U.S. patent application number 13/952962 was filed with the patent office on 2015-04-16 for protective padding assembly for a sports apparel article.
This patent application is currently assigned to Wilson Sporting Goods Co.. The applicant listed for this patent is Wilson Sporting Goods Co.. Invention is credited to Damon Clegg, Rey C. Corpuz, Bradley L. Gaff, Shaun P. Gilday, Chris Hill, Don Reardon, Allen G. Wagner.
Application Number | 20150101110 13/952962 |
Document ID | / |
Family ID | 52808382 |
Filed Date | 2015-04-16 |
United States Patent
Application |
20150101110 |
Kind Code |
A1 |
Wagner; Allen G. ; et
al. |
April 16, 2015 |
PROTECTIVE PADDING ASSEMBLY FOR A SPORTS APPAREL ARTICLE
Abstract
A protective sports garment comprising including an article of
clothing and at least a first pad assembly having an inner surface
and an outer surface defining a pad area. The pad assembly includes
a plurality of spaced apart cells coupled together by a plurality
of linking members, and first and second regions. Each of the first
and second regions extends over at least 25 percent of the pad
area. The first region is formed of a first inner layer and a first
outer layer, and the second region is formed of the first inner
layer and does not include the first outer layer. The first inner
and outer layers are formed of first and second materials having
first and second durometer values measured on a hardness scale,
respectively. The second durometer value is greater than the first
durometer value. The inner surface of the pad assembly engages the
article.
Inventors: |
Wagner; Allen G.; (Chicago,
IL) ; Corpuz; Rey C.; (Hinsdale, IL) ; Gaff;
Bradley L.; (Woodridge, IL) ; Gilday; Shaun P.;
(Chicago, IL) ; Clegg; Damon; (Hood River, OR)
; Reardon; Don; (Portland, OR) ; Hill; Chris;
(Portland, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wilson Sporting Goods Co. |
Chicago |
IL |
US |
|
|
Assignee: |
Wilson Sporting Goods Co.
Chicago
IL
|
Family ID: |
52808382 |
Appl. No.: |
13/952962 |
Filed: |
October 10, 2013 |
Current U.S.
Class: |
2/455 |
Current CPC
Class: |
A41D 13/015 20130101;
A41D 13/0156 20130101; A41D 13/0153 20130101; A41D 31/285
20190201 |
Class at
Publication: |
2/455 |
International
Class: |
A41D 13/015 20060101
A41D013/015 |
Claims
1. A multi-layered pad assembly configured for use with an article
of athletic apparel, the pad assembly comprising: a plurality of
spaced apart cells, the cells including, an inner layer having an
inner surface, an outer surface and a side surface and being formed
of a first material having a first durometer value measured on an
Asker C hardness scale, the inner surface coupled to the article of
athletic apparel, and at least two of the plurality of cells
including an outer layer formed of a second material, the second
material having a second durometer value measured on an Asker C
hardness scale, the second durometer value being greater than the
first durometer value; and a plurality of linking members, each of
the linking members having first and second ends, the first end
connected to one of the cells and the second end connected to
another of the cells.
2. The pad assembly of claim 1, wherein the first end of the
linking member is connected only to a single one of the cells, and
wherein the second end of the linking member is connected only to
another one of the cells.
3. The pad assembly of claim 1, wherein each the plurality of cells
include the inner and outer layers.
4. The pad assembly of claim 1, wherein the at least two cells
including the inner and outer layers defining a first region of the
pad assembly, and wherein the cells formed without the outer layer
defining a second region of the pad assembly.
5. The pad assembly of claim 1, wherein the linking members are
formed of at least the first material.
6. The pad assembly of claim 5, wherein at least one of the linking
members is formed of the first and second materials.
7. The pad assembly of claim 1 wherein the plurality of cells
define at least one shape having area within the range 200 mm.sup.2
to 2000 mm.sup.2.
8. The pad assembly of claim 7, wherein the outer layer of the at
least two cells extends over at least 30 percent of the outer
surface of the inner layer.
9. The pad assembly of claim 1, wherein at least one of the inner
and outer layers define an opening that extends through at least
one of the inner and outer layers.
10. The pad assembly of claim 1, wherein at least 40 percent of the
cells are directly connected to no more than two adjacent cells by
the linking members.
11. The pad assembly of claim 1, wherein the first material is a
foam material, and wherein the second material is a compressed,
thermal molded foam material.
12. The pad assembly of claim 1, wherein the first end of the
linking member is directly connected to the side surface of one of
the cells and wherein the second end is directly connected to the
side surface of another of the cells.
13. A pad assembly configured for use with an article of athletic
apparel, the pad assembly comprising: a plurality of spaced apart
cells including an inner layer having an inner surface and an outer
surface and being formed of a first material, the inner surface
coupled to the article of athletic apparel; a plurality of linearly
extending linking members connecting the cells together, the
plurality of linearly extending linking members including at least
first and second linking members defining at least first and second
axes, respectively, the first and second axes defining a first
angle, the first angle being within the range of 20 degrees to 90
degrees, each of the linking members having first and second ends,
the first end connected to one of the cells and the second end
connected to another of the cells.
14. The pad assembly of claim 13, wherein the at least first and
second linking members defining at least first and second axes
include at least first, second and third linking members defining
at least first, second and third axes, respectively, and wherein
the third axes is substantially parallel to the first axis.
15. The pad assembly of claim 13, wherein the at least first and
second linking members defining at least first and second axes
include at least first, second, third and fourth linking members
defining at least first, second, third and fourth axes,
respectively, and wherein the fourth and first axes define a second
angle.
16. The pad assembly of claim 15, wherein the second angle is
approximately the same as the first angle, and wherein the polarity
of the second angle is opposite the first angle.
17. The pad assembly of claim 13 wherein the plurality of cells
define at least one shape having area within the range 200 mm.sup.2
to 2000 mm.sup.2.
18. The pad assembly of claim 17 wherein the shape of the cells is
ovular.
19. The pad assembly of claim 17 wherein the shape of the cells is
selected from the group consisting of are circular, triangular,
rectangular, hour glass shaped, polygonal shaped, semi-circular, an
alphanumeric shape and combinations thereof.
20. The pad assembly of claim 17, wherein the cells are formed in
at least first and second different sizes.
21. The pad assembly of claim 17, wherein the cells are formed in
at least first, second and third different sizes
22. The pad assembly of claim 13, wherein a majority of the
plurality of cells define a through-cell opening extending from the
outer surface to the inner surface.
23. The pad assembly of claim 20, wherein the through cell openings
define cell opening area of at least 50 mm.sup.2.
24. A protective sports garment comprising: an article of clothing;
at least a first pad assembly having an inner surface and an outer
surface, the pad assembly including a plurality of spaced apart
cells coupled together by a plurality of linking members, and first
and second regions, the outer surface of the first pad assembly
defining a pad area, each of the first and second regions extending
over at least 25 percent of the pad area, the first region being
formed of a first inner layer and a first outer layer, and the
second region being formed of the first inner layer and not
including the first outer layer, the first inner and outer layers
being formed of first and second materials having first and second
durometer values measured on a hardness scale, respectively, the
second durometer value being greater than the first durometer
value, the inner surface of the pad assembly engaging the article
of clothing.
25. The protective sports garment of claim 24, further comprising a
second pad assembly, wherein the second pad assembly is formed of a
second inner layer and a second outer layer, wherein the second
inner and outer layers are formed of third and fourth materials
having third and fourth materials durometer values, respectively,
the third durometer value being greater than the fourth durometer
value, wherein the second pad assembly includes a plurality of
cells, and wherein each of the cells includes the second and outer
layers.
26. The protective sports garment of claim 24, further comprising a
third pad assembly formed of a continuous third padding layer
having an outer surface, wherein the third pad assembly includes a
plurality of cells coupled together by a plurality of linking
members, wherein the outer surface of the third layer is the outer
surface of the third pad assembly.
27. The protective sports garment of claim 24, wherein the inner
surface of the first pad assembly is fixedly attached to the
article of clothing.
28. The protective sports garment of claim 24, wherein the article
of clothing includes a flexible cover layer extending over the
outer surface of the first pad assembly.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a sports apparel
article including a padding assembly. In particular, the present
invention relates to protective sports apparel incorporating one or
more improved padding assemblies to enhance the protection,
performance and comfort of the user.
BACKGROUND OF THE INVENTION
[0002] Many sports require protective equipment including padding
assemblies to help protect players from impacts and injury.
Protective equipment can include a variety of external pads applied
over the players clothing and/or uniform. Protective equipment pads
are worn by players in a number of contact sports, such as
football, hockey, lacrosse, basketball and soccer. In recent years,
sports apparel articles such as pants, shirts, shorts and sleeves
have been configured to incorporate one or more protective pads.
The padding can be attached directly to the inside or outside of
the apparel article or placed within pockets on the apparel
article. Such protective apparel items can be worn as the only
protective equipment for the player or worn in conjunction with
other external protective equipment, such as shoulder pads, hip
pads, shin guards, thigh pads, rib pads, etc.
[0003] Although protective sports apparel has improved in recent
years, some drawbacks remain. Many sports apparel articles
incorporating protective pads can be bulky, heavy, provide only
limited flexibility, and inhibit breathability of the apparel
article. When such sport protective apparel articles are worn with
external pads, the combination can be uncomfortable and
unnecessarily inhibit the movement and flexibility of the user.
Some existing pads incorporated into apparel items provide only
limited articulation or flexibility. As a result, some movement can
be restrained by the padding. Other existing pad assemblies include
a group of separate smaller pads constrained within a pouch or
pocket of the apparel article. Such pad assemblies can offer
insufficient support and protection from sharp impacts. In some
designs, the pouch or packet can be large enough to allow for
bunching of some small pad and excessive separation of other pads
leaving areas of the user's body unprotected and vulnerable to
impacts.
[0004] Accordingly, a continuing need exists to a protective sports
apparel article with one or more padding assemblies configured to
protect the user without negatively affecting the user's
performance. What is needed it a lightweight breathable padding
assembly for a sports apparel article that enables the user to
comfortably perform all the desired movements for a particular
sport or activity without causing binding, obstruction or
undesirable restriction. It is desirable to provide a protective
sport apparel article with a protective padding assembly that is
configured to be used, worn and perform with other external pad
assemblies, such as, for example, shoulder pads. What is needed is
a padding assembly that provides exceptional structural integrity,
durability and reliability while conforming to the contour of the
user's body and allowing for free uninhibited movement by the user.
Additionally, there is a continuing need for a protective sports
apparel item that is provides a pleasing unique aesthetic.
SUMMARY OF THE INVENTION
[0005] The present invention provides a multi-layered pad assembly
configured for use with an article of athletic apparel. The pad
assembly includes a plurality of spaced apart cells and a plurality
of linking members. The cells include an inner layer having an
inner surface, an outer surface and a side surface. The cells are
formed of a first material having a first durometer value measured
on an Asker C hardness scale. The inner surface is coupled to the
article of athletic apparel. At least two of the plurality of cells
includes an outer layer formed of a second material. The second
material has a second durometer value measured on an Asker C
hardness scale. The second durometer value is greater than the
first durometer value. Each of the linking members has first and
second ends. The first end is connected to one of the cells and the
second end is connected to another of the cells.
[0006] According to a principal aspect of a preferred form of the
invention, a pad assembly configured for use with an article of
athletic apparel includes a plurality of spaced apart cells and a
plurality of linearly extending linking members connecting the
cells together. The plurality of spaced apart cells includes an
inner layer having an inner surface and an outer surface. The inner
layer is formed of a first material. The inner surface is coupled
to the article of athletic apparel. The plurality of linearly
extending linking members includes at least first and second
linking members defining at least first and second axes,
respectively. The first and second axes define a first angle that
is within the range of 20 degrees to 90 degrees. Each of the
linking members has first and second ends. The first end is
connected to one of the cells and the second end is connected to
another of the cells.
[0007] According to another preferred aspect of the invention, a
protective sports garment including an article of clothing and at
least a first pad assembly. The first pad assembly has an inner
surface and an outer surface. The pad assembly includes a plurality
of spaced apart cells coupled together by a plurality of linking
members, and first and second regions. The outer surface of the
first pad assembly defines a pad area. Each of the first and second
regions extends over at least 25 percent of the pad area. The first
region is formed of a first inner layer and a first outer layer,
and the second region being formed of the first inner layer and not
including the first outer layer. The first inner and outer layers
is formed of first and second materials having first and second
durometer values measured on a hardness scale, respectively. The
second durometer value is greater than the first durometer value.
The inner surface of the pad assembly engages the article of
clothing.
[0008] This invention will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying drawings described herein below, and wherein like
reference numerals refer to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a front view of a set of protective apparel
articles incorporating protective padding assemblies in accordance
with a preferred embodiment of the present invention
[0010] FIG. 2 is a rear view of the set of protective apparel
articles of FIG. 1.
[0011] FIG. 3 is a front view of the protective shirt of FIG. 1
with a silhouette of shoulder pads positioned over the shirt.
[0012] FIG. 4a is a front view of a pair of protective shorts in
accordance with a preferred embodiment of the present
invention.
[0013] FIG. 4b is a rear view of the pair of protective shorts of
FIG. 4a.
[0014] FIG. 5a is a front view of a shirt in accordance with a
preferred embodiment of the present invention.
[0015] FIG. 5b is a rear view of the shirt of FIG. 5a.
[0016] FIG. 6 is a top view of a rib padding assembly of the
protective shirt of FIG. 1.
[0017] FIG. 7 is a top view of a spine padding assembly of the
protective shirt of FIG. 1.
[0018] FIG. 8 is a top view of a right thigh padding assembly of
the protective pant of FIG. 1.
[0019] FIG. 9 is a top view of a right hip padding assembly of the
protective pant of FIG. 1.
[0020] FIG. 10 is a top view of a tail bone padding assembly of the
protective pant of FIG. 1.
[0021] FIG. 11 is a top view of a knee padding assembly of the
protective pant of FIG. 1.
[0022] FIG. 12 is a top view of a right shoulder padding assembly
of the protective shirt of FIG. 1.
[0023] FIG. 13 is a top view of a right thigh padding assembly in
accordance with an alternative preferred embodiments of the present
invention.
[0024] FIG. 14a is a top view of a pair of cells and linking
members of a padding assembly in accordance with a preferred
embodiment of the present invention.
[0025] FIG. 14b is a side view of the pair of cell and the linking
members of
[0026] FIG. 12a.
[0027] FIG. 15 is a side view of a pair of cells and linking
members of a padding assembly in accordance with an alternative
preferred embodiment of the present invention.
[0028] FIG. 16 is a side view of a pair of cells and linking
members of a padding assembly in accordance with an alternative
preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to FIGS. 1 through 3, a protective sports apparel
system is shown generally as 10. The sports apparel system 10 can
include a pair of sports protective pants 20 and a sports
protective shirt 30 in accordance with one implementation of the
present invention is illustrated. The sports protective pants 20
and shirt 30 are configured for use in American football. The
present application is directly applicable to other sports apparel
items and padding assemblies, such as, for example, use in the
following sports, baseball, softball, lacrosse, soccer, hockey,
rugby, basketball, skiing, snowboarding, cycling and
volleyball.
[0030] The pants 20 can include left and right leg sections 12 and
14, a waist section 16 and a crotch section 18. The shirt 30 can
include left and right arm sections 22 and 24, front and rear torso
sections 26 and 28, and left and right shoulder sections 32 and 34.
The pants 20 and the shirt 30 can be formed of one or more woven or
non-woven textile materials, such as nylon. In other
implementations, the pants and/or shirt can be made of other
materials, such as, for example, Lycra.RTM. (a registered trademark
of Invista North America S.A.R.L), rayon, polyester, elastane,
polyacrylic, spandex, linen, wool, cotton, silk and combinations
thereof The textile materials used to form the pants and/or shirt
can be highly resilient, breathable, and have moisture wicking
properties. The textile materials used to form the pants and/or
shirt can include microfibers, knits, or coatings that form a
breathable and/or water-resistant barrier or polymer sheet. The
textile materials can be laminated or otherwise layered in two or
more sheets of similar or different materials.
[0031] The protective sports apparel system 10 includes one or more
padding assemblies. The padding assemblies can include one or more
rib padding assemblies 40, thigh padding assemblies 42, left and
right hip padding assemblies 44 and 46, a tail bone padding
assembly 48, a spine padding assembly 50, left and right shoulder
padding assemblies 52 and 54, elbow padding assemblies 56, forearm
padding assemblies 58, knee padding assemblies 64 and other padding
assemblies. The padding assemblies include a plurality of spaced
apart cells 60 coupled together by a plurality of linking members
62. The cells 60 and/or the linking members 62 can be formed as a
single layered structure or as a multi-layered structure having two
or more layers of resilient padding material. The spaced apart
cells 60 and linking members 62 can be arranged in a large variety
of different sizes, shapes, and configurations. The spacing between
the cells 62 and the arrangement and/or alignment of the linking
members 62 can be varied to provide the optimum level of
flexibility, comfort and structural integrity to meet a particular
user's needs, or a particular application. The padding assemblies
40-58 and 64 can be directly coupled to the respective sports
apparel articles such as the pants 20 or the shirt 30 through one
or more adhesives, stitching, snap fit connections, hook, loop
fastening mechanisms, thermal bonding, chemical bonding, rivets and
combinations thereof.
