Patent Application
20110256346
The present system and methods relate to protective pads. More specifically, the present exemplary system and methods relate to protective pads configured to disperse the energy associated with an impact.
Protective shoulder pads and other sports related protective pads are worn by players in a number of contact sports, such as football, hockey, soccer, cricket, and lacrosse. Because of the physical nature of such sports, it is important for the protective gear to fit the players with the protective padding aligned with the intended areas on the players' bodies. Misaligned protective gear could jeopardize a player's safety. It is also important for the protective gear to fit comfortably. An uncomfortable fit could hinder a player's physical and mental performance.
Specifically, football shoulder pads are meant to protect athletes from injuries to their upper body. The focus of current shoulder pad design, in football for example, is impact dispersion.
The illustrated traditional shoulder pad assembly (20) may include a rigid upper shoulder pad (26) and a rigid lower shoulder pad (28) operatively connected to one another. For example, the upper shoulder pad (26) may be secured to the vest (22) atop the shoulder while the lower shoulder pad (28) is connected to the vest (22) by a strap. The lower shoulder pads may hang somewhat freely above the wearer's biceps, thus protecting the wearer while not hindering the wearer's freedom of movement. Additional examples of known traditional protective pads are shown in: U.S. Pat. No. 4,610,304; U.S. Pat. No. 4,985,931; U.S. Pat. No. 7,168,104; and U.S. Pat. No. 7,647,651.
Shoulder pads should not be overly heavy such that the player loses speed and energy nor overly bulky so as to limit the mobility of the player. Traditional athletic pad systems use a two piece system with a soft pad below a hard plastic shell. However, there are many different ways to effectively disperse impact, improve player safety, be lightweight, and allow for the player to remain mobile. By dispersing the energy of an impact more efficiently, a player will be able to play for longer periods of time due to reduced bodily injury and at higher levels due to increased mobility and confidence.
In one of many possible embodiments, the present exemplary protective pad includes a pad configuration for enhancing protection provided to athletes while reducing weight and improving mobility. Specifically, according to one exemplary embodiment, a protective pad configuration is provided that includes a corrugated energy dispersing plate disposed between at least one foam member, and in one embodiment, between an upper and a lower foam member. The corrugated energy dispersing plate provides stiffness along a first direction and flexibility in a second direction to enable pad design that maximizes both athlete protection and mobility.
According to another exemplary embodiment, the present exemplary protective pad includes a corrugated energy dispersing plate.
According to yet another exemplary embodiment, the present exemplary protective pad including a corrugated energy dispersing plate includes a plurality of holes configured to reduce overall weight while strengthening the structural integrity of the plate.
According to yet another exemplary embodiment, the present exemplary protective pad includes a living hinge that is configured to provide structural support to the protective pad in a first direction while enabling bending and mobility in a second direction.
According to one exemplary embodiment, a pad system includes a first foam member, a second foam member, and a structural member disposed between the first foam member and the second foam member, wherein the structural member assumes a substantially sinusoidal cross-sectional shape.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the structural member being a polymer sheet.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the first foam member and the second foam member each being one of a polyurethane foam or a SHOCKtec™ Air2Gel Foam.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the structural member being one of a polypropylene or a polycarbonate material.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the structural member being manufactured such that said sinusoidal cross-sectional shape has an average ratio of wavelength to height or amplitude (λ/H) of 2:1.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the sinusoidal cross-sectional shape being maintained in a single direction to form ridges on a top surface of the structural member.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the pad being configured to bend in a plane transverse to the ridges.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include the pad being positioned on an athletic shoulder pad assembly such that said ridges are oriented to mimic a natural movement of a player.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include a structural member having a sinusoidal cross-sectional shape exhibiting an average wavelength to amplitude ratio (λ/H) of 2:1.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include a structural member having a sinusoidal cross-sectional shape exhibiting an average wavelength to amplitude ratio (λ/H) ranging from approximately 0.5:1 to 4:1.
Yet another aspect of the disclosure may include any combination of the above-mentioned features and may further include a structural member having a cross-sectional shape exhibiting a varying wavelength to amplitude ratio throughout the structural member to predictably vary the bending characteristics of the protective pad.
The accompanying drawings illustrate various embodiments of the present system and method and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope thereof.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
The present specification describes a system and a method for forming and using an exemplary protective pad. According to one exemplary embodiment, a pad configuration is provided for enhancing impact protection to athletes or any user wearing the pad while reducing weight and improving mobility. Specifically, according to one exemplary embodiment, a protective pad configuration is provided that includes a corrugated energy dispersing plate disposed between an upper and a lower foam member. According to one exemplary embodiment, the protective pad configuration is then encased in an encasement member. The corrugated energy dispersing plate disposed between the upper and lower foam members provides stiffness along a first direction and flexibility in a second direction to enable pad design that maximizes both athlete protection and mobility.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present systems and methods. It will be apparent, however, to one skilled in the art that the present systems and methods may be practiced without these specific details. Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
As used in the present specification and in the appended claims, the term “sinusoidal” or “sinusoidal wave” shall be interpreted broadly to include any member or feature having a pattern that is similar to the curve of a sine function having crests and troughs. According to the present exemplary disclosure, a member having a “sinusoidal” or “sinusoidal wave” can exhibit varying amplitudes and frequency throughout the member. Additionally, the shape of the repeating waves may assume any number of shape profiles including, but in no way limited to, curves, triangles, squared corners, stepped waveforms, and the like.
