U.S. patent application number 16/206112 was filed with the patent office on 2019-06-06 for athletic gear or other devices comprising pads or other cushioning components.
The applicant listed for this patent is BAUER HOCKEY LTD.. Invention is credited to CHARLES-ANTOINE DESROCHERS, JEAN-FRAN OIS LAPERRI RE.
Application Number | 20190166947 16/206112 |
Document ID | / |
Family ID | 66657464 |
Filed Date | 2019-06-06 |
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United States Patent
Application |
20190166947 |
Kind Code |
A1 |
LAPERRI RE; JEAN-FRAN OIS ;
et al. |
June 6, 2019 |
ATHLETIC GEAR OR OTHER DEVICES COMPRISING PADS OR OTHER CUSHIONING
COMPONENTS
Abstract
A device (e.g., an article of athletic gear) comprising a
cushioning component for absorbing energy when the device is
contacted (i.e., impacted or otherwise contacted), in which the
cushioning component comprises a core comprising a plurality of
zones of different materials (e.g., which may differ in one or more
materials properties such as density, stiffness, resilience, etc.)
and a covering disposed on the core. In some embodiments, a given
one of the zones of different materials may be a zone of expanded
microspheres. The cushioning component may provide enhanced
protection, comfort, and/or vibration or other shock absorption
while being relatively lightweight.
Inventors: |
LAPERRI RE; JEAN-FRAN OIS;
(PREVOST, CA) ; DESROCHERS; CHARLES-ANTOINE;
(PREVOST, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BAUER HOCKEY LTD. |
Blainville |
|
CA |
|
|
Family ID: |
66657464 |
Appl. No.: |
16/206112 |
Filed: |
November 30, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62592853 |
Nov 30, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2307/72 20130101;
A63B 2102/18 20151001; A42B 3/128 20130101; A43B 5/1625 20130101;
A63B 2209/02 20130101; A63B 2071/1208 20130101; B32B 1/00 20130101;
A42B 3/08 20130101; A63B 59/70 20151001; A63B 2102/14 20151001;
A42B 3/06 20130101; A63B 59/54 20151001; A63B 2209/00 20130101;
B32B 2307/51 20130101; A63B 2102/24 20151001; A63B 71/14 20130101;
A42B 3/324 20130101; B32B 2571/00 20130101; A43B 23/028 20130101;
A63B 71/10 20130101; A63B 71/141 20130101; A43B 5/00 20130101; A63B
59/20 20151001; A63B 71/12 20130101; A63B 71/1225 20130101; B32B
2307/558 20130101; B32B 27/065 20130101; A63B 60/08 20151001; A42B
3/121 20130101; B32B 2437/04 20130101 |
International
Class: |
A42B 3/12 20060101
A42B003/12 |
Claims
1. A cushioning component comprising: a core comprising a plurality
of zones of different materials; and a covering disposed on the
core; wherein a given one of the zones of different materials is a
zone of expanded microspheres.
2. The cushioning component of claim 1, wherein a density of a
first zone of the different materials is different from a density
of a second one of the zones of different materials.
3. The cushioning component of claim 2, wherein the cushioning
component is configured to protect a user, the second one of the
zone of different materials is configured to be located closer to
the user than the first one of the zones of different materials,
and the density of the second one of the zones of different
materials is less than the density of the first one of the zones of
different materials.
4. (canceled)
5. The cushioning component of claim 2, wherein the density of the
second one of the zones of different materials is no more than 50%
of the density of the first one of the zones of different
materials.
6. (canceled)
7. The cushioning component of claim 2, wherein a modulus of
elasticity of a first zone of the different materials is different
from a modulus of elasticity of a second one of the zones of
different materials.
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. The cushioning component of claim 1, wherein a resilience of a
first zone of the different materials is different from a
resilience of a second one of the zones of different materials.
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. The cushioning component of claim 1, wherein an elongation at
break of a first zone of the different materials is different from
an elongation at break of a second one of the zones of different
materials.
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. The cushioning component of claim 1, wherein the given one of
the zones of different materials is a first given one of the zones
of different materials, the zone of expanded microspheres is a
first zone of expanded microspheres, a second given one of the
zones of different materials is a second zone of expanded
microspheres, and a density of the first zone of expanded
microspheres is different from a density of the second zone of
expanded microspheres.
23. The cushioning component of claim 22, wherein the cushioning
component is configured to protect a user, the second zone of
expanded microspheres is configured to be located closer to the
user than the first zone of expanded microspheres, and the density
of the second zone of expanded microspheres is less than the
density of the first zone of expanded microspheres.
24. (canceled)
25. (canceled)
26. (canceled)
27. The cushioning component of claim 1, wherein the zone of
expanded microspheres constitutes at least one-quarter of the core
by weight.
28. (canceled)
29. The cushioning component of claim 1, wherein the zone of
expanded microspheres constitutes at least half of the core by
weight.
30. The cushioning component of claim 1, wherein the given one of
the zones of different materials is a first given one of the zones
of different materials, the zone of expanded microspheres is a
first zone of expanded microspheres, and a second given one of the
zones of different materials is a second zone of expanded
microspheres.
31. The cushioning component of claim 30, wherein a state of the
first zone of expanded microspheres is different from a state of
the second zone of expanded microspheres.
32. The cushioning component of claim 30, wherein the first zone of
expanded microspheres is consolidated and the second zone of
expanded microspheres is unconsolidated.
33. The cushioning component of claim 1, wherein expanded
microspheres constitute at least one-quarter of the core by
weight.
34. (canceled)
35. The cushioning component of claim 1, wherein expanded
microspheres constitute at least a majority of the core by
weight.
36. The cushioning component of claim 1, wherein the given one of
the zones of different materials is a first given one of the zones
of different materials, and a second given one of the zones of
different materials is not a zone of expanded microspheres.
37. The cushioning component of claim 1, wherein: the given one of
the zones of different materials is a first given one of the zones
of different materials; and a second given one of the zones of
different materials is a zone of foam.
38. The cushioning component of claim 37, wherein the zone of foam
is a first zone of foam, a third given one of the zones of
different materials is a second zone of foam, and a density of the
second zone of foam is different from a density of the second zone
of foam.
39. (canceled)
40. (canceled)
41. (canceled)
42. The cushioning component of claim 1, wherein the zones of
different materials include at least three zones of different
materials.
43. The cushioning component of claim 1, wherein a peripheral one
of the zones of different materials comprises a projection
projecting from an adjacent part of a surface of the core.
44. The cushioning component of claim 1, wherein a peripheral one
of the zones of different materials comprises a plurality of
projections projecting from an adjacent part of a surface of the
core and spaced from one another.
45. The cushioning component of claim 1, wherein a thickness of the
zone of expanded microspheres corresponds to at least one-quarter
of a thickness of the core.
46. (canceled)
47. The cushioning component of claim 1, wherein a thickness of the
zone of expanded microspheres corresponds to at least a majority of
a thickness of the core.
48. (canceled)
49. (canceled)
50. The cushioning component of claim 1, wherein a particular one
of the zones of different materials and an adjacent one of the
zones of different materials are interlocked by an interlocking
part of the particular one of the zones of different materials
extending into an interlocking void of the adjacent one of the
zones of different materials.
51. The cushioning component of claim 1, wherein the core comprises
a first side and a second side opposite to the first side of the
core and the first side of the core is uneven.
52. The cushioning component of claim 1, wherein the first side of
the core is concave.
53. The cushioning component of claim 1, wherein the core comprises
a first side and a second side opposite to the first side of the
core and the covering covers at least part of the first side of the
core and at least part of the second side of the core.
54. The cushioning component of claim 53, wherein the covering
covers at least a majority of the first side of the core and at
least a majority of the second side of the core.
