U.S. patent application number 13/827788 was filed with the patent office on 2013-11-28 for two-way protective pad construction.
This patent application is currently assigned to Warrior Sports, Inc.. The applicant listed for this patent is WARRIOR SPORTS, INC.. Invention is credited to Vincent Arpin, Olivier C. Jajko, Michel S. Paul.
Application Number | 20130312152 13/827788 |
Document ID | / |
Family ID | 49620394 |
Filed Date | 2013-11-28 |
United States Patent
Application |
20130312152 |
Kind Code |
A1 |
Paul; Michel S. ; et
al. |
November 28, 2013 |
TWO-WAY PROTECTIVE PAD CONSTRUCTION
Abstract
A protective pad including a rigid shell bounded by a perimeter
and a gasket engaging the perimeter so that forces applied to the
shell are dissipated through the gasket before transferring to a
wearer of the protective pad. The rigid shell cooperates with the
gasket to provide a trampoline effect or two way spring. This
effectively absorbs shock from forces generated by the opponent, so
that the wearer and a colliding opponent both encounter reduced
forces. The shell can bow outwardly to form a cavity above the
wearer when the gasket is placed adjacent the wearer, which can
prevent the rigid shell from bottoming out against the wearer upon
impact. The protective pad can be implemented in a thumb protector
including a stopper disposed between adjacent rigid shells covering
proximal and distal portions of a digit. The stopper can engage the
shells and effectively prevent hyperextension of the digit.
Inventors: |
Paul; Michel S.; (Hudson,
CA) ; Jajko; Olivier C.; (Ile-Bizard, CA) ;
Arpin; Vincent; (Montreal, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WARRIOR SPORTS, INC. |
Warren |
MI |
US |
|
|
Assignee: |
Warrior Sports, Inc.
Warren
MI
|
Family ID: |
49620394 |
Appl. No.: |
13/827788 |
Filed: |
March 14, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61650740 |
May 23, 2012 |
|
|
|
Current U.S.
Class: |
2/16 ; 2/455 |
Current CPC
Class: |
A63B 71/1291 20130101;
A41D 13/015 20130101; A63B 71/12 20130101; A63B 71/141 20130101;
A63B 71/1225 20130101; A63B 2071/1208 20130101; A63B 71/08
20130101 |
Class at
Publication: |
2/16 ; 2/455 |
International
Class: |
A41D 13/015 20060101
A41D013/015 |
Claims
1. A protective pad comprising: a rigid shell having a concave
interior surface, the rigid shell bounded by a shell edge around a
shell perimeter immediately adjacent the shell edge; a gasket
constructed from a high density compliant material, the gasket
including an outer gasket perimeter and an opposing inner gasket
perimeter, the gasket including an upper surface and a lower
surface joined by an outer gasket edge, the gasket including an
inner gasket edge opposite the outer gasket edge, the gasket upper
surface transitioning to a boundary wall located between the inner
gasket edge and the outer gasket edge, the gasket including a
support shelf that is transverse to the boundary wall and that
transitions toward the inner gasket edge; a shell recess defined by
the gasket and extending around the inner gasket perimeter of the
gasket, the shell recess cooperatively bounded by the boundary wall
and the support shelf, the shell recess opening upward, with the
shell perimeter disposed in the shell recess; and an inner layer
joined with the gasket and positioned adjacent the lower surface of
the gasket, the inner layer separated from the concave interior
surface of the rigid shell so that a cavity is formed therebetween,
the inner layer being configured in an untensioned state, wherein
the rigid shell and gasket are configured so that forces of impact
transferred from an impacting player to the rigid shell are
transferred through the shell perimeter substantially entirely to
the gasket to absorb the shock imparted by the force of impact,
thereby decreasing the potential for injury to a wearer of the
protective pad and the impacting player.
2. The protective pad of claim 1 comprising a cushion layer
disposed above the convex exterior surface of the rigid shell and
joined with the rigid shell.
3. The protective pad of claim 1 wherein the upper surface of the
gasket terminates at the boundary wall, without extending over the
support shelf and the shell recess, wherein the boundary wall
extends downwardly from the upper surface to the support shelf.
4. The protective pad of claim 1 wherein the support shelf extends
to the inner gasket edge, and wherein the boundary wall extends to
the upper surface of the gasket.
5. The protective pad of claim 1 wherein the gasket outer edge at
least one of abuts and is disposed adjacent the boundary wall, and
wherein the concave interior surface engages the support shelf, but
is not bonded to the support shelf, around the shell perimeter, and
wherein the inner layer includes a lower surface, with the gasket
being distal from the lower surface.
6. The protective pad of claim 1 wherein the shell perimeter is
stitched to the gasket through the support shelf.
7. The protective pad of claim 1 comprising a cushion layer atop a
convex exterior surface of the rigid shell, wherein the cushion
layer includes an upper surface, wherein the cushion layer is
disposed in the shell recess.
8. The protective pad of claim 7 wherein the upper surface of the
cushion layer is generally coplanar with the upper surface of the
gasket.
9. The protective pad of claim 1 wherein the shell edge is disposed
in the shell recess but offset a distance from the boundary
wall.
10. The protective pad of claim 1 wherein the rigid shell is
constructed from plastic, the gasket is constructed from high
density foam, and the inner layer is constructed from low density
foam.
11. A protective pad comprising: a rigid shell cap bounded by a
perimeter and an outer edge, the rigid shell cap having an interior
surface and an exterior surface; an outer cushion layer disposed
over the rigid shell cap; and a gasket including an upper surface
and defining an upwardly opening inner gasket perimeter recess
bounded by a boundary wall and a support shelf that are transverse
to one another, the upper surface terminating at the boundary wall
so that the upper surface of the gasket extends outwardly away from
the support shelf, without extending over the inner gasket
perimeter recess; wherein the outer edge of the rigid shell cap
abuts the boundary wall, wherein the interior surface of the rigid
shell cap engages the support shelf of the gasket, wherein the
rigid shell cap bows outwardly above a wearer when the gasket is
placed adjacent the wearer, wherein the rigid shell cap transfers a
force applied by an opponent to the rigid shell cap through the
gasket to a wearer of the pad to absorb shock associated with the
force, whereby the rigid shell cap cooperates with the gasket to
provide a trampoline effect to absorb shock from a force generated
by the opponent, so that the wearer of the pad and the opponent
both encounter a reduced amount of the force.
12. The protective pad of claim 11 wherein the outer edge of the
rigid shell cap engages the boundary wall and transfers at least a
portion of the forces through the boundary wall to the gasket.
13. The protective pad of claim 12 wherein at least one of the
perimeter and the outer edge is stitched to the gasket.
14. The protective pad of claim 11 wherein the inner gasket
perimeter recess is an open face recess, wherein the outer edge of
the rigid shell cap is located in the recess without being
overlapped on an exterior surface by the gasket, wherein the rigid
shell cap exterior surface remains uncovered by the gasket.
15. The protective pad of claim 11 comprising an inner layer of low
density compliant material extending in a substantially
un-tensioned state under the rigid shell cap, from a first side of
the gasket to a second side of the gasket, wherein the rigid shell
cap exterior surface remains uncovered by the gasket.
16. The protective pad of claim 11 comprising an inner layer of low
density com pliant material disposed below the rigid shell cap,
wherein the cavity is located between the inner layer and the
interior surface of the of the rigid shell cap, wherein the inner
layer is joined with the gasket and configured to prevent the rigid
shell cap interior surface from engaging the inner layer and the
wearer.
17. The protective pad of claim 11 wherein the gasket extends
laterally away from the outer edge at least 10 mm, wherein the
support shelf is at least 3 mm thick, and wherein the gasket is
constructed from a high density foam having a density of at least
0.05 grams per cm.sup.3.
