U.S. patent application number 10/712825 was filed with the patent office on 2004-07-08 for protective pad apparatus having air ventilating and restrictive radiant heat transfer/absorption aspects.
Invention is credited to Monica, Mark D..
Application Number | 20040128748 10/712825 |
Document ID | / |
Family ID | 32685498 |
Filed Date | 2004-07-08 |
United States Patent
Application |
20040128748 |
Kind Code |
A1 |
Monica, Mark D. |
July 8, 2004 |
Protective pad apparatus having air ventilating and restrictive
radiant heat transfer/absorption aspects
Abstract
A protective pad apparatus having a shell assembly and an impact
absorbing cushioning pad assembly lining the inner surfaces of the
shell assembly. The cushioning pad assembly may include a plurality
of discrete cushioning pads wherein at least one of the pads
includes a laminate having at least one impact absorbing layer
which allows air to flow therethrough. The shell assembly may
include a plurality of discrete protector panels. At least one of
the protector panels may include one or more raised
embossments.
Inventors: |
Monica, Mark D.; (Madison,
NJ) |
Correspondence
Address: |
DUANE MORRIS LLP
100 COLLEGE ROAD WEST, SUITE 100
PRINCETON
NJ
08540-6604
US
|
Family ID: |
32685498 |
Appl. No.: |
10/712825 |
Filed: |
November 13, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60437952 |
Jan 3, 2003 |
|
|
|
Current U.S.
Class: |
2/462 |
Current CPC
Class: |
A63B 71/12 20130101;
A63B 2071/1208 20130101 |
Class at
Publication: |
002/462 |
International
Class: |
A41D 027/26 |
Claims
What is claimed is:
1. A protective pad apparatus for protecting a user's chest, back,
and shoulders, the apparatus comprising: a shell assembly; and a
cushioning pad fastened to the shell assembly, the cushioning pad
comprising a laminate having at least one impact absorbing layer
which allows air to flow therethrough.
2. The protective pad apparatus according to claim 1, wherein the
laminate further comprises an outer fabric layer.
3. The protective pad apparatus according to claim 2, wherein the
outer fabric layer allows air to flow therethrough.
4. The protective pad apparatus according to claim 2, wherein the
outer fabric layer functions as a radiant heat barrier.
5. The protective pad apparatus according to claim 4, wherein the
outer fabric layer comprises an aluminized polyester.
6. The protective pad apparatus according to claim 2, wherein the
laminate further comprises an inner fabric layer.
7. The protective pad apparatus according to claim 6, wherein the
inner fabric layer allows air to flow therethrough.
8. The protective pad apparatus according to claim 1, wherein the
laminate further comprises an inner fabric layer.
9. The protective pad apparatus according to claim 8, wherein the
inner fabric layer allows air to flow therethrough.
10. A protective pad apparatus for protecting a user's chest, back,
and shoulders, the apparatus comprising: a shell assembly; and a
cushioning pad fastened to the shell assembly, the cushioning pad
comprising a laminate having at least two impact absorbing layers,
at least one of the at least two impact absorbing layers allowing
air to flow therethrough.
11. The protective pad apparatus according to claim 10, wherein one
of the at least two impact absorbing layers comprises at least one
substrate of reticulated foam.
12. The protective pad apparatus according to claim 11, wherein the
at least one substrate of reticulated foam has a black color.
13. The protective pad apparatus according to claim 11, wherein the
other one of the at least two impact absorbing layers comprises at
least one substrate of foam beads that are fused together only
where the beads contact one another.
14. The protective pad apparatus according to claim 13, wherein the
laminate further comprises an outer fabric layer, the outer fabric
layer allowing air to flow therethrough.
15. The protective pad apparatus according to claim 14, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
16. The protective pad apparatus according to claim 13, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
17. The protective pad apparatus according to claim 10, wherein the
laminate further comprises an outer fabric layer, the outer fabric
layer allowing air to flow therethrough.
18. The protective pad apparatus according to claim 17, wherein the
outer fabric layer faces toward the shell assembly and comprises a
light color.
19. The protective pad apparatus according to claim 10, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
20. The protective pad apparatus according to claim 19, wherein the
inner fabric layer faces away from the shell assembly and comprises
a dark color.
21. The protective pad apparatus according to claim 10, wherein one
of the at least two impact absorbing layers comprises at least one
substrate of foam beads which are fused together only where the
beads contact one another.
22. The protective pad apparatus according to claim 10, wherein the
laminate further comprises a radiant hear barrier layer.
23. The protective pad apparatus according to claim 21, wherein the
radiant heat barrier layer comprises an aluminized polyester.
24. A protective pad apparatus for protecting a user's chest, back,
and shoulders, the apparatus comprising: a shell assembly; and a
cushioning pad fastened to the shell assembly, the cushioning pad
comprising a laminate having at least three impact absorbing
layers, at least one of the three impact absorbing layers allowing
air to flow therethrough.
25. The protective pad apparatus according to claim 24, wherein one
of the at least three impact absorbing layers comprises at least
one substrate of reticulated foam.
26. The protective pad apparatus according to claim 25, wherein the
at least one substrate of reticulated foam has a black color.
27. The protective pad apparatus according to claim 25, wherein a
second one of the at least three impact absorbing layers comprises
at least one substrate of foam beads which are fused together only
where the beads contact one another.
28. The protective pad apparatus according to claim 27, wherein a
third one of the at least three impact absorbing layers comprises
at least one substrate of visco-elastic polymer.
29. The protective pad apparatus according to claim 28, wherein the
at least one substrate of visco-elastic polymer includes at least
one air ventilation aperture.
30. The protective pad apparatus according to claim 28, wherein the
laminate further comprises an outer fabric layer, the outer fabric
layer allowing air to flow therethrough.
31. The protective pad apparatus according to claim 30, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
32. The protective pad apparatus according to claim 28, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
33. The protective pad apparatus according to claim 24, wherein one
of the at least three impact absorbing layers comprises at least
one substrate of foam beads which are fused together only where the
beads contact one another.
34. The protective pad apparatus according to claim 24, wherein one
of the at least three impact absorbing layers comprises at least
one substrate of visco-elastic polymer.
35. The protective pad apparatus according to claim 34, wherein the
at least one substrate of visco-elastic polymer includes at least
one air ventilation aperture.
36. The protective pad apparatus according to claim 24, wherein the
laminate further comprises a radiant hear barrier layer.
37. The protective pad apparatus according to claim 36, wherein the
radiant heat barrier layer comprises an aluminized polyester.
38. The protective pad apparatus according to claim 24, wherein the
laminate further comprises an outer fabric layer, the outer fabric
layer allowing air to flow therethrough.
39. The protective pad apparatus according to claim 38, wherein the
outer fabric layer faces toward the shell assembly and comprises a
light color.
40. The protective pad apparatus according to claim 24, wherein the
laminate further comprises an inner fabric layer, the inner fabric
layer allowing air to flow therethrough.
41. The protective pad apparatus according to claim 40, wherein the
inner fabric layer faces away from the shell assembly and comprises
a dark color.
42. The protective pad apparatus according to claim 24, further
comprising at least a second cushioning pad detachably fastened to
an inner surface of the cushioning pad, the at least second
cushioning pad comprising a laminate having at least one impact
absorbing layer which allows air to flow therethrough.
43. The protective pad apparatus according to claim 42, wherein the
laminate of the at least second cushioning pad further comprises
outer and inner fabric layers.
44. The protective pad apparatus according to claim 43, wherein the
outer and inner fabric layers of the laminate of the at least
second cushioning pad each allow air to flow therethrough.
45. The protective pad apparatus according to claim 44, wherein the
outer fabric layer of the laminate of the at least second
cushioning pad faces toward the inner surface of the cushioning pad
and comprises a light color and the inner fabric layer of the
laminate of the at least second cushioning pad faces away from the
inner surface of the cushioning pad and comprises a dark color.
46. The protective pad apparatus according to claim 1, wherein the
cushioning pad comprises one of a plurality of discrete cushioning
pads forming a cushioning pad assembly.
47. The protective pad apparatus according to claim 10, wherein the
cushioning pad comprises one of a plurality of discrete cushioning
pads forming a cushioning pad assembly.
48. The protective pad apparatus according to claim 24, wherein the
cushioning pad comprises one of a plurality of discrete cushioning
pads forming a cushioning pad assembly.
49. The protective pad apparatus according to claim 1, wherein the
shell assembly comprises a plurality of discrete protector
panels.
50. The protective pad apparatus according to claim 10, wherein the
shell assembly comprises a plurality of discrete protector
panels.
51. The protective pad apparatus according to claim 24, wherein the
shell assembly comprises a plurality of discrete protector
panels.