55. The cushioning component of claim 54, wherein the covering
covers an entirety of the first side of the core and an entirety of
the second side of the core.
56. The cushioning component of claim 1, wherein the covering
covers at least a majority of a periphery of the core.
57. The cushioning component of claim 1, wherein the covering
envelops the core.
58. The cushioning component of claim 1, wherein the covering is
molded to conform to the core.
59. The cushioning component of claim 58, wherein at least part of
the covering is vacuum-formed.
60. The cushioning component of claim 1, wherein the covering
comprises a layer of polymeric material molded to conform to the
core.
61. The cushioning component of claim 60, wherein the layer of
polymeric material is a layer of polyurethane.
62. The cushioning component of claim 1, wherein the covering
comprises a layer of fabric molded to conform to the core.
63. The cushioning component of claim 1, wherein the covering
comprises a layer of a first material molded to conform to a first
side of the core and a layer of a second material different from
the first material molded to conform to a second side of the core
opposite to the first side of the core.
64. The cushioning component of claim 1, wherein the first material
is a polymeric material and the second material is a fabric.
65. The cushioning component of claim 1, wherein the covering is
bonded to the core.
66. (canceled)
67. (canceled)
68. (canceled)
69. (canceled)
70. (canceled)
71. The cushioning component of claim 1, wherein the core comprises
a hole extending through the core and defined by an internal
surface of the core, and the covering extends into the hole and
covers at least part of the internal surface of the core.
72. A device comprising the cushioning component of claim 1.
73. The device of claim 72, wherein the device is an article of
athletic gear for a user.
74. The device of claim 73, wherein the article of athletic gear is
an article of protective athletic gear wearable by the user and the
cushioning component is a pad to protect the user.
75. The device of claim 74, wherein the article of protective
athletic gear is a helmet for protecting a head of the user.
76. The device of claim 75, wherein the helmet comprises an outer
shell and an inner liner that includes the pad.
77. The device of claim 72, wherein the device is an article of
personal protective gear wearable by a user and the cushioning
component is a pad to protect the user.
78. (canceled)
79. (canceled)
80. (canceled)
81. (canceled)
82. (canceled)
83. (canceled)
84. The device of claim 73, wherein the article of athletic gear is
a sports implement for handling by the user.
85. The device of claim 84, wherein the sports implement is a
hockey stick.
86. The device of claim 84, wherein the sports implement is a
lacrosse stick.
87. The device of claim 84, wherein the sports implement is a ball
bat.
88. A device comprising the cushioning component of claim 1,
wherein the device comprises a first side and a second side
opposite to the first side, the core comprises a first side facing
towards the first side of the device and a second side facing
towards the second side of the device, and the core occupies a
majority of a thickness of the device from the first side of the
device to the second side of the core.
89. A device comprising a plurality of cushioning components as
claimed in claim 1.
90. A cushioning component comprising: a core comprising a zone of
expanded microspheres and a zone materially different from the zone
of expanded microspheres; and a covering disposed on the core.
91. An article of athletic gear for a user, the article of athletic
gear comprising a cushioning component that comprises: a core
comprising a plurality of zones of different materials; and a
covering disposed on the core; wherein a given one of the zones of
different materials is a zone of expanded microspheres.
92.-166. (canceled)
Description
FIELD
[0001] This disclosure relates to devices (e.g., athletic gear,
personal protective equipment, etc.) comprising pads or other
cushioning (e.g., shock-absorbing) components.
BACKGROUND
[0002] Various devices comprise pads or other cushioning (e.g.,
shock-absorbing) components to absorb energy when they are impacted
or otherwise contacted. For example, athletic gear such as helmets,
shoulder pads, sporting implements (e.g., hockey sticks, ball bats,
lacrosse sticks, etc.), footwear, etc., and personal protective
equipment typically comprise pads or other cushioning components,
which may be provided for protection, comfort, and/or vibration or
other shock absorption.
