insignia, emblem or mascot. Often, fans simply wear a helmet identical to those worn by the players on the field. Unlike the present invention, these helmets only have two-dimensional images, rather than three-dimensional sculptures.

Helmets or baseball style hats having a three-dimensional team insignias are known. Such helmets and hats are often adorned with soft, spongy sculptures indicative of a particular team. Heretofore, the sculptures have been attached to the hats or helmets via non-permanent means, such as hook and loop type fasteners, buttons, sewn seams, adhesives, and the like. Generally, the transition between the hat or helmet and the sculptured portion is very distinct. No apparent effort has been made to incorporate a smooth transition from the sculpted image to the hat or helmet.

Helmets with three-dimensional sculptures adorned thereon are also known, such as those used as motorcycle helmets. In use for motorcycle helmets, the sculpted images are generally made from rubbery or other soft or elastic material such as latex and simply adhered to an existing helmet. Helmets of this type specifically utilize rubbery or flexible material, as this material absorbs impacts for increased safety and is less likely to be broken off upon use. Again, no apparent attempt has been made to incorporate a smooth transition from the sculpted image to the helmet. In addition, there has been no apparent attempt to form the helmet and sculpted object in such a manner as to give an impression that the sculpted object is anything but simply adhered to the helmet.

It would therefore be desirable to have a novel article or item of paraphernalia, preferably a helmet, which may be worn or displayed and which incorporates a secondary element appearing to effect the overall integrity of the helmet. For example, it would be desirable to incorporate a secondary element with a helmet where the secondary element is either extending from the torn article, morphing from within the article, splashing through a “liquefied” article, extending from a cracked article, or extending through an article having undergone a phase change, such as by melting. Preferably, these secondary elements would be associated with a particular sporting team.

SUMMARY OF THE INVENTION

In one preferred embodiment, the present invention provides for headgear comprising a generally domed-shaped crown having an exterior surface and a decorative secondary element extending from the exterior surface at an intersection area between the crown and the secondary element. A portion of the exterior surface of the crown may be raised above the intersection area to evince an association between the secondary element and the manner in which it extends from the crown.

The secondary element and the crown may be integrally molded to one another.

The secondary element may be indicia suggesting or identifying one of a particular sporting club, a business name and a corporate logo.

The secondary element may be indicia identifying one of a mascot and a team name.

The secondary element may be only partially formed.

The headgear may further comprise a facemask connected to the crown.

The raised portion of the exterior surface of the crown may give the appearance of the secondary element tearing through the crown.

The raised portion of the exterior surface of the crown may give the appearance of the secondary element morphing out of the crown.

The raised portion of the exterior surface of the crown may give the appearance of the secondary element splashing through the crown in a liquefied state.

The raised portion of the exterior surface of the crown may give the appearance of the secondary element cracking the crown.

The raised portion of the exterior surface of the crown may give the appearance of the secondary element altering the phase of the crown. The phase altering may be melting.

The intersection area may be non-linear. The intersection area may be non-geometric.

The raised portion of the exterior surface of the crown may be jagged.

The headgear may further comprise crown particles in the raised portion, the crown particles having the appearance of having been separated from the crown. The appearance of separation may be by cracking.

The raised portion of the exterior surface of the crown may completely circumscribe the intersection area.

The secondary element may be non-elastomeric.

The crown may further include an interior surface with the headgear further comprising padding attached to the interior surface.

The crown and the secondary element may be monolithic.

The secondary element may be horns to identify or suggest the Los Angeles Rams of the National Football League.

The secondary element may be a block of cheese to identify or suggest the Green Bay Packers of the National Football League.

The secondary element may be a dolphin fin to identify or suggest the Miami Dolphins of the National Football League.

The secondary element may be a rivet to identify or suggest the Pittsburgh Steelers of the National Football League.

The headgear may further comprise artwork adorning the crown, wherein the secondary element may be associated with the artwork.

In another embodiment, a helmet comprises a crown having a generally domed-shaped first portion and a second portion raised from the first portion. A secondary element may be attached to the first portion at an attachment area and the second portion may extend above the attachment area.

The crown and the secondary element may be integrally molded to one another.

The secondary element may be indicative of a sporting club.

The secondary element may be non-elastomeric.

The crown and the secondary element may be monolithic.

In yet another embodiment, a helmet may comprise a crown having a generally domed-shaped first portion and a second portion raised from the first portion. A secondary element may be attached to the second portion at an attachment area and the second portion may extend above the attachment area.

The crown and the secondary element are integrally molded to one another.

The secondary element may be indicative of a sporting club.

The secondary element may be non-elastomeric.

The crown and the secondary element may be monolithic.