18. A method for absorbing shock caused by an opponent applying a
force to a wearer of a protective pad, the method comprising:
placing a protective pad adjacent a wearer, the protective pad
including a rigid shell bounded by a perimeter and an outer edge,
the rigid shell cap having an interior surface, an outer cushion
layer disposed over the rigid shell cap, and a gasket defining an
upwardly opening inner gasket perimeter recess having a boundary
wall and a support shelf, the outer edge at least one of adjacent
and abutting the boundary wall, the interior surface engaging the
support shelf, the rigid shell cap bowing outwardly so as to form a
cavity above a wearer when the gasket is placed adjacent the
wearer, applying a force from the opponent to the wearer through
the protective pad; transferring applied force from the rigid shell
cap substantially only through the perimeter and the outer edge of
the rigid shell directly to the gasket; absorbing the shock
generated by the applied force by way of the rigid shell
cooperating with the gasket to provide a trampoline effect so that
the wearer and the opponent both encounter a reduced amount of the
force.
19. A glove comprising: a thumb member, a protective pad joined
with the thumb member, the protective pad comprising: a gasket
constructed from a high density foam padding, the gasket including
an upper surface and defining a first upwardly opening inner gasket
recess bounded by a first boundary wall and a first support shelf
that are generally transverse to one another, the gasket defining a
second upwardly opening inner gasket recess bounded by a second
boundary wall and a second support shelf that are generally
transverse to one another, the first upwardly opening inner gasket
recess and the second upwardly opening inner gasket recess
separated from one another by a gap; a stopper disposed within the
gap and separated from the first and second support shelves, the
stopper joined with the gasket at a zone of flexure, the stopper
and gasket being of a monolithic single piece construction, a
proximal rigid shell disposed within the first upwardly opening
inner gasket recess, the proximal rigid shell including a first
contact surface facing toward the stopper; a distal rigid shell
disposed within the second upwardly opening inner gasket recess,
the distal rigid shell including a second contact surface facing
toward the stopper; wherein the protective pad is operable in a
flexed mode when a digit in the thumb member is flexed, the first
contact surface of the proximal rigid shell and the second contact
surface of the distal rigid shell moving away from the stopper in
the flexed mode, wherein the protective pad is operable in an
extended mode when a digit in the thumb member is extended, the
first contact surface of the proximal rigid shell and the second
contact surface of the distal rigid shell moving toward and
engaging the stopper in the extended mode to prevent the digit from
hyperextending.
20. The glove of claim 19 wherein the proximal and distal rigid
shells articulate away from one another in the flexed mode, wherein
the gasket dynamically flexes within the zone of flexure in the
flexed mode.
21. The glove of claim 19 wherein the gasket includes a gasket
base, wherein the stopper is joined with the gasket base, wherein
the stopper is constructed in the form of an arch that arches over
a user's digit within the thumb member.
22. The glove of claim 19 wherein the proximal rigid shell includes
an exterior surface, wherein the stopper includes an exterior
surface, wherein the stopper exterior surface is positioned above
the rigid shell exterior surface when the protective pad is in the
extended mode.
23. The glove of claim 19 wherein the proximal rigid shell includes
a forward edge and the stopper includes a rearward engagement
surface, wherein the forward edge engages the rearward engagement
surface of the stopper in the extended mode, but disengages the
rearward engagement surface of the stopper in the flexed mode.
24. The glove of claim 23 wherein the distal rigid shell includes a
rearward edge and the stopper includes a forward engagement
surface, wherein the rearward edge engages the forward engagement
surface of the stopper in the extended mode, but disengages the
forward engagement surface of the stopper in the flexed mode.
25. A glove comprising: a thumb member; a protective pad joined
with the thumb member, the protective pad comprising: a gasket
including a first gasket recess and a second gasket recess
separated from one another by a gap, the gasket including a
proximal portion and a distal portion movably joined with one
another; a proximal rigid shell disposed in the first gasket
recess, the proximal rigid shell including a first engagement
surface; a distal rigid shell disposed in the second gasket recess,
the distal rigid shell including a second engagement surface; and a
stopper joined with the gasket and disposed in the gap, the stopper
disposed between the first and second engagement surfaces, wherein
the first and second engagement surfaces engage the stopper when
the pad reconfigures from a flexed mode to an extended mode to
prevent a user's digit in the thumb protector from hyperextending.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to protective equipment that
shields forces, which are exerted on a wearer, and more
particularly, to a multi-layered padding construction that provides
minimal bulk and impediment to movement, yet maximizes protective
coverage and protection to both the wearer, and optionally another
person impacting the protective equipment.
[0002] Protective padding is used to protect its wearer from injury
or from experiencing an impact due to applied forces. The increased
popularity of physical sports has increased the need for personal
protective padding. Sporting activities, such as hockey, lacrosse,
baseball, basketball, football, soccer, biking, motorcycling and
other activities all can lead to falls, collisions and impacts,
which can cause pain, injury and damage to unprotected parts of the
body.
[0003] Conventional protective padding, however, uses "one-way"
padding constructions. This means they are primarily designed to
protect the wearer of the padding. During a collision or check, the
pad makes contact with an external object, for example, an
opponent, another player, the ice, the ground, boards or another
object. The padding typically includes a layer of plastic
sandwiched between and directly contacting layers of foam. The
padding helps reduce pressure on the wearer by distributing the
impact force over a large area. The two foam layers act as a
cushion and provide comfort; however, they frequently attain their
compression limit, bottoming out and doing little to attenuate
further transferred impact forces.
[0004] This usually is not much of an issue because injuries are
the result of pressure. Pressure is a specific amount of force over
a given area. Therefore, as the contact area increases, the
pressure decreases, and so does the risk of injury. For the wearer
of the protective padding during a collision, the impact is spread
over a large surface due to the plastic layer. The plastic layer
alleviates pressure from the wearer, for example, their appendages
or joints, by deflecting impact energy toward the edge of the
plastic layer. The wearer may feel the pressure from the impact,
but it typically is not enough to cause injury.
[0005] The reason the present protective padding described above
works for the wearer, is the same reason that it is ineffective for
protecting opponents or other players during collisions with the
wearer of the protective padding. When dealing with impacts and the
related forces, a relevant axiom is that for every action there is
an equal and opposite reaction. Conventional protective padding is
frequently implemented in shoulder pad or elbow pad caps.
Typically, these caps are rounded in contour. Usually, the surface
of the object with which the cap collides--be it another player,
person or object--many times is flat or convex. Accordingly, the
force exerted by the cap on that surface is concentrated at a
single point, which is usually a small contact area on the surface
of the other player or person impacting the wearer of the
protection padding. The foam, as mentioned above, does not provide
much cushioning between the wearer and the other player or person,
particularly where the force exceeds the compressive strength and
the foam bottoms out. With this reduced shock absorption, the
player or person impacting or being impacted by the wearer of the
protective padding usually experiences a great deal of pressure in
a very localized area. As a result, that other player or person can
be injured by the impact, even though the wearer of the protective
padding is not injured.
SUMMARY OF THE INVENTION
[0006] A protective pad is provided including a layered pad having
a rigid protective shell joined with a base or gasket. The gasket,
which optionally can be constructed from a high density compliant
material, substantially surrounds and contacts the perimeter of the
shell. The shell is elevated a distance above the base and/or the
wearer, generally in a central region of the pad so that a cavity
is formed therebetween. Forces generated from an impact with the
pad and/or shell are transmitted primarily through the shell to the
gasket, and from there to wearer's body. This can dissipate the
impact forces, cushion the blow and absorb energy, thereby
providing protection to the wearer, as well as the person or item
impacting the wearer.
[0007] In one embodiment, the protective pad includes a rigid shell
bounded by a perimeter and a gasket engaging the perimeter so that
forces applied to the rigid shell are dissipated through the
gasket. The rigid shell cooperates with the gasket to provide a
trampoline effect or two way spring, which can protect both the
wearer and the person or item impacting the wearer effectively
absorbing the energy and/or dissipating the impact forces.
[0008] In another embodiment, the gasket can define an open gasket
recess or ring, generally bounded by a boundary wall and a support
shelf. The rigid shell perimeter can rest on the support shelf in
the gasket recess. An outer edge of the rigid shell can be placed
adjacent and/or abut the boundary wall.
[0009] In still another embodiment, the support shelf can be of a
predetermined thickness and width to accommodate the perimeter
and/or edge of the rigid shell, and effectively absorb shock
generated by impacts to the rigid shell.
[0010] In yet another embodiment, the protective pad can include an
inner layer, optionally constructed from low density foam. The
inner layer can be configured to engage the wearer. The rigid shell
can bow outwardly to form a cavity above the wearer, and generally
between the shell and the inner layer, when the gasket is placed
adjacent the wearer. The dimension of the cavity and distance from
the inner layer and/or wearer can be preselected to prevent the
rigid shell from bottoming out against the wearer upon impact.
[0011] In even another embodiment, the rigid shell and gasket, and
optionally the inner layer, cooperate to ensure that impacts to the
shell are spread over the entire surface of the shell, which in
turn enables the shell to utilize more of the available gasket on
the protective pad, thereby protecting both the wearer and an
opponent engaging the wearer during the impact.
[0012] The protective pad herein is well suited for a variety of
protective equipment, for example, shoulder pads, elbow pads, knee
pads, shin guards, wrist pads, gloves, thumb protectors, digit
protectors, leg pads, ankle pads and even body armor. Moreover, the
protective pad described herein optionally can maintain pad weight
in acceptable range, facilitate player movement, reduce the amount
of plastic and shell size, increase impact time, and decrease
impact pressure.
[0013] In a further embodiment the protective pad can be
implemented in a thumb protector (which includes any protectors for
the thumb and/or any digit) to both protect the wearer's digit from
blows and to prevent hyperextension of the digit. In such a
construction, the protective pad can include a proximal rigid shell
and a distal rigid shell, separated by a gap. The shells can be
further joined with a gasket assembly including a region of
flexure. The region of flexure can be configured to overlap a joint
of the user's digit.
[0014] In still a further embodiment, the thumb protector can
include a separate and independent stopper disposed between the
proximal and distal rigid shells. The stopper can be engaged by the
respective proximal and distal rigid shells, thereby stopping
movement relative to one another, and preventing hyperextension or
overextension of a digit with which the protective pad is
associated.
[0015] In still yet a further embodiment, the thumb protector
protective pad can include a proximal rigid shell and a distal
rigid shell, separated by a gap. The shells can be further joined
with one or more gaskets. The shells and gaskets can be isolated or
independent from one another, generally attached to a thumb or
digit gusset, and independently moveable. The shells and gaskets
can be configured to include the components of the other protective
pads herein.
[0016] Before the embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited to
the details of operation or to the details of construction and the
arrangement of the components set forth in the following
description or illustrated in the drawings. The invention may be
implemented in various other embodiments and of being practiced or
being carried out in alternative ways not expressly disclosed
herein. Also, it is to be understood that the phraseology and
terminology used herein are for the purpose of description and
should not be regarded as limiting. The use of "including" and
"comprising" and variations thereof is meant to encompass the items
listed thereafter and equivalents thereof as well as additional
items and equivalents thereof. Further, enumeration may be used in
the description of various embodiments. Unless otherwise expressly
stated, the use of enumeration should not be construed as limiting
the invention to any specific order or number of components. Nor
should the use of enumeration be construed as excluding from the
scope of the invention any additional steps or components that
might be combined with or into the enumerated steps or
components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a front perspective view of a shoulder pad system
incorporating a current embodiment of a protective pad;
[0018] FIG. 2 is a rear perspective view of the shoulder pad
system;
[0019] FIG. 3 is a close-up perspective view of the protective pad
in the form of a shoulder pad cap;
[0020] FIG. 4 is a exploded perspective view of the protective
pad;
[0021] FIG. 5 is another exploded view of the protective pad;
[0022] FIG. 6 is a perspective view of a liner or inner layer of
the protective pad;
[0023] FIG. 7 is a section view of the protective pad;
[0024] FIG. 8 is a cross section view of an alternative embodiment
of the protective pad;
[0025] FIG. 9 is an exterior side view of an elbow pad
incorporating the protective pad;
[0026] FIG. 10 is an interior view of the elbow pad incorporating
the protective pad of the current embodiment;
[0027] FIG. 11 is a bottom view of a rigid shell included in the
elbow pad incorporating the protective pad;
[0028] FIG. 12 is a side view of the rigid shell included in the
elbow pad incorporating the protective pad;
[0029] FIG. 13 is a side perspective view of the elbow pad
including the protective pad joined with a wearer's appendage;
[0030] FIG. 14 is an exploded view of the elbow pad incorporating
the protective pad;
[0031] FIG. 15 is another perspective exploded view of the elbow
pad incorporating the protective pad;
[0032] FIG. 16 is a bottom view of the elbow pad incorporating the
protective pad;
[0033] FIG. 17 is a sectional view of the elbow pad incorporating
the protective pad taken along lines 17-17 of FIG. 16;
[0034] FIG. 18 is a table generally illustrating force versus
impact duration;
[0035] FIG. 19 is a table illustrating force versus impact duration
relative to no protection, a conventional shoulder cap, and a
shoulder cap including a protective pad of the current
embodiments;
[0036] FIG. 20 is a side view of a thumb protector incorporating
the protective pad;
[0037] FIG. 21 is a top view of the thumb protector incorporating
the protective pad;
[0038] FIG. 22 is an exploded view of the thumb protector
incorporating the protective pad;
[0039] FIG. 23 is a section view of the thumb protector
incorporating the protective pad taken along lines 23-23 of FIG.
21;
[0040] FIG. 24 is a section view illustrating the thumb protector
moving from a curled or flexed mode to an extended mode which can
prevent hyperextension of the digit or thumb;
[0041] FIG. 25 is a top view of an alternative thumb protector
incorporating the protective pads;
[0042] FIG. 26 is a section view of the alternative thumb protector
incorporating the protective pad taken along lines 26-26 of FIG.
25; and
[0043] FIG. 27 is a section view of the thumb protector
incorporating the protective pad taken along lines 27-27 of FIG.
25.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIGS. 1-8 illustrate a shoulder pad system 10 including a
current embodiment of the protective pad 20. In general, the
shoulder pad system 10 includes a pair of shoulder caps 20, also
referred to as shoulder pads or protective pads, which are joined
with a chest protector 12 and back protector 14. The shoulder pad
system 10 can also include a sternum protector 12A associated with
the chest protector 12, and a spine protector 15 associated with
the back protector 14. The shoulder system 10 can include rib
protectors 16 and collar bone protectors 18. Of course, the
protector pad 20, in the form of a shoulder pad in the pad system
10, can be in a variety of different configurations and can take on
a variety of different pad formations. Although described in
conjunction with a shoulder pad and elbow pad, as noted above, the
protective pad 20 can be incorporated into knee pads, shin guards,
wrist pads, gloves, thumb protectors, digit protectors, leg pads,
ankle pads, body armor, helmets, hip pads, rib pads, sternum
protectors, spine protectors and a variety of other protective
equipment.
[0045] Turning now to FIGS. 3-7, the protective pad 20 will now be
described in more detail. As shown, the protective pad 20 is
attached to the shoulder pad system 10 via a system of straps. The
protective pad 20 can be associated with one or more bicep pads 13
and 17. Each of the protective pads can be generally configured to
conform to the shape of the body part received by the protective
pad, for example, the shoulder, elbow, kneecap, shin, leg and the
like. As a result, the protective pad 20 can provide protection
without negatively affecting mobility of the wearer.
[0046] The protective pad 20 can include an outer layer, or a
cushion layer 30. The cushion layer can be secured to a rigid shell
50 and/or a gasket 40. Generally, the outer layer or cushion layer
can be constructed from a low density foam or other compliant
material. By low density foam or low density compliant material, it
is meant that the foam/compliant material has a density generally
of about 0.02 grams per cm.sup.3 to about 0.09 grams per cm.sup.3,
optionally, less than 0.07 grams per cm.sup.3, further optionally
about 0.045 grams per cm.sup.3. The particular foam or compliant
material can be constructed from low density ethyl vinyl acetate
(EVA), polyurethane, or open pore polystyrene. The outer cushion
layer 30 can be constructed from foams or other materials that
deform under pressure, thus absorbing some of the force generated
by an impact. As a result, the impact on the player transferred
through the pad is lessened because of the deformation of the
compressible material absorbing some of the overall shock of the
impact.
