Protective gear, such as chest protectors, helmets, masks, and shin guards, has long been used to protect baseball and softball catchers from pitched balls and balls deflected or “foul-tipped” off of bats. Chest protectors are typically made from a relatively flexible material, and generally have energy-absorbing foam or other energy-absorbing padding sewn or stitched into the flexible material for absorbing the impact of a pitched or tipped baseball or softball. Straps are commonly attached to the chest protector for securing the chest protector around the back of the catcher.
Chest protectors often include energy-absorbing padding that is stacked asymmetrically to absorb impact particularly well from objects striking the front-facing surface of the chest protector. The energy-absorbing padding is typically a closed-cell foam material capable of withstanding and absorbing significant impacts from a ball. As a result, the wearer is protected, and the ball is prevented from deflecting or bouncing a great distance from the wearer due to the energy-absorbing characteristics. An outer layer of fabric is typically stitched to the energy-absorbing padding, while an inner layer of fabric is typically stitched or compression-molded to the energy-absorbing padding.
A reversible chest protector includes internal padding configured to absorb impacts against both the front and rear-facing surfaces of the chest protector. The chest protector includes inner and outer layers of fabric that are molded to an internal foam core. The foam core optionally includes outer layers of closed-cell foam molded to the fabric layers, and an internal layer of open-cell foam molded to the closed-cell foam layers, such that the padding layup is symmetrical. Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.
In the drawings, wherein the same reference number indicates the same element throughout the views:
Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments.
The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.
Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of items in the list.
Turning now in detail to the drawings, as shown in
As shown in
Because the outer fabric layers 22 are compression-molded to the outer foam core elements 20—and each outer surface of the protector 10 is therefore relatively rigid and capable of dissipating energy—the inner foam core element 18 does not need to absorb as much energy as a traditional foam core to dissipate the same amount of impact energy. Thus, in one embodiment, the inner foam core element 18 may be an open-cell foam, such as polyurethane foam. This inner core material preferably has a density of approximately 22 to 28 kg/m3. Such a foam is typically much less expensive than a traditional closed cell, energy-absorbing foam. In this embodiment, the two outer foam core elements 20 may each be a closed-cell, energy-absorbing foam, such as a cross-linked polyethylene. This outer core material preferably has a density of approximately 100 to 110 kg/m3.
The inner foam core element 18 may be substantially thicker than the two outer foam core elements 20 combined, since the compression-molding process provides rigid, energy-dissipating outer surfaces. In one embodiment, the inner foam core element 18 has a thickness of approximately 14.5 mm to 15.5 mm, while each outer foam core element 20 has a thickness of approximately 3.5 mm to 4.5 mm.
The compression-molded chest protector 10 has the surprising ability to “deaden” a ball upon impact, such that the ball does not deflect or bounce far from the catcher. It was initially expected that the ball would bounce a great distance off of the protector 10 due to the relative rigidity of the outer surfaces. The compression-molded outer surfaces, however, effectively dissipate energy over a large area such that ball deflections are minimal. Thus, the compression-molded chest protector 10 provides not only reversibility and sufficient energy absorption to protect the wearer, but it also sufficiently deadens a ball upon impact such that the ball does not end up a great distance from the catcher.
As shown in
Receiving elements 32 are preferably attached, directly or indirectly (e.g., via straps), to lower side regions and to an upper region of the chest protector 10, for receiving the attachment elements 30. Alternatively, the attachment elements 30 may be attached to the lower side regions and the upper region of the chest protector, while the receiving elements 32 may be attached to the free ends of the adjustable straps 28. A wearer may don the chest protector 10 by pulling it over his or her head, such that the shoulder-protecting regions 16 rest on the wearer's shoulders. The wearer may then insert the attachment elements 30 into the corresponding receiving elements 32. If necessary, the wearer (or another person) may tighten or loosen the adjustable straps 28 to provide a proper, secure fit. Any other suitable connecting mechanisms or fastening elements that allow for reversibility of the chest protector 10 may be used to secure the chest protector 10 to the wearer.
Additional padding may optionally be permanently or removably attached to the chest protector 10. As shown in
The reversible chest protector 10 may be assembled by cutting the various foam and fabric layers to a desired size, positioning the outer foam cores 20 over the inner foam core 18, and positioning the'fabric layers 22 over the outer foam cores 20 to form a chest protector pre-form structure. The pre-form structure may then be placed into a molding apparatus, such as a compression-molding apparatus. The chest protector pre-form is heated at a temperature of approximately 140° C. to 160° C. for approximately five to seven minutes to form the main body of the chest protector 10. The main body is then allowed to cool, after which it is removed from the molding apparatus.
The receiving elements 32 (or fasteners 30) may then be sewed, or attached via straps, to the side and upper regions of the chest protector 10. Adjustable straps 28 may then be attached to the receiving elements via the fasteners 30 at the distal ends of the straps 28 (or via receiving elements 32 at the distal ends of the straps 28, if the fasteners 30 are instead included on the main body of the chest protector 10).
To reverse the chest protector 10 from an outwardly facing home-side to an outwardly facing away-side, for example, a user may disconnect one or more of the fasteners 30, move the straps 28 to the other side of the protector 10, then reattach the fasteners 30 to the receiving elements 32. For example, a user may disconnect the side-fasteners 30 from the side-receiving elements 32, flip the upper receiving element 32 over to the other side of the protector 10, then re-insert the fasteners 30 into the receiving elements 32. The chest protector 10 may alternatively be reversed in any other suitable manner. For example, the adjustable straps 28 may be detached completely from the protector 10, and then reattached to the other side of the protector.
Any of the above-described embodiments may be used alone or in combination with one another. Furthermore, the reversible chest protector may include additional features not described herein. While several embodiments have been shown and described, various changes and substitutions may of course be made, without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents.