U.S. patent application number 10/598986 was filed with the patent office on 2008-08-14 for personal protection device.
This patent application is currently assigned to SPORT SPLINT DA. Invention is credited to Kare Martin Hagen, Egil Johannessen, Tor Henning Wiik.
Application Number | 20080189822 10/598986 |
Document ID | / |
Family ID | 32118056 |
Filed Date | 2008-08-14 |
United States Patent
Application |
20080189822 |
Kind Code |
A1 |
Johannessen; Egil ; et
al. |
August 14, 2008 |
Personal Protection Device
Abstract
The invention regards a method for manufacturing a personal
protection device for protecting a part of a body of a user. The
device is manufactured by providing an image of the shape of the
body part to be protected, based on the image of the body part,
milling out a model of the body part, providing at least one blank
with a curved inner surface, the surface form being adapted to the
outer surface of the model, and cutting and/or finishing the edge
of the blank(s) to obtain the desired shape.
Inventors: |
Johannessen; Egil; (Bodo,
NO) ; Hagen; Kare Martin; (Bodo, NO) ; Wiik;
Tor Henning; (Bodo, NO) |
Correspondence
Address: |
CHRISTIAN D. ABEL
ONSAGERS AS, POSTBOKS 6963 ST. OLAVS PLASS
NORWAY
N-0130
omitted
|
Assignee: |
SPORT SPLINT DA
Bodo
NO
|
Family ID: |
32118056 |
Appl. No.: |
10/598986 |
Filed: |
March 18, 2005 |
PCT Filed: |
March 18, 2005 |
PCT NO: |
PCT/NO2005/000097 |
371 Date: |
July 6, 2007 |
Current U.S.
Class: |
2/22 ;
33/17R |
Current CPC
Class: |
A63B 2071/1266 20130101;
A63B 2071/1241 20130101; A63B 2209/10 20130101; A63B 2071/1258
20130101; A63B 2209/02 20130101; A63B 71/1225 20130101 |
Class at
Publication: |
2/22 ;
33/17.R |
International
Class: |
A63B 71/12 20060101
A63B071/12; A43D 1/02 20060101 A43D001/02 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 19, 2004 |
GB |
0406261.8 |
Claims
1. Method for manufacturing a personal protection device for
protecting a part of a body of a user from injuries caused by
physical impacts, for example strokes or kicks, during sports,
characterized in that it comprises the steps of: providing an image
of the shape of the body part to be protected, based on the image
of the body part, milling out a model of the body part with the
same shape as the body part, providing at least one blank with a
curved inner surface form fit to the outer surface of the model,
cutting and/or finishing the edge of the blank(s) to obtain a
desired shape, and providing the blank(s) with fixing devices for
fixing the protection device to the body part.
2. Method according to claim 1, characterised in that the fixing
devices are semi-rigid with flexibility to provide room for
expanding muscles and rigidity to provide pressure to the body
part.
3. Method according to claim 1, characterized in that the image is
acquired by means transferring a number of cameras surrounding the
body part along the full length of the body part.
4. according to claim 3, characterized in that the cameras are
arranged in a substantially circular pattern.
5. Method according to claim 1, characterized in that the blank is
made of a thermoplastic material.
6. Method according to claim 1, characterized in that the blank is
made of a carbon composite material.
7. Method according to claim 1, characterized in that the fixing
devices are hook-and-loop fasteners.
8. Method according to claim 5, characterized in that the blank is
formed by thermoforming a sheet of a thermoplastic material.
9. Method according to claim 1, characterized in that there is
provided at least two blanks which in combination covers
substantially all of the body part to be protected.
10. Method according to claim 9, characterized in that the adjacent
edges of the blanks have complementary forms.
11. Method according to claim 10, characterized in that the
blank(s) when assembled form a tubular device.
12. Method according to claim 1, characterized in that it further
comprises: providing the blank with padding.
13. Method according to claim 12, characterized in that the blanks
are covered by a upholstery.
14. Method according to claim 13, characterized in that the
blank(s) at the inside is covered by a temperature transporting
material.
15. Method according to claim 14, characterized in that the
blank(s) at the outside is covered by a flexible, shock absorbing
material.
16. Method according to claim 11, characterized in that the body
part to be protected is the leg below the knee.