In a further embodiment, a helmet may comprise a generally domed-shaped crown having an exterior surface, a facemask attached to the crown, and a secondary element extending from the exterior surface of the crown. The secondary element and the crown may be integrally molded to one another.

The crown and the secondary element may be monolithic.

The secondary element may be non-elastomeric.

The secondary element and the crown may be molded to give the appearance of the crown tearing from pressure applied by the secondary element.

The secondary element and the crown may be molded to give the appearance of the secondary element morphing from the crown.

The secondary element and the crown may be molded to give the appearance of the secondary element splashing through the crown in a liquefied state.

The secondary element and the crown may be molded to give the appearance of the secondary element cracking the crown.

The secondary element and the crown may be molded to give the appearance of the crown having undergone a phase alteration.

In another embodiment, a helmet may comprise a generally domed-shaped crown having an exterior surface, a facemask attached to the crown, and a secondary element extending from the exterior surface of the crown. The secondary element and the crown may be integrally molded to one another and the secondary element may appear to have morphed from the crown.

In still a further embodiment, an article for promoting a sporting club may comprise a base having a concave underside surface and a skirt at least partially circumscribing the underside surface. The article may be adapted to be attached to the convex crown of a helmet such that the skirt extends above the attachment point of the concave underside surface with the convex crown.

The skirt may be adapted to give the appearance of the article tearing through the helmet when attached thereto.

The skirt may be adapted to give the appearance of the article morphing from the helmet when attached thereto.

The skirt may be adapted to give the appearance of the article splashing through the helmet when attached thereto.

The skirt may be adapted to give the appearance of the helmet being cracked when attached thereto.

The skirt may be adapted to give the appearance of the helmet having undergone a phase alteration when attached thereto.

The skirt may be non-geometric.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof will be or become apparent to one with skill in the art upon reference to the following detailed description when read with the accompanying drawings. It is intended that any additional organizations, methods of operation, features, objects or advantages ascertained by one skilled in the art be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.

In regard to the drawings,

FIG. 1 is a frontal view of a helmet in accordance with a first embodiment of the present invention;

FIG. 2 is a side view of the helmet of FIG. 1;

FIG. 3 is a perspective view of the helmet of FIG. 1;

FIG. 4 is a rear view of the helmet of FIG. 1;

FIG. 5 is a bottom view of the helmet of FIG. 1;

FIG. 6 is a frontal view of a helmet in accordance with a second embodiment of the present invention;

FIG. 7 is a side view of the helmet of FIG. 6;

FIG. 8 is a perspective view of the helmet of FIG. 6;

FIG. 9 is a frontal view of a helmet in accordance with a third embodiment of the present invention;

FIG. 10 is a side view of the helmet of FIG. 9;

FIG. 11 is a frontal view of a helmet in accordance with a fourth embodiment of the present invention;

FIG. 12 is a side view of the helmet of FIG. 11;

FIG. 13 is a frontal view of a helmet in accordance with a fifth embodiment of the present invention; and,

FIG. 14 is a perspective view of the helmet of FIG. 13.

DETAILED DESCRIPTION

In the following is described the preferred embodiments of my article with three-dimensional secondary element. In describing the embodiments illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

My invention is generally directed to articles having three-dimensional secondary elements. Preferred articles include helmets and hats. For ease of description, the concluding portions of this specification will generally discuss my invention in regard to the most preferred embodiment, that of a football helmet. It will be appreciated, however, that various other types of helmets, including sporting helmets such as hockey, baseball batting helmets, skiing, skateboarding, in-line skating, roller skating, motor sport helmets, climbing helmets, and the like may be utilized. Various non-sport related helmets may also be included. These include fireman's helmets, diving helmets, helmets for individuals with certain medical conditions, and the like. Other embodiments of the present invention may be directed to articles which are neither helmets or hats. Such embodiments include furniture such a headboards or chairs, office supplies such a staplers or tape dispensers, or other articles of manufacture.

Although sharing ties with each other, my invention can be broken down into general categories, which I refer to as tearing, morphing, splashing, cracking, and phase altering. The categories include similar characteristics that may not always be discussed with regard to each embodiment. Rather, the differences between embodiments will generally be detailed below.

Generally, the tearing category refers to helmets in which a secondary element is extending either from within the helmet or into the helmet and where the helmet appears to be torn by the secondary element. A torn helmet is typically one that is molded to included jagged edges which may also be bent slightly either into the helmet in the instance where the secondary element extends into the helmet, or out of the helmet in the instance where the object extends from within the helmet. Examples of a helmet having undergone a tearing effect are shown in FIGS. 1-5.

