LEG GUARD

FIELD OF THE INVENTION

The present disclosure relates generally to sports equipment. In particular, the present disclosure relates to a leg guard for a baseball or softball catcher.

BACKGROUND OF THE INVENTION

Baseball and softball catchers are positioned behind home plate and perform many important functions during a game, from calling plays and protecting the plate to catching the ball thrown by the pitcher. Due to impacts from pitches, sometimes in excess of 90 mph, and home plate crashes with other players, the bodies of catchers are regularly exposed to physical trauma. One particular physical injury that catchers are especially prone to is knee injuries. Due to the crouching position catchers assume behind home plate, catchers commonly injure their knees. For instance, the crouching position exposes the inner legs of a catcher to impacts from pitches. Because of this exposure, the inner side portions of a catcher's knees are often struck by the ball. Collisions at home plate from opposing team players trying to score also often result in slides that impact or injure the catcher's lower legs and knees. These types of injuries can seriously hinder the catcher's ability to perform vital functions during the game.

Current leg guards exist that provide some protection to the knee, thigh, and shin areas. Existing leg guards typically include a triple kneecap design, where three separate protective paddings come together to cover and protect the knee. However, existing triple kneecap designs have several shortcomings. For example, while the triple kneecap designs cover the kneecap, they do not provide sufficient protection for the lateral portions of the knee where players are often struck. In addition, existing triple kneecap designs tend to become misaligned and mispositioned as players move through different positions. For instance, a catcher's blocking motions for stopping wild pitches requires that the catcher drop quickly onto their knees from the crouching position and just as quickly either reassume the crouching position or stand upright to throw out any potential base stealers. When the catcher reassumes a standing upright position from the crouching position, the leg guard often does not slide back up into place to protect the thigh. Not only can this be distracting to the catcher, but it also requires the catcher to quickly reposition and align the pads. Moreover, leg guards are not a “one size fits all” type of equipment. Leg guards should be fitted to the size and shape of each individual player. Current leg guards on the market lack features to customize the fit of the leg guard for different sized players.

Accordingly, there remains a need for a leg guard that more adequately protects the player's leg, allows players, such as catchers, to move freely and quickly to or through different stances without having to re-position the pads of the leg guard, and provides for a customized fit.

SUMMARY OF THE INVENTION

The problems expounded above, as well as others, are addressed by the following inventions, although it is to be understood that not every embodiment of the inventions described herein will address each of the problems described above.

In some embodiments, a leg guard is provided, the leg guard including a first cover shell including a first hinge member, a second cover shell attached to the first cover shell, the second cover shell including a second hinge member, wherein the first cover shell is configured to pivot relative to the second cover shell and the first hinge member is configured to interlock with the second hinge member when the first hinge member and the second hinge member meet at an interlocking angle. In one embodiment, the first hinge member is formed along a bottom edge of the first cover shell. In another embodiment, the second hinge member is formed along a top edge of the second cover shell. In still another embodiment, the second cover shell is attached to the first cover shell at a lateral pivot point. In yet another embodiment, the interlocking angle is met when the first cover shell is configured to pivot to an angle of about 65 degrees to about 105 degrees relative to the second cover shell. In another embodiment, the first cover shell is configured to cover a thigh of a user and the second cover shell is configured to cover a knee of the user.

In further embodiments, a leg guard is provided, the leg guard including a thigh guard including a first hinge member, a knee guard pivotally attached to the thigh guard and positioned below the thigh guard, the knee guard including a second hinge member, wherein the thigh guard is configured to pivot relative to the knee guard and the first hinge member is configured to interlock with the second hinge member when the first hinge member and the second hinge member meet at an interlocking angle. In one embodiment, the first hinge member is formed along a bottom edge of the thigh guard and the second hinge member is formed along a top edge of the knee guard. In another embodiment, the first hinge member and the second hinge member are complementary in shape. In still another embodiment, the thigh guard is configured to pivot upward and downward relative to the knee guard. In yet another embodiment, the interlocking angle is met when the thigh guard is configured to pivot to an angle of about 65 degrees to about 105 degrees relative to the knee guard. In another embodiment, the knee guard is attached to the thigh guard at a pivot point positioned on a lateral portion of the knee guard. In some embodiments, the pivot point is located about 2 inches to about 3 inches from a center line of the knee guard.

In still further embodiments, a leg guard is provided, the leg guard including a thigh guard including a first cover shell, the first cover shell having a bottom edge formed as a first lip, a knee guard pivotally attached to the thigh guard and positioned below the thigh guard, the knee guard including a second cover shell, the second cover shell having an upper edge formed as a second lip, wherein the first lip and the second lip are complementary in shape, wherein the thigh guard is configured to pivot relative to the knee guard and the first lip is configured to interlock with the second lip when the first lip and the second lip meet at an interlocking angle. In one embodiment, the first lip is formed as an inward facing lip and the second lip is formed as an outward facing lip. In another embodiment, the interlocking angle is met when the thigh guard is configured to pivot to an angle of about 65 degrees to about 100 degrees relative to the knee guard. In still another embodiment, the first lip and the second lip have a height of about 0.10 inches to about 0.30 inches. In yet another embodiment, the first lip and the second lip are L-shaped.

In yet further embodiments, a thigh guard is provided, the thigh guard including a cushion pad, a cover shell slidably attached to the cushion pad by a slide member, and wherein the cover shell is configured to slide in a longitudinal direction relative to the cushion pad. In one embodiment, the thigh guard further includes a plate positioned in between the cover shell and the cushion pad, wherein the plate is formed of polyethylene. In another embodiment, the cover shell includes a guide slot and the slide member is slidably mounted within the guide slot. In still another embodiment, the slide member is fixedly secured to the cushion pad. In yet another embodiment, the guide slot has a length of about 0.25 inches to about 1.75 inches. In another embodiment, the guide slot has a length of about 0.50 inches to about 1.25 inches. In yet another embodiment, the cover shell is slidably attached to the cushion pad by a first slide member and a second slide member, the first slide member and the second slide member positioned on opposite lateral sides of the cover shell. In further embodiments, a leg guard is provided, the leg guard including the thigh guard described above.

In other embodiments, a leg guard is provided, the leg guard including a thigh guard including a first cover shell slidably attached to a cushion pad by a slide member, wherein the first cover shell includes a first hinge member, a knee guard pivotally attached to the thigh guard and positioned below the thigh guard, the knee guard including a second cover shell, the second cover shell including a second hinge member, wherein, when the thigh guard pivots relative to the knee guard, the first hinge member is configured to interlock with the second hinge member at an interlocking angle and the first cover shell is configured to slide in a longitudinal direction relative to the cushion pad. In one embodiment, the first cover shell includes a guide slot and the slide member is slidably mounted within the guide slot. In another embodiment, the slide member is fixedly secured to the cushion pad. In still another embodiment, the interlocking angle is met when the thigh guard pivots to an angle of about 65 degrees to about 105 degrees relative to the knee guard.

In still other embodiments, a leg guard is provided, the leg guard including a shin guard including a first fastener attached thereto, wherein the first fastener has at least two connection points, each connection point spaced at a different height, an ankle extension adjustably attached to the shin guard, wherein the ankle extension includes a second fastener configured to connect to at least one of the connection points on the first fastener, and a toe guard adjustably attached to the ankle extension. In one embodiment, the first fastener is positioned on a back surface of the shin guard. In another embodiment, the second fastener is positioned on a front surface of the ankle extension. In still another embodiment, the first fastener and the second fastener are corresponding hook and loop fasteners.