52. The protective pad apparatus according to claim 1, wherein the
cushioning pad is fastened to the shell assembly with at least one
snap fastener.
53. The protective pad apparatus according to claim 10, wherein the
cushioning pad is fastened to the shell assembly with at least one
snap fastener.
54. The protective pad apparatus according to claim 24, wherein the
cushioning pad is fastened to the shell assembly with at least one
snap fastener.
55. The protective pad apparatus according to claim 1, wherein
shell assembly includes first and second halves.
56. The protective pad apparatus according to claim 55, wherein the
first and second halves are connected by a first protector
plate.
57. The protective pad apparatus according to claim 56, wherein the
first protector plate allows the first and second halves of the
shell assembly to move relative to one another.
58. The protective pad apparatus according to claim 56, wherein the
first and second halves are further connected by a second protector
plate.
59. The protective pad apparatus according to claim 58, wherein the
protector plates allow the first and second halves of the shell
assembly to move relative to one another.
60. The protective pad apparatus according to claim 55, wherein the
first and second halves of the shell assembly are connected to one
another in a manner which allows the halves to move relative to one
another.
61. The protective pad apparatus according to claim 49, wherein
shell assembly includes first and second halves.
62. The protective pad apparatus according to claim 61, wherein the
first and second halves are connected by a first protector
plate.
63. The protective pad apparatus according to claim 62, wherein the
first protector plate allows the first and second halves of the
shell assembly to move relative to one another.
64. The protective pad apparatus according to claim 62, wherein the
first and second halves are further connected by a second protector
plate.
65. The protective pad apparatus according to claim 64, wherein the
protector plates allow the first and second halves of the shell
assembly to move relative to one another.
66. The protective pad apparatus according to claim 61, wherein the
first and second halves of the shell assembly are connected to one
another in a manner which allows the halves to move relative to one
another.
67. The protective pad apparatus according to claim 1, further
comprising a belt strap system for securing the apparatus to a
user, the belt strap system comprising at least one cushioning pad
comprising a laminate having at least one impact absorbing layer
which allows air to flow therethrough.
68. The protective pad apparatus according to claim 1, wherein the
shell assembly includes a plurality of raised embossments.
69. The protective pad apparatus according to claim 49, wherein at
least one of the protector panels includes at least one raised
embossment.
70. The protective pad apparatus according to claim 49, wherein the
protector panels comprise at least one chest protector panel that
includes at least one raised embossment.
71. The protective pad apparatus according to claim 49, wherein the
protector panels comprise at least one back protector panel that
includes at least one raised embossment.
72. The protective pad apparatus according to claim 49, wherein the
protector panels comprise at least one inner shoulder protector
panel that includes at least one raised embossment.
73. The protective pad apparatus according to claim 1, wherein the
shell assembly comprises a pearlized white metallic color.
74. The protective pad apparatus according to claim 1, wherein the
shell assembly comprises a plurality of ventilation holes.
75. The protective pad apparatus according to claim 1, further
comprising at least one spring element for strengthening an inner
shoulder portion of the shell assembly.
76. The protective pad apparatus according to claim 75, wherein the
at least one spring element is fastened to the shell assembly with
fasteners that allow the at least one spring element to swing
laterally.
77. The protective pad apparatus according to claim 75, wherein the
at least one spring element includes an impact absorbing layer.
78. The protective pad apparatus according to claim 49, further
comprising at least one spring element for strengthening an inner
shoulder portion of the shell assembly.
79. The protective pad apparatus according to claim 78, wherein the
at least one spring element is fastened to the shell assembly with
fasteners that allow the at least one spring element to swing
laterally.
80. The protective pad apparatus according to claim 78, wherein the
at least one spring element includes an impact absorbing layer.
81. The protective pad apparatus according to claim 1, wherein the
shell assembly includes a lower shoulder panel fastened to an inner
shoulder area by two straps that cross one another.
82. The protective pad apparatus according to claim 49, wherein the
protector panels comprise a lower shoulder protector panel and an
inner shoulder protector panel, the lower shoulder protector panel
fastened to the inner shoulder protector panel by two straps that
cross one another.
83. The protective pad apparatus according to claim 49, wherein at
least one of the protector panels comprises a plurality of
ventilation holes.
84. The protective pad apparatus according to claim 49, wherein
each of the protector panels has at least one of a predetermined
size and a predetermined shape and wherein each of the protector
panels can be individually replaced with a protector panel having
one of at least a different predetermined size and a different
predetermined shape.
85. The protective pad apparatus according to claim 49, wherein the
cushioning pad comprises one of a plurality of discrete cushioning
pads forming a cushioning pad assembly.
86. The protective pad apparatus according to claim 85, wherein
each of the protector panels having at least one of a predetermined
size and a predetermined shape and each of the protector panels
being individually replaceable with a protector panel having at
least one of a different predetermined size and a different
predetermined shape.
87. The protective pad apparatus according to claim 86, wherein
each of the cushioning pads having a predetermined size and a
predetermined shape and each of the cushioning pads being
individually replaceable with a cushioning pad having at least one
of a different predetermined size and a different predetermined
shape.
88. The protective pad apparatus according to claim 85, wherein
each of the cushioning pads having a predetermined size and a
predetermined shape and each of the cushioning pads being
individually replaceable with a cushioning pad having at least one
of a different predetermined size and a different predetermined
shape.
89. The protective pad apparatus according to claim 1, wherein the
cushioning pad comprising one of a plurality of discrete cushioning
pads forming a cushioning pad assembly, each of the cushioning pads
having a predetermined size and a predetermined shape and each of
the cushioning pads being individually replaceable with a
cushioning pad having at least one of a different predetermined
size and a different predetermined shape.
90. A cushioning pad for use with a protective pad apparatus that
protects a user's chest, back, and shoulders, the cushioning pad
comprising: a laminate having at least one impact absorbing layer
that allows air to flow therethrough.
91. The cushioning pad according to claim 90, wherein the at least
one impact absorbing layer comprises at least one substrate of
reticulated foam.
92. The cushioning pad according to claim 91, wherein the at least
one substrate of reticulated foam has a black color.
93. The cushioning pad according to claim 90, wherein the at least
one impact absorbing layer comprises at least one substrate of foam
beads which are fused together only where the beads contact one
another.
94. The cushioning pad according to claim 90, wherein the at least
one impact absorbing layer comprises at least one substrate of
visco-elastic polymer.
95. The cushioning pad according to claim 94, wherein the at least
one substrate of visco-elastic polymer includes at least one air
ventilation aperture.
96. The cushioning pad according to claim 90, wherein the laminate
further comprises at least one substrate of visco-elastic
polymer.
97. The cushioning pad according to claim 90, wherein the laminate
further comprises an outer fabric layer, the outer fabric layer
allowing air to flow therethrough.
98. The cushioning pad according to claim 97, wherein the laminate
further comprises an inner fabric layer, the inner fabric layer
allowing air to flow therethrough.
99. The cushioning pad according to claim 90, wherein the laminate
further comprises an inner fabric layer, the inner fabric layer
allowing air to flow therethrough.
100. The cushioning pad according to claim 90, wherein the laminate
further comprises a radiant hear barrier layer.
101. The cushioning pad according to claim 100, wherein the radiant
heat barrier layer comprises an aluminized polyester.
102. The cushioning pad according to claim 90, wherein the at least
one impact absorbing layer comprises two impact absorbing layers,
the two impact absorbing layers including at least one impact
absorbing layer comprises at least one substrate of reticulated
foam and at least one substrate of foam beads which are fused
together only where the beads contact one another.
103. The cushioning pad according to claim 102, wherein the
laminate further comprises outer and inner fabric layers, the outer
and inner fabric layers each allowing air to flow therethrough.
104. The cushioning pad according to claim 102, wherein the
laminate further comprises a radiant hear barrier layer.
105. The cushioning pad according to claim 102, wherein the
laminate further comprises a third impact absorbing layer, the
third impact absorbing layer including at least one substrate of
visco-elastic polymer.
106. The cushioning pad according to claim 105, wherein the at
least one substrate of visco-elastic polymer includes at least one
air ventilation aperture.
107. The cushioning pad according to claim 102, wherein the
laminate further comprises at least one substrate of visco-elastic
polymer.
108. The cushioning pad according to claim 107, wherein the at
least one substrate of visco-elastic polymer includes at least one
air ventilation aperture.
109. The cushioning pad according to claim 97, wherein the outer
fabric layer faces toward the shell assembly and comprises a light
color.
110. The cushioning pad according to claim 99, wherein the inner
fabric layer faces away from the shell assembly and comprises a
dark color.
111. The cushioning pad according to claim 90 in combination with
at least a second cushioning pad detachably fastened to an inner
surface of the cushioning pad, the at least second cushioning pad
comprising a laminate having at least one impact absorbing layer
which allows air to flow therethrough.