[0047] The outer cushion 30 layer can generally be enveloped or
covered with a covering. The covering can be a fabric, woven or
non-woven, such as Lycra.RTM., spandex, vinyl, polyester, nylon or
some other generally soft, pliable lightweight material. Although
not shown, the covering can be glued, stitched, cemented or
otherwise secured with fasteners to the outer cushion layer. The
outer cushion layer 30 can include a stitching channel 32 (FIG. 3)
if stitching is the construction for attaching the cushion layer 30
and other elements together.
[0048] The outer cushion layer 30 can be of a predetermined
thickness. This predetermined thickness can be a minimum thickness
mandated by the particular rules of the sport in which the
protective pad is used. As shown in FIG. 7, the thickness 33 of the
outer cushion layer 30 can range from about 2 mm to about 12 mm, 5
mm to about 10 mm, and optionally about 7 mm to 8 mm. Depending on
the particular location of the outer cushion layer 30 over the
shell 50, the outer layer can vary in thickness. For example, as
illustrated, it is of about 10 mm at the thickness 33 generally in
the center or central region of the protective pad 20. Nearing the
outer edges of the shell 50, close to the gasket 40, the outer
cushion layer 30 can decrease in thickness. In some cases, it can
decrease down to 8 mm, 5 mm or 3 mm or other thicknesses depending
on the particular application. Optionally, the outer cushion layer
can have a durometer of 65 Shore 00. Of course, the durometers for
the material making up the outer cushion layer can be adjusted as
desired, depending on the particular application.
[0049] The outer layer 30 and any optional covering thereof can
further be joined with the shell 50. The shell 50 can be
constructed from a rigid or semi-rigid, self-supporting, generally
slightly deformable materials such as high density polyethylene,
polypropylene, polycarbonate, metals, laminates, polyesters and
polyamide materials. Generally, the rigid shell can be a variety of
thicknesses, for example, it can be about 0.5 mm to about 5 mm,
optionally about 1 mm to about 3 mm and further optionally about 2
mm in thickness. Of course, the thicker the piece, the more weight
that is added to the protective pad.
[0050] The shell 50 can generally be contoured so that it is of a
relatively low profile and follows the contours of the body part
which is designed to protect. The shell 50 generally can include a
convex, exterior surface 52 and a concave inner surface 53. The
shell 50 also can be constructed to be bounded by an outer edge 54.
Depending on the particular configuration, the outer edge generally
can conform to the boundary wall 42, also referred to as a "ring"
of the gasket, as described further below. The shell 50 also can
include a zone of engagement 56 which is the region around the
perimeter 57 of the shell that engages the gasket 40 directly. More
particularly, the zone of engagement 56 is a region where the
interior surface, for example the concave angled or other interior
surface 53 of the shell 50 engages or lays upon the support shelf
41 of the gasket 40. The zone of engagement 56 can extend about 3
mm to about 10 mm, or more inward from the outer edge 54. The zone
of engagement is usually sized so that it fits substantially
entirely within the ring or boundary wall 42 of the gasket 40.
[0051] Optionally, the zone of engagement 56 can be constructed so
that it transitions to a stepped or angled portion 58 (FIG. 7)
which itself transitions to an upper level or bridge portion 59 of
the shell. This stepped portion or transition level 58 can provide
extra springiness, rebound characteristics and/or shock absorption
to the shell 50 when it is impacted by a force F. Optionally, this
stepped or angled portion 58 of the shell can provide a geometry to
the cap that improves stiffness and increases the height of the
cavity near the edge by a distance, for example, by a distance DE
of about 3 mm to about 10 mm, closer to the gasket 40.
[0052] The shell can terminate at the shell edge 54. The shell edge
can correspond closely to the edge 37 of the overlying cushion or
outer layer 30. Indeed, the two elements can be coterminous so that
they closely fit adjacent or abut the boundary wall 44.
[0053] Referring to FIG. 7, the shell 50 is constructed so that in
its finished form it is positioned a distance D above the inner
liner or layer 60. Where the gasket 40 extends across the liner,
under the shell 50, the shell 50 also can extend that distance D
above the innermost portion of the gasket 40. Generally, the
distance D is selected so that even upon impact of a force F the
inner liner or layer 60, the innermost or central portion 43A
(where optionally included) of the gasket does not engage or
contact the interior surface 53 of the shell. For example, this
distance D can range from about 1 mm to about 25 mm, 2 mm to about
15 mm, 5 mm to about 10 mm, or any other distance depending on the
particular application, so that the inner layer 60 or the central
portion 43A of the gasket 40 does not contact the interior surface
53 of the shell 50.
[0054] As shown in FIG. 7, with the shell 50 separated from the
liner 60 and/or central portion 43A of the gasket, an air cavity 61
is formed therebetween, or between the interior 53 of the shell and
the central portion 43A of the gasket 40.
[0055] Generally, the pad 20 can include the inner layer or liner
60. This inner layer 60 can be constructed from a low density
compliant material, such as a low density foam. This low density
foam or low density compliant material can be an EVA or
polyurethane foam generally ranging in density from about 0.03
grams per cm.sup.3 to about 0.9 grams per cm.sup.3, optionally
about 0.045 grams per cm.sup.3. The inner layer can have a
durometer of about 55 Shore OO. The inner layer can be joined with
the gasket 40 and positioned adjacent a lower surface 46 of the
gasket. This inner layer 60 can be of any desired thickness, for
example, it can be about 1 mm to about 15 mm, 2 to about 10 mm, and
optionally about 6 mm in thickness. The thickness can be uniform
across the entire layer, or the thickness can follow the contour of
the gasket to reduce in bulk and improve upon pressure
distribution.
[0056] Optionally, the inner layer 60 can be of a laminate
construction with a fabric covering its interior and exterior
sides. The fabric can be Lycra.RTM., or any other suitable fabric
for engagement against a wearer's skin or clothing. As shown in
FIG. 6, the inner layer 60 can include an upper surface 62 that is
covered with a fabric and opposing lower surface 63 that is also
covered with the same fabric 63 wrapped around the layer. The
fabric can be any woven or non-woven fabric or elastic support
including, but not limited to, spandex, Lycra.RTM., vinyl,
polyester and/or nylon. The inner layer or liner 60 can be
constructed from the low density foam or low density compliant
material as mentioned above. Optionally, it can be formed with a
fabric or other covering or lining. Generally, however, the inner
layer is in a substantially un-tensioned state when it is located
under the rigid shell cap and attached to the gasket. By
un-tensioned state, it is meant that the inner layer is not
stretched and put under an internal stress when the pad is not in
use on a wearer. Of course, however, the fabric covering of the
inner layer 60 can be slightly tensioned with the inner layer 60
still being generally in an un-tensioned state.
[0057] Turning now to FIGS. 4-7, the gasket 40 generally includes
an upper surface 45 and a lower surface 46, with an open-faced
recess 44 that is defined by the upper surface 45. The gasket also
includes an outer gasket perimeter 49 and an inner gasket perimeter
48, along with a corresponding outer gasket edge 49A and inner
gasket edge 48A. The inner gasket perimeter 48 and edge 48A can be
eliminated where the gasket includes a central region 43A (FIG. 7)
that extends from one side of the gasket 40 to another. The gasket
upper surface 45 and lower surface 46 can be joined at the gasket
outer edge 49A, which can also define the outermost portion of the
outer gasket perimeter 49. That outer gasket edge 49A can be
rounded, squared or angled depending on the particular application.
The same is true for the inner gasket edge 48A. Optionally, the
inner gasket edge 48A can join the lower surface 46 with the
support shelf 41, rather than the upper surface 45.
