U.S. patent application number 10/273985 was filed with the patent office on 2004-09-02 for washable, protective hip pad construction.
Invention is credited to Goodwin, Edward L..
Application Number | 20040168245 10/273985 |
Document ID | / |
Family ID | 32106466 |
Filed Date | 2004-09-02 |
United States Patent
Application |
20040168245 |
Kind Code |
A1 |
Goodwin, Edward L. |
September 2, 2004 |
Washable, protective hip pad construction
Abstract
A thin, light weight, flexible, washable protective hip pad is
incorporated into a pocket of washable underwear at the hip. This
pad comprises a hermetically sealed plastic envelope extending
substantially throughout the pocket, a solid foam insert layer
having a configuration that extends substantially throughout the
envelope in contiguity with the inner walls of the envelope, and a
junction arrangement between the insert layer and at least one
inner face of the envelope. The arrangement is such that the extent
of the configuration of the insert layer is maintained
substantially throughout the envelope, flexibility is maintained by
slippage between contiguous faces of the insert layer and at least
a wall of the envelope, and compression and redistribution of air
occurs where and when any point of the hip pad assemblage is
subject to impact. The arrangement remains intact when the pad is
repeatedly bent, twisted or otherwise deformed during washing or
wearing.
Inventors: |
Goodwin, Edward L.; (Canton,
MA) |
Correspondence
Address: |
BROMBERG & SUNSTEIN LLP
125 SUMMER STREET
BOSTON
MA
02110-1618
US
|
Family ID: |
32106466 |
Appl. No.: |
10/273985 |
Filed: |
October 18, 2002 |
Current U.S.
Class: |
2/267 |
Current CPC
Class: |
A41D 13/0506 20130101;
A41D 13/0593 20130101 |
Class at
Publication: |
002/267 |
International
Class: |
A41D 027/26 |
Claims
What is claimed is:
1. A washable protective hip pad for incorporation into a pocket in
the region of a hip in washable underwear, said pad comprising an
assemblage of a hermetically sealed plastic envelope, an insert
layer therein, and restricted connection between said envelope and
said layer; (a) said hermetically sealed plastic envelope extending
substantially throughout said pocket; (b) said hermetically sealed
plastic envelope containing said insert layer and a cleavage
between said insert layer and at least a portion of one of the
inner faces of the walls of said envelope; (c) said insert layer
being a solid foam having an internal phase composed of air and an
external phase composed of a polymer; (d) at least a partial
cleavage between said insert layer and at least one inner face of
said walls; (e) said restricted connection including at least one
physical junction; (f) said restricted connection being
sufficiently limited in lateral extent to permit redistribution of
air in said insert and said cleavage and being strategically placed
to maintain said predetermined configuration substantially
throughout said envelope despite repetitive deformation of said
assemblage.
2. The protective hip pad of claim 1 wherein said solid foam
includes an internal phase composed of air and an external phase
composed of an elastomer.
3. The protective hip pad of claim 1 wherein each of said walls is
composed of an outer layer of polymeric fabric and an inner layer
of thermoplastic polymer.
4. The protective hip pad of claim 1 wherein said restricted
connection is in the form of junctions that are composed of
thermoplastic welds.
5. The protective hip pad of claim 1 wherein said restricted
connection is in the form of junctions that are composed of bonding
adhesive.
6. The protective hip pad of claim 1 wherein said restricted
connection is in the form of junctions that are composed of
peripherally spaced spots.
7. The protective hip pad of claim 1 wherein said restricted
connection is in the form of an adhesive stratum bonding one face
of said insert layer to an inner face of one of the walls.
8. The protective hip pad of claim 1 wherein said foam has open
cells.
9. Washable underwear having at the hips a pair of opposed pockets
incorporating a pair of the thin, light weight, flexible, washable
protective hip pads, each hip pad comprising: (a) a hermetically
sealed plastic envelope extending substantially throughout its
pocket; (b) a solid foam insert layer having a configuration that
extends substantially throughout said envelope in contiguity with
the inner walls of said envelope; and (c) junctions between said
insert layer and at least one inner face of said envelope; (d) a
slight cleavage between major contiguous spans of said insert layer
and said envelope in order to ensure that the extent of said
configuration of said insert layer remains substantially throughout
the envelope; (e) flexibility being maintained by permitting
slippage between the contiguous faces of said insert layer and at
least a wall of said envelope; (f) compression and redistribution
of air occurring where and when any point of said hip pad
assemblage is subject to impact; (g) said junction arrangements
maintaining the generally contiguous and coextensive condition of
the envelope and the insert layers when the assemblages of the
envelope and insert layer are repeatedly bent, twisted or otherwise
deformed during washing or wearing.