17. Personal protection device for protecting a part of a body of a
specific user from injuries caused by physical impacts, for example
strokes or kicks during sports, comprising at least two elements
and fixing members for connecting the elements, characterized in
that the elements have a curved inner surface, the curved surface
having curvature form fit to a model of the user's body part with
the same shape as the user's body part.
18. Personal protection device according to claim 17, characterized
in that it is adapted for protecting the user from physical
impacts.
19. Personal protection device according to claim 17 characterized
in that the fixing members are hook-and-loop fasteners.
20. Personal protection device according to claim 17 characterized
in that the body part to be protected is the leg below the
knee.
21. Personal protection device according to claim 17 characterized
in that the adjacent edges of the elements have complementary forms
to provide a tubular shape of the device.
22. Personal protection device according to claim 17, characterized
in that it further comprises: providing the elements with
padding.
23. Personal protection device according to claim 17, characterized
in that the elements are covered by a upholstery.
24. Personal protection device according to claim 17, characterized
in that the element(s) at the inside is covered by a temperature
transporting material.
25. Personal protection device according to claim 17, characterized
in that the element(s) at the outside is covered by a flexible,
shock absorbing material.
Description
[0001] The invention regards a method for manufacturing a personal
protection device for use in contact sports, and other activities
with a high risk for strokes or kicks to parts of the body.
[0002] In contact sports such as football, soccer, land hockey, ice
hockey, rugby, etc, there are often physical impacts. Injuries
following such impacts are common and can be severe and in many
sports is it obligatory to use protective equipment such as shin
pads, shoulder pads, knee pads, or other protection devices. For
some kinds of labour there is also a need for protecting certain
parts of the body to prevent injuries.
[0003] There is a problem with existing protective equipment for
example for the leg/calf area for football/soccer that it does not
protect the calf area. A stroke in this area can cause fractures
and severe soft tissue damages. The available protective equipments
in e.g. football, shin pads, are uncomfortable to wear, and the
players often fail to wear them during training.
[0004] U.S. Pat. No. 6,298,484 B1 discloses a protective guard
comprising a shin guard, calf guard and an ankle sock. The shin
guard and calf guard are connected in use by Velcro straps.
[0005] The shin guards and calf guards are standard components and
are not custom fit to the user. This leads to less comfort for the
user, and fully use of the muscles becomes uncomfortable if not
impossible. This product is not widely used in soccer today.
[0006] U.S. Pat. No. 5,544,663 regards custom fitting of shin pads
or other body protection equipment to individual sportsmen. This is
done by manufacturing one part of the shin pad of a
moisture-curable material. The shin pad is placed against the shin
of the sportsman to adapt the shape to the shin, and moist is added
to start curing.
[0007] This is a complicated and time consuming method and the
publication does not describe protection of the calf. A hit in the
calf area can cause fractures in the leg, and it would be desirable
to be able to protect also this area.
[0008] The object of the invention is to provide a method for
manufacturing a protection device, that is comfortable to use and
which protects the user without restraining the use of the muscles
in the body part. It is also an object of the invention to provide
the device itself.
[0009] The object of the invention is achieved by means of the
features in the patent claims.
[0010] According to the invention, there is provided a personal
protection device for protecting a part of a body of a user
comprising at least two elements and fixing members for connecting
the elements, wherein the elements have a curved inner surface, the
curved surface being form-fitted to the shape of the body part to
be protected by means of fitting to the outer surface of a model of
the body part, the model being formed based on an image of the
user's body part.
[0011] The device according to the invention comprises at least two
elements and fixing members for connecting the elements. The number
of elements will depend on the body part to be protected, the
application of the device and/or on which sport event and level the
device will be used. In football, for example, the device can be
used for protecting the part of the leg below the knee, and two
elements will be suitable, one for protecting the shin and one for
protecting the calf. For protecting other body parts, other numbers
of elements can be of interest, for example three or four elements
for protecting the thigh/femur or one element for protecting the
wrist. Usually, the number of elements will be chosen according to
the exposed areas of the body part. For example as mentioned above
for protecting the leg below the knee, the elements protect the
shin to avoid fractures in tibia and the calf to avoid fractures in
fibula, respectively.
[0012] The elements are form-fit to the shape of the body part to
be protected to give the best protection and comfort for the user.