In still further embodiments, a leg guard is provided, the leg guard including a knee guard, a shin guard attached to the knee guard by a knee-protecting pad spanning therebetween, wherein the knee-protecting pad is attached to a lower edge of the knee guard and an upper edge of the shin guard, and the knee-protecting pad is formed of a material selected from the group consisting of polyvinyl chloride (PVC), thermoplastic rubber (TPR), thermoset rubber (TSR), nitrile rubber, and combinations thereof. In one embodiment, the knee guard includes a first cover shell, the shin guard includes a second cover shell, and the knee-protecting pad is affixed to a lower edge of the first cover shell and an upper edge of the second cover shell. In another embodiment, the knee-protecting pad is formed of PVC. In still another embodiment, the knee-protecting pad is formed of TPR.

In yet further embodiments, a knee guard is provided, the knee guard including a cover shell having a first surface area, a cushion pad affixed to a bottom side of the cover shell and having a second surface area, wherein the first surface area is less than the second surface area and the first surface area overlaps with about 70 percent to about 95 percent of the second surface area. In one embodiment, the first surface area overlaps with about 75 percent to about 85 percent of the second surface area. In another embodiment, the cover shell includes a center point and an outer edge, and the cover shell has a width from the center point to the outer edge of about 3 inches to about 5 inches. In still another embodiment, a leg guard is provided, the leg guard including the knee guard described above.

In further embodiments, a leg guard is provided, the leg guard including a knee guard including a first cover shell having a first aperture formed therein, a shin guard attached to the knee guard, wherein the shin guard includes a second cover shell having a second aperture formed therein and a first fastener attached to a back surface of the shin guard, wherein the first fastener has at least two connection points, each connection point spaced at a different height, and wherein the first aperture and the second aperture each include an outer edge having a convex-shaped curvature, an ankle extension adjustably attached to the shin guard, wherein the ankle extension includes a second fastener attached to a front surface, the second fastener configured to connect to at least one of the connection points on the first fastener, and a strapping system configured to removably and adjustably attach the leg guard to a user, wherein the strapping system includes at least one strap comprising an adjustable end, the adjustable end including an inner surface having a third fastener attached thereto, and a hook having an opening for looping the adjustable end therethrough, wherein the hook is configured to be fastened to the first aperture or the second aperture at the outer edge. In one embodiment, the at least one strap further includes a fourth fastener attached to an outer surface thereof, the fourth fastener configured to connect to the third fastener and the fourth fastener includes at least two connection points. In another embodiment, the convex-shaped curvature has a thickness along the outer edge that is about 0.030 inches to about 0.040 inches thicker than other portions of the cover shells. In still another embodiment, the ankle extension is substantially butterfly shaped and includes a pair of lateral ankle guards extending along each side of the ankle extension. In still another embodiment, the ankle extension includes a cover formed of polyethylene (PE). In yet another embodiment, the first fastener and the second fastener are corresponding hook and loop fasteners.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the invention can be ascertained from the following detailed description that is provided in connection with the drawings described below:

FIG. 1 is a front view of a leg guard according to one embodiment of the present disclosure.

FIG. 2 is a perspective view of the leg guard shown in FIG. 1.

FIG. 3A is a cross sectional view of a portion of the leg guard shown in FIG. 1 in an upright position.

FIG. 3B is a cross sectional view of a portion of the leg guard shown in FIG. 1 in a crouching position.

FIG. 4 is a perspective view of a portion of the leg guard shown in FIG. 1 in a crouching position.

FIG. 5A is a perspective view of a slider assembly on a portion of the leg guard shown in FIG. 1 when the leg guard is configured in an upright position according to one embodiment.

FIG. 5B is a perspective view of the slider assembly on a portion of the leg guard shown in FIG. 1 when the leg guard is configured in a crouching position according to one embodiment.

FIG. 6A is a side view of a portion of the leg guard shown in FIG. 1 illustrating a knee guard according to one embodiment.

FIG. 6B is another cross-sectional view of a portion of the leg guard shown in FIG. 1 in an upright position.

FIG. 7A is a back view of an upper shin strap according to one embodiment of the present disclosure.

FIG. 7B is a back view of the upper shin strap according to another embodiment of the present disclosure.

FIG. 8A is a perspective view of a portion of a shin guard showing a hook and an aperture to which it can attach according to one embodiment of the present disclosure.

FIG. 8B is a perspective view of a portion of the shin guard showing the hook attached to the aperture according to one embodiment of the present disclosure.

FIG. 9A is a front view of an ankle extension with a toe guard attached thereto according to one embodiment of the present disclosure.

FIG. 9B is a front view of an ankle extension with a toe guard attached thereto according to another embodiment of the present disclosure.

FIG. 10A is a back view of an ankle extension with a toe guard partially attached thereto according to one embodiment of the present disclosure.

FIG. 10B is a back view of an ankle extension with a toe guard attached thereto according to another embodiment of the present disclosure.

FIG. 11 is an exploded back view of a portion of the shin guard and the ankle extension and the toe guard according to one embodiment of the present disclosure.

FIG. 12 is a back view of the leg guard shown in FIG. 1 according to one embodiment of the present disclosure.

FIG. 13 is a perspective view of a portion of the leg guard shown in FIG. 1 in a partially bent position.

DETAILED DESCRIPTION OF THE INVENTION

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art of this disclosure. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well known functions or constructions may not be described in detail for brevity or clarity.

The terms “about” and “approximately” shall generally mean an acceptable degree of error or variation for the quantity measured given the nature or precision of the measurements. Numerical quantities given in this description are approximate unless stated otherwise, meaning that the term “about” or “approximately” can be inferred when not expressly stated.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well (i.e., at least one of whatever the article modifies), unless the context clearly indicates otherwise.

The terms “first,” “second,” “third,” and the like are used herein to describe various features or elements, but these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present disclosure.

Spatially relative terms, such as “above,” “under,” “below,” “lower,” “over,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another when the apparatus is right side up as shown in the accompanying drawings.

The term “substantially” allows for deviations from the descriptor that do not negatively impact the intended purpose. Descriptive terms are understood to be modified by the term “substantially” even if the word “substantially” is not explicitly recited.

It is to be understood that any given element of the disclosed embodiments of the invention may be embodied in a single structure, a single step, a single substance, or the like. Similarly, a given element of the disclosed embodiment may be embodied in multiple structures, steps, substances, or the like.

Referring to FIGS. 1 and 2, a leg guard 100 in accordance with the present disclosure is shown. The leg guard 100 is suitable for both adults and youths. As will be apparent to those of ordinary skill in the art, the design and dimensions of a youth version of the leg guard according to the present disclosure is proportional to an adult version of the leg guard. In addition, while only one leg guard 100 is shown in the figures, it should be appreciated that typically a catcher (or other user) would wear a leg guard 100 on each leg, both of which are substantially similar to the leg guard 100.

The leg guard 100 includes a toe guard 10 coupled to a shin guard 12, a knee guard 14 coupled to the shin guard 12 via a knee-protecting pad portion 18, and a thigh guard 16 coupled to the knee guard 14. As shown in FIGS. 1 and 2, the leg guard 100 of the present disclosure utilizes a dual kneecap design that eliminates the need for an extended knee guard. Each of the toe guard 10, shin guard 12, knee guard, 14 and thigh guard 16 is arranged in vertical alignment with one another. The shin guard 12 and the knee guard 14 also include a plurality of apertures 20 formed therein to which one or more straps, such as a thigh strap 46A, an upper shin strap 46B, and a lower shin strap 46C, may be fastened with hooks 49, as will be described in more detail below.

In one embodiment, the toe guard 10 is shaped to cover and fit around a top portion of the user's foot. The toe guard 10 may be contoured to follow the contour typical of the top portion of the foot of a user. The toe guard 10 includes a cover shell 22 that covers a cushion pad 24 affixed thereto. The affixation of the cover shell 22 to the cushion pad 24 may occur in any manner that results in a semi-permanent or permanent attachment between the two components. For example, the cover shell 22 may be affixed atop the cushion pad 24 with rivets, fasteners, stitching, or a combination thereof.

In some embodiments, to accommodate the extreme angle of the ankle joint while the user is in a crouching or upright position, the toe guard 10 may be removably or fixedly attached (though flexibly coupled) to an ankle extension 25. The ankle extension 25 is configured to protect the ankles of the user. The ankle extension 25 may be a separate component with one end connected to the shin guard 12 and the other end to the toe guard 10. The ankle extension 25 includes a cover 23 that covers a cushion pad (not shown) affixed thereto. As will be described in detail below, the ankle extension 25 can be removably attached at different heights on the shin guard 12 to adjust the length of the overall leg guard 100. In addition, the ankle extension 25 may include lateral ankle guards 32. The ankle guards 32 extend along the sides of the user's ankle to provide additional protection. That is, the ankle guards 32 shield the user's ankles from impact.

The shin guard 12 is shaped to cover and fit around a shin of the user's leg. The shin guard 12 may be contoured to follow the contour typical of the shin portion of the leg of the user. In one embodiment, the shin guard 12 includes a cover shell 26 that covers a cushion pad 28 affixed thereto. The affixation of the cover shell 26 to the cushion pad 28 may occur in any manner that results in a semi-permanent or permanent attachment between the cover shell 26 and the cushion pad 28. For example, the cover shell 26 may be affixed atop the cushion pad 28 with rivets, fasteners, stitching, or a combination thereof.

The cover shell 26 may include a plurality of air vents 34 that extend through the cover shell 26 to allow for ventilation and expelling of sweat. The positioning and quantity of air vents are not limited. For instance, the cover shell 26 may include a plurality of air vents 34 along the median of the shell, the lateral sides of the shell, or any combinations thereof. As shown in FIG. 1, a plurality of air vents 34 may be positioned along the left and right sides of the cover shell 26 as well as along the median.

The knee guard 14 is shaped to cover and fit around a knee of the user's leg. The knee guard 14 may be contoured to follow the contour typical of the knee portion of the leg of the user. The knee guard 14 includes a cover shell 36 that covers a cushion pad 38 affixed thereto. The affixation of the cover shell 36 to the cushion pad 38 may occur in any manner that results in a semi-permanent or permanent attachment between the cover shell 36 and the cushion pad 38. For example, the cover shell 36 may be affixed atop the cushion pad 38 with rivets, fasteners, stitching, or a combination thereof.

In one embodiment, a gap between an upper edge of the shin guard 12 and a lower edge of the knee guard 14 is spanned by a knee-protecting pad portion 18. The knee-protecting pad portion 18 provides a layer of padding that covers the area spanning between the upper edge of the shin guard 12 and the lower edge of the knee guard 14. In one embodiment, the knee-protecting pad portion 18 is affixed to the upper edge of the cover shell 26 and the lower edge of the cover shell 36. Suitable materials for forming the knee-protecting pad portion 18 of the present disclosure include, but are not limited to, polyvinyl chloride (PVC), thermoplastic rubber (TPR), polypropylene (PP), expanded polypropylene (EPP), thermoset rubber (TSR), nitrile rubber, acrylonitrile butadiene styrene (ABS), PC/ABS compounds, styrene and/or high impact styrene (HIPS), vinyl nitrile, ethylene vinyl acetate (EVA), and any combination of the foregoing materials. For example, the knee-protecting pad portion 18 may be formed of thermoplastic rubber. In another embodiment, the knee-protecting pad portion 18 may be formed of polyvinyl chloride.

The thigh guard 16 is attached to the knee guard 14 at pivot point 56. Pivot point 56 allows for the thigh guard 16 to pivot relative to the knee guard 14 as the user moves through a plurality of positions. As will be discussed in detail below, the thigh guard 16 is configured to pivot about pivot point 56 with the use of an interlocking hinge 50 (the exterior of which is shown in FIGS. 1 and 2). The thigh guard 16 may be attached to the knee guard 14 at pivot point 56 using any type of attachment mechanism that allows for pivotal movement. In one embodiment, the thigh guard 16 may be attached to the knee guard 14 with a rivet. In another embodiment, the thigh guard 16 may be attached to the knee guard 14 with a fastener. While FIG. 2 illustrates the pivot point 56 on the right side of the leg guard 100, the present disclosure contemplates the use of pivot points 56 on both the left and right sides of the leg guard 100.

The thigh guard 16 is shaped to cover and fit around a thigh of the user's leg. The thigh guard 16 may be contoured to follow the contour typical of the thigh portion of the leg of the user. The thigh guard 16 includes a cover shell 40 that covers a cushion pad 42. In some embodiments, the thigh guard 16 includes a thigh plate 41 positioned between the cover shell 40 and the cushion pad 42 and affixed to the cushion pad 42. In some embodiments, the thigh plate 41 is a flexible plate formed of polyethylene, for example, high impact polyethylene. In one embodiment, the thigh plate 41 may have a thickness ranging from about 1 mm to about 4 mm. In another embodiment, the thigh plate 41 may have a thickness ranging from about 1.5 mm to about 3.5 mm. In another embodiment, the thigh plate 41 may have a thickness ranging from about 2 mm to about 4 mm. In still another embodiment, the thigh plate 41 may have a thickness ranging from about 2.5 mm to about 3.5 mm. In still another embodiment, the thigh plate 41 may have a thickness ranging from about 3 mm to about 4 mm. In yet another embodiment, the thigh plate 41 may have a thickness ranging from about 3.5 mm to about 4 mm.

As shown in the illustrated embodiment, the thigh plate 41 and the cushion pad 42 are attached to the cover shell 40 by a slider assembly 44. The slider assembly 44, as will be described in greater detail below, allows for the thigh plate 41 and the cushion pad 42 to remain fixed against the thigh of the user while the cover shell 40 slides up and down the leg as the user assumes any one of a plurality of positions from squatting or crouching to/through an intermediate position to/through an upright position. The slider assembly 44 increases comfortability of the thigh guard 16 and prevents the entire leg guard 100 from sliding downward when the user changes position. Like the cover shell 26, the cover shell 40 may also include one or more of the air vents 34 that extend through the shell to allow for ventilation and expelling of sweat.

FIGS. 3A and 3B are cross sectional views showing the coupling of the thigh guard 16 to the knee guard 14 and the use of the interlocking hinge 50. More specifically, FIG. 3A shows the configuration of the thigh guard 16 and the knee guard 14 when the leg guard 100 is positioned in an upright position and the components of the interlocking hinge 50 are separated. FIG. 3B shows the configuration of the thigh guard 16 and the knee guard 14 when the leg guard 100 is positioned in a crouching position and the components of the interlocking hinge 50 are interlocked. Advantageously, the coupling configuration shown in FIGS. 3A and 3B prevents an opening from forming between the thigh guard 16 and the knee guard 14 during play. Indeed, as shown in the upright position of FIG. 3A, the thigh guard 16 and the knee guard 14 are coupled such that the thigh guard 16 overlaps with the knee guard 14. Similarly, as shown in the crouching position of FIG. 3B, the interlocking hinge 50 creates a strong, durable seam between the thigh guard 16 and the knee guard 14. In both positions (and as the player moves through the respective positions), the player's frontal knee portion is fully protected from any potential impact. The configuration also dispenses of the need for an extended knee guard. Moreover, the interlocking hinge 50 prevents the leg guard 100 from moving or rotating about the user's leg during movement.