10. The washable underwear of claim 9 wherein said solid foam
includes an internal phase composed of air and an external phase
composed of an elastomer.
11. The washable underwear of claim 9 wherein each of said walls is
composed of an outer layer of polymeric fabric and an inner layer
of thermoplastic polymer.
12. The washable underwear of claim 9 wherein said restricted
connection is in the form of junctions that are composed of
thermoplastic welds.
13. The washable underwear of claim 9 wherein said restricted
connection is in the form of junctions that are composed of plastic
adhesive.
14. The washable underwear of wherein said restricted connection is
in the form of junctions that are composed of peripherally spaced
spots.
15. The washable underwear of claim 9 wherein said restricted
connection is in the form of an adhesive stratum bonding one face
of said insert layer to an inner face of one of the walls.
16. The washable underwear of claim 9 wherein said foam has open
cells.
17. A washable protective hip pad for incorporation into a pocket
in the region of a hip in washable underwear, said pad comprising
an assemblage of a hermetically sealed plastic envelope, an insert
layer therein, and restricted connection between said envelope and
said layer; (a) said hermetically sealed plastic envelope extending
substantially throughout said pocket; (b) said hermetically sealed
plastic envelope containing said insert layer and a cleavage
between said insert layer and at least one of the inner faces of
the walls of said envelope; (c) said insert layer being a solid
foam having an internal phase composed of air and an external phase
composed of a polymer; (d) a cleavage between said insert layer and
at least one inner face of said walls; (e) said restricted
connection including one or more physical junctions; (f) said
junctions being sufficiently limited in lateral extent to permit
redistribution of air in said insert and said cleavage and being
strategically placed to maintain said predetermined configuration
substantially throughout said envelope despite repetitive
deformation of said assemblage; (g) each of said walls being
composed of a laminate having an outer fabric stratum and an inner
thermoplastic stratum; (h) said insert layer being composed of an
open cell solid foam having an internal air phase and an external
thermoplastic phase; (i) the inner thermoplastic stratum of each
wall and the external phase of said insert layer being composed
essentially of polyurethane; (j) said fabric stratum being composed
of a textile produced from a high melting point plastic; (k) said
fabric being in the range of from 50 to 500 denier; (l) the
thickness of said laminate ranging from 1 to 6 mils.
18. The washable protective hip pad of claim 17 wherein said
thermoplastic of said walls and the thermoplastic of said insert
layer is polyurethane.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND
DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to protective anatomical pads,
and, more particularly, to protective hip pads that are worn as
underwear accessories by the elderly and/or infirm to guard against
random injuries to the hip that often occur as a result of
inattention, accident, or the like.
[0005] 2. Description of the Prior Art
[0006] What might be a minor injury to a young person might
constitute a serious trauma to an elderly or infirm person.
Injuries to the hip are a relatively common and important case in
point. Protective pads have been provided for permanent
incorporation in patch pockets of underbriefs for elderly and/or
infirm men and women. These patch pockets and the protective pads
they contain cover the hip bones and overlap adjacent anterior and
posterior regions, particularly of the buttocks. Such patch pockets
position the protective pads to protect against physical shock due
to inadvertent falling or other physical contact. For this purpose,
one example of a protective pad of the prior art is a thin
assemblage that comprises a hermetically sealed plastic envelope
and an open cell foam insert layer contained freely therein. In a
particular prior art example, the envelope is in the form of a thin
film, composed for example of polyurethane backed by nylon fabric,
and the insert layer is in the form of a thin solid foam stratum
having an internal phase composed of open cells of air, and an
external phase composed of elastomeric polyurethane.