A form fit shape facilitates distribution of any impact force over
a larger area of the body part, thus leading to less risk for
injury. The form fit shape also provides room for the muscles to
expand, leading to both comfort and optimal performance for the
user.
[0013] In one embodiment of the invention, the number and size of
the elements are chosen to ensure that the elements in combination
cover substantially all of the body part to be protected. In this
or other embodiment(s) of the invention, the elements are shaped in
such a way that the adjacent edges of the elements have
complementary forms. In this way the elements may be arranged with
a small or no gap between them to ensure complete protection of the
body part and to provide a tubular assembly. The tubular shape
provides torsional stiffness and an enclosed rigid construction to
further protect towards injuries caused by torsion and providing
extra support to the bone structure.
[0014] The elements are preferably covered by upholstery and in
most cases a padding. The padding may be integrated in the
upholstery or be a separate part. The upholstery and/or padding
provides a more comfortable application towards the body part and
may comprise a temperature and/or humidity transporting material
between the body and the element(s) and/or a shock absorbing
material on the areas facing outwards. The temperature transporting
material may e.g. be Dri-Lex or other suitable materials for
providing a comfortable temperature and avoid accumulation of
humidity which is both uncomfortable and may cause soreness of the
skin. The upholstery and/or padding can be fixed to the elements by
means of sewing, adhesive, nailing, clamping or other suitable
means, or can be removable for changing or washing.
[0015] The fixing members are connected to the elements to
interconnect them and/or to attach the device to the body. The
fixing members are made of a material with some flexibility to
further provide room for an expanding muscle, but which is rigid
enough to provide sufficient pressure to the body part to stabilize
it, e.g. a semi-rigid material. Pressure exerted on the muscle
compartments surrounding the bones stabilise the bones and leads to
less risk for injuries. The fixing members can be attached to the
elements, or to the upholstery/padding.
[0016] The fixing members may for example be adhesive tape,
strings, straps, etc. In one embodiment the fixing members are
Velcro fasteners.
[0017] The fixing elements may also be a hinge device/hinge joint
which interconnects two or more elements along at least one edge.
This hinge element may also be designed to be semi-rigid.
[0018] The device is manufactured by performing the following
steps: [0019] providing an image of the shape of the body part to
be protected, [0020] based on the image of the body part, milling
out a model of the body part, [0021] providing at least one blank
with a curved inner surface, the surface form being adapted to the
outer surface of the model, and [0022] cutting and/or finishing the
edge of the blank(s) to obtain the desired shape.
[0023] The image of the body part to be protected can be provided
by means of imaging devices, such as digital cameras, IR cameras,
film cameras, single CCD chips, etc. In one embodiment the image is
acquired by means of moving a number of cameras surrounding the
body part along the full length of the body part. The cameras may
e.g. be arranged in a pattern adapted for surrounding the body
part, e.g. a substantially circular pattern, a square pattern, or
any suitable pattern which can provide the desired amounts of
imaging points sufficient for providing a 3-dimensional image of
the whole body part. The image data from the cameras may be
processed by means of image processing means, such as e.g. a
computer or dedicated processing means adapted for providing the
desired data format. Some processing may also be performed for
correcting obvious errors in the images and/or add or remove
features from the image.
[0024] Image data from the cameras are transferred to a milling
machine where they are used as input data for milling out a model
of the body part of interest. The milling machine is preferably a
three dimensional milling machine for production of a model of an
imaged object. The milling machine may be adapted for receiving and
using the processed image data from the imaging devices, or the
milling machine itself may comprise image data processing
means.
[0025] The model produced by the milling machine is used for
forming the blank(s). The blank(s) should have a curved inner
surface which fit the body part to be protected to ensure optimal
support and comfort for the user.
[0026] As earlier mentioned, there may be provided one or a number
of blanks, the number depending on the body part to be protected,
the application of the device, and on which sport event and level
the device will be used. In one embodiment there is provided at
least two blanks which in combination covers substantially all of
the body part to be protected.
[0027] The blank(s) is made of a material with sufficient strength,
rigidity, power distribution capability, and which is light and
ductile.
[0028] In one embodiment the blank is made of a thermoplastic
material. Such a material is rigid and has a stable shape when
under a certain transition temperature, while being ductile when
heated over the transition temperature. In this embodiment, the
blank is provided by thermoforming a sheet of thermoplastic
material. The sheet is formed by first heating it above the
transition temperature to make it plastic. The plastic sheet is
then brought into contact with the model and pressed against the
model to achieve the desired formed blank.