112. A cushioning pad assembly for use with a protective pad
apparatus that protects a user's chest, back, and shoulders, the
cushioning pad assembly comprising a plurality of discrete
cushioning pads, at least one of the plurality of discrete
cushioning pads comprising a laminate having at least one impact
absorbing layer that allows air to flow therethrough.
113. The cushioning pad assembly according to claim 113, wherein
the at least one impact absorbing layer comprises at least one
substrate of reticulated foam.
114. The cushioning pad assembly according to claim 114, wherein
the at least one substrate of reticulated foam has a black
color.
115. The cushioning pad assembly according to claim 113, wherein
the at least one impact absorbing layer comprises at least one
substrate of foam beads which are fused together only where the
beads contact one another.
116. The cushioning pad assembly according to claim 113, wherein
the at least one impact absorbing layer comprises at least one
substrate of visco-elastic polymer.
117. The cushioning pad assembly according to claim 117, wherein
the at least one substrate of visco-elastic polymer includes at
least one air ventilation aperture.
118. The cushioning pad assembly according to claim 113, wherein
the laminate further comprises at least one substrate of
visco-elastic polymer.
119. The cushioning pad assembly according to claim 113, wherein
the laminate further comprises an outer fabric layer, the outer
fabric layer allowing air to flow therethrough.
120. The cushioning pad assembly according to claim 120, wherein
the laminate further comprises an inner fabric layer, the inner
fabric layer allowing air to flow therethrough.
121. The cushioning pad assembly according to claim 113, wherein
the laminate further comprises an inner fabric layer, the inner
fabric layer allowing air to flow therethrough.
122. The cushioning pad assembly according to claim 113, wherein
the laminate further comprises a radiant hear barrier layer.
123. The cushioning pad assembly according to claim 123, wherein
the radiant heat barrier layer comprises an aluminized
polyester.
124. The cushioning pad assembly according to claim 113, wherein
the at least one impact absorbing layer comprises two impact
absorbing layers, the two impact absorbing layers including at
least one impact absorbing layer comprises at least one substrate
of reticulated foam and at least one substrate of foam beads which
are fused together only where the beads contact one another.
125. The cushioning pad assembly according to claim 125, wherein
the laminate further comprises outer and inner fabric layers, the
outer and inner fabric layers each allowing air to flow
therethrough.
126. The cushioning pad assembly according to claim 125, wherein
the laminate further comprises a radiant hear barrier layer.
127. The cushioning pad assembly according to claim 125, wherein
the laminate further comprises a third impact absorbing layer, the
third impact absorbing layer including at least one substrate of
visco-elastic polymer.
128. The cushioning pad assembly according to claim 128, wherein
the at least one substrate of visco-elastic polymer includes at
least one air ventilation aperture.
129. The cushioning pad assembly according to claim 125, wherein
the laminate further comprises at least one substrate of
visco-elastic polymer.
130. The cushioning pad assembly according to claim 130, wherein
the at least one substrate of visco-elastic polymer includes at
least one air ventilation aperture.
131. The cushioning pad assembly according to claim 119, wherein
the outer fabric layer faces toward the shell assembly and
comprises a light color.
132. The cushioning pad assembly according to claim 121, wherein
the inner fabric layer faces away from the shell assembly and
comprises a dark color.
133. The cushioning pad assembly according to claim 112, wherein at
least a second cushioning pad is detachably fastened to an inner
surface of the at least one cushioning pad, the at least second
cushioning pad comprising a laminate having at least one impact
absorbing layer which allows air to flow therethrough.
134. The cushioning pad assembly according to claim 112, wherein
the protective pad apparatus includes a shell assembly.
135. The cushioning pad according to claim 90, wherein the
protective pad apparatus includes a shell assembly.
134. A shell assembly for a protective pad apparatus that protects
a user's chest, back, and shoulders, the shell assembly comprising
a plurality of discrete protector panels.
135. The shell assembly according to claim 134, wherein the
protector panels include at least one inner shoulder protector
panel, at least one chest panel fastened to a first end of the
inner shoulder protector panel, and at least one back panel
fastened to a second end of the inner shoulder protector panel.
136. The shell assembly according to claim 134, wherein shell
assembly defines first and second halves.
137. The shell assembly according to claim 136, wherein the first
and second halves are connected by a first protector plate.
138. The shell assembly according to claim 137, wherein the first
protector plate allows the first and second halves of the shell
assembly to move relative to one another.
139. The shell assembly according to claim 137, wherein the first
and second halves are further connected by a second protector
plate.
140. The shell assembly according to claim 139, wherein the
protector plates allow the first and second halves of the shell
assembly to move relative to one another.
141. The shell assembly according to claim 136, wherein the first
and second halves of the shell assembly are connected to one
another in a manner which allows the halves to move relative to one
another.
142. The shell assembly according to claim 134, further comprising
a belt strap system for securing the apparatus to a user, the belt
strap system comprising at least one cushioning pad comprising a
laminate having at least one impact absorbing layer which allows
air to flow therethrough.
143. The shell assembly according to claim 134, wherein at least
one of the protector panels includes at least one raised
embossment.
144. The shell assembly according to claim 135, wherein at least
one of the chest protector panel and the back protector panel
includes at least one raised embossment.
145. The shell assembly according to claim 134, wherein the
protector panels are a pearlized white metallic color.
146. The shell assembly according to claim 134, wherein at least
one of the protector panels comprises at least one ventilation
hole.
147. The shell assembly according to claim 135, further comprising
at least one spring element for strengthening the at least one
inner shoulder protector panel.
148. The shell assembly according to claim 147, wherein the at
least one spring element is fastened to the shell assembly with
fasteners that allow the spring element to swing laterally.
149. The shell assembly according to claim 147, wherein the at
least one spring element includes an impact absorbing layer.
150. The shell assembly according to claim 134, wherein one of the
protector panels comprises a lower shoulder panel fastened to the
shell assembly by two straps that cross one another.
151. The shell assembly according to claim 134, wherein each of the
protector panels has at least one of a predetermined size and a
predetermined shape and wherein each of the protector panels can be
individually replaced with a protector panel having at least one of
a different predetermined size and a different predetermined
shape.
152. A shell assembly for a protective pad apparatus that protects
a user's chest, back, and shoulders, the shell assembly comprising
a pearlized white metallic color.
153. A shell assembly for a protective pad apparatus that protects
a user's chest, back, and shoulders, the shell assembly comprising
at least one spring element for strengthening the at least one
inner shoulder area of the shell assembly.
Description
[0001] This application claims the benefit under 35 USC 119(e) of
U.S. Provisional Application No. 60/437,952, filed on Jan. 3,
2003.
FIELD OF THE INVENTION
[0002] This invention relates to an apparatus for protecting the
shoulders, chest, and back of an athlete or other user.
BACKGROUND OF THE INVENTION
[0003] In present day football, football players are instructed to
tackle or block by directing the impact forces of the tackle or
block into their shoulders and driving with their legs.
Consequentially, there are fewer head and neck injuries than years
ago, when tacking or blocking was performed by leading with the
helmeted head into the chest area of the ball carrier.
[0004] Conventional shoulder, chest, and back pad apparatuses
designed for use by football players (football shoulder pads),
usually allow the players to tackle or block using the above
shoulder impaction technique, without suffering injury. However,
Brachial Plexus injuries, i.e., injury to the Acromio Clavicular
Joint more commonly known as a separated shoulder, have been rising
in frequency. The increase in Brachial Plexus injuries has lead
football equipment managers and trainers to demand more protection
from football shoulder pads.
[0005] Most conventional football shoulder pads typically have an
outer shell which is molded in a high-density-high molecular weight
polyethylene. This material has been proven effective in
withstanding impacts commonly encountered in football. However, the
most popular designs are molded in a dark colors, such as gray,
which undesirably aid the shell in absorbing external ambient heat
from the sun. Moreover, the outer shell of these popular designs,
do not allow air ventilation.
[0006] The outer shell is typically constructed in two halves,
wherein each halve includes an arch-shape inner shoulder protector
portion, a chest protector or front blade portion extending from
one end of the inner shoulder protector portion, a back protector
or rear blade portion extending from the other end of the inner
shoulder protector portion, an outer shoulder protector panel, and
a lower shoulder protector panel. The rear blade portions of the
two halves of the outer shell are connected to one another so that
the rear blade portions are fixedly positioned relative to one
another and are incapable of moving independently of one another.