Additionally, as used in the present specification and in the appended claims, the term “wavelength to amplitude ratio” (λ/H) shall be interpreted broadly as defining the ratio of the wavelength or period of the sinusoidal wave in relation to the amplitude value of the corresponding wavelength. Similarly, the term “average wavelength to amplitude ratio” shall be interpreted broadly as a ratio of the average wavelength or period of the sinusoidal wave in relation to the average amplitude value of the corresponding wavelength.
As mentioned, the present exemplary system and method provide pads to disperse impact energy so that there is a low transfer of the impact energy to the wearer. According to one exemplary embodiment, the present exemplary system may be incorporated into any number of impact absorption members including, but in no way limited to sports related pads, shoes, helmets, industrial protection equipment, combat gear, and the like. For consistency and ease of explanation only, the present protective pad system and configuration will be described in the context of a football pad system. However, it will be readily understood that the present exemplary protective pad configuration may be incorporated into any number of protective pad applications including, but in no way limited to, hockey pads, cricket pads, baseball pads, lacrosse pads, gloves, helmets, industrial protective clothing, shoes, riot gear, and the like.
Traditional football based shoulder pad systems currently on the market, similar to those illustrated in
As noted above, the corrugated member (210) is disposed adjacent to at least one foam member, and, according to one exemplary embodiment, between a foam upper member (220) and a foam lower member (230). According to one exemplary embodiment, the foam upper member (220) and the foam lower member (230) may be formed of similar or disparate foam materials to vary both energy absorption and user feel. As used in the present specification, the term “foam” shall be interpreted as any substance that is formed by a trapping of gas bubbles in a liquid or a solid, and shall include open and closed cell configurations. According to one exemplary embodiment, a polyurethane foam may be used to form the foam upper member (220) and the foam lower member (230). Alternatively, any number of or combinations of foams may be used to form the foam upper member (220) and a foam lower member (230) including, but in no way limited to as quantum foam, polyurethane foam (foam rubber), XPS foam, Polystyrene, phenolic, Syntactic foam, or any other manufactured foam. According to one exemplary embodiment, the foam upper member (220) and the foam lower member (230) are formed out of commercially available SHOCKtec™ Air2Gel Foam for enhanced impact dispersion. The present exemplary systems and methods were initially implemented using polyurethane foam manufactured by Utah Foam Products (Nephi, Utah) having varying densities and stiffness.
According to the present exemplary system and method, the foam upper member (220) and the foam lower member (230) may be formed around the corrugated member (210) via any number of foam forming methods including, but in no way limited to foaming the foam members in place around the corrugated member (210), pressing the foam around the corrugated member, extruding the foam to mate with the corrugated member, adhering the foam around the corrugated member, mechanically fastening the foam to the corrugated member, shaving or otherwise shaping the foam to mate with the corrugated member, or otherwise forming the foam as is known in the art.
Additionally, as noted above, the exemplary corrugated foam cell concept (200) includes a corrugated member (210) formed of a structural material disposed between the foam upper member (220) and the foam lower member (230). According to this exemplary embodiment, the corrugated member (210) may be formed of any number of thermoplastics or other bendable structural materials. While the present exemplary system is described in the context of the plate being formed of polypropylene or polycarbonate, any number of structural materials may be used to form the corrugated plate including, but in no way limited to polypropylene, polycarbonate including Lexan® from SABIC Innovative Plastics, polyamides such as nylon, and the like. According to one embodiment, Lexan® from SABIC Innovative Plastics is used to form the corrugated member (210) due to its fracture resistance and relatively large modulus of elasticity.
According to one exemplary embodiment, the corrugated member (210) is formed to exhibit a sinusoidal cross-sectional shape. As noted above, while the present exemplary system is described as having a corrugated member (210) with a repeating curved pattern that is similar to the curve of a sine function having crests and troughs. According to the present exemplary system and method, the corrugated member (210) the corrugations of the corrugated member (210) may assume any number of shape profiles to form the alternating grooves and ridges including, but in no way limited to, curves, triangles, substantially squared corners, stepped wave forms, and the like.
According to one exemplary embodiment, the use of a corrugated member (210) having the wave profile (300) illustrated in
According to one exemplary embodiment, the corrugated member (210) exhibits a nearly linear relationship between the applied force (F) and the deformation rates of the corrugated member for small deflections (approximately less than 35% of the original height and 20% of the original width). This linear relationship between the applied force (F) and the deformation rates allows for energy storage in the corrugated member (210) so that less of the impact force (F) is directly and immediately transferred to the body of the user as in the case of a flat plate.