[0029] In one embodiment the blank comprises a carbon composite
material which is light and strong. The carbon composite material
may be saturated with a ductile material, for example a
thermoplastic material as mentioned above. The forming may thus be
performed as described before. The forming can also be performed by
first threading a net of carbon fibres over the model, then
applying a ductile curable material, e.g. a thermocurable material,
thus after curing having gained the shaped blank.
[0030] In another embodiment the blank is made of a carbon fiber
material with or without aramid fibre (Kevlar) which is
pre-saturated by an epoxy plastic. The model should then be applied
a slip agent on its outer surface before carbon fibre mats are
arranged onto the surface in different angles. For example may four
layers of carbon fibre mats be applied with mutual angles of 45
degrees, which provides a thickness of approximately 0.7 mm for the
blanks. The carbon fibre layer is then covered by another slip
agent and the model is put under vacuum and exposed to heat, for
example in an oven, for curing, eg. 90.degree. C. for 6 hours.
[0031] The blank may alternatively be made of other formable and
curable material with sufficient strength when cured. Other
suitable forming methods may of course also be applied.
[0032] After curing, the blanks must in most cases be further
finished to obtain the desired formed edges. The edge forming may
be performed by cutting, sawing, filing, grinding, or other
suitable forming method. In one embodiment with two or more blanks,
the edges may be formed to provide that the adjacent edges of the
blanks have complementary forms. This ensures a close fit between
the blanks, thus preventing any part of the body part from being
exposed to outer forces and thus being injured, and preventing the
blanks from dislocating. In this way a tubular assembly can be
achieved providing torsional rigidity and thus improving the
supporting feature of the device.
[0033] To obtain an even more comfortable product, the blanks may
be provided with upholstery and/or padding. The padding may be
integrated in the upholstery or be a separate part. The padding is
preferably facing the body part. The padding can be connected to
the blanks by means of nails, pins, sewing, adhesive, etc. The
upholstery can be connected to the blank in the same manner, or the
upholstery can be provided with pockets for inserting the blanks.
The upholstery can also be provided with pockets for inserting the
padding.
[0034] The padding may be disposable or washable to enable the user
to have a fresh and clean padding each time the protection device
is used.
[0035] The padding may also be provided with ventilating means such
as channels or holes. The ventilating channels may be arranged
directly in the padding, or in the padding/blank interface. There
may also be provided ventilating holes in the blanks.
[0036] The blanks must be connected to the body for providing the
protection. The blanks may be connected to the body by means of
adhesive tape, strings, straps, etc. In one embodiment the blanks
are connected to the body part by means of Velcro fasteners. The
Velcro fasteners may be a separate part, may be connected to the
blank(s) or to the upholstery/padding.
[0037] In the above, the device is described as being custom fit to
each user. It is however possible to use the same manufacturing
method for manufacturing less customized, but still form fit,
devices. The model may be produced based on data gained from
experience data or from synthetically produced data.
[0038] One possibility is to measure characteristic features of the
body of many people, possibly average them, and classify them by
size and/or shape. In this way a set of sizes may be provided. A
number of models and corresponding blanks/devices may then be
produced based on these data, and a user can choose between these
to have a device with excellent fit.
[0039] One possible solution for choosing the adequate size/shape
of the blanks may be to scan the body part of interest to achieve
data regarding a number of characteristic features of the body
part. The scanning may be an imaging device and the characteristic
features may be e.g. the length of a leg from the foot to the knee
and the circumference of the leg in three different locations. The
characteristic features may be derived from the scanning manually
or by means of data processing equipment which may be permanently
connected to the scanning device, or may be a separate unit. The
characteristic features may then be compared to the set of sizes
described above, and the size which gives the best match may be
picked out. In a more simple procedure, the characteristic features
may be manually measured and the best fit size picked out of a
table.
[0040] The invention will now be described in more detail by means
of an example with reference to the accompanying figures where:
[0041] FIG. 1 is a schematic representation of the method according
to the invention for producing a protection device.
[0042] FIG. 2 is a detailed view of one kind of protection
device.