The inner shoulder protector portion, the front blade portion and
the rear blade portions of each shell halve are molded as a single
unitary member. The front and rear blade portions, which are molded
flat, tend to be susceptible to stress fractures or cracking over
time or from repeated impacts. When fracturing or cracking occur,
the front blade/inner shoulder/rear blade unit must be discarded
and replaced by a person with the knowledge and tooling to make
such repairs. The front blade portions of the outer shell halves
are typically tied to one another using strings or shoelaces, which
are threaded through "eye holes" in the front blade portions. When
the strings or shoelaces are properly tightened, a gap of
approximately two inches exists between the front blade portions.
Although this gap is relatively small, it does leave the football
player's body open and unprotected in this area.
[0007] The inner surface of the outer shell is lined with a
protective padding that rests against the player's body. In
conventional football shoulder pads, this padding is typically
comprised of "open cell" polyurethane and/or "closed cell" vinyl
nitrile foam. A substantially non-air-ventilating nylon cover
encapsulates the foam(s) and operates in conjunction therewith to
create an "air system". In the air system, air trapped in the cells
of a section of foam which has been compressed from an impact, is
transferred, to a section of the foam not compressed from the
impact. The non-air-ventilating nylon cover functions in this
system to control and regulate the air being transferred in the
foam during the impact.
[0008] Although the nylon cover is substantially
non-air-ventilating, the foam can still manages to absorb
perspiration and water. Since existing padding design provide no
practical way to open the cover to clean or disinfect the foam,
mold and mildew can grow inside the padding and potentially make
the wearer ill. The perspiration and water absorbed in the foam
also increases the weight of the padding which must be carried by
the football player during play. Furthermore, when the nylon cover
of the padding becomes wet with oily perspiration, the shoulder
pads become slippery and may shift dangerously when a collision
occurs.
[0009] The padding of conventional football shoulder pads has
proven to be somewhat effective in absorbing the shock of an
impact, the padding, however, does not allow the football player's
body to cool itself. This is because the foam used in the padding
has heat transfer properties (high R factors) that do not allow
heat dissipation, and thus, operates as an heat insulator. The
non-air-ventilating nylon does not allow heat and air to flow
through the padding, thus, effectively adding to the heat
insulative nature of the padding. Hence, the padding employed in
conventional football shoulder pads actually speeds up the
overheating of the player's body by not allowing internally
generated heat to escape. Accordingly, conventional football
shoulder pads are actually a major contributor to the overheating
process of the body.
[0010] The protective padding is typically permanently attached to
the outer shell, or removably attached to the outer shell with a
hook and loop fastening system. The hook and loop fastening system
is very labor intensive and often difficult to master on some
football shoulder pad designs.
[0011] A football player experiences a total heat load which is
determined by the time spent on the field, the intensity of play,
the clothing and equipment worn, the temperature on the field, and
the air circulation on the field. If the heat load is sufficiently
severe, effects on the player's health and performance will occur.
These effects range from decreased concentration to injuries
including painful cramps, fainting, heat exhaustion, heat stroke,
and sometimes death, which require immediate medical attention by
the team trainer or doctor. As should be apparent from the above
discussion, conventional football shoulder pads only address
injuries related to impact, and do not address injuries relating to
heat load. Moreover, conventional football shoulder pads actually
increase the heat load because they block the body's ability to
dissipate heat generated thereby.
[0012] Body cooling safety issues should be especially important in
football shoulder pad apparatus design because June, July, August,
and September have the highest temperatures during the year and are
the months when football programs commence, at every level of
competition. Furthermore, the "bowl" shape of the typical football
stadium, traps the sun's infrared rays and causes what is known as
the "greenhouse" effect. As a result, the field temperature during
competition may be as high as 120 degrees Fahrenheit. Athletes who
participate in these conditions generate body heat internally with
physical activity, which is augmented by exposure to the hot sun.
The resultant high level of body heat mitigates against an
effective performance and can be dangerous and sometimes
lethal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a front elevational view of an illustrative
embodiment of a protective pad apparatus.
[0014] FIG. 2 is a rear elevational view of the protective pad
apparatus of FIG. 1.
[0015] FIG. 3 is a side view of the protective pad apparatus of
FIG. 1.
[0016] FIG. 4 is a plan view of the protective pad apparatus of
FIG. 1 showing the interior or athlete body side of the apparatus
of FIG. 1 with one of the front, inner and back shoulder cushioning
pads removed.
[0017] FIG. 5 is an enlarged view of a section of the interior of
the apparatus of FIG. 4 showing one of two spring elements.
[0018] FIG. 6 is a plan view of an embodiment of one of the chest
cushioning pads illustrating an outer surface (faces the shell
assembly) thereof.
[0019] FIG. 7 is a plan view of the chest cushioning pad shown in
FIG. 6 illustrating an inner surface (faces the athlete)
thereof.
[0020] FIG. 8 is a plan view of an embodiment of one of the inner
shoulder cushioning pads illustrating an outer surface (faces the
shell assembly) thereof.
[0021] FIG. 9 is a plan view of the inner shoulder cushioning pad
shown in FIG. 8 illustrating an inner surface (faces the athlete)
thereof.
[0022] FIG. 10 is a plan view of an embodiment of one of the back
cushioning pads illustrating an outer surface (faces the shell
assembly) thereof.
[0023] FIG. 11 is a plan view of the back cushioning pad shown in
FIG. 10 illustrating an inner surface (faces the athlete)
thereof.
[0024] FIG. 12A is a cross-sectional view illustrating the
construction of an embodiment of the inner shoulder cushioning
pad.
[0025] FIG. 12B is a cross-sectional view illustrating the
construction of another embodiment of the inner shoulder cushioning
pad.
[0026] FIG. 12C a cross-sectional view illustrating the
construction of a further embodiment of the inner shoulder
cushioning pad.
[0027] FIG. 12D is a cross-sectional view illustrating the
construction of an embodiment of the channel cushioning pad.
[0028] FIG. 13A is a cross-sectional view illustrating the
construction of an embodiment of the chest, back, lower shoulder,
and deltoid cushioning pads.
[0029] FIG. 13B is a cross-sectional view illustrating the
construction of an another embodiment of the chest, back, lower
shoulder, and deltoid cushioning pads.
[0030] FIG. 14 is a cross-section view illustrating the
construction of an embodiment of the outer shoulder cushioning
pad.
[0031] FIG. 15A is a plan view of a section of the protective pad
apparatus illustrating an embodiment of a strap which may be used
for connecting the lower shoulder panel to the inner shoulder
panel.
[0032] FIG. 15B is a plan view of a section of the protective pad
apparatus illustrating an embodiment of a dual strap which may be
used connecting the lower shoulder panel to the inner shoulder
panel.
[0033] FIG. 16A is an elevational view of an embodiment of a
sternum protector plate of the protective pad apparatus.
[0034] FIG. 16B is an elevational view of another embodiment of a
sternum protector plate of the protective pad apparatus.
[0035] FIG. 17A is an elevational view of an embodiment of a spine
protector plate of the protective pad apparatus.
[0036] FIG. 17B is an elevational view of another embodiment of a
spine protector plate of the protective pad apparatus.
[0037] FIG. 18A is an elevational view of a shell assembly panel
illustrating an embodiment of a raised embossment.
[0038] FIG. 18B is an elevational view of a shell assembly panel
illustrating another embodiment of a raised embossment.
[0039] FIG. 19 is an elevational view of one of the shell assembly
halves.
[0040] FIG. 20 is cross-sectional view illustrating the
construction of an embodiment of the spring element.
[0041] FIG. 21 is a front elevational view of another illustrative
embodiment of a protective pad apparatus.
[0042] FIG. 22 is a rear elevational view of the protective pad
apparatus of FIG. 21.
[0043] FIG. 23 is a side view of the protective pad apparatus of
FIG. 21.
[0044] FIG. 24 is a side elevational view of an embodiment of a
belt strap cushioning pad.
[0045] FIG. 25 is a plan view of another embodiment of a chest or
back cushioning pad illustrating an outer surface (faces the shell
assembly) thereof.
[0046] FIG. 26 is a front elevational view of a further
illustrative embodiment of a protective pad apparatus.
[0047] FIG. 27 is a rear elevational view of the protective pad
apparatus of FIG. 26.
DETAILED DESCRIPTION OF THE INVENTION
[0048] A protective pad apparatus made according to the principles
of the present invention comprises a shell assembly and an impact
absorbing cushioning pad assembly lining the inner surfaces (the
surfaces facing the athlete's body) of the shell assembly. The
protective pad apparatus of the present invention is intended for
use by athletes and other users who participate in contact sports,
such as football players. It should be understood, however, that
the protective pad apparatus of the present invention may also be
used or adapted for use in other types of activities, which require
impact protection, such as hockey, lacrosse, skateboarding,
snowboarding, roller-skating, rodeo, stuntman, equestrian, motor
sports, and all other activities where protective padding is
necessary.