[0003] Pads and other cushioning components may sometimes face
conflicting requirements, such as providing adequate protection,
comfort, and/or vibration or other shock absorption while being
lightweight.
[0004] For these and other reasons, there is a need to improve
devices comprising pads or other cushioning components.
SUMMARY
[0005] According to various aspects of this disclosure, there is
provided a device (e.g., an article of athletic gear) comprising a
cushioning component for absorbing energy when the device is
contacted (i.e., impacted or otherwise contacted), in which the
cushioning component comprises a core comprising a plurality of
zones of different materials (e.g., which may differ in one or more
materials properties such as density, stiffness, resilience, etc.)
and a covering disposed on the core. In some embodiments, a given
one of the zones of different materials may be a zone of expanded
microspheres. The cushioning component may provide enhanced
protection, comfort, and/or vibration or other shock absorption
while being relatively lightweight.
[0006] For example, according to an aspect of this disclosure,
there is provided a cushioning component that comprises a core
comprising a plurality of zones of different materials and a
covering disposed on the core. A given one of the zones of
different materials is a zone of expanded microspheres.
[0007] According to another aspect of this disclosure, there is
provided a cushioning component that comprises a core comprising a
zone of expanded microspheres and a zone materially different from
the zone of expanded microspheres. The cushioning component also
comprises a covering disposed on the core.
[0008] According to another aspect of this disclosure, there is
provided an article of athletic gear for a user. The article of
athletic gear comprises a cushioning component that comprises a
core comprising a plurality of zones of different materials and a
covering disposed on the core. A given one of the zones of
different materials is a zone of expanded microspheres.
[0009] According to another aspect of this disclosure, there is
provided an article of personal protective gear wearable by a user.
The article of personal protective gear comprises a pad that
comprises a core comprising a plurality of zones of different
materials and a covering disposed on the core. A given one of the
zones of different materials is a zone of expanded
microspheres.
[0010] According to another aspect of this disclosure, there is
provided a helmet for protecting a head of a user. The helmet
comprises an outer shell and an inner liner disposed within the
outer shell. The inner liner comprises a pad that comprises a core
comprising a plurality of zones of different materials and a
covering disposed on the core.
[0011] These and other aspects of this disclosure will now become
apparent to those of ordinary skill in the art upon review of a
description of embodiments in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A detailed description of embodiments is provided below, by
way of example only, with reference to the accompanying drawings,
in which:
[0013] FIG. 1 shows an example of a device comprising cushioning
components for absorbing energy when the device is impacted or
otherwise contacted, in accordance with an embodiment, in which the
device is a helmet for protecting a user's head and respective ones
of the cushioning components constitute a plurality of pads of an
inner liner of the helmet;
[0014] FIG. 2 shows a front view of the helmet;
[0015] FIGS. 3 and 4 show rear perspective views of the helmet;
[0016] FIGS. 5 to 8 show operation of an example of an adjustment
mechanism of the helmet;
[0017] FIGS. 9A and 9B show the head of the user;
[0018] FIG. 9C shows a cavity of the helmet;
[0019] FIGS. 10 and 11 show an example of shell members of an outer
shell of the helmet;
[0020] FIGS. 12 to 16 show respective ones of the pads;
[0021] FIG. 17 shows a front view of an example of a given one of
the pads;
[0022] FIG. 18 shows a cross-sectional view the given one of the
pads;
[0023] FIG. 18A shows an example of part of a zone of expanded
microspheres of the given one of the pads;
[0024] FIG. 19 shows a schematic side view of an example of parts
of molding equipment to mold the given one of the pads;
[0025] FIG. 20 shows a cross-sectional view of an example of
another embodiment of the given one of the pads;
[0026] FIG. 21A shows a cross-sectional view of an example of
another embodiment of the given one of the pads;
[0027] FIG. 21B shows parts of the given one of the pads;
[0028] FIG. 22 shows a cross-sectional view of an example of
another embodiment of the given one of the pads;
[0029] FIG. 23 shows a front view of the given one of the pads
shown in FIG. 22;
[0030] FIG. 24 shows parts of the given one of the pads shown in
FIG. 22;
[0031] FIG. 25 shows a front view of an example of another
embodiment of the given one of the pads;
[0032] FIG. 26 shows an embodiment in which the device is an arm
guard;
[0033] FIG. 27 shows an embodiment in which the device is shoulder
pads;
[0034] FIG. 28 shows an embodiment in which the device is a leg
guard;
[0035] FIG. 29 shows an embodiment in which the device is a chest
protector;
[0036] FIG. 30 shows an embodiment in which the device is a
glove;
[0037] FIGS. 31A and 31B show an embodiment in which the device is
a hockey stick;
[0038] FIG. 32 shows an embodiment in which the device is a
lacrosse stick;
[0039] FIG. 33 shows an embodiment in which the device is a ball
bat; and
[0040] FIG. 34 shows an embodiment in which the device is an
article of footwear, in this example a skate.
[0041] It is to be expressly understood that the description and
drawings are only for the purpose of illustrating certain
embodiments and are an aid for understanding. They are not intended
to be and are not limiting.
DETAILED DESCRIPTION OF EMBODIMENTS
[0042] FIG. 1 shows an example of an embodiment of a device 10
comprising a plurality of cushioning components 12.sub.1-12.sub.C
for absorbing energy when the device 10 is impacted or otherwise
contacted. In this embodiment, the device 10 is an article of
athletic gear for a user engaging in a sport or other athletic
activity. More particularly, in this embodiment, the article of
athletic gear 10 is an article of protective athletic gear wearable
by the user to protect him/her. Specifically, in this example, the
article of protective athletic gear 10 is a helmet for protecting a
head of the user against impacts. In this case, the helmet 10 is a
hockey helmet for protecting the head of the user, who is a hockey
player, against impacts (e.g., from a puck or ball, a hockey stick,
a board, ice or another playing surface, etc., with another player,
etc.).
[0043] Each of the cushioning components 12.sub.1-12.sub.C of the
helmet 10 is configured to protect the player's head by absorbing
energy when the helmet 10 is impacted, and may also be provided for
comfort of the helmet 10 on the player's head. As further discussed
later, in this embodiment, each of the cushioning components
12.sub.1-12.sub.C of the helmet 10 may provide enhanced protection
and/or comfort for the player's head while being relatively
lightweight, notably by including different materials (e.g., which
may differ in density, stiffness, resilience, etc.).
[0044] In this embodiment, the helmet 10 comprises an outer shell
11 and an inner liner 15 that includes the cushioning components
12.sub.1-12.sub.C. The helmet 10 also comprises a chinstrap 16 for
securing the helmet 10 to the player's head. The helmet 10 may also
comprise a faceguard (not shown) to protect at least part of the
player's face (e.g., a grid (sometimes referred to as a "cage") or
a visor (sometimes referred to as a "shield")).
[0045] The helmet 10 defines a cavity 13 for receiving the player's
head. In response to an impact, the helmet 10 absorbs energy from
the impact to protect the player's head. The helmet 10 protects
various regions of the player's head. As shown in FIGS. 9A and 9B,
the player's head comprises a front region FR, a top region TR,
left and right side regions LS, RS, a back region BR, and an
occipital region OR. The front region FR includes a forehead and a
front top part of the player's head and generally corresponds to a
frontal bone region of the player's head. The left and right side
regions LS, RS are approximately located above the player's ears.
The back region BR is opposite the front region FR and includes a
rear upper part of the player's head. The occipital region OR
substantially corresponds to a region around and under the head's
occipital protuberance.
[0046] The helmet 10 comprises an external surface 18 and an
internal surface 20 that contacts the player's head when the helmet
10 is worn. The helmet 10 has a front-back axis FBA, a left-right
axis LRA, and a vertical axis VA which are respectively generally
parallel to a dorsoventral axis, a dextrosinistral axis, and a
cephalocaudal axis of the player when the helmet 10 is worn and
which respectively define a front-back direction, a lateral
direction, and a vertical direction of the helmet 10. Since they
are generally oriented longitudinally and transversally of the
helmet 10, the front-back axis FBA and the left-right axis LRA can
also be referred to as a longitudinal axis and a transversal axis,
respectively, while the front-back direction and the lateral
direction can also be referred to a longitudinal direction and a
transversal direction, respectively.
[0047] The outer shell 11 provides strength and rigidity to the
helmet 10. To that end, the outer shell 11 comprises rigid material
27. For example, in various embodiments, the rigid material 27 of
the outer shell 11 may be a thermoplastic material such as
polyethylene (PE), polyamide (nylon), or polycarbonate, a
thermosetting resin, or any other suitable material. The outer
shell 11 includes an inner surface 17 facing the inner liner 15 and
an outer surface 19 opposite the inner surface 17. The outer
surface 19 of the outer shell 11 constitutes at least part of the
external surface 18 of the helmet 10.
[0048] In this embodiment, the outer shell 11 comprises a plurality
of shell members 22, 24 that are connected to one another. More
particularly, in this embodiment, the shell member 22 is a front
shell member and the shell member 24 is a rear shell member. The
front shell member 22 comprises a front portion 23 for facing at
least part of the front region FR of the player's head, a top
portion 21 for facing at least part of the top region TR of the
player's head, and left and right lateral side portions 25L, 25R
extending rearwardly from the front portion 23 and downwardly from
the top portion 21 for facing at least part of the left and right
side regions LS, RS of the player's head, respectively. The rear
shell member 24 comprises a back portion 31 for facing at least
part of the back region BR of the player's head, a top portion 29
for facing at least part of the top region TR of the player's head,
an occipital portion 33 for facing at least part of the occipital
region OR of the player's head, and left and right lateral side
portions 35L, 35R extending forwardly from the back portion 31 and
downwardly from the top portion 29 for facing at least part of the
left and right side regions LS, RS of the player's head,
respectively.
[0049] In this embodiment, the helmet 10 is adjustable to adjust
how it fits on the player's head. To that end, the helmet 10
comprises an adjustment mechanism 40 for adjusting a fit of the
helmet 10 on the player's head. The adjustment mechanism 40 may
allow the fit of the helmet 10 to be adjusted by adjusting one or
more internal dimensions of the cavity 13 of the helmet 10, such as
a front-back internal dimension FBD of the cavity 13 in the
front-back direction of the helmet 10 and/or a left-right internal
dimension LRD of the cavity 13 in the left-right direction of the
helmet 10, as shown in FIG. 9C.
[0050] More particularly, in this embodiment, the adjustment
mechanism 40 is configured such that the outer shell 11 and the
inner liner 15 are adjustable to adjust the fit of the helmet 10 on
the player's head. To that end, in this embodiment, the shell
members 22, 24 are movable relative to one another to adjust the
fit of the helmet 10 on the player's head. In this example,
relative movement of the shell members 22, 24 for adjustment
purposes is in the front-back direction of the helmet 10 such that
the front-back internal dimension FBD of the cavity 13 of the
helmet 10 is adjusted. This is shown in FIGS. 5 to 8 in which the
rear shell member 24 is moved relative to the front shell member 22
from a first position, which is shown in FIG. 5 and which
corresponds to a minimum size of the helmet 10, to a second
position, which is shown in FIG. 6 and which corresponds to an
intermediate size of the helmet 10, and to a third position, which
is shown in FIGS. 7 and 8 and which corresponds to a maximum size
of the helmet 10.