[0032] Referring to FIGS. 4a and 4b, and FIGS. 5a and 5b, the
protective sports apparel system 10 can be applied to a pair of
shorts 70 and to other configurations of the shirt 80 having the
padding assemblies 40-54. The shorts 70 and the shirt 80 can be
substantially the same as the pants 20 and the shirt 30 of FIGS.
1-3 including the various sections of the apparel articles. The
shorts 70 and the shirt 80 can include additional seams 82 or
stitch patterns than the pants 20 and the shirt 30. The present
invention contemplates numerous combinations and patterns, shapes
and sizes of seams, stitches or other section configurations.
[0033] The padding assemblies 40-54 can be positioned over the base
layer or layers forming the shorts 70 and/or shirt 80 and an
additional protective layer 72 can be applied over the padding
assemblies 40-54 to secures retain the padding assemblies 40-50 to
the shorts 70 and/or the shirt 30. The protective layer 72 can be
attached to the base layer or layers of the shorts and/or the shirt
80 through a stitching 74. In other implementations, the protective
layer 72 can attached to the base layer or layers of the shorts 70
or the shirt 80 through other means, such as, for example, bonding,
welding, adhesives, snap-fit connections, hook and loop fastening
mechanisms, zippers, buckles, and combinations thereof. The
protective layer 72 in combination with the base layer or layers of
the shorts 70 or the shirt 80 can define a cavity 76 for retaining
the padding assembly 40-54 to the apparel article. In one
implementation, the padding assembly 40-54 can free to move within
the cavity 76. In another implementation, the padding assembly
40-54 can also be secured to one or both of the base layer or
layers of the shorts 70 or the shirt 80, or to the protective layer
72 through an adhesive, stitching, hook and loop fastening
mechanisms, snaps, buckles, rivets, other fasteners, or
combinations thereof. Referring to FIG. 4a, a zipper 84 can be
attached to the protective layer 72, and/or to the adjacent
material of the apparel article, to provide an opening for
installing, removing and/or replacing the padding assembly 42. In
other implementations, other mechanisms can be used to provide a
releasable opening in association with the protective layer 72 and
to provide access to the cavity 76. In other implementations,
snaps, buckles, clips, hook and loop fastening mechanisms, other
recloseable fasteners and combinations thereof can be used.
[0034] The protective layer 72 is preferably formed of a
lightweight, breathable woven or non-woven textile material, such
as a Lycra.RTM.. In other implementations, other materials, such
as, for example, nylon, rayon, polyester, elastane, polyacrylic,
spandex, linen, wool, cotton, silk and combinations thereof. In
some implementations, the protective layer 72 can be formed of a
translucent, semi-translucent, transparent or semi-transparent
material. In other implementations, the protective layer 72 can
include a mesh or a knit to facilitate breathability, heat
transfer, and/or air flow through the protective layer 72. In
another implementation, the protective layer 72 help form a water
proof barrier for the padding assembly 40-54. The protective layer
72 can increase the structural integrity, durability and
reliability of the protective apparel system 10. In other
implementations, one or more of the padding assemblies can be
applied to other forms of protective apparel articles, such as, for
example arm sleeves, leg sleeves, jackets, etc. In other
implementations, the sports apparel article can be formed without a
protective layer extending over one or more of the padding
assemblies.
[0035] Referring to FIGS. 1 and 6, one implementation of the
padding assembly, the rib padding assembly 40, is shown in greater
detail. The padding assembly 40 includes an inner padding layer 86
having an inner surface 88 (see FIG. 14b), an outer surface 90 and
a side surface 92. The inner layer 86 is formed of a sheet of a
first material that is formed into the desired pattern to form the
cells 60 and the linking members 62. The cells 60 can be formed of
one size and one shape. In another implementation, the cells 60 can
be formed of two or more sizes, and/or two or more shapes. The
cells 60 of FIG. 6 have three distinct ovular sizes. The cells 60
can define a cell area that is within the range of 200 mm.sup.2 to
2000 mm.sup.2. In other implementations, one or more of the cells
can be formed with an area outside of this range.
[0036] The first material is a compressible, highly resilient,
shock absorbing material, such as an ethylene vinyl acetate (EVA)
foam. In alternative embodiments, the first material can be other
resilient materials, such as, for example, other compressible
polymeric foam materials, a non-foamed polymeric material, and
combinations thereof. In one implementation, the inner layer 86 is
die cut into the desired pattern and the inner layer 86 extends
throughout the entire padding assembly 40 including all of the
cells 60 and all of the linking members 62. In other
implementations, the inner layer can be molded, formed and/or cut
into the desired shape and configuration. In another
implementation, the inner layer can extend over just the cells 60
and not the linking members. In another implementation, the inner
layer can be used to form a portion of the cells and/or a portion
of the linking members. The first material has a first density and
a first durometer within the range of 20 to 40 when measured on an
Asker C hardness scale. The inner layer 86 can define one or more
inner layer holes 94 extending through one or more of the cells 60.
In one implementation, the holes 94 extend entirely through the
inner layer 86 from the inner surface 88 to the outer surface 90.
In another implementation, each inner layer hole 94 extends over a
cell opening area of at least 50 mm.sup.2. The inner layer 86 of
some of the cells 60 can include the inner layer hole 94 and the
inner layer 86 of other cells 60 of the padding assembly 40 can be
formed without the inner layer hole 94. The inner layer 86 has a
thickness within the range 2 to 20 millimeters. In one
implementation, the inner layer 86 has a thickness within the range
of 4 to 8 millimeters. The protective inner layer 86 provides
protection for the user from impacts with other players, balls or
other projectiles, the ground or playing surface, and/or other
sport implements. In another implementation, the inner layer 86 can
be formed of two or more layers that are laminated or otherwise
position over each other to collectively form the inner layer
86.