[0049] The protective pad apparatus is typically worn over the
shoulders of the athlete's body to provide impact protection for
the athlete's shoulders and upper torso, i.e., the chest, and back.
As will become apparent further on, the protective pad apparatus 10
of the present invention features increased impact protection,
allows the athlete's body to cool or thermo-regulate itself,
provides the athlete with greater ease of movement and mobility,
and restricts radiant heat transfer/absorption from the sun.
[0050] FIGS. 1-4 show an embodiment of a protective pad apparatus
10 of the present invention. The shell assembly of the pad
apparatus 10 may comprise a plurality of discrete, substantially
rigid protector panels which form a first shell halve H1 and a
complementary second shell halve H2. The protector panels of each
shell halve H1, H2 may include an arch-shape inner shoulder panel
12b, a chest panel 12a, a back panel 12e, an outer shoulder panel
12c, and a lower shoulder panel 12d. The outer shoulder panel 12c
may be cup-shaped and somewhat elongated. The lower shoulder panel
12d may also be cup-shaped. The ends of the inner shoulder panel
12b may overlap the upper ends of the chest and back panels 12a and
12e, as shown in FIG. 19. Fasteners 31 may be used to fasten the
overlapping ends of the inner shoulder panel 12b and the chest and
back panels 12a, 12e together. The outer shoulder panel 12c may be
fastened to the inner shoulder panel 12b with a flexible strap 30a
that may be constructed, without limitation, from a polyester
webbing, which may be coated with polyurethane. A first end of the
strap 30a may be fastened with one or more fasteners 31 to an inner
surface (the surface facing the athlete) of the outer shoulder
panel 12c and a second end of the strap 30a may be fastened with a
rigid mounting plate 32 and one or more fasteners 31 to an exterior
surface (the surface facing away from the athlete) of the inner
shoulder panel 12b.
[0051] Still referring to FIGS. 1-4, the lower shoulder panel 12d
may be fastened to the inner shoulder panel 12b with a flexible
strap 30b that may also be constructed, without limitation, from a
nylon web material and which may be coated with an elastomeric
material. As shown in FIG. 15A, a first end of the strap 30b may be
fastened with one or more fasteners 31 to an inner surface of the
lower shoulder panel 12d and a second end of the strap 30b may be
fastened with one or more fasteners 31 to an inner surface of the
inner shoulder panel 12b. Alternatively, the lower shoulder panel
12d may be fastened to the inner shoulder panel 12b by a pair of
flexible straps that may each be constructed, without limitation,
from polyester webbing, which may be coated with polyurethane. As
shown in the embodiment of FIG. 15B, the flexible strap, denoted by
reference characters 130a and 130b, may cross one another and be
connected together at the crossing point. The dual straps 130a and
130b allow the lower shoulder panel 12d to twist more freely, which
in turn allows less restrictive movement of the shoulder.
[0052] A sternum protector plate 16 and a spine protector plate 18
may be used to connect the shell assembly halves H1 and H2
together. As shown in FIG. 16A, the sternum plate 16 may include
upper corner areas 16a and 16b, lower corner areas 16c and 16d, and
fastener apertures 17a-d. As shown in FIG. 17A, the spine plate 18
may include upper corner areas 18a and 18b, intermediate areas 18c
and 18d, lower corner areas 18e and 18f, and fastener apertures
19a-f. The upper and lower corner areas 16a-16d of the sternum
plate 16 are fastened to the chest panels 12a with fasteners 31 as
shown in FIG. 1. The upper and lower corner areas 18a-b and 18e-f,
and the intermediate areas 18c-d of the spine plate 18 are fastened
to the back panels 12b with fasteners 31, as shown in FIG. 2.
[0053] Referring again to FIG. 16A, the fastener apertures 17a-d of
the sternum plate 16 may be horizontally elongated with the upper
corner fastener apertures 17a-b slanted upwardly, and the lower
corner area fastener apertures 17c-d slanted downwardly. Referring
again to FIG. 17A, the fastener apertures 19a-f of the spine plate
18 may be horizontally elongated with the upper corner fastener
apertures 19a-b slanted upwardly, and the lower corner area
fastener apertures 19e-f slanted downwardly. The sternum and spine
plates of FIGS. 16A and 17A, allow the tops or bottoms of the
shells halves H1 and H2 to tilt inwardly toward one another as
indicated by arrows 81 (FIGS. 1 and 2). The tilting feature allows
the pad apparatus to move freely with the athlete's body so as not
to hinder the athlete's flexibility or movement during play.
[0054] In an alternative embodiment of the sternum plate 16 shown
in FIG. 16B, the upper corner area fastener apertures 17a-b may be
horizontally elongated and slanted upwardly and the lower corner
area fastener apertures 17c-d may be vertically elongated.
Similarly in a corresponding alternative embodiment of the spine
plate 18 shown in FIG. 17B, the upper corner area and intermediate
area fastener apertures 19a-d are horizontally elongated and
slanted upwardly (the intermediate area fastener apertures 19c-d
may be slanted upwardly at a greater angle than the upper corner
area fastener aperture 19a-b), and the lower corner area fastener
apertures 17c-d may be vertically elongated. The sternum and spine
plates of FIGS. 16B and 17B, allow the tops of the shells halves
H1' and H2' to tilt inwardly toward one another as indicated by
arrows 81' (FIGS. 21 and 22). As in the previous embodiment, the
tilting feature also allows the pad apparatus to move freely with
the athlete's body so as not to hinder the athlete's flexibility or
movement during play.
[0055] The spinal plate may also include preformed openings 34
(FIG. 2) for allowing accessories such as collars and neck rolls to
be attached thereto without drilling holes which may weaken the
shell assembly.
[0056] Referring again to FIGS. 1-3, one or more of the shell
assembly panels 12a-e and the sternum and spine plates 16, 18 may
be embossed in areas of the panels 12a-e and plates 16, 18 that are
susceptible to stress fractures and cracks. The raised embossments
33 strengthen the panels 12a-e and plates 16, 18, thus, enhancing
the overall structural integrity thereof and allowing the use of a
thinner plastic, which in turn lowers the total weight of the pad
apparatus 10. The raised embossments 33 may be configured in a
variety shapes. For example, FIGS. 21-23 collectively show a pad
apparatus 10' with differently shaped embossments 33' formed on the
shell assembly panels 12a-e. The embossments may have one or more
levels (the more levels, the stronger the panel area). For example,
in the embodiment shown in the side elevational view of FIG. 18A,
the raised embossment has a single level. In the embodiment shown
in the side elevational view of FIG. 18B, the raised embodiment has
two levels. Since the panels 12a-e and the protector plates 16, 18
of the shell assembly may be formed from plastic, they can be
easily thermoformed with the embossments in conventional
male/female molds.
[0057] The upper ends of the chest panels 12a, the inner shoulder
panels 12b, and the upper ends of the back panels 12e may curve or
bend away from one another to provide an opening O for the
athlete's neck. The inner edges of the inner shoulder panels 12b
may be covered with a biased binding 24, which may be made from
nylon or any other material that prevents the inner edges from
scraping or cutting of the neck.
[0058] The shell assembly panels 12a-e, the sternum and spine
plates 16, 18, and the strap mounting plates 32 may be formed from
a substantially rigid material or combination of materials,
including without limitation plastic, aluminized plastic, and
carbon fiber. In one embodiment, the shell assembly panels 12a-e,
the sternum and spine plates 16, 18, and the strap mounting plates
32 are made from a plastic comprising a high density, high
molecular weight polyethylene, and may be formed using conventional
plastic forming techniques, such as thermoforming or injection
molding. The thickness of the panels 12a-e and the plates 16, 18
may range, without limitation, between 0.110 inches and 0.140
inches.
[0059] The shell assembly panels 12a-e, the sternum and spine
plates 16, 18, and the strap mounting plates 32 may be transparent,
translucent, opaque or any combination thereof, and be any color or
combination of colors. In one embodiment, the shell assembly panels
12a-e, the sternum and spine plates 16, 18, and the strap mounting
plates 32 are opaque and a pearlized white metallic color. The
white color reflects and retains less heat, and the metallic
property acts to reduce the amount of heat absorbed by the shell
assembly panels 12a-e, the sternum and spine plates 16, 18 and the
strap mounting plates 32, by reflecting the light.
[0060] One or more venting apertures 26 may be formed in one or
more of the shell assembly panels 12a-e and the sternum and spine
plates 16, 18. The venting apertures 26 may circular and about
0.1875 inches in diameter. Such apertures may be placed between
about 0.5 inches to about 1.5 inches apart from one another.
Venting apertures of other shapes, dimensions and spacings may also
be used. The venting apertures 26 aid in transferring the heat
generated by the athlete's body through the pad apparatus 10.
