Protective clothing can help a wearer (e.g., athlete, soldier, bicyclist, tradesperson, etc.) reduce or prevent impact-related injuries. However, the clothing's structural features that provide this protection often adds bulk and reduces flexibility, which can reduce the wearer's performance during the activity. For example, bulky padding can interfere with an athlete's performance during a sporting event.
This document describes a novel impact absorbing pad, garments containing such pads, and methods of manufacturing such pads that may help address the issues described above.
In an embodiment, an impact absorbing pad includes a first layer of foam material having a plurality of voids that extend through the layer in a plurality of positions. As an example, in one embodiment, the first layer includes a body-facing surface and an outer surface that is opposite the body-facing surface. A covering covers the outer surface of the first layer, extends beyond at least a portion of the outer surface, and forms a frame around at least a portion of the outer surface. Alternatively, the covering may be attached to the outer surface of the first layer. Optionally, the first layer may exhibit a Shore durometer value between 25 and 50. In another embodiment, the impact absorbing pad may be included in a garment.
Optionally, the voids may include a pattern of shapes, each shape having three void arms of equal lengths and that extend from a central vertex point. As an example, in one embodiment, each void arm may have a distal end and each distal end of each void arm may be equidistant from the distal ends of each closest adjacent void arm in the pattern in which the void is positioned. Alternatively, the distance between the distal end of each void arm may be equidistant from the central vertex point of each adjacent void. In an embodiment, the voids may exhibit equal widths no greater than 10 mm.
Optionally, a second layer of foam material having a plurality of voids that extend through the layer in a plurality of positions may be included adjacent the first layer. As an example, in one embodiment, the second layer includes a body-facing surface and an outer surface that is opposite the body-facing surface. As an example, in an embodiment, the foam material of the first layer may have a first density, the foam material of the second layer may have a second density, and the first density may be different than the second density.
In an alternate embodiment, an impact absorbing pad includes a first layer of foam material having a plurality of voids that extend through the first layer in a plurality of positions and a second layer of foam material having a plurality of voids that extend through the second layer in a plurality of positions. As an example, in one embodiment, the first layer includes a body-facing surface and an outer surface that is opposite the body-facing surface and the second layer includes a body-facing surface that is adjacent to the outer surface of the first layer and an outer surface that is opposite the body-facing surface of the second layer. A covering covers the outer surface of the first layer, extends beyond at least a portion of the outer surface, and forms a frame around at least a portion of the outer surface. As an example, in an embodiment, the foam material of the first layer may have a first density, the foam material of the second layer may have a second density, and the first density may be different than the second density. Optionally, the first foam of the first layer may have a Shore durometer value between 20 and 30, while the second foam of the second layer may have a Shore durometer value between 35 and 45. In another embodiment, the impact absorbing pad may be included in a garment.
Optionally, the voids of the first layer and the voids of the second layer may have a pattern of shapes, each shape having three void arms that extend from a central vertex point. As an example, in one embodiment, each void arm has a distal end and each distal end of each void arm may be equidistant from the distal ends of each closest adjacent void arm in the pattern in which the void is positioned. Alternatively, the distance between the distal end of any void arm in each pattern may be equidistant from the central vertex point of each adjacent void.
Optionally, the positions of voids of the first layer may correspond to the positions of the voids of the second layer. As an example, in one embodiment, the voids of the first layer may exhibit a first size, and the voids of the second layer may exhibit a second size that is larger than the first size so that portions of the outer surface of the first layer are visible through the voids of the second layer. Alternatively, the second size may be smaller than the first size.
Optionally, the outer surface of the first layer may attached to the body-facing surface of the second layer. As an example, in one embodiment, an adhesive may attach the outer surface of the first layer to the body-facing surface of the second layer.