In addition to dispersing energy imparted from an impact, the present exemplary pad plate system simultaneously provides selective support and mobility to the athlete incorporating the system. Specifically, according to one exemplary embodiment, the wave profile (300) of the plate provides a high level of stiffness in the direction parallel with the ridges, while providing flexibility in the direction transverse to the ridges of the sinusoidal plate. That is, the present exemplary configuration allows the plate to be bent and rotated about an axis that is perpendicular with the ridges. According to one exemplary embodiment, as illustrated below in
While the exemplary corrugated member illustrated in
Furthermore, as illustrated in
In addition to the above-mentioned pad configurations, modifications may be made to the underlying plate system to vary the weight and characteristics of the resulting pad system. According to one exemplary embodiment, the
According to one alternative embodiment, the foam may be replaced with another dampening material. According to this exemplary embodiment, one or more of the foam upper (220) and a foam lower member (230) may be replaced by or further include additional dampening materials including, but in no way limited to gels, fluids, particulates, and the like.
Furthermore,
According to yet another alternative embodiment, the present exemplary system and method may be incorporated into any number of articles worn or used by humans. According to one embodiment, the present system and methods may be incorporated into a shoe. The shoe base plays a critical role in comfort, protection, and athletic performance. The mechanical characteristics of a shoe base are represented by its elastic stiffness (providing energy return), energy absorption, and energy dispersion. These mechanical characteristics are obtained through a combination of material selection and geometric design. Previous shoe base implementations have utilized a wide variety of materials (synthetic polymers, foams, leather, natural rubbers, etc.) either by themselves, layered to form a composite, or integrated to provide a synergistic effect. These materials have been combined with a wide variety of geometric inclusions and/or voids to obtain a customized stiffness, energy absorption, and/or energy dispersion to provide a potential benefit for the wearer.
According to the present exemplary alternative embodiment, the present exemplary system and method is incorporated into a shoe to provide a particular combination of material properties and geometric features that result in increased energy dispersion and customized elastic stiffness when compared to traditional shoe systems. With a suitable choice of viscoelastic material, the system can also provide customized energy absorption.
As noted above, a corrugated energy dispersing plate is interposed between layers of foam, polymer, leather, or other material such that as energy is imparted to the plate, it is dispersed both through the plate and parallel to the plane of the plate. This plate may or may not contain a plurality of holes configured to reduce weight while strengthening the structural integrity of the plate. The geometry of the corrugation provides for distinct elastic stiffness in directions parallel to the centerlines of the corrugation patterns as compared to directions perpendicular to the centerlines of the corrugation patterns. This feature of the corrugation geometry can provide enhanced flexibility in one preferred direction while providing increased stiffness in other directions and is desirable in a shoe base.
As illustrated noted above, choice of corrugation wavelength (spacing) and amplitude (height), combined with choices of the materials allow customization of elastic stiffness, energy dispersion, and energy absorption of the system.
While the present protective pad system has been described in the context of protective pads for athletic events, the present exemplary system and method may also be applied to any structure or article of clothing configured to provide enhanced safety to the user while maintaining flexibility and reducing weight. By way of example, the present exemplary protective pad system may be incorporated in to any number of sports pads, helmets, toe guards, shoe tops, hard hats, and other construction safety equipment.
According to one exemplary embodiment, the present exemplary system and method may be incorporated into a football and/or baseball helmet to prevent damage to a user's brain, such as by a concussion. As noted above, the use of the present exemplary system including both the foam upper member (220) and the foam lower member (230) will help prevent concussions in a number of ways. First, if incorporated into a helmet and/or pads, the impact between the equipment incorporating the present exemplary system will have a substantially soft outer surface that will not impart as much instantaneous force as a rigid member striking a rigid member—such as traditional helmet striking another helmet or a traditional shoulder pad. Furthermore, the player using the helmet incorporating the present exemplary system will have less of an instantaneous force imparted from the collision as the energy is dispersed throughout the helmet. According one exemplary embodiment, the corrugated member (210) disposed in a helmet embodiment may assume more of an egg carton shape, free of directional ridges, in order to disperse any number of impacts thereto without imparting a directional rigidity.
In conclusion, the present exemplary system and method provides a pad configuration for enhancing protection provided to athletes while reducing weight and improving mobility. Specifically, according to one exemplary embodiment, a protective pad configuration is provided that includes a corrugated energy dispersing plate associated with at least one dampening member. Specifically, according to one exemplary embodiment, the energy dispersing plate is disposed between an upper and a lower foam member. The corrugated energy dispersing plate provides stiffness along a first direction and flexibility in a second direction to enable pad design that maximizes both athlete protection and mobility.
The preceding description has been presented only to illustrate and describe embodiments of the present exemplary pad structure and system. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
The present application claims the priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/319,830, filed Mar. 31, 2010 titled “Protective Pad,” the contents of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61319830 | Mar 2010 | US |