A morphed helmet is one in which a secondary element appears to be formed or otherwise molded from the helmet itself. The transition from the helmet itself into the secondary element is typically smooth and continuous. Colorings, such as images or emblems, may also morph such that they smoothly transition from the helmet to the extending object. Although the helmet crown itself may morph to some degree, it is preferred that the general appearance and functionality of the helmet be retained. Examples of a helmet having undergone a morphing effect are shown in FIGS. 6-8.

The splashed helmet gives the impression of a secondary element splashing through a helmet, such as would occur if the helmet were liquified. The splashing may either be into the helmet, so as to form a splash or ripple of the type formed when a diver dives into a pool, or from the helmet so as to form a wave or a wake of the type a boat forms as it sails across water. Examples of a helmet having undergone the splashing effect are shown in FIGS. 9-10.

A helmet which gives the impression of being cracked is similar to that previously described as being torn. However, in a cracked helmet, the helmet itself generally does not bend or otherwise distort a great enough degree to give the impression of having been torn. Rather, a cracked helmet retains the general shape of an undisturbed helmet, but includes cracked edges, which may bend slightly, as the secondary object penetrates through. Particles broken from the cracked helmet may also appear, such as in the examples shown in FIGS. 11 and 12.

A helmet which gives the impression of having undergone a phase altering effect is one that has had the material comprising the helmet altered from its conventional phase, such as from a solid to a liquid by melting. Portions of the helmet may appear as a free flowing liquid, such as shown in the examples presented in FIGS. 14 and 15, where a secondary object which has been heated is shown to be piercing a helmet with localized melted areas.

I have found it most advantageous to create my novel helmet through the use of a retrofitting process incorporating manufactured helmets readily available in the marketplace. Of course, it may also be possible to form the helmet of my invention directly, without retrofitting a conventional helmet. Such direct formation is likely preferred for a mass produced set of helmets meeting the specifications herein detailed.

The method I utilize for constructing the inventive helmet is described below. In no means is this method intended to be the only method possible. In addition, each of the steps I performed was performed in the order indicated. Nevertheless, the steps may be performed in different orders, with equally successful results. The present listing is in no means intended to be exclusive of other orders of operation, or additional or fewer steps.

I first obtain a sport helmet of the type readily available in the marketplace. I then remove all of the hardware and padding, including the facemask, padding and chinstrap assemblies. I also remove all adhesive logos, such as the vinyl logos typically applied to helmets of this type. I then mount the helmet on a temporary base.

In order to mount the helmet on a temporary base I drill a ¼″ diameter hole in the uppermost portion of the crown of the helmet. I also drill ⅛″ diameter holes on the front left and front right sides of the helmet approximately ¾″ down from the middle and 2″ back from the front edge, in the vicinity of the conventional ear hole. Utilizing a 4″×4″×6″ wooden block securing a ¼″ diameter threaded rod approximately 1½′ in length extending outwardly from the block, I create a mount for the helmet. I secure the helmet onto the threaded rod by first installing a nut on the rod, then placing the helmet over the rod through the ¼″ diameter hole drilled in the top of the helmet crown, and then securing the helmet with a second nut placed over the top of the crown. Washers may also be used between the helmet and the nuts.

While the initial steps may be utilized for any helmet, the following steps will be described with relation to a helmet formed with three-dimensional ram horns tearing through the crown, such as might be produced for fans of the St. Louis Rams of the National Football League or the Colorado State Rams of National Collegiate Athletic Association. A helmet of the type produced by this procedure is shown in FIGS. 1-5.

Once secured on the wooden base, I then coat the outside of the helmet with a thin layer of petroleum jelly. I then place ⅛″ diameter aluminum armature wire through each of the ⅛″ diameter holes previously drilled on the left and right sides of the helmet. The ends of the armature wire are then anchored on the inside of the helmet by bending the wire into the helmet, against the inner surface. The remainder of the wire exterior to the crown of the helmet is formed into the configuration of ram horns. Each of the armature wires is then built up with layers of a two-part epoxy putty shaped to form ram horns. At the point of intersection between the helmet and the newly formed horns, the epoxy putty is molded and feathered into a skirt to create the illusion that the horns are tearing through the helmet. Additional epoxy is then added to the skirt at the intersection of the helmet and the horn to represent the torn portion of the helmet now folded over to give the appearance of having been torn away by the sudden growth of the ram horn. Once all of the epoxy dries, fine details are added using files and rotary tools.

At this point in the process the horned helmet is then ready to be molded. In order to form the mold, I clean off the horned sculpture with brushes and air supplied from an air gun. I also use a clean, dry cloth with rubbing alcohol to clean off any remaining dust or debris. I then drill holes to accommodate a size 4×1″ long sheet metal screw on the bottom outside curve of each horn. On each screw I place a 5/16″ outside diameter by 3/16″ inside diameter rubber vent to approximately 3″ in length. I then apply a thin coat of petroleum jelly over the horn sculptures, the helmet, and the vent tubes.