The interlocking hinge 50 is comprised of a first hinge member 47 and a second hinge member 48. The first hinge member 47 is formed along a bottom edge of the cover shell 40 of the thigh guard 16. As illustrated in FIG. 3A, the first hinge member 47 is defined as an inwardly facing L-shaped lip that extends along the entire length of the bottom edge of the cover shell 40. The second hinge member 48 is formed along a top edge of the cover shell 36 of the knee guard 14. As shown in FIG. 3A, the second hinge member 48 is defined as an outwardly facing L-shaped lip oppositely directed from the first hinge member 47 that extends along the entire length of the top edge of the cover shell 36.

The first hinge member 47 and the second hinge member 48 are configured to interlock in a hinging and separable engagement as the thigh guard 16 pivots relative to the knee guard 14. Starting in the upright position shown in FIG. 3A, the first hinge member 47 is configured to rotate in an upward direction along the curvature of the cover shell 36 of the knee guard 14 (as the thigh guard 16 pivots relative to the knee guard 14) until it reaches an interlocking position with the second hinge member 48, as shown in FIG. 3B. To return to the upright position, the first hinge member 47 is configured to rotate in a downward direction along the curvature of the cover shell 36 of the knee guard 14 until it returns to a fully separated position, as shown in FIG. 3A.

Pivot point 56 allows for the thigh guard 16 to pivot relative to the knee guard 14 as the user moves through a plurality of positions, including from squatting or crouching to/through an intermediate position to/through an upright position. In this embodiment, the lateral placement of the pivot point 56 on both the thigh guard 16 and the knee guard 14 should not interfere with the rotation of the interlocking hinge 50. In one embodiment, the pivot point 56 is located about 2 inches to about 3 inches from a center line C of the knee guard 14, as shown in FIG. 3A. In another embodiment, the pivot point 56 is located about 2.15 inches to about 2.85 inches from the center line C of the knee guard 14, as shown in FIG. 3A. In still another embodiment, the pivot point 56 is located about 2.2 inches to about 2.8 inches from the center line C of the knee guard 14. In still another embodiment, the pivot point 56 is located about 2.25 inches to about 2.75 inches from the center line C of the knee guard 14, as shown in FIG. 3A. In yet another embodiment, the pivot point 56 is located about 2.3 inches to about 2.5 inches from the center line C of the knee guard 14, as shown in FIG. 3A. In another embodiment, the pivot point 56 is located about 2.3 inches to about 2.4 inches from the center line C of the knee guard 14, as shown in FIG. 3A.

The first hinge member 47 has a hinge side 52 which is defined along the interior of the L-shaped bottom edge of the cover shell 40. The second hinge member 48 has a hinge side 54 which is defined along the exterior of the oppositely disposed L-shaped upper edge of the cover shell 36. In other words, the hinge side 52 is positioned on an interior side of the first hinge member 47 and the hinge side 54 is positioned on an exterior side of the second hinge member 48. The hinge side 52 of the first hinge member 47 hingedly engages with the hinge side 54 of the second hinge member 48. The hinge sides 52 and 54 hingedly engage to each other or interlock when the first hinge member 47 and the second hinge member 48 meet at an interlocking angle θ_I. In this embodiment, the interlocking angle θ_Iis met when the first hinge member 47 rotates to an angle in which the first hinge member 47 engages with the second hinge member 48 and any further upward movement is impeded.

In one embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of about 65 degrees to about 105 degrees relative to the knee guard 14. In one embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of less than 100 degrees relative to the knee guard 14. For example, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of less than 90 degrees relative to the knee guard 14. In another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of about 85 degrees relative to the knee guard 14. In another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of about 70 degrees relative to the knee guard 14. In still another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle of about 65 degrees relative to the knee guard 14. Having an interlocking angle θ_Iless than 65 degrees may prevent the thigh guard 16 from laying flat against the user's leg in a crouching position. For example, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle between about 65 degrees to about 100 degrees relative to the knee guard 14. In another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle between about 65 degrees to about 90 degrees relative to the knee guard 14. In another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle between about 75 degrees to about 90 degrees relative to the knee guard 14. In still another embodiment, the interlocking angle θ_Imay be reached when the thigh guard 16 pivots to an angle between about 80 degrees to about 90 degrees relative to the knee guard 14. The interlocking configuration formed by the first hinge member 47 and the second hinge member 48 creates a strong seam between the knee guard 14 and the thigh guard 16 and prevents a hole or opening from forming therebetween.

The first hinge member 47 and the second hinge member 48 should have a sufficient height H (or thickness) so as to avoid any risk of the interlocking hinge 50 breaking or failing and a gap forming in between the thigh guard 16 and the knee guard 14. In one embodiment, the first hinge member 47 and the second hinge member 48 have a height of about 0.10 inches to about 0.50 inches. In another embodiment, the first hinge member 47 and the second hinge member 48 have a height of about 0.12 inches to about 0.40 inches. In still another embodiment, the first hinge member 47 and the second hinge member 48 have a height of about 0.15 inches to about 0.35 inches. In yet another embodiment, the first hinge member 47 and the second hinge member 48 have a height of about 0.17 inches to about 0.34 inches. In another embodiment, the first hinge member 47 and the second hinge member 48 have a height of about 0.18 inches to about 0.30 inches. In some embodiments, the first hinge member 47 and the second hinge member 48 have substantially the same height. In further embodiments, the first hinge member 47 and the second hinge member 48 may have different heights, though the heights should not differ by more than 0.20 inches. The slight difference in height between the first hinge member 47 and the second hinge member 48 can create clearance between the two pieces so that the knee guard 14 does not scrape against the thigh guard 16 as it rotates. In still further embodiments, the first hinge member 47 and the second hinge member 48 may have different heights, though the heights should not differ by more than 0.17 inches.

FIG. 4 shows the use of the interlocking hinge 50 when the user is in the crouching position. As the user changes position from a standing upright position to a crouching position, the first hinge member 47 rotates relative to the second hinge member 48, and at a certain point in the hinging, the hinge side 52 of the first hinge member 47 and the hinge side 54 of the second hinge member 48 interlock with one another at the interlocking angle θ_I, as shown in FIG. 4. The seam created by the hinge 50 at the interlocking angle θ_Iprevents a gap from forming between the thigh guard 16 and the knee guard 14. As the user changes position, the first hinge member 47 and the second hinge member 48 separate as the hinge sides 52 and 54 move apart from one another. That is, the first hinge member 47 and the second hinge member 48 will separate as the user moves from squatting or crouching to/through an intermediate position to/through an upright position. The first hinge member 47 and the second hinge member 48 may separate to the extent the thigh guard 16 returns to a position in which it is vertically aligned with the knee guard 14.

FIGS. 5A and 5B show the slider assembly 44 by which the cushion pad 42 and the thigh plate 41 are attached to the cover shell 40 of the thigh guard 16. The slider assembly 44 allows for the cushion pad 42 (and the thigh plate 41) to remain fixed against the thigh of the user while only the cover shell 40 slides up and down the leg as the user assumes any one of a plurality of positions from squatting or crouching to/through an intermediate position to/through an upright position. In other words, unlike conventional leg guards where the cushion pad and the cover shell are affixed to one another such that they both move in unison, the slider assembly 44 allows for the cushion pad 42 to be decoupled from the cover shell 40 so that the cushion pad 42 remains positioned against the thigh of the user while the cover shell 40 slides up and down the leg as the user assumes any one of a plurality of positions from squatting or crouching to/through an intermediate position to/through an upright position.

In the illustrated embodiment, the thigh guard 16 includes two slider assemblies 44—one on each of the left and right sides of the cover shell 40 (though only the slider assembly 44 on the right side is shown). As shown in FIGS. 5A and 5B, the slider assembly 44 includes a longitudinal guide slot 58 extending along the cover shell 40. The longitudinal guide slot 58 is a hollow slot formed within the cover shell 40. A slide member 60 is slidably mounted within the longitudinal guide slot 58 for vertical movement therein. The slide member 60 secures the cover shell 40 to the thigh plate 41 and the cushion pad 42 positioned thereunder. In one embodiment, the slide member 60 extends through the longitudinal guide slot 58 and the thigh plate 41 such that the bottom end of the slide member 60 sits between the thigh plate 41 and the cushion pad 42. The thigh plate 41 serves as an intermediary between the cover shell 40 and the cushion pad 42 to which the slide member 60 can attach. This increases the comfortability of the thigh guard 16 against the user's leg. However, as will be appreciated by those skilled in the art, the slider assembly 44 may be used without the thigh plate 41 positioned in between the cover shell 40 and the cushion pad 42. For example, the slide member 60 may extend through the longitudinal guide slot 58 and attach directly to the cushion pad 42.

The length of the longitudinal guide slot 58 should be sufficient to allow for the cover shell 40 to slide in a vertical direction such that the user can reach a comfortable crouching position. Indeed, if the length of the longitudinal guide slot 58 is too short, the thigh guard 16 will merely rotate without sliding movement. If the length of the longitudinal guide slot 58 is too long, the thigh guard 16 will not fit comfortably on the user. In one embodiment, the length of the longitudinal guide slot 58 is about 0.25 inches to about 1.75 inches. In another embodiment, the length of the longitudinal guide slot 58 is about 0.3 inches to about 1.6 inches. In another embodiment, the length of the longitudinal guide slot 58 is about 0.50 inches to about 1.5 inches. In still another embodiment, the length of the longitudinal guide slot 58 is about 0.75 inches to about 1.25 inches. For example, the length of the longitudinal guide slot 58 is about 0.90 inches to about 1.10 inches.

The slide member 60 may be any type of fastener capable of slidable movement within the longitudinal guide slot 58. In one embodiment, as shown in FIGS. 5A and 5B, the slide member 60 is a rivet. The rivet may have a smooth cylindrical shaft with a head on one end to prevent the rivet from falling through the longitudinal guide slot 58. In another embodiment, the slide member 60 may be a screw having a head on one end. In still another embodiment, the slide member 60 may be a pin having a head on one end. In yet another embodiment, the slide member 60 may be a T-nut. The length of the slide member 60 is sufficient to extend through the longitudinal guide slot 58 and the thigh plate 41. In some embodiments, the length of the slide member 60 is about 0.10 inches to about 0.75 inches. In another embodiment, the length of the slide member 60 is about 0.20 inches to about 0.60 inches. In still another embodiment, the length of the slide member 60 is about 0.25 inches to about 0.50 inches. In another embodiment, the length of the slide member 60 is about 0.25 inches to about 0.40 inches. In yet another embodiment, the length of the slide member 60 is about 0.25 inches to about 0.30 inches.

In use, the slide member 60 is configured to slide in a vertical direction within the longitudinal guide slot 58 as the player moves through a plurality of positions. For instance, FIG. 5A shows the thigh guard 16 portion of the leg guard 100 in a fully upright position. As shown in FIG. 5A, the slide member 60 is positioned at the bottom end of the longitudinal guide slot 58. However, as the player moves from a fully upright position to/through an intermediate position to/through a squatting or crouching position, the slide member 60 slides upward within the longitudinal guide slot 58 until the player reaches the crouching position (i.e., until the slide member 60 reaches the top of the longitudinal guide slot 58). As the slide member 60 slides upward, the thigh plate 41 and the cushion pad 42 remain fixed against the user's leg while the cover shell 40 slides downward, as illustrated in FIG. 5B.

FIGS. 6A and 6B are a side view and a cross sectional view, respectively, of the knee guard 14 that illustrate the increased coverage of protection provided by the knee guard 14. As shown in FIG. 6A, the cover shell 36 of the knee guard 14 covers not only the kneecap region, but also extends to cover a significant portion of the lateral sides of the knee. That is, the cover shell 36 wraps around the knee and protects both the kneecap and the lateral sides of the knee. As demonstrated in FIG. 6A, the cover shell 36 protects substantially the entire lateral portion of the user's knee. The additional coverage provided by the knee guard 14 can help prevent serious injuries caused by blows to the lateral portions of the knee, such as injury to the tibia bone.

FIG. 6B shows a cross-sectional view of the cover shell 36 of the knee guard 14 from the center line C to the edge line E. In one embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3 inches to about 5 inches. In another embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3 inches to about 4.50 inches. In still another embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3.25 inches to about 4.25 inches. In yet another embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3.50 inches to about 4.00 inches. In another embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3.70 inches to about 3.80 inches. In still another embodiment, the width from the center line C to the edge line E (W_C-E) of the cover shell 36 ranges from about 3.75 inches to about 3.80 inches.

In some embodiments, the cover shell 36 has a surface area covering at least about 70 percent of the total surface area of the cushion pad 38. In one embodiment, the cover shell 36 has a surface area covering at least about 72 percent of the total surface area of the cushion pad 38. In another embodiment, the cover shell 36 has a surface area covering at least about 75 percent of the total surface area of the cushion pad 38. In still another embodiment, the cover shell 36 has a surface area covering at least about 80 percent of the total surface area of the cushion pad 38. In yet another embodiment, the cover shell 36 has a surface area covering at least about 82 percent of the total surface area of the cushion pad 38. In yet another embodiment, the cover shell 36 has a surface area covering at least about 85 percent of the total surface area of the cushion pad 38. In another embodiment, the cover shell 36 has a surface area covering at least about 90 percent of the total surface area of the cushion pad 38. For instance, the cover shell 36 has a surface area covering (or overlapping) about 70 percent to about 95 percent of the total surface area of the cushion pad 38. In another embodiment, the cover shell 36 has a surface area covering (or overlapping) about 75 percent to about 85 percent of the total surface area of the cushion pad 38. In still another embodiment, the cover shell 36 has a surface area covering (or overlapping) from about 80 percent to about 85 percent of the total surface area of the cushion pad 38.

With the design of the knee guard 14, the cover shell 36 covers a significantly greater surface area of the cushion pad 38 as compared to knee guards on conventional leg guards. In one embodiment, the cover shell 36 covers at least 10 percent more of the surface area of the cushion pad 38 as compared to knee guard on conventional leg guards. In another embodiment, the cover shell 36 covers at least 15 percent more of the surface area of the cushion pad 38 as compared to knee guard on conventional leg guards. In still another embodiment, the cover shell 36 covers at least 20 percent more of the surface area of the cushion pad 38 as compared to knee guard on conventional leg guards. In yet another embodiment, the cover shell 36 covers at least 25 percent more of the surface area of the cushion pad 38 as compared to knee guard on conventional leg guards. In still another embodiment, the cover shell 36 covers at least 30 percent more of the surface area of the cushion pad 38 as compared to knee guard on conventional leg guards.

The leg guard 100 is removably and adjustably attachable to the leg of a user. In one embodiment, the leg guard 100 includes a strapping system that is provided to secure the leg guard 100 in position. The strapping system of the present invention includes a plurality of straps, including, for instance, the thigh strap 46A, the upper shin strap 46B, and the lower shin strap 46C. The thigh strap 46A is configured to secure the thigh guard 16 to the user's thigh. The upper shin strap 46B is designed to secure the knee guard 14 and shin guard 12 to the leg of the user while the lower shin strap 46C is configured to secure the lower portion of the shin guard 12 to the user's leg. In some embodiments, the straps 46A-C are made of a durable, resilient material. For example, the straps 46A-C are made of neoprene. In another embodiment, the straps 46A-C may be made of elastic. In still another embodiment, the straps 46A-C are made of a woven natural or synthetic material, such as woven nylon. As will be described below, the use of the robust neoprene straps 46A-C in combination with the adjustability of the straps 46A-C and the mechanism by which the straps 46A-C are fastened to the leg guard 100 provide the user with a more secure fit than conventional leg guards on the market.