[0037] The padding assembly 40 can also include an outer padding
layer 96 formed of a second material. The second material is a
compressible, resilient, shock absorbing material, such as an EVA
foam. In alternative embodiments, the first material can be other
resilient materials, such as, for example, other compressible
polymeric foam materials, a non-foamed polymeric material, and
combinations thereof. The second material has a second density and
a second durometer within the range of 50 to 70 when measured on an
Asker C hardness scale. In one implementation, the second density
is greater than the first density. In another implementation, the
second durometer value is greater than the first durometer value.
Accordingly, the second material is a harder material than the
first material providing additional strength to the padding
assembly and an extra layer of protection for the user. In another
implementation, the durometer values of the first and second
materials can be outside of the above-listed ranges. In one
implementation, the second material is die cut and then thermal
compression molded to increase the density and hardness of the
second material. In other implementations, the outer layer 96 can
be formed by injection molded, cut from preformed sheets or
produced in other conventional manners. In one implementation, the
density and the hardness (durometer value) of the outer layer 96 is
consistent throughout the outer layer 96. In other implementations,
the density and/or durometer value of the outer layer 96 can be
varied over it thickness, width or length.
[0038] The outer padding layer 96 can be bonded to the outer
surface 90 of the inner padding layer 86. In other implementations,
the outer layer 96 can be attached to the inner padding layer 86 by
thermal bonding, ultrasonic welding, stitching, hook and loop type
fasteners, snaps, rivets, other fasteners and combinations thereof.
In one implementation, the outer layer 96 is fixedly and
non-removably attached to the inner layer 86. In another
implementation, the outer layer 96 is removably connected to the
inner layer 86. In one implementation, the second layer 96 extends
over at least 30 percent of the outer surface 90 of the inner layer
86. In other implementations, the second layer 96 can extend over
more than 30 percent of the outer surface 90 and can extend over
the entire outer surface 90 of the inner layer 86. In one
implementation, the second layer 96 extends over the perimeter of
the outer surface 90 of the first layer 86 forming a loop and
defining an outer layer hole 98 in the second layer 96. In one
implementation, each outer layer hole 98 extends over a cell
opening area of at least 50 mm.sup.2.
[0039] In one implementation, the outer layer 96 extends over at
least two of the plurality of the cells 60 such that at least two
of the cells 60 include the inner layer 86 and the outer layer 96.
In one implementation, the outer peripheral edges of the padding
assembly 40 generally define a pad area 100 having first and second
pad regions 102 and 104. The first pad region 102 includes cells 60
having inner and outer layers 86 and 96 and the first pad region is
defined by the outer peripheral edges of the cells 60 that include
the inner and outer layers 86 and 96. The second pad region 104
includes cells 60 formed of the inner layer 86 but without the
outer layer 96, and is defined by the area within the pad area 100
that is not included in the first pad region 102. In one
implementation, each of the first and second pad regions extends
over at least 25 percent of the pad area 100. In one
implementation, the first region 102 extends over greater than 50
percent of the pad area 100. In another implementation, the second
region 104 extends over greater than 50 percent of the pad area
100. In one implementation, the linking members 62 within the first
region 102 include the inner layer 86 and the outer layer 96, and
the linking members 62 of the second region 104 include only the
linking members 62. In another implementation, the linking members
62 of the first and/or the second regions can be formed of one or
both of the inner and/or outer layers, or of another layer of
flexible material.
[0040] In one implementation, the linking members 62 are linearly
extending linking members that each extend about an axis, when the
padding assembly 40 is positioned about a flat surface. One of
skill in the art will understand that the first and second
materials of the inner layer 86 and the outer layer 96 have
sufficient flexibility to enable the padding assembly 40 to conform
or curve to follow the contour of the user's body. As the padding
assembly 40 curves to conform to the user's body, the linearly
extending linking members 62 can bend or curve to follow the
contour. When lying on a horizontal surface, such as shown in FIG.
6, the linking members 62 will define a plurality of axes. For
example, the linking members 62 of the padding assembly 40 define
at least first, second, third, fourth, fifth and six axes 110, 112,
114, 116, 118 and 120. The first axis 110 and the second axis 112
define a first angle .alpha. and the first axis 110 and the fourth
axis 116 define a second angle .beta.. The first angle .alpha. can
be within the range of 20 to 90 degrees. The second angle .beta.
can also be within the range of 20 to 90 degrees. In one
implementation, the first and second angles .alpha. and .beta. and
are substantially the same with the exception of the second angle
.beta. having a angular polarity that is opposite the angular
polarity of the first angle .alpha.. In one particular
implementation, as illustrated in FIG. 6, the first angle .alpha.
is approximately positive 45 degrees and the second angle .beta. is
approximately negative 45 degrees. In another implementation, the
angles between pairs of axes can vary between the pairs such that
angles of different magnitude or polarity can be used. Two or more
of the axes can be configured to be substantially parallel with
each other. For example, the first axis 110 can be parallel to the
third axis 114, the second axis 112 can be parallel to fifth axis
118, and the fourth axis 116 can be parallel to the sixth axis 120.
Other axes can also be defined by the linking members 62 of the pad
assembly 40. The spacing of the cells 60, the positioning and
alignment of the axes, and the size of angles between the axes can
be varied to provide the optimal protection, freedom of movement
and performance for each padding assembly. The present invention
contemplates these factors and the characteristics of the inner and
outer layers 86 and 96 such as thickness, density, hardness,
porosity, etc., to be varied to provide an optimized padding
assembly for every position on the user's body and for every
application.