In another alternate embodiment, a garment includes an impact absorbing pad made from a foam material and having a plurality of voids that extend through the impact absorbing pad in a plurality of positions. As an example, in one embodiment, the impact absorbing pad includes a body-facing surface and an outer surface that is opposite the body-facing surface. Optionally, the voids may have a pattern of shapes, each shape having three void arms of equal lengths and that extend from a central vertex point. As an example, in one embodiment, each void arm has a distal end and each distal end of each void arm may be equidistant from the distal ends of each closest adjacent void arm in the pattern in which the void is positioned. Alternatively, the distance between the distal end of any void arm in each pattern may be equidistant from the central vertex point of each adjacent void.
As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” (or “comprises”) means “including (or includes), but not limited to.” When used in this document, the term “exemplary” is intended to mean “by way of example” and is not intended to indicate that a particular exemplary item is preferred or required.
In this document, when terms such “first” and “second” are used to modify a noun, such use is simply intended to distinguish one item from another, and is not intended to require a sequential order unless specifically stated. The terms “approximately” and “about” when used in connection with a numeric value, is intended to include values that are close to, but not exactly, the number. For example, in some embodiments, the term “approximately” may include values that are within +/−10 percent of the value.
When used in this document, terms such as “top” and “bottom,” “upper” and “lower”, or “outer” and “inner,” are not intended to have absolute orientations but are instead intended to describe relative positions of various components with respect to each other. For example, a first component may be an “upper” component and a second component may be a “lower” component when a device of which the components are a part is oriented in a first direction. The relative orientations of the components may be reversed, or the components may be on the same plane, if the orientation of the structure that contains the components is changed. The claims are intended to include all orientations of a device containing such components.
The impact absorbing pad 100 may have a planar or curved form having one or more layers of impact absorbing material. The pad 100, as shown in
As shown in
The mesh panel 130 has an inner surface 132, an outer surface 134, and a perimeter edge 136. The mesh panel 130 may be made of a fabric material such as, for example, Spandex (e.g., LYCRA), nylon, polyester, cotton, or the like and/or a combination of these materials. The perimeter edge 136 of the mesh panel 130 may create a surface area having a width that is greater than the width of the surface area created by the perimeter edge 116 of the first pad layer 116. The mesh panel 130 may be sewn to the garment fabric adjacent all perimeter edges 136 thus permanently enclosing the first pad layer 110 adjacent to the garment fabric. Alternatively, the mesh panel 130 may be sewn along all but one perimeter edge 136 forming a pocket matching the shape of the first pad layer 110. The mesh panel 130 serves as a cover that extends beyond and forms a frame 138 along one or more perimeter edges 136 of the pad 110 for fixing the mesh panel 130 to the garment fabric, for example, by sewing.
The impact absorbing pad 100 may be a multi-part component formed by a mesh panel 130 separated from a first pad layer 110 or may be an integral component formed by a mesh panel 130 joined to a first pad layer 110. For example, a portion of the inner surface 132 of the mesh panel 130 may be fixed to a portion of the outer surface 114 of the first pad layer 110. Examples of fixing the two parts together are sewing, gluing (e.g., adhesives), hot welding, or the like. Other methods of forming an integral pad component may be placing a portion of the oversized mesh panel 130 in the bottom of a mold form prior to injecting foam material for the first pad layer 110 thus forming the foam into, through, and around a portion of the mesh holes of the mesh panel 130.
The first pad layer 110 and mesh panel 130 may have the same color or may have different colors from each other and/or the garment to be attached to. For example, a garment having a first color may have a mesh panel 130 with the same color and a first pad layer 110 with a second color so as to contrast below the mesh panel 130.
The distal ends 306 of each void 302 may be spaced equidistant d from the adjacent distal ends 306 of the closest adjacent void 302. The equidistant spacing d is equal in length to the length d of the arms 304. Referring by way of example to void 302d in
The vertex 308 of each void 302 may be spaced equidistant d from the distal end 306 of the closest adjacent void 302. The equidistant spacing d is also equal in length to the length d of the arms 304 and the equidistant spacing d between adjacent distal ends 306. Referring by way of example to void 302d in
Likewise, the vertex 308 of each void 302 may be spaced equidistant d+d from the vertex 308 of each adjacent void 302. The equidistant spacing d+d is equal in length to twice the length d of the arms 304, twice the equidistant spacing d between adjacent distal ends 306; and twice the equidistant spacing d between adjacent distal ends 306 and vertices 308. Referring by way of example to void 302d in
The distance d may be in the range of approximately 8 mm to approximately 12 mm, such as about 8 mm. All voids 302 may follow this repeating geometric pattern 300 to provide an impact absorbing pad having a flexible form capable of conforming to the wearer's body. The tri-arm shape of the voids 302 provide improved flexure in multiple directions such that a pad may flex in multiple directions more than a pad having no voids or a pad having other shaped voids.