[0061] As shown collectively in FIGS. 4 and 5, an elongated spring
element 20 may be provided that generally extends over the inner
surface of each inner shoulder panel 12b. The front end 20a of each
spring element 20 may be fastened to the inner surface of the shell
assembly at the location where the inner shoulder panel 12b and
chest panel 12a overlap one another, using fastener 31. Similarly,
the rear end 20b of each spring element 20 may be fastened to the
inner surface of the shell assembly at the location where the inner
shoulder panel/back panel overlap one another, using fastener 31.
The fasteners 31 may allow the spring elements to swing laterally a
small amount as indicated by arrows 82. The spring element 20
functions to strengthen the inner shoulder panel 12b so that it
resists "flattening" when impacted, and to absorb the energy and
shock of the impact before it reaches the underlying cushioning pad
assembly.
[0062] As shown in FIG. 20, each spring element 20 may comprise
laminate including a somewhat rigid plastic substrate 20a, which
may be, without limitation, about 0.60 inches in thickness. The
outer surface of the substrate 20a (the surface facing the inner
shoulder panel 12b) may be laminated with a impact absorbing
material, such as a dense ethylene vinyl acetate (EVA) foam 20b, to
pad the spring element 20. The inner surface (the surface facing
the athlete) of the plastic substrate 20a may be laminated with a
non-skid material 20c, such as rubber. The peripheral edge of the
laminate may be covered with a fabric material 20d that is sewn to
the edge of the laminate.
[0063] Referring again to FIGS. 1-4, the cushioning pad assembly
lining the inner surfaces of the shell assembly, may comprise a
plurality of discrete cushioning pads. The cushioning pads may
comprise, for each shell assembly halve H1 and H2, a chest
cushioning pad 14a (shown separately in FIGS. 6 and 7), which may
be removably fastened with conventional snap-fasteners 22 to the
inner surface of the chest protector panel 12a, a back cushioning
pad 14e (shown separately in FIGS. 10 and 11), which may be
removably fastened with conventional snap-fasteners 22 to the inner
surface of back protector panel 12e, an inner shoulder cushioning
pad 14b (shown separately in FIGS. 8 and 9), which may be removably
fastened with conventional snap-fasteners 22 to the inner surface
of the spring element 20, an outer shoulder cushioning pad 14c,
which may be fastened with fasteners 31 to the inner surface of the
outer shoulder panel 12c, a lower shoulder cushioning pad 14d,
which may be fastened to the inner surface of the lower shoulder
protector panel 12d, and a front deltoid cushioning pad 14f, which
may extend between the outer shoulder pad 14c and chest pad 14a.
The deltoid pad 14f does not line any of the shell assembly panels
12a-e but may have an unpadded or padded portion that allows it to
fastened to the inner surface of the chest panel 12a and the inner
surface of the inner shoulder panel 12b with fasteners 31.
[0064] As shown in FIG. 1, one or both of the chest pads 14a may be
dimensioned to partially overlap the inner surface of the sternum
protector plate 16 to provided cushioning under the sternum plate
16 to protect the athlete's sternum. Similarly, as shown in FIG. 2,
one or both of the back pads 14e may be dimensioned to partially
overlap the inner surface of the spine protector plate 18 to
provide cushioning under the spine plate 18 to protect the
athlete's spine. One or both of the chest pads 14a (shown in FIGS.
1, 6 and 7) may be configured to flare outwardly at the bottom
thereof (denoted by reference character F) to provide impact
protection from belt buckle(s) 35b.
[0065] The fasteners 31 described herein may comprise conventional
rivots or any other suitable fasteners. The snap-fasteners 22
described herein may comprise conventional circular snap-fasteners
of the type having a male element 22a provided on the assembly
panel or the pad and a female element 22b provided on the
corresponding assembly panel or pad. The male and female snap
fastener elements 22a and 22b may include alignment tabs (not
shown), which provide a high degree of strength and allow
separation thereof only when the tabs are properly aligned. The use
of such snap-fasteners ensures that the pads will not come loose
during impact and leave the athlete unprotected. The use of
snap-fasteners 22 also aids in the efficient removal or addition of
the cushioning pads. The cushioning pads utilizing the
snap-fasteners can usually be replaced while the athlete or user is
wearing the pad apparatus 10. Although less desirable, it should be
understood, that hook and loop fasteners, zippers, and the like, or
any combination of such fasteners may be used in place of the
snap-fasteners 22.
[0066] Each shell assembly panel 12a-e and cushioning pad 14a-f of
pad apparatus 10 can be individually replaced with a new or
differently sized and/or shaped panel 12a-e or pad 14a-f using
ordinary tools (to remove and reinstall fasteners 31). It is
contemplated that each shell assembly panel 12a-e and cushioning
pad 14a-f may be offered in a plurality of different lengths and/or
widths and/or shapes to accommodate a wide variety of player body
sizes, types and needs. Thus, if an athlete desires a differently
sized and/or shaped assembly shell panel 12a-e and/or cushioning
pad 14a-f because of injury, or just as a change of preference in
style, the existing assembly shell panel 12a-e and/or cushioning
pad 14a-f can be removed and replaced with the differently sized
and/or shaped assembly shell panel 12a-e and/or cushioning pad
14a-f as described above, to accommodate the athlete without the
need to purchase a different pad apparatus. Still further, an
athlete desiring more protection in the chest area and less
protection in the back area, may remove the existing chest panel
12a and associated chest pad 14a and replace them with a longer and
or wider chest panel 12a and chest pad 14a, and remove the back
panel 12e and back pad 14e and add a shorter and slimmer back panel
12e and back pad 14e. If the athlete should then desire to change
back to the original configuration, this can be accomplished at any
time. All the shell assembly panels 12a-e and cushioning pads 14a-f
may be made interchangeable to create a wide variety of models.
Also, if one or more of the shell assembly panels 12a-e becomes
damaged, the damaged panel or panels can be easily replaced.
[0067] The ability of the athlete's body to expel heat is of major
importance in enabling the body to effectively cool itself. The
cushioning pads 14a-14f are specifically constructed to allow the
athlete's body to expel heat.
[0068] Referring to FIG. 12A, the inner shoulder pad 14b may
comprise a laminate formed by an inner fabric layer 40 that faces
the athlete's body, a first impact absorbing (IA) layer 41, a
second IA layer 42, a third IA layer 43, and an outer fabric layer
44 that faces the shell assembly. The third IA layer 43 may be the
firmest of the IA layers 41, 42, and 43 and the second IA layer 42
may be firmer than the first IA layer 41. The layers of the
laminate may be held together using a very thin, web-like glue (not
shown) disposed between adjacent layers, which allows air
ventilation therethrough. One such glue is available from Bostick
of Middleton, Mass., under the trade name, Sharnet. The peripheral
edge of the inner shoulder pad 12b may be covered or trimmed with a
conventional fabric trimming 45 made, without limitation, from
woven nylon, which may be sewn to the edge of the pad 14b.
[0069] The inner fabric layer 40 may comprise any well known
brushed nylon material or other air-ventilating fabric, which is
capable of functioning as the loop member of a hook and loop
fastening system. The inner fabric layer 40 may be a dark color,
such as black, for body heat absorption. The inner fabric layer 40
may alternatively comprise a fabric sold under the trade name,
Dri-Lex, by Faytex Corporation of Weymouth, Mass. The Dri-Lex
fabric is available as a perforated fabric or as a doeskin-like
fabric. Both types of Dri-Lex fabric are air-ventilating.
[0070] The first IA layer 41 may comprise one or more substrates of
reticulated (open cell), polyurethane foam or other air-ventilating
foam. In one embodiment, the first IA layer 41 may have a thickness
of about 0.250 inches and a density of 1.30 pounds/cubic-foot. The
first IA layer 41 may be a dark color, such as black, to absorb
heat generated by the athlete's body. Reticulated polyurethane foam
is available from a variety of vendors. For example, reticulated
polyurethane foam may be obtained from Crest Foam Industries of
Moonachie, N.J. The first IA layer 41 may alternatively comprise
one or more substrates of a mesh-like, three-dimensional spacer
material made from polyester. Such a mesh-like spacer material is
sold by Muller Textiles, Inc. of Woonsocket, R.I., under the trade
name 3 mesh. The mesh-like spacer material comprises two
warp-knitted layers connected by pile monofilaments. When the
mesh-like spacer material is used for the first IA layer 41, the
inner fabric layer 40 may be omitted.
[0071] The second IA layer 42 may comprise one or more substrates
of closed-cell foam beads made of cross-linked polyethylene, or
polypropylene. The foam beads are fused together only at their
contact points so that air can be ventilated through the substrate.