[0041] The linking member 62 includes first and second ends 130 and
132. The first end 130 extends from and is coupled to the side
surface 92 of one of the cells 60 and the second end 132 of the
linking member 62 is coupled to the side surface 92 of another one
of the cells 60. In one implementation, every one of the cells 60
of the padding assembly 40 is directly connected to at least one
linking member 62. In another implementation, a majority of the
cells 60 of the padding assembly are directly connected to at least
one of the linking members 62. In one implementation, at least 40
percent of the cells 60 are to no more than two adjacent cells by
linking members 62. In one implementation, at least 40 percent of
the cells 60 are directly connected to no more than two adjacent
cells by linking members 62. In another implementation, at least 70
percent of the cells 60 are directly connected to no more than two
adjacent cells by two or one linking members 62. In another
implementation, at least 20 percent of the cells are directly
connected to only one other of the cells 60 by no more than one of
the linking members 62.
[0042] In one implementation, when the padding assembly 40 is
positioned on a flat surface, the cells 60 are preferably spaced
apart from each other by at least 2 mm. In another implementation,
the cells 60 are spaced apart from each other by at least 5 mm. The
spaced apart configuration of the cells 60 and the linking members
62 and the resilient properties of the first and second materials
of the inner and outer layers 86 and 96 provide a flexible,
comfortable padding assembly that enables the user to flex, move,
turn, twist his or her body, and move his or her extremities
without binding, discomfort or pad assemblies inhibiting the
movement. The spaced apart arrangement of the cells 60 and the
small number of linking members 62 provides for a padding assembly
that readily allows for air flow between, through and around the
cells 60 and the linking members 62. The spaced apart arrangement
of the cells 60 and the linking members 62 allows for a high level
of flexibility while maintaining the structural integrity of the
padding assembly as a whole. The alignment of the linking members
62 and the axes of the linking members enables the padding assembly
to be tailored and customized to move, flex and function with
different locations of the user, such as the rib padding assembly
40, without degrading the performance of the user or the padding
assembly.
[0043] Referring to FIGS. 1, 3 and 6, the second region 104 of the
padding assembly 40 is sized and positioned to underlie the
external shoulder pads 120 of a player, and the first region 102 of
the padding assembly is sized and positioned to not be overlapped
by the external shoulder pads 120. Accordingly, the second region
104 of the padding assembly 40 provides an extra layer of padding,
comfort and protection to the player in the locations beneath the
external shoulder pads 120. Additionally, the first region 102 of
the rib padding assembly 40 provides a higher level of protection
for the player in the locations just outside of the area covered by
the external shoulder pads and further protects the player's ribs
from impacts thereby reducing the risk of potential injury. The use
of the rib padding assembly 40 can enable players who would
normally wear an external rib pad in addition to the external
shoulder pads 120 to go without the external rib pad. As a result,
the player can receive an exceptional level of protection without
having to put on and carry around another external padding assembly
that typically reduces the movement and flexibility of the user.
The rib padding assembly 40 with the first and second regions 102
and 104 provides the appropriate level of comfort and protection to
the user over the entire portion of the body covered by the rib
padding assembly 40. The player is not burdened with an excessively
thick or hard pad beneath the external shoulder pad, and yet
receives reinforced, dual density pad protection in areas just
outside the coverage of the external shoulder pads 120.
[0044] Referring to FIG. 7, the spine padding assembly 50 is shown
in greater detail. The spine padding assembly 50 is substantially
the same as the rib padding assembly 40 with the exception of the
configuration, number, size, shape and orientation of the cells 60
and the linking members 62. Accordingly, the discussion above
relating to the rib padding assembly 40 is directly applicable to
the spine padding assembly 50.
[0045] Like the rib padding assembly 40, the spine padding assembly
50 is positioned on the shirt 30 to extend partially beneath the
external shoulder pads 120 and partially outside of the external
shoulder pads 120. Accordingly, the spine padding assembly 50
includes the pad area 100 and the first and second regions 102 and
104.
[0046] The orientation and sizes of the cells 60 are selected for
optimal protection of the player's spine in area covered by the
spine padding assembly 50. In one implementation, the spine padding
assembly 50 can include a single set of cells 60 and linking
members 62 extending along, and generally parallel with, the
portion of the user's spine when worn by the player. The padding
assembly 50 can also include a plurality of cells and linking
members extending at an angle with respect to the parallel set of
cells discussed above. The padding assembly 50 can include three
separate sizes of cells 60. In other implementations, two or four
or more different sized cells could also be used. In other
implementations, other numbers, configurations, sizes, and
orientations of the padding assembly 50 can be used.
[0047] Referring to FIG. 8, the thigh padding assembly 42 is shown
in greater detail. The thigh padding assembly 42 is substantially
the same as the rib padding assembly 40 with the exception of the
configuration, number, size, shape and orientation of the cells 60
and the linking members 62, and the use of the inner and outer
layers 86 and 96 over the entire padding assembly 42. Accordingly,
the discussion above relating to the rib padding assembly 40 is
directly applicable to the thigh padding assembly 42.
[0048] The thigh padding assembly 42 is configured to be worn by
the user without the need to also use an external thigh pad.
Accordingly, the thigh padding assembly 42 includes the inner and
the outer layers 86 and 96 over each of the cells 60 and each of
the linking members 62. The orientation and sizes of the cells 60
are selected for optimal protection of the player's thigh. In one
implementation, the thigh padding assembly 42 can include five
parallel sets of cells 60 and linking members 62 extending along,
and generally parallel with, the length of the player's thigh when
worn by the player. The padding assembly 42 can also include a
plurality of cells and linking members extending at an angle with
respect to the parallel set of cells discussed above. The padding
assembly 42 can include three separate sizes of cells 60. In other
implementations, two or four or more different sized cells could
also be used. The inner layer 86 of the padding assembly 42 is
formed without inner layer holes 94, and the second layer 96
extends over all of the cells and includes the outer layer holes 98
in each of the cells 60. In other implementations, other numbers,
configurations, sizes, and orientations of the padding assembly 42
can be used.