[0058] The support shelf 41 of the gasket 40 generally is
transversely oriented, for example, perpendicular to, the boundary
wall or ring 42. The boundary wall 42 can extend upwardly from the
support shelf 41 to the upper surface 45 of the gasket 40. At the
transition from the boundary wall 42 to the upper surface 45, the
boundary wall can be rounded for a gentle transition to the upper
surface. Indeed, the entire ring or boundary wall 42 can be of a
generally rounded or angled configuration from the shelf to the
upper surface if desired. Optionally, the support shelf can
transition from a first, lower level, upward to a second higher
level of the upper surface via the boundary wall. The upper surface
45 can extend outwardly, away from the boundary wall 42 so that it
does not overlap or extend over the support shelf.
[0059] The support shelf 41, as shown in FIGS. 4, 7 and 8 can
engage the interior surface 53 of the shell 50 in the engagement
zone 56. This engagement can be of the type where these elements
are simply adjacent and nesting against one another, for example,
by virtue of these elements being stitched to one another.
Alternatively, these elements can be glued, cemented, mated or
otherwise fastened to one another. Optionally, however, the shell
is not encapsulated with the gasket, and therefore is not bonded to
the support shelf and/or boundary wall.
[0060] The support shelf 41 can be of a predetermined thickness D9
(FIG. 8) to ensure that the force is transferred through the shell
50 are effectively transferred to the gasket 40 and to the wearer
in a dissipated, shock absorbing manner. In the embodiment
illustrated, the thickness D9 of the gasket from the support shelf
41 to the lower surface 46 of the gasket 40 can be about 2 mm to
about 8 mm, optionally about 4 mm to about 5 mm and further
optionally about 4.5 mm. The support shelf 41 can also be of a
width D2 (FIG. 4) extending generally from the boundary wall 42 to
the inner gasket edge 48A. This distance D2 can be about 5 mm to
about 20 mm, optionally about 10 mm to about 15 mm. The precise
width D2 can be selected depending on the zone of engagement 56
with the gasket 40 and the overall size of the protective pad
20.
[0061] As shown in FIG. 7, the support shelf 41 can engage the zone
of engagement 56 of the shell 50 around the perimeter 57 of the
shell. The edge 54 of the shell can rest adjacent the support shelf
41. Optionally, the shell edge 54 can be spaced on the shelf 41 a
preselected distance D3 from the ring or boundary wall 42, in which
case the edge 54 is considered adjacent but offset from the ring or
wall also referred to as the boundary wall 42. Alternatively, the
edge 54 can be placed in abutment with the boundary wall 42, in
which case it is directly engaging that boundary wall 42.
[0062] The gap D3 (FIG. 7) established between the outer edge 54 of
the shell 50 and the boundary wall 42 can be of any of the
distances described above. Generally, it can be said to be offset a
distance from the boundary wall 42 of the recess 44. Optionally,
the outer edge 54 of the shell 50 can be located in the recess 44
without being overlapped by any other portion of the gasket 140.
For example, the exterior or upper surface of the shell 52 around
the perimeter 57 or near the edges 54 is not overlapped by the
gasket or any portions of the gasket 40. Further optionally, the
recess can be formed so that that it opens upwardly, forming a
shoulder in the gasket. The shoulder can be such that the upper
surface 45 terminates at and transitions to the boundary wall 42,
which further transitions to the support shelf 41. The support
shelf can be free from any other components of the gasket being
located over it, such as the upper surface 45, so that the shell
can be dropped or placed directly onto the shelf.
[0063] The gasket 40 optionally can be constructed to have a margin
47 that extends around the gasket from the boundary wall 42 to the
outer edge 49A of the gasket. This margin 47 can generally be
referred to as the outer width of the gasket surrounding the shell
50. As shown in FIGS. 4 and 7, this margin can be of a width D5.
This width D5 can be about 0.5 mm to about 50 mm, 10 mm to about 30
mm, and optionally about 15 mm, or other widths depending on the
particular application and desired force dissipation. This margin
can be of a predefined, preselected depth D4, extending generally
from the upper surface 45 of the gasket 40 to the lower surface 46
of the gasket. This depth D4 can range from about 5 mm to about 20
mm, optionally about 7 mm to about 15 mm, and even further
optionally about 10 mm in thickness.
[0064] Generally, the gasket 40 can be constructed from a high
density compliant material. The high density compliant material can
be foam, such as expanded polypropylene foam, ethyl vinyl acetate
(EVA), polyurethane, or open pore polystyrene or other foams,
thermoplastic polyurethane, gels and the like. By high density
compliant material or high density foam, it is meant that the
material/foam has a density generally of about 0.05 grams per
cm.sup.3 to about 0.30 grams per cm.sup.3, optionally, greater than
0.05 grams per cm.sup.3, further optionally greater than 0.10 grams
per cm.sup.3, even further optionally about 0.15 grams per cm.sup.3
or greater, depending on the application.
[0065] As shown in FIG. 7, when the shell 50 and its corresponding
outer or cushion layer 30 are installed with the perimeter 57
and/or zone of engagement 56 located in the recess 44, the outer or
upper surface of the cushion layer 30 can be generally flush or
even with the upper surface 45 of the gasket 40. This can provide a
clean and neat transition between these two surfaces. Of course, if
desired, these surfaces can be offset from one another, on
completely different levels.
[0066] As further shown in FIG. 7, the gasket 40 also includes a
central portion 43A extending from one side of the gasket to the
other. The central portion 43A can be of a minimal dimension, for
example about 0.5 mm to about 2 mm, optionally about 1 mm. Of
course, if desired, this central portion 43A can be completely
eliminated as shown in the embodiment in FIG. 8. This embodiment is
substantially the same as the embodiment shown in FIG. 7 except
that it does not include the respective skin in the central portion
43A of the gasket. Further, as shown in FIG. 8, the figure
illustrates the variability in the distance between the interior
surface 53 of the shell 50 and the upper surface 56 of the inner
layer 60. For example, generally, in the center of the pad 20, the
distance D is greater than the distance DE closer to the gasket.
These distances DE can vary from distance D by 25% to 50%, or more
depending on the particular application the compression
characteristics of the pad 20.
[0067] FIG. 8 also illustrates a close up view of the gasket and
its connection with the shell 50 and outer cushion layer 30. As
shown, the outer cushion layer 30 and shell 50 can be joined with
the gasket 40 via a stitch 73 passing through those elements.
Generally, the stitch 73 also passes through the shelf 41 and the
entire thickness D9 of the gasket below the shelf. To conceal the
ends and protect the gasket and inner layer 60 from de-lamination,
a binding 70 can be wrapped around the edges of these elements.
This binding 70 can be held in place by stitching 72. Of course, in
place of the stitching, the respective elements can be joined
together with cement, adhesives, RF welding or other fasteners
depending on the particular application. Further, although shown as
being a generally squared-off at their edges, the gasket 40 and
liner 60 can terminate at any type of geometric configuration, for
example, the ends can be rounded, triangular, boxed and/or
polygonal.
[0068] Another embodiment of the protective pad is shown in FIGS.
9-17 and generally designated 120. This protective pad 120 is
substantially the same as the protective pad in the embodiment
above, however, it is implemented in an elbow pad system 110 and
can generally include the protective pad 120 which includes an
outer cushion layer 130, a gasket 140, a shell 150 and an inner
liner or layer 160. The elbow pad system 110 can include a bicep
strap 111 that straps the pad around the bicep of the wearer. A
central elbow strap 112 can further join the pad with the elbow. A
forearm strap 113 can even further join the elbow pad system 110
with the arm of the wearer. The protective pad 120 can be divided
into first and second protective pad portions 120A and 120B.
Generally, each of these protective portions are identical to the
protective pad described above with a few exceptions. For example,
the first portion 120A can generally be configured to cover an
elbow of the wearer. The second portion 120B can be configured to
cover the forearm or arm immediately adjacent the elbow. The
elements 120A and 120B can be segmented and/or separated by a
portion of the gasket 140. This can provide added articulation and
movement to the wearer. Of course for other appendages, similar
constructions can be used.
[0069] Another embodiment of the protective pad is shown in FIGS.
20-24 and generally designated 220. This protective pad 220 is
essentially the same as the protective pad in the embodiments
above, however it is omitted in a thumb protector or digit
protector system. As used herein, thumb protector is used to mean
that the protective pad is used to protect the thumb or any digit
of the hand. Moreover, although described in connection with a
thumb protector, the protective pad construction described herein
could be used with any digit or the hand or other appendage.