[0051] In this example of implementation, the adjustment mechanism
40 comprises an actuator 41 that can be moved (e.g., in this case
pivoted) by the player between a locked position, in which the
actuator 41 engages a locking part 45 (as best shown in FIGS. 8 and
10) of the front shell member 22 and thereby locks the shell
members 22, 24 relative to one another, and an unlocked position,
in which the actuator 41 is disengaged from the locking part 45 of
the front shell member 22 and thereby permits the shell members 22,
24 to move relative to one another so as to adjust the size of the
helmet 10. The adjustment mechanism 40 may be implemented in any
other suitably way in other embodiments.
[0052] The inner liner 15 is disposed within the outer shell 11,
i.e., between the outer shell 11 and the player's head when the
helmet 10 is worn. More particularly, the inner liner 15 comprises
a shock-absorbing structure 32 that includes an outer surface 38
facing towards the outer shell 11 and an inner surface 34 facing
towards the player's head. For example, in some embodiments, the
shock-absorbing structure 32 of the inner liner 15 may comprise a
shock-absorbing material. For instance, in some cases, the
shock-absorbing material may include a polymeric cellular material,
such as a polymeric foam (e.g., expanded polypropylene (EPP) foam,
expanded polyethylene (EPE) foam, or any other suitable polymeric
foam material), or expanded microspheres (e.g., Expancel.TM.
microspheres commercialized by Akzo Nobel). Any other material with
suitable impact energy absorption may be used in other embodiments.
Additionally or alternatively, in some embodiments, the
shock-absorbing structure 32 of the inner liner 15 may comprise an
array of shock absorbers that are configured to deform when the
helmet 10 is impacted. For instance, in some cases, the array of
shock absorbers may include an array of compressible cells that can
compress when the helmet 10 is impacted. Examples of this are
described in U.S. Pat. No. 7,677,538 and U.S. Patent Application
Publication 2010/0258988, which are incorporated by reference
herein.
[0053] The inner liner 15 may be mounted to the outer shell 11 in
any suitable way. For example, in some embodiments, the inner liner
15 may be mounted to the outer shell 11 by one or more fasteners
such as mechanical fasteners (e.g., tacks, staples, rivets, screws,
stitches, etc.), an adhesive, or any other suitable fastener.
[0054] In this embodiment, the inner liner 15 comprises a plurality
of pads 36.sub.1-36.sub.C, 37.sub.1-37.sub.B. In this example,
respective ones of the pads 36.sub.1-36.sub.C, 37.sub.1-37.sub.B
are movable relative to one another and with the shell members 22,
24 to allow adjustment of the fit of the helmet 10 using the
adjustment mechanism 40.
[0055] The pads 36.sub.1-36.sub.C are responsible for absorbing at
least a bulk of the energy transmitted to the inner liner 15 when
the helmet 10 is impacted and can therefore be referred to as
"absorption" pads. In this embodiment, the pad 36.sub.1 is for
facing at least part of the front region FR and left side region LS
of the player's head, the pad 36.sub.2 is for facing at least part
of the front region FR and right side region RS of the player's
head, the pad 36.sub.3 is for facing at least part of the back
region BR and left side region LS of the player's head, the pad
36.sub.4 is for facing at least part of the back region BR and
right side region RS of the player's head, and the pad 36.sub.5 is
for facing at least part of the top region TR and back region BR of
the player's head. The front shell member 22 overlays the pads
36.sub.1, 36.sub.2, while the rear shell member 24 overlays the
pads 36.sub.3, 36.sub.4.
[0056] The pads 37.sub.1-37.sub.B are responsible to provide
comfort to the player's head and can therefore be referred to as
"comfort" pads. The comfort pads 37.sub.1-37.sub.B may comprise any
suitable soft material providing comfort to the player. For
example, in some embodiments, the comfort pads 37.sub.1-37.sub.B
may comprise polymeric foam such as polyvinyl chloride (PVC) foam,
polyurethane foam (e.g., PORON XRD foam commercialized by Rogers
Corporation), vinyl nitrile foam or any other suitable polymeric
foam material. In some embodiments, given ones of the comfort pads
37.sub.1-37.sub.B may be secured (e.g., adhered, fastened, etc.) to
respective ones of the absorption pads 36.sub.1-36.sub.C. In other
embodiments, given ones of the comfort pads 37.sub.1-37.sub.B may
be mounted such that they are movable relative to the absorption
pads 36.sub.1-36.sub.C. For example, in some embodiments, one or
more of the comfort pads 37.sub.1-37.sub.B may be part of a
floating liner as described in U.S. Patent Application Publication
2013/0025032. The comfort pads 37.sub.1-37.sub.B may assist in
absorption of energy from impacts, in particular, low-energy
impacts.