Such a foam is sold under the trade name BROCK FOAM by Brock USA of
Boulder, Colo. In one embodiment, the second IA layer 42 may be
about 0.250 inches in thickness and have a density of 4.0
pounds/cubic-foot (if more the one substrate, the substrates may
have the same or different densities). It should be understood that
any dense foam capable of ventilating air may be used as the second
IA layer 42.
[0072] The third IA layer 43 may comprise one or more substrates of
a visco-elastic dry polymer available from Magister Corporation of
Chattanooga, Tenn. In one embodiment, the IA layer 43 may be about
0.250 inches in thickness, and may be sized such that it covers
only an intermediate area (the area disposed between stitching
lines 46 as can be seen in FIGS. 12A-C, 8, and 9) of the second IA
layer 42. It is contemplated that other very firm and/or dense
materials capable of resiliently absorbing the impact forces that
occur in contact sports and the like, may be utilized for the third
IA layer 43.
[0073] The outer fabric layer 44 may comprise any well known
air-ventilating fabric, such as a nylon mesh or perforated fabric.
The outer fabric layer 44 may cover the portions of the second IA
layer 42 not covered by the third IA layer 43. The outer fabric
layer 44 may be light color, such as white, to reflect and not
absorb heat generated from the sun's ultra-violet rays.
[0074] In other embodiments, the inner shoulder pad laminate may
comprise the L1 layers 41, 42, and 43 in a different order or
position. For example, the position of the first and second IA
layers 41 and 42 may be reversed such that the second IA layer 42
is laminated to the inner fabric layer 40 instead of the first IA
layer 41.
[0075] In a further embodiment, as shown in FIG. 12B, the inner
shoulder laminate may comprise a fourth IA layer 47 disposed
between the outer fabric layer 44 and the portions of the second IA
layer 42 not covered by the third IA layer 43. The fourth IA layer
47 may comprise one or more substrates of the closed-cell foam
beads. The fourth IA layer 47 may be about 0.125 inches in
thickness have density of about 5.5 pounds/cubic-foot.
[0076] In still another embodiment, as shown in FIG. 12C, the inner
shoulder laminate may comprise a radiant heat barrier layer 48
disposed under the outer fabric layer 44. The radiant heat barrier
layer 48 may comprise an aluminized polyester film. The aluminized
polyester film may comprise an industrial grade aluminum film
laminated to a polyester film or other type of fabric which
provides the requisite tensile strength. Such an aluminized fabric
may be obtained from Gentex Corporation (through Performance
Textiles of Carbondale, Pa.).
[0077] The inner shoulder pad 14b may include one or more channel
pads 70 detachably fastened to the inner surface thereof as shown
in FIG. 9. In the shown embodiment, the channel pads 70 may be
fastened to ends of the inner shoulder pad 14b. Fastening may be
accomplished using a conventional hook and loop fastening system.
When the inner fabric layer 40 of the inner shoulder pad 14b
comprises a material that is not hook and loop compatible, the
earlier described snap fasteners (not shown) may be alternatively
employed for detachably fastening the channel pads 70 to the inner
surface of the inner shoulder pad 14b.
[0078] As shown in FIG. 12D, the channel pad 70 may comprise a
laminate formed by an inner fabric layer 71 which faces the
athlete's body, a IA layer 72, an outer fabric layer 73, and a hook
layer 74. The outer fabric layer 73 and the hook layer 74 face the
shell assembly. The layers of the laminate may be held together
using the air-ventilating web-like glue (not shown) described
above. The peripheral edge of the channel pad 70 may be covered or
trimmed with a conventional fabric trimming 75 made, without
limitation, from woven nylon, which may be sewn to the edge of the
pad 70.
[0079] The inner fabric layer 71 may comprise a perforated fabric
(e.g., perforated Dri-Lex), a brushed nylon fabric, or other
air-ventilating fabric. The fabric may be a dark color, such as
black, for body heat absorption.
[0080] The IA layer 72 may comprise one or more substrates of the
earlier described closed-cell foam beads made of cross-linked
polyethylene, or polypropylene, sold under the trade name BROCK
FOAM by Brock USA of Boulder, Colo. In one embodiment, the IA layer
72 may be about 0.250 inches in thickness and have a density of 4.0
pounds/cubic-foot (if more the one substrate, the substrates may
have the same or different densities). In another embodiment, the
IA layer 72 may comprise any dense foam capable of ventilating
air.
[0081] The outer fabric layer 73 may comprise any well known
air-ventilating fabric, such as nylon mesh fabric. The outer fabric
layer 73 may be light color, such as white, to reflect and not
absorb heat generated from the sun's ultra-violet rays.
[0082] The hook layer 74 may comprise a layer of hook material
which is capable of detachably gripping to the inner fabric layer
70 of the inner shoulder pad 12b to detachably fasten the channel
pad 70 thereto.
[0083] In another embodiment the channel pad laminate may comprise
a radiant heat barrier layer disposed under the outer fabric layer.
The radiant heat barrier layer may comprise the aluminized
polyester fabric mentioned above. The channel pad laminate may also
comprise additional IA layers of air-ventilating foams including,
for example, one or more substrates of the earlier described
reticulated foam and/or one or more substrates of the
earlier-described mesh-like spacer material.
[0084] Referring to FIG. 13A, the chest, back, lower shoulder, and
deltoid pads 14a, 14e, 14d, and 14f respectively, may each comprise
a laminate formed by an inner fabric layer 50 which faces the
athlete's body, a first IA layer 51, a second IA layer 52, and an
outer fabric layer 53 which faces the shell assembly. The channel
pad 70 described earlier may also comprise such a laminate. The
second IA layer 52 may be firmer than the first IA layer 51. The
layers of the laminate may be held together using the
air-ventilating web-like glue (not shown) described earlier. The
peripheral edges of the pads 14a, 14e, 14d, and 14f may be covered
or trimmed with a conventional fabric trimming 54 made, without
limitation, from woven nylon, which may be sewn to the edges of the
pads 14a, 14e, 14d, and 14f.
[0085] The inner fabric layer 50 may comprise a perforated fabric,
such as the perforated or doeskin Dri-Lex fabric. The inner fabric
layer 50 may also comprise other types of air-ventilating fabrics.
The inner fabric layer 50 may be a dark color, such as black, for
body heat absorption.
[0086] The first IA layer 51 may comprise one or more substrates of
the earlier-described reticulated (open cell), polyurethane foam or
other air-ventilating foam. The first IA layer 51 may have a total
thickness of about 0.250 inches in thickness and a density of 1.30
pounds/cubic-foot. The first IA layer 51 may be a dark color, such
as black, to absorb heat generated by the athlete's body. The first
IA layer 51 may alternatively comprise one or more substrates of
the mesh-like, three-dimensional spacer material sold by Muller
Textiles, Inc. of Woonsocket, R.I. under the trade name 3 mesh.
When the mesh-like spacer material is used for the first IA layer
51, the inner fabric layer 50 may be omitted.
[0087] The second IA layer 52 may comprise one or more substrates
of the earlier described closed-cell foam beads made of
cross-linked polyethylene, or polypropylene, sold under the trade
name BROCK FOAM by Brock USA of Boulder, Colo. The IA layer 51 may
be about 0.250 inches in thickness and have a density of 4.0
pounds/cubic-foot (if more the one substrate, the substrates may
have the same or different densities). Alternatively, any dense
foam capable of ventilating air may be used as the second IA layer
52.
[0088] The outer fabric layer 53 may comprise any well known
air-ventilating fabric, such as a nylon mesh fabric. The outer
fabric layer 53 may be light color, such as white, to reflect and
not absorb heat generated from the sun's ultra-violet rays.
[0089] In an alternate embodiment as shown in FIG. 13B, one or more
of the chest, back, lower shoulder, and deltoid pad laminates may
comprise a radiant heat barrier layer 55 disposed under the outer
fabric layer 53. The radiant heat barrier layer 55 may comprise the
aluminized polyester fabric mentioned above.
[0090] Referring to FIG. 14, the outer shoulder pads 14c may
comprise a laminate formed of an inner fabric layer 60, which faces
the athlete's body, a IA layer 61, and an outer fabric layer 62,
which faces the shell assembly. The layers of the laminate may be
held together using the air-ventilating web-like glue (not shown)
described earlier. The peripheral edge of the pad 14c may be
covered or trimmed with a fabric trimming 63 made, without
limitation, from woven nylon, which may be sewn to the edge of the
pad 14c.
[0091] The inner fabric layer 60 may comprise any of the
air-ventilating fabrics described herein. The inner fabric layer 60
may be a dark color, such as black, for body heat absorption.