Generally, the thumb protector provides not only impact absorption
and force dissipation as described in connection with the other
embodiments, but also can prevent a thumb within a glove including
the thumb protector from bending backwards, thereby preventing
hyperextension of the wearer's thumb. Generally, the protective pad
can be incorporated into a finger or thumb portion of a protective
glove 202. The protective pad 220 can be attached to the finger
portion or thumb portion using a conventional means for example,
via stitching, gluing, adhering, RF welding and/or fastening. The
protective pad 220 can generally include a gasket 240 and a rigid
shell 250. The gasket can be joined to one or more inner layers
(not shown) which is further attached to the finger or thumb
portion 202 of the glove.
[0070] Generally the gasket 240 can be substantially similar to the
gaskets 40 and 140 above. The shell 250 can be separated into first
shell portion 250A and second shell portion 250B. The first shell
portion 250A can also be referred to as the proximal shell portion
while the portion 250B can be referred to as the distal shell
portion. The shells making up these portions can be substantially
identical to the other shells described in connection with the
other protective pads herein. Generally the distal shell portion
250B can be configured to cover and provide protection for the
distal phalanx while the proximal shell 250A provides protection
for the proximal phalanx. Each of the respective proximal and
distal shells 250A and 250B can include the interior and exterior
surfaces. The interior surface 253 can be generally concave. The
shells can also include an outer edge 254 like the other pads noted
above.
[0071] The gasket 240 can be similar to the gaskets of the
embodiments above with several exceptions. For example, the gasket
240 can include a support shell or portion 241 that is bounded by a
boundary wall or ring 242. The boundary shell in this embodiment,
however, can extend entirely under respective proximal and distal
shell portions 250A and 250B so that the inner surfaces 253 thereof
are in contact with the shell 241 across substantially all the
underside of the respective shell portions. Of course, however,
there can be gaps established between the interior surface 253 and
the support shell 241 in particular locations are desired.
[0072] The forward edge 256A of the proximal shell portion 250A and
the rear edge 256B of the distal shell 250B can be however
unbounded by the boundary wall or ring 242. Generally as shown in
FIG. 23 these edges 256A and 256B can be free, extending beyond the
shell 241. In this construction however, and as further described
below, these edges 256A and 256B can be positioned so that in the
extended state they are immediately adjacent the proximal and
distal walls of the stopper 281 and 282.
[0073] Returning to the gasket 240 shown on FIGS. 22 and 23, the
gasket can include a margin 247 that effectively forms a base for
both of the proximal and distal shells. The base extends from
adjacent the proximal shell 250A and around the distal shell 250B.
The base can include a margin 247 as described above in connection
with the margin of the gasket in the other embodiments above.
Likewise the respective surfaces and other constructions of the
gasket 240 can be similar to that of the gaskets in the other
embodiments for protective pads above.
[0074] One exception is that the base 245 can include a zone or
region of flexion. Within the zone or region of flexion, a stopper
280 can be located. The zone of flexion can include one or more
gaps 248A that are established between the stopper 280 and in
particular the proximal 256A and distal 256B surfaces of the
stopper 280, relative to the edges 241A and 241B. These gaps can be
anywhere from 0.01 m to 2 mm, or other distances depending on the
particular application. The gaps can extend from a lateral side of
the gasket 240 to a medial side of the gasket 240. The zone of
flexion can allow the portion of the gasket 240 associated with the
proximal shell 258 to flex or move about the region of flexion 248
relative to the portion of the gasket associated with the distal
shell 250B. Generally there is no fixed pivot in the region of
flexion 248, rather the shell can flex somewhat dynamically in
multiple different locations of the gasket, particularly in the
margin 247. Without a designated, specific point of pivot, the
thumb protector can accommodate a variety of different length and
oriented and configured thumbs of a variety of different
wearers.
[0075] The zone of flexion 248 as shown above also can be joined
with the stopper 280. Again the stopper can be constructed
monolithically from a single piece construction with the remainder
of the gasket 240. The stopper 280 can extend from the margin 247
on a medial side of the thumb protector pad to a lateral side of
the protector pad. The stopper itself can include an exterior
surface 283 and an interior surface 284 opposite the exterior
surface. Generally the interior surface 284 can be flush with the
interior surface of the remainder of the gasket while the exterior
surface 283 can be flush with and/or extend above the proximal 250A
and distal 250B shells.
[0076] The stopper is illustrated in FIGS. 22 and 23 and can
generally be an arch shape extending across the gasket 240 and
disposed generally between the edges or end portions 256A and 256B,
respective proximal 250A and distal 250B shells.
[0077] In operation, the thumb protector 220 can operate to prevent
hyper or over extension of the digit, for example the thumb, in
which the thumb protector is implemented. For example, as shown
there, the thumb protector is shown in a partially flexed state in
solid lines. In that configuration, a first gap G1 is established
between the edge 256B of the distal shell 250B and the front or
forward surface 281 of the stopper 280. Further, a second gap is
optionally established between the forward edge 256A of the
proximal shell 250A and the rear surface 283 of the stopper 280.
The gaps 248A and 248B respectively open up between the portions of
the gasket adjacent the stopper 280.
[0078] When the thumb, however, is forced rearwardly in the
direction of the arrows as shown toward a hyper extended or over
extended state, the gap G1 and optional gap G2 are closed so that
the respective edges 256B contacts the surface 281 of the stopper
280 and the edge 256A contacts the rear surface 283 of the stopper
280. This collision or engagement of the respective proximal and
distal shells 250A, 250B of the stopper surfaces stops or impairs
the rearward motion of the digit within the glove to which the
protective pad 220 is associated so that that digit does not
hyperextend. The forces of the edges impacting the surfaces of the
stopper 280 can also be transmitted through these proximal and
distal shells to the respective boundary walls 242 to further
decrease the likelihood of hyper extension.
[0079] As shown in FIGS. 10-13 and 16-17, the pad portion 120A
covering the elbow can include specialized shell 150. This shell
can include virtually all of the components of the shell in the
shoulder pad embodiment above. In addition, or alternatively, it
can also include a cupped portion 181. This cupped portion can be
of a particular depth, which is best illustrated in FIGS. 14 and
17. This depth D6 can provide a larger cavity 161 under the point
of the wearer's elbow. This can provide better protection for the
wearer and another person or player contacting the protective pad
120. The distance D6 can range from about 5 mm to about 25 mm,
optionally about 10 mm to about 15 mm.
[0080] The distance D6 can be substantially greater than the
distance D8 (FIG. 17) between the shell 150 and the remainder of
the inner layer 160, for example, closer to the forearm, away from
the point of the elbow. Distance D8 can range from about 0.5 mm to
about 2 mm, optionally about 1 mm. With this construction, the
forces F2 applied over the point of the elbow to the pad can be
dissipated, and the shock absorbed rapidly by contact of the shell
150 with the underlying liner 160. Moreover, the forces F2 can be
dissipated over a larger surface area of the liner or inner layer
160, which can reduce the impact felt by both the wearer and the
opponent impacting the wearer.
[0081] As shown in FIGS. 14 and 15, the elbow protective pad 120
and its respective portions 120A and 120B, generally each include
an outer cushion layer 130, a shell layer 150, a gasket layer 140
and an inner or liner layer 160. Each of these respective elements
can be constructed similarly to and include the same features and
characteristics of those described in connection with the
embodiment above. An exception concerns the gasket 140. For
example, the gasket 140 can include a bridge portion or separator
portion 140A. On opposite sides of the separator portion 140A the
boundary walls 142A and 142B can be formed. Likewise, the
respective support shelves 141A and 141 B can be formed immediately
adjacent those respective boundary walls. The margin 147 of the
gasket 140 can extend around the respective outer perimeters of the
shell 150, and likewise between the adjacent shell portions 150A
and 150B. The respective perimeters 154A and 154B of the respective
shell portions 150A and 150B can be placed adjacent and/or abut the
respective rings or boundary walls 142A, 142B.