[0049] Referring to FIG. 9, the right hip padding assembly 46 is
shown in greater detail. The right hip padding assembly 46 is
substantially the same as the left hip padding assembly 44, except
the left hip padding assembly is essentially a mirror image of the
right hip padding assembly 46. Further, the right hip padding
assembly 46 is substantially the same as the rib padding assembly
40 with the exception of the configuration, number, size, shape and
orientation of the cells 60 and the linking members 62, and the use
of the inner and outer layers 86 and 96 over the entire padding
assembly 42. Accordingly, the discussion above relating to the rib
padding assembly 40 is directly applicable to the hip padding
assembly 46.
[0050] The right hip padding assembly 46 is configured to be worn
by the user without the need to also use an external hip pad.
Accordingly, the right hip padding assembly 46 includes the inner
and the outer layers 86 and 96 over each of the cells 60 and each
of the linking members 62. The orientation and sizes of the cells
60 are selected for optimal protection of the player's hip. The
right hip padding assembly 46 can include three parallel sets of
cells 60 and linking members 62 vertically extending along, and
generally parallel with, the player's hip when worn by the player.
The padding assembly 46 can also include a plurality of cells 60
and linking members 62 extending at an angle with respect to the
parallel set of cells 60 discussed above. The padding assembly 46
can include three separate sizes of cells 60. In other
implementations, two or four or more different sized cells could
also be used. The inner layer 86 of the padding assembly 46 is
formed without inner layer holes 94, and the second layer 96
extends over all of the cells and includes the outer layer holes 98
in each of the cells 60. In other implementations, other numbers,
configurations, sizes, and orientations of the padding assembly 46
can be used.
[0051] Referring to FIG. 10, the tail bone padding assembly 48 is
shown in greater detail. The tail bone padding assembly 48 is
substantially the same as the rib padding assembly 40 with the
exception of the configuration, number, size, shape and orientation
of the cells 60 and the linking members 62, and the use of the
inner and outer layers 86 and 96 over the entire padding assembly
42. Accordingly, the discussion above relating to the rib padding
assembly 40 is directly applicable to the tail bone padding
assembly 48.
[0052] The tail bone padding assembly 48 is configured to be worn
by the user without the need to also use an external tail bone pad.
Accordingly, the tail bone padding assembly 48 includes the inner
and the outer layers 86 and 96 over each of the cells 60 and each
of the linking members 62. The orientation and sizes of the cells
60 are selected for optimal protection of the player's hip. The
tail bone padding assembly 48 can include a set of cells 60 and
linking members 62 vertically extending along, and generally
parallel with, the player's tail bone when worn by the player. The
padding assembly 48 can also include a plurality of cells 60 and
linking members 62 extending at an angle with respect to the
parallel set of cells 60 discussed above. The padding assembly 48
can include three separate sizes of cells 60. In other
implementations, two or four or more different sized cells could
also be used. The inner layer 86 of the padding assembly 46 is
formed without inner layer holes 94, and the second layer 96
extends over all of the cells and includes the outer layer holes 98
in each of the cells 60. In other implementations, other numbers,
configurations, sizes, and orientations of the padding assembly 48
can be used.
[0053] Referring to FIG. 11, the knee padding assembly 64 is shown
in greater detail. The knee padding assembly 64 is substantially
the same as the rib padding assembly 40 with the exception of the
configuration, number, size, shape and orientation of the cells 60
and the linking members 62, and the use of the inner and outer
layers 86 and 96 over the entire padding assembly 42. Accordingly,
the discussion above relating to the rib padding assembly 40 is
directly applicable to the knee padding assembly 64.
[0054] The knee padding assembly 64 is configured to be worn by the
user without the need to also use an external knee pad.
Accordingly, the knee padding assembly 64 includes the inner and
the outer layers 86 and 96 over each of the cells 60 and each of
the linking members 62. The orientation and sizes of the cells 60
are selected for optimal protection of the player's knee. The knee
padding assembly 64 can include a set of cells 60 and linking
members 62 vertically extending along, and generally parallel with,
the player's knee when worn by the player. The padding assembly 64
can also include a plurality of cells 60 and linking members 62
extending at an angle with respect to the parallel set of cells 60
discussed above. The padding assembly 64 can include three separate
sizes of cells 60. In other implementations, two or four or more
different sized cells could also be used. The inner layer 86 of the
padding assembly 64 is formed without inner layer holes 94, and the
second layer 96 extends over all of the cells and includes the
outer layer holes 98 in each of the cells 60. In other
implementations, other numbers, configurations, sizes, and
orientations of the padding assembly 64 can be used.
[0055] Referring to FIG. 12, the right shoulder padding assembly 54
is shown in greater detail. The right shoulder padding assembly 54
is substantially the same as the left shoulder padding assembly 52,
except the left shoulder padding assembly is essentially a mirror
image of the right shoulder padding assembly 54. Further, the right
shoulder padding assembly 54 is substantially the same as the rib
padding assembly 40 with the exception of the configuration,
number, size, shape and orientation of the cells 60 and the linking
members 62, and the use of only the inner layer 86 over the entire
padding assembly 42. Accordingly, the discussion above relating to
the rib padding assembly 40 can be directly applicable to the
shoulder padding assembly 54.
[0056] The right shoulder padding assembly 54 is configured to be
worn by the user under the external shoulder pads 120 (FIG. 3).
Accordingly, the right shoulder padding assembly 54 includes only
the inner layer 86 to provide an extra layer of protection and
comfort for the user without providing a bulky hard cumbersome pad
that would interfere with the comfort and performance of the
external shoulder pads 120. The orientation and sizes of the cells
60 are selected for optimal protection of the player's shoulder.
The right shoulder padding assembly 54 can include a first single
set of cells 60 and linking members 62 and can also include a
plurality of cells 60 and linking members 62 extending at an angle
with respect to the first single set of cells 60 discussed above.