[0007] The intent of the pad design is such: (1) that it be
sufficiently flexible for comfort, and (2) that, on impact at any
point or region of the pad, air inside the insert layer and the
cleavage between the insert layer and a contiguous region of the
envelope, thereby distributes the force of the impact and reduces
its intensity at the point or region of impact. One problem has
been difficulty in maintaining these requirements due to a tendency
of the insert layer to crumple and/or roll up during the tumbling
that occurs when the underbrief and pad assemblage is machine
washed. Specifically, when the insert layer is not fully extended
within the envelope but is crumpled into a mass, the product
becomes unwearable. This problem is resolved by the present
invention.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide a thin,
light weight, flexible, washable protective hip pad, for
incorporation into a pocket, preferably a patch pocket, of washable
underwear at the hip, which pad comprises: a hermetically sealed
plastic envelope extending substantially throughout the pocket; a
solid foam insert layer having a configuration that extends
substantially throughout the envelope in contiguity with the inner
walls of the envelope; and one or more strategically structured
physical junctions between the insert layer and at least one inner
face of the envelope. The physical junction arrangement is such as
to provide and to maintain a slight cleavage between major
contiguous spans of the insert layer and the inner face or faces of
the envelope in order to ensure the following. The junction
arrangement: (1) operates to maintain the extent of the
configuration of the insert layer substantially throughout the
envelope; (2) maintains flexibility by permitting slippage between
contiguous faces of the insert layer and at least a wall of the
envelope; and (3) permits compression and redistribution of air
where and when any point of the hip pad assemblage is subject to
impact. In other words, the junction arrangement maintains the
generally contiguous and coextensive condition of the envelope and
the insert layer when the assemblage of the envelope and insert
layer is repeatedly bent, twisted or otherwise deformed during
laundering. Preferably, the insert layer is composed of a solid
foam having and internal phase of open air cells and an external
phase of visco-elastic urethane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a fuller understanding of the nature and objects of the
present invention, reference is to be made to the following
specification, which is to be taken with the accompanying drawings
wherein:
[0010] FIG. I is a perspective view of a hip pad embodying the
present invention;
[0011] FIG. 2 is a view of a washable underbrief that permanently
incorporates a pair of washable hip pads in accordance with the
present invention;
[0012] FIG. 3 is an exaggerated cross-sectional view of the hip pad
of FIG. 1, taken along the lines 3-3 of FIG. 1;
[0013] FIG. 4 is an exaggerated cross-sectional view, analogous to
that of FIG. 3, illustrating details of another embodiment of the
present invention; and
[0014] FIG. 5 is an exaggerated cross-sectional view, analogous to
that of FIG. 3, illustrating details of a further embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The embodiment of the present invention illustrated in FIGS.
1 to 3 comprises an underbrief 20 having a pair of opposed patch
pockets 22 and 24. Each pocket extends over a hip and overlaps
regions of the body that are anterior and posterior with respect to
the hip. Confined within and extending throughout the pockets are
identical hip pad assemblages 26 and 28. Typically, each pad is
round, more specifically circular or oval with dimensions ranging
from 5 to 10 inches in its longest diameter, and preferably
approximately 8 inches in its longest diameter. Generally, the area
and thickness of the pad are less than 60 square inches and less
than 1 inch, respectively.
[0016] As shown in FIG. 3, hip pad assemblage 26 comprises an
external envelope 30 and an insert layer 32. Preferably, the
external envelope and the insert layer are substantially
coextensive, and circular or oval in shape. The walls of the
envelope define an inner laminar region 38, the edges of which are
bonded together as at 40 and 42 throughout their peripheries to
provide an outwardly extending peripheral flange shown at 44 and
46. Insert layer 32 preferably is an open cell, solid foam having a
laminar configuration that extends substantially throughout inner
laminar region 38 in contiguity with the opposed inner faces of
walls 34 and 36.
[0017] As shown in FIGS. 1 and 3, the opposed faces of insert layer
32 are generally contiguous with, i.e. in free contact with or
slightly spaced from, the inner faces of walls 34 and 36 at
cleavage regions 35 and 37. Insert layer 32 is bonded to the inner
face of wall 36 by four spot junctions 48, 50, 52 and 54, which are
located equidistantly around the circumference of the envelope.