[0082] Another difference between the cushion layer 130 of this
embodiment and the embodiment above concerns the edges or perimeter
of the that layer. For example, as shown in FIG. 17, the cushion
layer 130 can include a cushion layer margin 135 that can extend or
wrap around the edge 154 of the shell 150. This margin 135 of the
cushion layer 130 also can wrap and extend under the undersurface
153 of the shell with secondary margin portion 136. Stitching 173
can be stitched through the cushion layer 130, the shell 150, and
the inner layer 160 to attach all of these elements together.
[0083] Another embodiment of the protective pad is shown in FIGS.
20-24 and generally designated 220. This protective pad 220 is
similar to protective pads in the embodiments above, however it is
included in a thumb protector or digit protector 210. As used
herein, "thumb protector" means that the protective pad can be used
to protect the thumb or any digit of the hand, and includes both
thumb protectors and digit protectors. Generally, the thumb
protector 210 with the protective pad provides not only impact
absorption and force dissipation as described in connection with
the other embodiments, but also can prevent a thumb or digit (used
interchangeably herein) within a glove including the thumb
protector from bending backward, thereby preventing hyperextension
of the wearer's thumb or digit.
[0084] The protective pad can be incorporated into a finger or
thumb portion of a protective glove 202. The protective pad 220 can
be attached to the finger portion or thumb portion using any
conventional means, for example, via stitching, gluing, adhering,
radio frequency welding and/or fastening. The protective pad 220
can include a gasket 240 and rigid shell 250. The gasket 240 can be
joined to one or more inner layers (not shown) which are further
attached to the finger or thumb portion 202 of the glove.
[0085] The gasket 240 can be substantially similar to that of the
gaskets 40 and 140 above. The shell 250 (FIG. 20) can be separated
into first shell portion 250A and second shell portion 250B. First
shell portion 250A can be referred to as the proximal shell
portion, and the second shell portion 250B can be referred to as
the distal shell portion. The shells making up these portions can
be substantially identical to the other shells described in
connection with the other protective pads herein.
[0086] Generally, the distal shell portion 250B can be configured
to cover and provide protection for the distal phalanx while the
proximal shell 250A can be configured to cover and provide
protection for the proximal phalanx. Each of the respective
proximal and distal shells 250A and 250B can include interior and
exterior surfaces. The interior surface 253 of each can be
generally concave. The shells each can also include an outer edge
254 like the other protective pads in the embodiments above.
[0087] The gasket 240 can be similar to the gaskets of the
embodiments above with several exceptions. For example the gasket
240 can include a support shelf or portion 241 that is bounded by a
boundary wall or ring 242. The boundary shelf in this embodiment,
however, can extend entirely under the respective proximal and
distal shells 250A and 250B so that the inner surfaces 253 of the
shells thereof are in contact with the shelf 241 across
substantially all the underside of the respective shells 250A and
250B. Optionally, gaps or cavities can be established between the
interior surface 253 of the shells 250A and 250B and the support
shelf 241 in particular locations as desired.
[0088] The forward edge 256A of the proximal shell 250A and the
rear edge 256B of the distal shell 250B can be unbounded by the
boundary wall or ring 242. As shown in FIG. 23, generally these
edges 256A and 256B can be free, extending beyond the shelf 241. As
further described below, these edges 256A and 256B can be
positioned so that in the extended state they are immediately
adjacent the proximal 251 and distal 282 walls or engagement
surfaces of the stopper 280.
[0089] Returning to FIGS. 22 and 23, the gasket 240 can include a
base 245 for both of the proximal and distal shells. The base
extends from adjacent the proximal shell 250A and around the distal
shell 250B. The base can include a margin 247 as described in
connection with the margin of the gasket in the other embodiments
herein. Likewise, the respective surfaces of the gasket 240 can be
similar to that of the gaskets in the other embodiments herein.
[0090] One exception is that the base 245 can include a zone or
region of flexion 248. Within the zone or region of flexion, a
stopper 280 can be located. The zone of flexion, and more
generally, the gasket 240, can include one or more gaps 248A and
248B established between the stopper 280, and in particular, the
proximal 281 and distal 282 surfaces of the stopper 280 relative to
the edges 241A and 241B of the shelf or gasket. These gaps can be
anywhere from 0.01 mm to 2.0 mm, or other distances depending on
the particular application. The gaps can extend from a lateral L
side of the gasket 240 to a medial M side of the gasket 240. The
zone of flexion can allow the portion of the gasket 240 or base 245
associated with the proximal shell 250A to flex or move about the
region of flexion, and/or relative to the portion of the gasket 240
or base 245 associated with the distal shell 250B.
[0091] As illustrated, there is no fixed pivot in the region of
flexion 248, rather the shell flexes generally dynamically, in
multiple different locations of the gasket, particularly in the
margin 247. Without an isolated and specific pivot point, the thumb
protector can accommodate a variety of different length and
configured thumbs or digits to accommodate multiple users.
Optionally, if desired, the zone of flexion can be replaced with
one or more dedicated pivot points, with the gasket parts or shell
connected via one or more pins or fasteners.
[0092] The zone of flexion 248 as shown above also can be joined
with the stopper 280. The stopper 280 can be constructed with the
remainder of the gasket 240, monolithically from a single piece
construction. The stopper 280 can extend from the margin 247 on a
medial side M of a protective to a lateral side L of a protective
pad. The stopper itself can include an exterior surface 283 and an
interior surface 284 opposite the exterior surface. Generally, the
interior surface 284 can be flush with the interior surface of the
gasket, while the exterior surface 283 can be flush with and/or
extend above the proximal shell 250A and distal 250B shell.
[0093] The stopper 280, as illustrated in FIGS. 22 and 23 can be
configured in an arch shape extending across the gasket 240 and
disposed generally between the edges or end portions 256A and 256B
of the respective proximal 250A and distal 250B shells.
[0094] In operation, the thumb protector 220 can operate to prevent
hyper or over extension of a thumb or digit. As shown in FIG. 24,
the thumb protector 220 is shown in a partially flexed state in
solid lines. In that configuration, a first gap G1 can be
established between the edge 256B of the distal shell 250B and the
distal surface 282 of the stopper 280. Further, a second gap can be
optionally established between the forward edge 256A of the
proximal shell 250A and the proximal surface 282 of the stopper
280. The respective gaps 248A and 248B respectively are opened up
between the portions of the gasket adjacent the stopper 280 as
shown in FIG. 22 when the thumb is in a flexed mode.
[0095] When the thumb is forced rearwardly in the direction of the
arrows as shown, toward a hyperextended or overextended state, gap
G1 and gap G2 are closed so that the distal shell and its edge 256B
contacts the distal surface 282 of the stopper 280, and the
proximal shell and its edge 256A contacts the proximal surface 281
of the stopper 280. This collision or engagement of the respective
proximal and distal shells 250A, 250B with the stopper surfaces
stops or impairs the rearward motion of the digit within the glove,
so that digit is not hyperextended. The forces of the edges
impacting the surfaces of the stopper 280 can also be transmitted
through these proximal and distal shells to the respective shelf 24
and/or boundary walls 242, as well as the margin and gasket in
general (as discussed with the other embodiments herein), to
further decrease the likelihood of hyperextension.
[0096] Optionally, the protective pad in the thumb protector
described immediately above can be modified so that the respective
gaps 248A and 248B of the gasket 240 are eliminated. In this
construction, the proximal and distal shells 250A and 250B, and in
particular the edges 256A and 256B, can rest immediately adjacent
and/or in contact with the stopper 280. In this construction, the
protective pad operates similar to the protective pads of the other
embodiments herein. The shells and the boundary walls 242 as well
as the shelf 241 operate and transmit forces similar to the other
protective pads described herein. Further optionally, the thumb
protector described immediately above can be modified so that it is
more of a fixed nonmoving non-flexing construction with a unitary
rigid shell. For example as shown in FIGS. 25-27, the shell 350 can
be a rigid and unitary piece. This protective pad is similar to the
other shoulder cap and elbow pad constructions described above with
a few exceptions. For example, the thumb protector 320 includes a
shell 350 that is joined with a gasket 340. The edge of the shell
abuts against the foundry wall or ring 342 of the gasket like the
other embodiments above. The shell can also include reinforcing
ridges or recesses 355A and 355B that run along the portion of the
shell to provide structural reinforcement. The shell can also
include a secondary cushion 354 above it. Additional cushion
materials or finishing trim pieces 353 and 357 can be configured
around at least a portion of the shell 350 and its perimeter to
better hold it in securement with the gasket and protect it from
exposure to a stick or other item used that is held by hand within
the hand within the glove.