As shown in
The second pad layer 520 has an inner surface 522, an outer surface 524, a perimeter edge 526, and a thickness t3. The second pad layer 520, when in use, is placed on the outer region of the pad 500 (e.g., the outer pad layer). The second pad layer 520 may also be made of an elastomeric material as described above. For example, the second pad layer 520 may have a foam material having a second density different from the first density of the first pad layer 510 foam material (i.e., a pad 500 having a dual-density foam material). The second pad layer 520 may have a Shore durometer (e.g., hardness) value of about 45, about 40, about 35, or other values to further prevent impacts from injuring the wearer. The Shore durometer value of the second pad layer 520 may be the same as the Shore durometer value of the first pad 510, or it may be different. For example, the Shore durometer value of the second pad layer 520 may be about two times (2×) greater, about one and three quarter times (1.75×) greater, about one and half times (1.5×) greater, or other multiples of times greater than the Shore durometer value of the first pad 510 so as to provide a more rigid outer layer (i.e., the second pad layer 520) to provide more shock absorption and/or reduce deformation caused by objects that may impact the user and to provide a softer inner panel (i.e., the first pad layer 510) for a more conforming deformation against the user's body. As described below, the second pad layer 520 may also have one or more voids 528.
The mesh panel 530 has an inner surface 532, an outer surface 534, and a perimeter edge 536. The mesh panel 530 may also be made of a fabric material as described above. The perimeter edge 536 of the mesh panel 530 may create a surface area greater than the surface area created by the perimeter edges 516, 526 of the first pad layer 510 and second pad layer 520. The mesh panel 530 may also be sewn to the garment fabric as described above. The mesh panel 530 may also include a frame 538 along one or more perimeter edges 536 for fixing the mesh panel 530 to the garment fabric, for example, by sewing.
The impact absorbing pad 500 may be a multi-part component formed by a mesh panel 530 separated from a second pad layer 520 and a first pad layer 510 or may be an integral component formed by a mesh panel 530 joined to a second pad layer 520 which is likewise joined to a first pad layer 510 in a stacked layer design. For example, a portion of the inner surface 532 of the mesh panel 530 may be fixed to a portion of the outer surface 524 of the second pad layer 520 as described above. Likewise, a portion of the inner surface 522 of the second pad layer 520 may be fixed to a portion of the outer surface 514 of the first pad layer 510. For example, an adhesive layer 540 may be applied between a portion of the inner surface 522 of the second pad layer 520 and a portion of the outer surface 514 of the first pad layer 510.
The first pad layer 510, second pad layer 520, and mesh panel 530 may have the same color or may have different colors from each other and/or the garment to be attached to. For example, a garment having a first color may have a second pad layer 520 and mesh panel 530 with the same color and a first pad layer 510 with a second color so as to provide a color contrast. This variability would provide a selection of pads 500 having various colors to match the user's team colors.
Thus,
As shown in
For a dual-layer pad, the voids of the first pad layer and the voids of the second pad layer may have the same shape, size, placement, and orientation so as to create equal voids through the pad layers. Alternatively, the voids may have varying shapes, sizes, placements, and/or orientations.
The features and functions described above, as well as alternatives, may be combined into many other different systems or applications. Various alternatives, modifications, variations or improvements may be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.
This application is a divisional of U.S. patent application Ser. No. 16/560,032, filed Sep. 4, 2019, which is incorporated herein by reference in its entirety.
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Child | 18126219 | US |