[0018] Another embodiment is shown in FIG. 4. Here, the envelope
walls are shown at 56 and 58 as being bonded around their
periphery, as at 60 and 62. Within the envelope is an insert layer
64. One face of insert layer 64 is bonded to the inner face of wall
56 by four spot junctions, two of which are shown at 66 and 68. The
other face of insert layer 64 is bonded to the inner face of wall
58 by four spot junctions, two of which are shown at 70 and 72.
[0019] A further embodiment is shown in FIG. 5. Here, the envelope
walls are shown at 76 and 78 as being bonded around their
periphery, as at 80 and 82. Within the envelope is an insert layer
84. One face of insert layer 84 is connected to the inner face of
wall 78 by a junction in the form of a bonding stratum 86 between
the contiguous faces of insert layer 84 and wall 78. The other face
of insert layer 84 is free.
[0020] The following non-limiting examples further illustrate the
product of the present invention.
EXAMPLE I
[0021] In the example of the assemblage illustrated in FIG. 3,
details of the various components are as follows. Each of the
envelope walls is composed of a laminate having an outer fabric
stratum and an inner thermoplastic stratum. The insert layer is
composed of an open cell solid foam having an internal air phase
and an external thermoplastic phase. Preferably, the inner
thermoplastic stratum of each wall and the external phase of the
insert layer are composed of essentially the same thermoplastic,
for example, polyurethane. Preferably, the fabric stratum is
composed of a textile produced from a high melting point plastic
(450.degree. F.) sold by DuPont under the trade designation,
"NYLON". The fabric typically is in the range of from 50 to 90
denier, and preferably is approximately 70 denier. The thickness of
the laminate of each wall ranges from 1 to 6 mils and preferably is
approximately 3 mils.
EXAMPLE II
[0022] In furtherance of EXAMPLE I, the junctions are formed by
welding together the thermoplastic faces of the walls throughout
their perimeters, and spot welding the walls to the insert layer at
a temperature above the softening point of polyurethane and under a
pressure necessary to achieve coalescence and integration of the
polyurethane surfaces. Typically, the diameter of each of the spot
welds range from 1/2 to 11/2 inch, and preferably no greater than 1
inch. In essence the diameters of the junctions are limited to
preserve lateral flexibility and free flow of air between the open
cells of the insert layer and the adjacent cleavage regions.
EXAMPLE III
[0023] In the embodiment of FIG. 4, the materials of the walls and
the insert layer are respectively identical to their counterparts
in FIG. 3. However, here there area two sets of four equidistantly
spaced junctions. Two of the junctions of one of the sets are shown
at 66 and 68 between insert layer 64 and wall 56. Two of the
junctions of the other of the sets are shown at 70 and 72 between
insert layer 64 and wall 58.
EXAMPLE IV
[0024] In the embodiment of FIG. 5, the materials of the walls and
the insert layer are respectively identical to their counterparts
in FIG. 3. Here, chemical bonding is achieved with a flexible
polymeric adhesive, preferably a flexible polyurethane adhesive. As
shown, one of the faces of insert layer 84 is bonded by flexible
polyurethane adhesive stratum 86 to the inner face of wall 78. The
other of the faces of insert layer 84 is free for the purpose of
maintaining flexibility. Also, the two walls 76 and 78 are bonded
by flexible polyurethane adhesive throughout their peripheries as
shown at 80 and 82.
OPERATION
[0025] A pair of the thin, light weight, flexible, washable
protective hip pads is incorporated into opposed pockets of
washable underwear at the hips. Each pad comprises a hermetically
sealed plastic envelope extending substantially throughout the
pocket, a solid foam insert layer having a configuration that
extends substantially throughout the envelope in contiguity with
the inner walls of the envelope, and junctions between the insert
layer and at least one inner face of the envelope. The arrangement
operates to provide and to maintain a slight cleavage between major
contiguous spans of the insert layer and the inner face or faces of
the envelope in order to ensure that the extent of the
configuration of the insert layer remains substantially throughout
the envelope, flexibility is maintained by permitting slippage
between contiguous faces of the insert layer and at least a wall of
the envelope, and compression and redistribution of air occurs
where and when any point of either hip pad assemblage is subject to
impact. The junction arrangements maintain the generally contiguous
and coextensive condition of the envelope and the insert layers
when the assemblages of the envelope and insert layer are
repeatedly bent, twisted or otherwise deformed during washing or
wearing.
* * * * *