[0043] FIG. 3 is an example of an embodiment of a protection device
according to the invention.
[0044] FIG. 1 is a schematic representation of one embodiment of
the method according to the invention for producing a protection
device. The elements of the protection device which result from the
steps of the method is shown in FIG. 2 and will be described
accordingly.
[0045] First the body part to be protected is scanned in 11. The
scanning means providing a three dimensional image of the body
part. In this example the body part to be protected is the leg
below the knee, e.g. a shin guard protecting both the shin and the
calf of the leg. The leg may be scanned by means of a commercially
available shape capture device such as the Omega T-ring, a product
of Tracer, A Division of Ohio Willow Wood. After scanning, the
image may be adjusted or corrected in 12 by means of image
processing means.
[0046] The image data is transferred to a milling/carving machine
such as the OrthoCarve.TM. from Ortho Europe for milling out a
model of the leg 13, called a "plug". The model is then split in
two parts in 14. The two parts corresponds to two parts of the
protection device, one front part and one back part.
[0047] The two model parts are then used for forming blanks in 15.
The blanks are for example made of a laminate comprising a 1.5 mm
carbon fibre sheet saturated with polyamide plastics. The forming
of the blanks is performed using a diaphragm forming technique or
other adequate forming technique. In diaphragm forming, the sheet
is heated between two release films, normally from silicone rubber.
The softened laminate with the release films is than quickly placed
on top of the model, after which the diaphragm is closed and air
pressure of around 5 bars is applied to press the sheet towards the
model. After the material is sufficiently cooled down the product
has gained its desired form.
[0048] In 16 the blanks are cut to obtain the desired form of the
edges of the two parts of the protection device. The form may be
individually adapted according to the user's wishes and physical
needs, especially the height of the leg protection device can vary
substantially from person to person. In 17 it is performed further
edge processing for obtaining the optimal form, adapting the two
parts to each other, and/or remove any sharp edges.
[0049] In 21 padding is provided by thermoforming a thermoplastic
material such as EPE/EVA foam. In 22 the padding is cut by means of
e.g. a stamping machine or by cutting by hand to adapt the shape to
the blanks.
[0050] In 31 any finishing details are provided, such as edge
finishing.
[0051] In 32 are textiles produced, i.e. upholstery for covering
the protection device. The upholstery and/or padding provides a
more comfortable application towards the body part and may comprise
a temperature and/or humidity transporting material between the
body and the element(s) and/or a shock absorbing material on the
areas facing outwards. The temperature transporting material may
e.g. be Dri-Lex for providing a comfortable temperature and avoid
accumulation of humidity which is both uncomfortable and may cause
soreness of the skin.
[0052] In step 33 there is possibility for further customising of
the device and in 34 the seams, any edge features, straps, Velcro
fasteners, decorating elements etc, are provided and attached to
the padding and/or blanks.
[0053] In 35 the blanks and padding are assembled to form the final
device.
[0054] FIG. 2 is a detailed view of an example of a protection
device according to the invention. The device is in this example a
combined shin/calf guard for protecting the leg below the knee of a
sportsman. The device comprises two blanks 40, 46 of Tepex, which
are produced by thermoforming, thermoformed padding 41, 45, one for
each blank, edge details 42, 44 and Velcro fasteners 43a, 43b.
[0055] The parts shown in FIG. 2 are assembled and provided with
upholstery in step 34 in FIG. 1 to provide a finished protection
device.
[0056] FIG. 3 shows a similar embodiment as shown in FIG. 2, but
with some different features. The protection device comprises also
here two parts, or two "shells" comprising blank and padding. The
height and width of the shells may be individually adjusted
according to the user's wishes. The shown embodiment provide a
protection device with no gap between the two parts when assembled
50 for use. The assembled device 50 has a tubular shape, and this
leads to excellent protection towards external impacts and
torsional forces, while also providing a pressure in the tissue
which supports the leg to further prevent fractures.
[0057] The examples used here is for protecting the leg below the
knee, as is particular interesting for sports such as
soccer/football, rugby, hockey/land hockey, etc. It is however
clear that the method according to the invention can be applied for
manufacturing protection devices for other body parts and for other
applications, for example for other sport events and/or industrial
or other applications which demand protection equipment for
protection against impacts which may lead to fractures or body
tissue damages.
* * * * *