FIGS. 7A and 7B illustrate the adjustability of the straps 46A-C for use with the leg guard 100. FIG. 7A shows the upper shin strap 46B according to one embodiment of the present disclosure. As shown in FIG. 7A, the upper shin strap 46B includes a first strap portion 62 having a first adjustable end 64 and a second (opposite) adjustable end 66 and a second strap portion 68 having a first adjustable end 70 and a second (opposite) adjustable end 72. The first strap portion 62 and the second strap portion 68 are integrally formed with one another to form the upper shin strap 46B. Each of the adjustable ends 64, 66 of the first strap portion 62 and the adjustable ends 70, 72 of the second strap portion 68 are looped through an opening on hook 49 so that the adjustable ends are folded back around, as shown in FIG. 7A.

As more clearly shown in FIG. 7B, each of the adjustable ends 64, 66 of the first strap portion 62 and the adjustable ends 70, 72 of the second strap portion 68 have a hook and loop fastener 74 secured thereto. The hook and loop fasteners 74 allow for the adjustable ends 64, 66, 70, 72 to be removably attached to the surface of the upper shin strap 46B. In some embodiments, the surface of the upper shin strap 46B may include a complementary hook and loop fastener. This, in turn, provides the user with the ability to adjust the length of the upper shin strap 46B for a more secure fit. Indeed, the user can loosen or tighten the upper shin strap 46B by pressing the hook and loop fasteners 74 against the surface of the strap at the desired location to achieve a strong secure connection that also provides comfortability and a secure fit.

In some embodiments, each side of the adjustable strap portions 62, 68 can provide a sizing adjustment of at least about 0.5 inches for a total length adjustment of at least about 1 inch. For example, each side of the adjustable strap portions 62, 68 can loosen the shin strap 46B by at least 0.5 inches or tighten the shin strap 46B by at least 0.5 inches. In another embodiment, each side of the adjustable strap portions 62, 68 can provide a sizing adjustment of at least about 1 inch for a total length adjustment of at least about 2 inches. In still another embodiment, each side of the adjustable strap portions 62, 68 can provide a sizing adjustment of at least about 1.5 inches for a total length adjustment of at least about 3 inches. In yet another embodiment, each side of the adjustable strap portions 62, 68 can provide a sizing adjustment of at least about 2 inches for a total length adjustment of at least about 4 inches. In another embodiment, each side of the adjustable strap portions 62, 68 can provide a sizing adjustment of up to about 2.5 inches for a total length adjustment of up to about 5 inches.

While FIGS. 7A and 7B illustrate the adjustability mechanism of the present disclosure on the upper shin strap 46B, those of ordinary skill in the art will appreciate that the same mechanism can be used to adjust the other straps on the leg guard 100, including, for example, the thigh strap 46A and the lower shin strap 46C. In addition, while hook and loop fasteners have been exemplified herein, the present disclosure contemplates the use of other adjustable attachment mechanisms, such as snaps, clips, or the like, to secure the strap.

FIGS. 8A and 8B show a mechanism by which the straps 46A-C are fastened to the leg guard 100 according to one embodiment. FIG. 8A shows the hook 49 and the aperture 20 to which it can attach according to one embodiment of the present disclosure. The aperture 20 shown in FIGS. 8A and 8B is formed in the cover shell 26 of the shin guard 12. In this aspect, the aperture 20 can also function as an air vent. Additionally, while the aperture shown in FIGS. 8A and 8B is an aperture formed in the shin guard 12, other apertures formed on the leg guard 100 can be designed similarly to the one shown and function in the same way.

As illustrated in FIG. 8A, the hook 49 has a curved end that defines a hook end portion 76. The hook end portion 76 is integrally formed with a narrow neck portion 79. Opposite the hook end portion 76, the other end includes an opening 78 formed therein through which an adjustable end of any one of the straps 46A-C can be looped. The hook end portion 76 is configured for removable attachment to the aperture 20, as shown in FIG. 8B.

In the illustrated embodiment, the aperture 20 is triangular shaped and formed of three edges 80A, 80B, and 80C. The hook end portion 76 of the hook 49 is configured for removable attachment to the outer edge of the aperture 20, i.e., edge 80C. As best shown in FIG. 8A, the outer edge 80C is curved. Indeed, unlike the other two edges 80A, 80B which are straight, the outer edge 80C has a slight curvature where the hook end portion 76 is configured for attachment. In this embodiment, the edge 80C has a convex-shaped curvature. The curvature makes it easier for the user to release the hook and helps with attachment because the concave shape funnels the hook into the center for easy alignment. Forming the aperture 20 in the cover shell 26 also makes the leg guard 100 more lightweight since it dispenses of the need to attach rings or other mechanisms for receiving the hook. In addition, while the aperture 20 is described herein as triangular shaped, those skilled in the art will readily appreciate that other shapes suitable for the aperture 20 may include, for instance, V-shaped, U-shaped, circular, or rectangular.

In some embodiments, to form the curvature of the outer edge 80C, the thickness of the cover shell 26 along the outer edge 80C may be greater than the thickness of the cover shell 26 at portions not surrounding the aperture 20. For example, the thickness of the cover shell 26 along the outer edge 80C may be about 0.010 inches to about 0.050 inches thicker than other portions of the cover shell 26. In another embodiment, the thickness of the cover shell 26 along the outer edge 80C may be about 0.020 inches to about 0.050 inches thicker than other portions of the cover shell 26. In still another embodiment, the thickness of the cover shell 26 along the outer edge 80C may be about 0.020 inches to about 0.040 inches thicker than other portions of the cover shell 26. In yet another embodiment, the thickness of the cover shell 26 along the outer edge 80C may be about 0.030 inches to about 0.040 inches thicker than other portions of the cover shell 26. In further embodiments, the thickness of the cover shell 26 along the outer edge 80C may gradually increase until a certain point (for example, up until the middle of the outer edge 80C) and then gradually decrease to the thickness of the other portions of the cover shell 26. In this embodiment, the middle of the outer edge 80C has a greater thickness than the other portions of the outer edge 80C.

The dimensions of the aperture 20 may vary so long as the aperture 20 is large enough to insert and remove the hook 49. In other words, the aperture 20 should be slightly oversized so that the hook end portion 76 of the hook 49 clears the outer edge 80C of the aperture 20. In addition, as shown in FIGS. 8A and 8B, the aperture 20 is placed along an outer edge of the cover shell 26 of the shin guard 12 so that the hooks 49 do not bump into each other on the inside when the user is running.

As noted above, the apertures 20 described herein may be formed in any of the cover shells of the leg guard 100 and at any location that is deemed suitable for fastening a strap. In one embodiment, the apertures 20 are positioned on both the left and right sides of the various cover shells. While the straps have been presented herein as removably attachable to the apertures, the present disclosure also contemplates straps that are fixedly attached to one side of the leg guard, for example, by sewing, stitching, or riveting the straps to the corresponding cushion pads or cover shells. In this aspect, on the other side of the leg guard, the straps may include a securing mechanism that removably attaches to a corresponding slot, clip, or hook fixedly attached to the leg guard.