[0097] The thumb protector 320 can also optionally include a cavity
defined between the interior of the shell 350 and the shell 341 or
generally the gasket 340. Further optionally, the shell 350 can be
supported by a support ridge or projection 345 and this projection
345 can extend upwardly from the casket 340 as shown. The shell can
include a recess or other area 352 configured to interact with
and/or engage the ridge 345 effectively, the ridge, recess or area
352 of the shell 350. This can provide additional optional support,
enforce transmission capabilities of the protective pad 320.
[0098] A method for assembling the protective pad of the
embodiments above will now be described. To begin, the gasket of
the protective pad can be compression molded to obtain a desired
shape. The gasket may or may not be lined with a material for
cosmetic purposes. If it is, the material can be sewn, glued, radio
frequency welded or otherwise attached to the outer surfaces of the
gasket. The rigid shell material is molded, optionally injected
molded, and cut to the desired dimensions. It can be covered with
an outer protective layer or foam as described above, and an inner
lining if desired as well. These components can be held together
with an adhesive cement or other fastening mechanism. The shell,
along with the outer cushion layer and optional lining cover can be
sewn to the gasket along the inner edges or in the zone of
attachment and/or the ring. With these components constructed, the
inner layer or liner, which also can be lined with a material as
described above, can be added to the underside of the gasket and
stitched together along an outer perimeter. If desired, the nylon
binding can be added to the edge of the gasket and inner layer to
conceal the junction and interface between these elements.
[0099] The protective pad of the current embodiments can be used to
attenuate forces or absorb shock caused by a person or player
applying a force via impact to a wearer of a protective pad.
Generally, in use the method includes the wearer donning the
protective pad. For example, with reference to FIG. 1 or 13, the
respective shoulder pad system 10 or elbow system pad 110 can be
placed on the torso or elbow, respectively, of the wearer. The
rigid shell 50, 150 and inner layer 60, 160 cooperate so that a
cavity remains between these elements and generally above the
wearer's appendage when the gasket 40, 140 on the respective pads
is placed adjacent the wearer. With the protective pads 20, 120 in
place, the wearer can engage in activity. An opponent can apply a
force to the protective pad 20, 120, for example by impacting the
wearer with a force F, F2 (FIGS. 7, 17). The applied force is
somewhat attenuated by the outer cushion layer 30, 130. The
remaining force F, F2 is transferred to the shell 50, 150.
Regardless of whether the impact occurs at the center of the pad or
elsewhere, this force is transmitted through the zone of engagement
to the ring 42, 142 and/or shelf 41, 141 of the gasket 40, 140.
Where the outer edge 54, 154 of the shell engages or abuts the
boundary wall 42, 142, part of the force can also be transmitted
through the boundary wall to the gasket 40, 140. The forces are
generally distributed through the gasket 40, 140 and substantially
attenuated to the lesser forces FW, FW2 as shown in FIGS. 7 and
17.
[0100] The gasket and shell effectively cooperate to absorb the
shock generated by the applied force. It can be said that these
elements generally provide a trampoline effect or two-way spring
effect so that the wearer and the colliding opponent both encounter
a reduced amount of force. Further, the effective duration of the
forces and impact exerted on the wearer, and likewise felt by the
opponent contacting the protective pad is spread out over a greater
amount of time, which in turn causes a decrease in the peak force
felt by the wearer and the opponent.
[0101] As an example, reference is made to FIG. 18 which shows
force applied versus duration of impact. This example illustrates
that by increasing the impact duration, the impulse force or peak
force is decreased. The impact only lasts a fraction of a second
and is measured in milliseconds. The small increase in the duration
causes a substantial decrease in peak force. By reducing the peak
force the peak pressure also is reduced. This pressure is that felt
by the opponent as well as the wearer.
[0102] In effect, the protective pad of the embodiments herein
accomplishes two things. First, it slows down the impact and
thereby provides a cushion to the impact. Second, it also provides
a means to absorb the impact energy, and thus provide shock
absorption. Generally, the cushioning relates to the amount of
deceleration during impact or how much the impact is slowed which
is typically measured in units of gravity (Gs). The shock
absorption is the amount of energy absorbed by the material, and in
this case, by the combination of the outer cushion layer, the shell
and the gasket. The gasket, when constructed from higher density
compliant materials such as foams or other materials can absorb
even more impact energy.
[0103] To test the efficiency of the protective pad of the present
embodiments, two basic shoulder caps were constructed. The first
was a conventional shoulder cap construction including a first
outer layer of soft EVA foam, an inner or second layer of soft EVA
foam, with a plastic shell sandwiched therebetween, with no space
between the foam and the plastic. The second protective pad was
constructed like that shown in FIGS. 4 and 5. These shoulder cap
constructions were compared to one another and to a situation where
there was no protection, that is, no padding, located above the
sensors used to measure the impacting force.
[0104] The protective pad of the current embodiments repeatedly
performed better than the conventional pad in two ways. First, the
impact duration was increased as shown in FIG. 19. This corresponds
to a slowing down of the impact and the force gradually, thereby
reducing the deceleration caused by the force, that is the G force.
Second, the transmitted force also was reduced as a result to
establish that the protective pad provides increased cushioning and
shock absorption.
[0105] As shown in FIG. 19, the protective pad of the current
embodiment in the form of a shoulder pad reduced the impacting
force to 8,000 newtons versus the noted conventional shoulder cap
described above, which registered at about 11,000 newtons. This
equates to a surprising and unexpected 27% decrease in the
transferred impacting force. This force also is noted to be
decreased both for the wearer and the player impacting the wearer,
which is believed to reduce the potential for injury to both the
wearer of the protective pad, and the person impacting the
protective pad.
[0106] The protective pad may be used in many applications, such as
in athletic gear and apparel, protective clothing and protective
barriers. Objects that may be protected using an item comprising a
protective pad of the current embodiments include all parts of the
human body such as the elbows, shoulders, head, neck, arms, wrist,
hands, thumbs, digits, chest, torso, groin, legs, back, buttocks,
knees, shins, ankles and feet. Items that may comprise the
protective covering include shoulder pads, elbow pads, helmets,
neck braces, wrist pads, gloves, thumb protectors, body armor,
shoes, body garments, leg pads, knee pads, shin pads, ankle pads
and jackets. Any athletic gear and apparel, protective clothing or
protective barrier known in the sports and industrial protective
covering industry may be protected.
[0107] The above description is that of current embodiments of the
invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. This disclosure is presented for illustrative
purposes and should not be interpreted as an exhaustive description
of all embodiments of the invention or to limit the scope of the
claims to the specific elements illustrated or described in
connection with these embodiments. For example, and without
limitation, any individual element(s) of the described invention
may be replaced by alternative elements that provide substantially
similar functionality or otherwise provide adequate operation. This
includes, for example, presently known alternative elements, such
as those that might be currently known to one skilled in the art,
and alternative elements that may be developed in the future, such
as those that one skilled in the art might, upon development,
recognize as an alternative. Further, the disclosed embodiments
include a plurality of features that are described in concert and
that might cooperatively provide a collection of benefits. The
present invention is not limited to only those embodiments that
include all of these features or that provide all of the stated
benefits, except to the extent otherwise expressly set forth in the
issued claims. Any reference to claim elements in the singular, for
example, using the articles "a," "an," "the" or "said," is not to
be construed as limiting the element to the singular. Any reference
to claim elements as "at least one of X, Y and Z" is meant to
include any one of X, Y or Z individually, and any combination of
X, Y and Z, for example, X, Y, Z; X, Y; X, Z ; and Y, Z.
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