[0092] The IA layer 61 may comprise one or more substrates of firm,
dense EVA foam. The IA layer 61 may have a total thickness of about
0.250 inches in thickness, and may be a dark color, such as black,
to absorb heat generated by the athlete's body. The IA layer 61 may
alternatively comprise one or more substrates the earlier described
closed-cell foam beads made of cross-linked polyethylene, or
polypropylene, one or more substrates of the visco-elastic dry
polymer, or any combination of EVA foam, foam bead foam, or
visco-elastic dry polymer.
[0093] The outer fabric layer 62 may comprise the aluminized
polyester fabric described earlier, which operates as a radiant
hear barrier.
[0094] The reticulated polyurethane foam which may be used in the
pads is environmentally friendly and very versatile. When compared
to other foams, it offers substantial advantages in properties such
as tensile strength, ease of fabrication, and depending on grade,
its resistance to many chemicals, cleaning solutions, solvents,
acids and alkalis. Reticulated polyurethane foams are also
considered "non-nutrients" and are not ingested by microbial
organisms and are often available with permanent fungicidal and
bactericidal additives to enhance the antimicrobial activity.
Accordingly, the pads stay a cleaner than the padding in
conventional shoulder pad apparatus designs, which employ
conventional foams encapsulated in a sealed nylon shell.
[0095] Another feature of the reticulated polyurethane foam is its
ability to transport the perspiration from the wearers body into
the foam itself and allow evaporation to occur more quickly and
efficiently. When heat and pressure are used to manufacture
reticulated foam, they create a flexible skeletal structure without
cell membranes. The result is open-pore foam that can be produced
in a wide range of precisely controlled pore sizes that may contain
void volumes of up to 98%. This creates a large amount of "open
space" to allow both airflow and absorption of liquids. Unlike the
foams used in conventional pads, which smother the athlete's body
and retain the liquid, the reticulated polyurethane foam pulls the
heat and liquid into the foam while still allowing air circulation,
ventilation, and evaporation to cool the shoulder pad apparatus
more effectively and efficiently.
[0096] The closed-cell foam bead foam (BROCK FOAM) used in the pads
functions to absorb impacts and more importantly, allow air,
perspiration, and water to flow therethrough. Because the foam
beads are fused together only at their contact points, heat
generated by the athlete's body and outside air can flow freely
through this foam thereby reducing the possibility of heat stroke
and exhaustion.
[0097] The visco-elastic dry polymer is primarily provided in the
pads for impact protection. The visco-elastic dry polymer is a soft
synthetic rubber that is vulcanized by intensive cross-linking and
cured into a stable solid. Compared to other foams or gels,
visco-elastic dry polymer has superior load bearing capacity,
elongation, elasticity, firmness, and tensile strength. The
visco-elastic dry polymer resists full compression and evenly
distributes the force of impact over its entire surface, thereby
decreasing the chance that a high-risk area such as the Acromio
Clavicular Joint will be negatively affected, resulting in injury.
The visco-elastic dry polymer conforms comfortably to and moves
easily with the athlete's body, and retains its original shape
after deformation. The visco-elastic dry polymer is an excellent
heat conductor, and therefore, functions as a heat sink to evenly
absorb heat generated internally from the athlete's body. The heat
absorbed by the visco-elastic dry polymer is transferred
(conductive heat transfer), outwardly toward its edges, therefore,
preventing "hot spots" in the pad as this entire layer is
continually striving to become the same temperature. The conductive
heat transfer properties of the visco-elastic dry polymer reduces
tissue trauma because it prevents capillary closure (a breakdown of
capillary blood vessels in skin tissue). In embodiments where the
air-venting apertures are provided through the shell assembly
panels, the corresponding substrate of visco-elastic dry polymer
may be provided with a series of air venting apertures (not shown)
which approximately align with the air venting apertures of the
shell assembly panel, to provide additional heat dissipation.
[0098] The air-ventilating fabrics used in pads allow for free air
and liquid flow, which enable the athlete's body to naturally cool
itself. More specifically, the Dri-Lex fabrics may have a two-layer
construction. The inner layer, (the layer against the athlete's
body), is "hydrophobic" or water negative open cell foam. It
absorbs moisture but does not evaporate it, which is what most
"moisture absorbent" linings do. They simply hold moisture, which
means a damp, uncomfortable feeling against the body. To avoid this
problem, the outer layer comprises a 100% Hydrofil nylon
manufactured by Allied Signal Corporation, that draws the moisture
from the inner hydrophobic layer, keeping that layer dry, cool,
soft and comfortable against the body. This is a very important
part of the athlete's comfort and safety. A drier cushioning pad is
less likely to slip during a collision, keeping the pad in place
and the athlete protected. The two-layer construction also has its
own built-in ventilation system, which provides the shoulder
cushioning pad with a high level of breath-ability. The
high-quality fibers provide excellent wear resistance and retain
shape longer. Because of Dri-lex's "thermostatic control" inside,
the pads always feel dry, cool and comfortable to the athlete, as
well as making the pads more hygienic.
[0099] The radiant heat barrier used in pads provide the athlete
with an important level of thermal protection. Radiant heat
barriers are typically made of materials that restrict the transfer
of infrared radiation across an airspace. They do this by
reflecting the radiation that strikes them, and at the same time,
not radiating heat energy. A material that inhibits radiative
transfer in this manner is said to have a very low emissivity (the
relative power of a surface to emit heat by radiation). The lower
the emissivity, the better the radiant barrier. This features
enables the radiant heat barrier layer to be placed on either the
inner (athlete body side) or outer (shell assembly side) of the
pads, as one side reflects while the other side simply decreases
the amount of emitted radiation. It is not necessary to form
"airtight" seals with radiant barriers, as radiant energy travels
in a straight line through the air, but is not transported by the
air.
[0100] The thickness of the pads may be, without limitation, about
0.500 inches, although all of the pads of the cushioning pad
assembly may be offered in different thicknesses. For example, if
the athlete has an injury and needs more protective padding on the
left side of his body, the athlete can simply remove the existing
pads, with pads of a desired increased thickness, for example,
0.625 inches. When the injury has healed (or at any time), the
athlete may go back to the original pad thickness. Although not
shown, the pads may also be formed as accessory "donuts" or
"horseshoes" for specific orthopedic injuries in the shoulder
area.
[0101] The pad apparatus may be secured to the athlete's upper
torso with a belt strap system, as shown, for example, in FIGS.
1-4. The belt strap system may comprise a belt strap 35a and buckle
35b arrangement, provided on each halve H1, H2 of the pad apparatus
10. In other embodiments of the invention, the belt strap system
may comprise a slide-ratchet belt strap arrangement (not shown),
provided on each halve H1, H2 of the pad apparatus 10. The
slide-ratchet belt strap is similar to the type of slide-ratchet
belt strap system used on conventional ski boots or used to secure
freight from shifting during transit. The slide-ratchet belt strap
system allows for quick and easy placement and removable of the pad
apparatus 10 of the invention. As shown in FIG. 24, each belt strap
35a may be provided with a cushioning pad 90 which may constructed
similar to the chest or back pads or constructed from an
elastomeric coated strap material. The protector pad 90 includes
slots through which the strap 35a extends for cushioning the sides
of an athlete's torso, adjacent the waistline. In another
embodiment, as shown in FIG. 25, the chest and/or back pads can be
laterally extended and provided with slots 92 through which the
strap 35a extends for cushioning the sides of an athlete's torso,
adjacent the waistline. As shown in FIG. 21, a buckle pad 93
similar in construction to the chest and back pads, can be attached
to the inner surface of the buckle strap 35c to provide cushioning
between the buckle 35b and the athlete's body.
[0102] Referring again to FIGS. 21-23, additional belts 36 may be
provided on each halve H1, H2 of the pad apparatus for securing it
to the athlete's upper torso. The additional belts 36 may comprise
an elastic strap fastened to each shell assembly back panel 12e
(FIG. 22). The free end of each belt 36 may include a T-shape hook
36a (FIG. 23) which is inserted into an elongated slot 37 (FIG. 21)
in the corresponding shell assembly chest panel 12a and rotated 90
degrees to retain the hook 36a in the slot 37. The tension of the
belts 36 may be made adjustable using any conventional strap
tightening system.
[0103] In another embodiment, as shown in FIGS. 26 and 27, the
chest protector panel 12a", the inner shoulder protector panel
12b", and the back protector panel 12e" of each shell assembly
halve H1 and H2 may be formed as a single unitary member. The
unitarily formed chest/inner shoulder/back panels may be embossed
if desired.
[0104] While the foregoing invention has been described with
reference to the above embodiments, various modifications and
changes can be made without departing from the spirit of the
invention. Accordingly, all such modifications and changes are
considered to be within the scope of the appended claims.
* * * * *