FIGS. 9A-11 illustrate the adjustability of the ankle extension 25 and the toe guard 10 with respect to the leg guard 100 according to one embodiment of the present disclosure. In some embodiments, the ankle extension 25 includes an adjustment mechanism that allows it to be removably attached at a plurality of different user selectable positions, such as different user selectable heights, on the shin guard 12. This, in turn, allows the user to adjust the overall length of the leg guard 100 to provide a customized fit. Indeed, the overall length of the leg guard 100 can be lengthened or shortened to accommodate differently sized legs of different sports participants.

FIGS. 9A and 9B are front views of the adjustable ankle extension 25 with the toe guard 10 attached thereto according to various embodiments. In the illustrated embodiments, the ankle extension 25 is substantially butterfly shaped with a pair of lateral ankle guards 32 extending along each side of the ankle extension 25. The ankle guards 32 extend along the sides of the user's ankle to provide additional protection. That is, the ankle guards 32 shield the user's ankles from impact.

As shown in FIGS. 9A and 9B, the ankle extension 25 includes the cover 23 that covers a cushion pad 27 affixed thereto (shown in FIGS. 10A and 10B). The cover 23 is formed of a material having extra rigidity to protect the user's ankles from impact. Suitable materials for forming the cover 23 include, but are not limited to, thermoplastic rubber (TPR), polypropylene (PP), expanded polypropylene (EPP), thermoset rubber (TSR), acrylonitrile butadiene styrene (ABS), PC/ABS compounds, styrene and/or high impact styrene (HIPS), polyethylene (PE), and combinations thereof. In one embodiment, the cover 23 is formed of polyethylene (PE), for example, high impact polyethylene. The cover 23 may have a thickness ranging from about 0.5 mm to about 3 mm. For example, the cover 23 may have a thickness ranging from about 0.75 mm to about 2.5 mm. In another embodiment, the cover 23 may have a thickness ranging from about 1 mm to about 2 mm. In still another embodiment, the cover 23 may have a thickness ranging from about 0.75 mm to about 1.25 mm. In one embodiment, the cover 23 is configured to extend along substantially the entire front surface of the ankle extension 25. In another embodiment, as shown in FIG. 9B, the ankle extension 25 may include a cut out 86 in the cover 23. In this embodiment, a portion of the bottom edge of the cover 23 that is positioned directly above the toe guard 10 is cut out to allow for the cushion pad 27 affixed under the cover 23 to contact the user's foot. While the dimensions of the cut out 86 may vary, the cut out 86 should be sized to allow the cushion pad 27 sufficient room to contact the top of the user's foot.

The ankle extension 25 and the shin guard 12 are removably connected to one another with the use of a fastener 82 that allows the ankle extension 25 and the shin guard 12 to overlap with one another at a plurality of different heights. The fastener 82 serves as part of a connection interface that interlocks with a corresponding fastener at different connection points on the inner surface of the shin guard 12. In the illustrated embodiments, the fastener 82 includes loops. In this embodiment, as shown in FIG. 9A, the fastener 82 is a continuous section of loops that spans across substantially the entire upper half of the cover 23. As will be discussed with respect to FIG. 11 below, the shin guard 12 includes corresponding hooks that secure to the loops to removably fasten or bind the two components together. This allows for different portions of the ankle extension 25 to overlap with the shin guard 12, and hence, connect to the shin guard 12 at different heights. In further embodiments, as shown in FIG. 9B, the fastener 82 may be separate vertical strips of loops. In this aspect, the ankle extension 25 can connect to the shin guard 12 at various heights along the loops. As will be appreciated by those of ordinary skill in the art, the fastener 82 can be a variety of other shapes and sizes so long as the fastener 82 is strong enough to interlock with the corresponding fastener on the shin guard 12 during play and interlock at varying heights.

In another embodiment, the fastener 82 may include a plurality of snap fasteners that are vertically aligned at differing heights on the ankle extension 25. In this aspect, the ankle extension 25 may include a first portion of the snap fastener while the shin guard 12 may include a second portion of the snap fastener and vice versa. The second portion of the snap fastener may have a lip, for instance, a circular lip, under one disc that fits into a groove on the first portion to hold the two components together until an appropriate amount of force is applied. In still another embodiment, the fastener 82 may include a plurality of buttons that are vertically aligned at differing heights on the ankle extension 25. In this embodiment, the ankle extension 25 may include the buttons while the shin guard 12 may include corresponding loops or holes for fastening the button and vice versa. In another embodiment, the fastener 82 may be a plurality of magnets that are vertically aligned at differing heights on the ankle extension 25. In this embodiment, the ankle extension 25 may include one portion of the magnets while the shin guard 12 may include corresponding portions of the magnets. In yet another embodiment, the fastener 82 may be a slider mechanism. For example, the edges of the ankle extension 25 may be configured to slide upward and downward along grooves formed in the outer edges of the shin guard 12. The grooves may include one or more stopping points to secure the ankle extension 25 at differing heights.

FIGS. 10A and 10B are back views of the adjustable ankle extension 25 with the toe guard 10 attached thereto according to various embodiments. As shown in FIGS. 10A and 10B, the back portion of the ankle extension 25 includes the cushion pad 27, which is affixed to the cover 23. The toe guard 10, which has cushion pad 24 affixed thereto, includes a flexible band 88 that includes a band of flexible material configured to attach around the user's foot. The flexible material may be fabric, rubber, or a polymeric material. In one embodiment, the flexible band 88 is fastened or affixed to the toe guard 10.

In some embodiments, as shown in FIG. 10A, the toe guard 10 may be removably attached to the ankle extension 25. Similar to the adjustment mechanism described above, the toe guard 10 can be removably attached at different heights on the ankle extension 25. Indeed, the toe guard 10 and the ankle extension 25 are removably connected to one another with the use of a fastener that allows the toe guard 10 and the ankle extension 25 to overlap with one another at a plurality of different heights. The toe guard 10 includes a fastener 90 and the ankle extension 25 includes a corresponding fastener 91. In the illustrated embodiment, the fastener 90 and the corresponding fastener 91 are hook and loop fasteners. In this embodiment, as shown in FIG. 10A, the fastener 90 includes a vertical strip of loop material and the corresponding fastener 91 includes a vertical strip of corresponding hooks that secure to the loop material to removably fasten or bind the two components together. This allows for different portions of the toe guard 10 to overlap with the ankle extension 25 and, hence, connect to the ankle extension 25 at different heights. Not only does this connection mechanism allow for adjustability in the length of the toe guard 10, but it also provides a larger radius against the user's foot and ankle for better comfort. While the use of hook and loop fasteners have been exemplified in FIG. 10A, any of the fasteners discussed above with respect to the connection between the ankle extension 25 and the shin guard 12 can be used.

In further embodiments, as shown in FIG. 10B, the toe guard 10 may be affixed to the ankle extension 25. For instance, the toe guard 10 may be fixedly attached to the ankle extension 25 with stitching, sewing, threading, or other permanent means for attachment.

FIG. 11 shows the inner surface of the shin guard 12 to which the ankle extension 25 is configured to attach at different heights. As shown in FIG. 11, the inner surface of the shin guard 12 has a corresponding fastener 84 to which the fastener 82 on the ankle extension 25 can attach at different connection points. The corresponding fastener 84 is affixed to the shin guard 12. In the illustrated embodiment, the corresponding fastener 84 includes hooks that secure to the loop material on the ankle extension 25 to removably fasten the two components together such that the fastener 82 can attach at different heights along the corresponding fastener 84. However, as those skilled in the art will appreciate, the fastener 82 and the corresponding fastener 84 need not have identical shapes and sizes so long as the fastener 82 can connect to the corresponding fastener 84 at different heights.