The left side horn and the left side helmet are then covered with a rubber molding compound. I follow this by covering the right side horn and the right side of the helmet with a rubber molding compound, being careful not to permit the two sides to touch. By successively layering the rubber molding material, I build the material up to a thickness of approximately ¼″ around each horn, the helmet, and the vent tubes. Once the molding compound is dry, I straighten out each armature from inside the helmet and remove the rubber mold and horns together as a single piece per side.

On the base of each horn (the portion previously touching the helmet), I apply a second tube using the same process previously described. This tube is intended to be used as a fill tube, and is slipped over the armature wire. Approximately ¾″ from the fill tube I drill another hole to accommodate a size 4×1″ long sheet metal screw. I then place a third tube, identical to the others, over this screw. I apply a thin coat of petroleum jelly around the base of the horn, the vent tubes, and the edge of the rubber mold around the base of the horn. Finally, I apply a rubber molding compound to the base of the horn, the outer edge of the rubber mold, and around the tubes while keeping the openings clear. The horn mold is now ready to be cast.

In order to make the reinforcing cast, I first cut and soak approximately one hundred 1″×3″ strips of burlap fabric in cold water for 15 minutes each. I then wring out each strip until they are slightly damp. I also apply a thin coat of petroleum jelly around the entire outside of the ram horn mold and tubes.

The burlap strips are then soaked in plaster of paris for a short time. I take the strips and apply them to the outside of the rubber molds in three separate casting sections—one on the left side of the horn mold, one on the right side of the horn mold, and one on the base. Between the application of sections I wait for the previous section to dry. I also apply petroleum jelly to ensure that the three sections do not stick to each other. At this point it is helpful to note that while building the casts around the tubes, I make sure that each of the holes remain open. I build this cast thickness to about 1½″, and then repeat for the other molds.

In order to remove the sculpture from the mold, I use a screwdriver with a slotted head to pry away the casts, being careful not to apply enough pressure to break the mold. I then remove the rubber mold base by pulling it off of the casts. I utilize a razor knife to cut through the molding on the edge of the horn and then remove the sculptured horn. Each of these steps is then repeated for the other horn.

I then clean the inside of each rubber mold with soapy water and a sponge or cloth. The rubber molds are then rinsed off with clean water and air dried.

In order to cast the final plastic horn, I spray the inside of the rubber mold and the base of the mold, including the vent and fill tubes, with two thin coats of universal mold release. I assemble the rubber molds together with the plaster casts. Using a crank strap, I fasten the plaster cast together. I then prepare a 60 cc syringe for filling the molds.

I prepare the syringe by fastening a new fill tube to the syringe with electrical tape. I then remove the plunger from the syringe and spray a thin coat of universal mold release into the interior of the syringe and the plunger. I cover the outside of the fill tube with a thin coat of petroleum jelly. The syringe is then filled with an uncured rigid urethane casting compound. After inserting the fill tube of the syringe into the fill hole of the mold, I fill the mold until the urethane casting compound reaches the uppermost portion of the top vent tube. I then permit the casting compound to dry and remove the plaster cast and the rubber mold from the final plastic horn. I then repeat these steps for the second horn.

In order to mount the horns to the helmet, I obtain a second new helmet and remove all the hardware and padding. I do not remove the vinyl ram horn logo yet. Rather, I take a razor knife and cut along the outline of the vinyl horn logo to score, or otherwise cut a groove into, the helmet. Once the helmet is scored, I remove the vinyl ram logo.

The entire helmet may then be sanded on both its inside and outside surfaces using 400-600 grit wet sandpaper. While sanding, I am careful not to entirely sand away the scored outline of the logo. The helmet may then be cleaned with tap water, dried, and then cleaned with rubbing alcohol. Once completely cleaned and dried, the scored ram logo may be outlined with blue automotive tape which is typically 1/16″ to ⅛″ thick. This outlining is typically repeated five times in order to build up the thickness of the tape. It will be appreciated that the outlining is conducted on the outside of the logo such that the tape creates a wall surrounding the logo.

Metalset A-4 epoxy may then be used to fill the inside of the walled-in logo. A Popsicle stick may be utilized to level the epoxy to the height of the outlined tape. Once the initial layer is dried, the epoxy may be sanded, cleaned and recoated with additional epoxy until the logo is the correct thickness and smoothness. The tape outline may then be removed and the logo wet sanded. The helmet is now prepared for application of the ram horns.

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