The padding assembly 54 can include three separate sizes of cells
60. In other implementations, two or four or more different sized
cells could also be used. The inner layer 86 of the padding
assembly 54 is formed with inner layer holes 94 in each of the
cells 60. In other implementations, other numbers, configurations,
sizes, and orientations of the padding assembly 54 can be used. In
another implementation, the knee padding assembly 64 can be
configured like the shoulder padding assembly 54 with only the
inner padding layer 86 when the knee padding assembly 64 is
configured for use in with an external knee pad.
[0057] Referring to FIG. 13, another implementation of a thigh
padding assembly 142 is illustrated. The thigh padding assembly 142
is substantially the same as the thigh padding assembly 42 with the
exception of the shape and configuration of certain cells 60 of
thigh padding assembly 142. The cells 60a, 60b and 60c of the thigh
padding assembly 142 are ovular shaped and include the inner
padding layer 86 and the outer padding layer 96. Unlike the cells
shown in FIG. 8, the outer padding layer 96 can extend over
different portions of the inner padding layer 86 of the cells. The
cell 60a illustrates the outer padding layer 96 positioned at four
separate locations about the periphery of the cell 60a. The cell
60c illustrates the outer padding layer 96 positioned over two
separate portions of the outer periphery of the cell 60c. In other
implementations, one, three, five or more locations can be used for
the positioning of the outer padding layer 96 over the inner
padding layer 86. In other implementations, one or more of the
cells 60 can be formed without the outer padding layer 96. The 60b
illustrates the outer padding layer 96 positioned in a central
region of the ovular shaped cell away from the outer periphery of
the cell. In other implementations, the outer padding layer 96 can
be positioned in other locations away from or in contact with the
outer periphery of the cell. Accordingly, it is contemplated in the
present invention, that the outer padding layer can extend over the
inner padding layer in any shape, size or orientation.
[0058] The cells 60 can be formed in any shape. The cell 60d is
hexagonal in shape and the cell 60h is diamond shaped. In other
implementations, other polygonal shapes such as triangular,
rectangular, octagonal, etc. can be used. The cell 60e is generally
circular in shape. In other implementations, the cell 60 can be
formed in other curved shapes. The cell 60f is generally X-shaped,
the cell 60g is generally 8-shaped or hour glass shaped, and the
cell 60i is generally C-shaped. The other implementations, other
alphanumeric shaped cells can be used such as for example,
S-shaped, T-shaped, L-shaped, etc. In other implementations, any
combination of one or more cell shapes and sizes can be used.
[0059] Referring to FIGS. 14a and 14b, two adjoining cells 60 from
the padding assembly system 10 are shown in greater detail. The
inner padding layer 86 can extend along the entire cells 60 and the
linking members 62, and can be formed without the inner pad hole
94. The outer padding layer 96 can be applied over the perimeter of
the inner layer 86 of the cells 60 and over the inner padding layer
86 of the linking member 62. The outer padding layer 96 can be
formed with a variable thickness, such that the thickness of the
outer layer 96 can be smaller at the linking member 62 than at the
cells 60. The thickness can also vary about the cell 60. The inner
surface 88 of the inner padding layer 86 can be connected to the
apparel article.
[0060] Referring to FIG. 15, another implementation of two cells 60
and the linking member 62 of the system 10 are shown. The inner
padding layer 86 can have a variable thickness. For example, the
thickness of the inner padding layer 86 can be smaller at the
linking member 62 than at the cell 62. In other implementations,
other variations of thickness of the inner layer are contemplated.
Referring to FIG. 16, in another implementation, the configuration,
shape and thickness of the outer padding layer 96 can be varied to
provide a different appearance and configuration. Other variations
of the thickness of the outer padding layer are also
contemplated.
[0061] Many embodiments of the padding assemblies and of the
apparel articles of the present invention are specifically
configured for providing optimum performance in one or more levels
of competitive, organized play. For example, many embodiments are
built in accordance with the present application fully meet the
rules and/or requirements of one or more of the following sport
organizations, such as, for example, the Sports Rules of the
National Federation of State High School Associations ("NFHS"); the
Sports Rules and Interpretations of the National Collegiate
Athletic Association ("NCAA"); the Official Football Rules of the
National Football League ("NFL") and the Football Leagues of Pop
Warner Little Scholars, Inc., the rules of Little League baseball,
and the Official Rules of the Federation International de
Basketball Amateur ("FIBA"). Accordingly, the term "padding
assembly configured for organized, competitive play" or "apparel
article configured for organized, competitive play" refers to a
padding assembly or a sports apparel article, respectively that
fully meets the rules and/or requirements of, and is fully
functional for play in, one or more of the above listed
organizations.
[0062] The present invention provides a protective sports apparel
article with one or more padding assemblies configured to protect
the user without negatively affecting the user's performance.
Embodiments of the present application provide a lightweight
breathable padding assembly for a sports apparel article that
enables the user to comfortably perform all the desired movements
for a particular sport or activity without causing binding,
obstruction or undesirable restriction. Protective sport apparel
article with a protective padding assembly built in accordance with
the embodiments of the present invention can be configured to be
used, worn and perform with other external pad assemblies, such as,
for example, shoulder pads. The padding assembly of the present
invention provides exceptional structural integrity, durability and
reliability while conforming to the contour of the user's body and
allowing for free uninhibited movement by the user. Additionally,
the protective sports apparel articles of the present invention
provide a pleasing unique aesthetic.
[0063] While the preferred embodiments of the invention have been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention. One of skill in the art will understand
that the invention may also be practiced without many of the
details described above. Accordingly, it will be intended to
include all such alternatives, modifications and variations set
forth within the spirit and scope of the appended claims. Further,
some well-known structures or functions may not be shown or
described in detail because such structures or functions would be
known to one skilled in the art. Unless a term is specifically and
overtly defined in this specification, the terminology used in the
present specification is intended to be interpreted in its broadest
reasonable manner, even though may be used conjunction with the
description of certain specific embodiments of the present
invention.
* * * * *