The ability of the ankle extension 25 to attach to the shin guard 12 at varying heights allows for the user to customize the overall length of the leg guard 100. In one embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 0.50 inches. In another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 0.75 inches. In still another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 1 inch. In yet another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 1.25 inches. In another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 1.50 inches. In still another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by at least about 2 inches. In yet another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 by up to about 2.75 inches. In some embodiments, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 from about 0.50 inches to about 2.75 inches. For example, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 from about 0.75 inches to about 2 inches. In still another embodiment, the adjustment mechanism of the ankle extension 25 can lengthen the leg guard 100 from about 1 inch to about 2 inches.

FIG. 12 shows a back view of the leg guard 100 with the various cushion pads attached to the cover shells. The toe guard cushion pad 24, the ankle extension cushion pad 27, the shin guard cushion pad 28, the knee guard cushion pad 38, and the thigh guard cushion pad 42 are attached to their respective cover shells. This configuration provides the most comfortable protection against impacts and collisions, as the outer cover shell provides resistance to hard collisions while dissipating the impact force through the cushion pads. In one embodiment, the various cushion pads 24, 27, 28, 38, and 42 may be fixedly attached to their respective cover shells. For example, the cushion pads 24, 27, 28, 38, and 42 may be fixedly attached to the cover shells by stitching, such as continuous or discontinuous stitching generally around the perimeter of the cover shells. In this embodiment, with respect to the knee guard 14, the cover shell 36 may be attached to the cushion pad 38 with stitching around the front (kneecap) area of the cover shell 36 such that the side areas of the cover shell 36 corresponding to the left and right sides of the user's knee are not stitched or attached to the side areas of the cushion pad 38. In another embodiment, the cushion pads 24, 27, 28, 38, and 42 may be fixedly attached to the cover shells by a combination of rivets and stitching. In other embodiments, the cushion pads 24, 27, 28, 38, and 42 may be fixedly attached to the cover shells by any method known in the art, including one or more of adhesives, rivets, fasteners, stitches, or the like.

In further embodiments, the cushion pads 24, 27, 28, 38, and 42 may be removably attached to their respective cover shells. In this embodiment, the cushion pads 24, 27, 28, 38, and 42 may be removably attached to the cover shells by a hook and loop fastener. For instance, the cushion pads 24, 27, 28, 38, and 42 may include one portion of a hook and loop material and the cover shell may include a corresponding portion of the hook and loop material. In other embodiments, the cushion pads 24, 27, 28, 38, and 42 may be removably attached to the cover shells by snap fasteners, magnets, buttons, or any other removable attachment means.

For extra protection and support along the shin portion of the user's leg, the shin guard 12 may include additional padding. For instance, the cushion pad 28 may further include an inner shin pad 92 (as shown in FIG. 12). The inner shin pad 92 may be detachably and adjustably fastened to the inside of the cushion pad 28. For instance, the inner shin pad 92 may be removably attached to cushion pad 28 with hook-and-loop fasteners, such as Velcro®, snaps, clips, or the like. The inner shin pad 92 may be formed of open cell polyurethane, ethylene vinyl acetate (EVA) foam, memory foam, gel impact pads, and a variety of other padding materials that protect the shin from impact. In one embodiment, the inner shin pad 92 is formed of EVA foam. The inner shin pad 92 may also be formed from a combination of any of the above-discussed padding materials.

In some embodiments, the cushion pad 38 of the knee guard 14 may further include an inner knee pad 94 situated on the rear side of the knee guard 14. In this aspect, the shape of the inner knee pad 94 shares the shape of the knee guard 14 such that the inner knee pad 94 may be situated within the cover shell 36 of the knee guard 14. The inner knee pad 94 may be detachably and adjustably fastened to the inside of cushion pad 38. The inner knee pad 94 may be repositionable within the knee guard 14 to provide increased comfort and mobility for the user. For instance, the inner knee pad 94 may be removably attached to cushion pad 38 with hook-and-loop fasteners, such as Velcro®, snaps, clips, or the like. The inner knee pad 94 may also include a knee hole 96 designed to surround and support the kneecap portion of the knee, which provides additional stability to the joint when moving from the crouch stance to an upright position and vice versa.

The inner knee pad 94 and inner knee hole 96 may be made of any material that provides adequate support and shock absorbing properties. For example, the inner knee pad 94 may be made from open cell polyurethane, EVA foam, memory foam, gel impact pads, and a variety of other padding materials that protect the user's knee from impact. The inner knee pad 94 may also be made from a combination of any of the above-discussed padding materials. In another embodiment, the inner knee hole 96 may include Patella Plus™ d3_o™ material as padding, which may be covered with a silicone gel.

The cushion pads 24, 27, 28, 38, and 42 may be made of any material that allows for support and protection of the user's leg. In one embodiment, the cushion pads 24, 27, 28, 38, and 42 are formed of a compression molded foam, such as EVA. In other embodiments, the cushion pads 24, 27, 28, 38, and 42 may be formed of expanded polyurethane, cross-linked polyethylene, soft rubber foam, memory foam, gel padding, or any combination thereof. In some embodiments, the cushion pads 24, 27, 28, 38, and 42 may be encased in a thin, resilient covering of plastic material and the peripheral edges are covered by a plastic sewn-in-place binding. In another embodiment, the cushion pads 24, 27, 28, 38, and 42 may be coated with a microorganism-resisting and mildew-retarding treatment agent. The cushion pads 24, 27, 28, 38, and 42 may also include a plurality of air vents. In one embodiment, the air vents on the cushion pads 24, 27, 28, 38, and 42 may be in air communication with the plurality of air vents 34 on the cover shells for exhaust of air upon impact.

The cover shells of the present disclosure, for example, the toe guard cover shell 22, the shin guard cover shell 26, the knee guard cover shell 36, and the thigh guard cover shell 40, may be made of any material that allows for protection against impacts and collisions, for example, from a speeding ball. In one embodiment, the cover shells 22, 26, 36, and 40 are made of a rigid plastic or composite material. For example, the cover shells 22, 26, 36, and 40 are made of high-density polyethylene. In another embodiment, the cover shells 22, 26, 36, and 40 are made of fiberglass or carbon reinforced epoxy. In further embodiments, the cover shells 22, 26, 36, and 40 may be co-molded with a cushion pad such that the co-molded material is a combination of rigid and soft material. In this aspect, the selected material should be moldable such that the cover shells 22, 26, 36, and 40 may be curved to best match the curvature of the leg. Moldable materials also allow the user to squeeze and bend the cover shells to suitably wrap around their legs.

FIG. 13 shows a side view of a portion of the leg guard 100, specifically, the cover shell 36 and the cushion pad 38 of the knee guard 14 and the cover shell 26 and the cushion pad 28 of the shin guard 12. As shown in FIG. 13, the cushion pads 38 and 28 are positioned so that, when the leg guard 100 bends toward a crouching position, the cushion pad 38 overlaps with the cushion pad 28. The overlapping nature of the cushion pads 38, 28 creates an air pocket in between the cover shells 36, 26 and the cushion pads 38, 28 such that the cushion pads are offset from the cover shells (i.e., the cushion pads do not contact the cover shells). The air pocket provides additional shock absorbing properties for the user of the leg guard 100 upon impact of an object. Indeed, the air pocket helps suspend the cover shells 36, 26 away from the user's body so that the cover shells 36, 26 can deform into the air space. This, in turn, helps isolate the player's body from energy caused by direct impacts by absorbing and displacing unwanted energy on impact and reduces the severity of the impact against the cushion pads 38, 28 and the player's body.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.

The invention described and claimed herein is not to be limited in scope by the specific embodiments herein disclosed, since these embodiments are intended as illustrations of several aspects of the invention. Any equivalent embodiments are intended to be within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. All patents and patent applications cited in the foregoing text are expressly incorporated herein by reference in their entirety.

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