[0057] The inner liner 15 comprises the cushioning components
12.sub.1-12.sub.C of the helmet 10. More particularly, in this
embodiment, respective ones of the pads 36.sub.1-36.sub.C comprise
respective ones of the cushioning components 12.sub.1-12.sub.C of
the helmet 10. Specifically, in this example, each cushioning
component 12.sub.x of the helmet 10 constitutes a pad 36.sub.x.
[0058] The pad 36.sub.x comprises a periphery 39 that includes an
outer side 42 facing towards the outer shell 11 and an inner side
43 opposite to the outer side 42 for facing towards the player's
head. In this embodiment, the periphery 39 of the pad 36.sub.x has
a three-dimensional shape to accommodate the outer shell 11 and the
player's head. More particularly, in this embodiment, each of the
outer side 42 and the inner side 43 of the pad 36.sub.x is uneven
(i.e., nonplanar in that it comprises one or more angular parts
and/or one or more curved parts) to accommodate the outer shell 11
and the player's head. Specifically, in this example, the outer
side 42 of the pad 36.sub.x is convex to accommodate the outer
shell 11 and the inner side 43 of the pad 36.sub.x is concave to
accommodate the player's head.
[0059] In this embodiment, with additional reference to FIGS. 17
and 18, the pad 36.sub.x comprises a core 44 and a covering 46
disposed on the core 44.
[0060] The core 44 of the pad 36.sub.x comprises a periphery 67
that includes an outer side 47 facing towards the outer shell 11
and an inner side 49 opposite to the outer side 47 for facing
towards the player's head. The periphery 67 of the core 44 defines
the three-dimensional shape of the periphery 39 of the pad
36.sub.x. More particularly, in this embodiment, each of the outer
side 47 and the inner side 49 of the core 44 is uneven (i.e.,
nonplanar in that it comprises one or more angular parts and/or one
or more curved parts) to accommodate the outer shell 11 and the
player's head. Specifically, in this example, the outer side 47 of
the core 44 is convex to accommodate the outer shell 11 and the
inner side 49 of the core 44 is concave to accommodate the player's
head.
[0061] The core 44 of the pad 36.sub.x comprises a plurality of
zones of different materials 48.sub.1-48.sub.Z. Specifically, the
zones of different materials 48.sub.1-48.sub.Z of the core 44 are
zones differing in at least one material property (e.g., density,
modulus of elasticity, resilience, etc.). In some cases, respective
ones of the zones of different materials 48.sub.1-48.sub.Z may
differ in two or more material properties. The zones of different
materials 48.sub.1-48.sub.Z are thus parts of the core 44 that are
materially different from one another.
[0062] In this example, the zones of different materials
48.sub.1-48.sub.Z of the core 44 of the pad 36.sub.x include two
zones of different materials, namely an outer zone 48.sub.1 of the
core 44 and an inner zone 48.sub.2 of the core 44 that is
configured to be located closer to the player's head than the outer
zone 48.sub.1. A given one of the zones of different materials
48.sub.1-48.sub.Z of the core 44 can be designated as "outer" or
"inner" in that it is located outwardly or inwardly relative to
another one of the zones of different materials 48.sub.1-48.sub.Z
of the core 44. In this case, the outer zone 48.sub.1 of the core
44 constitutes at least part of the outer side 47 of the core 44
while the inner zone 48.sub.2 of the core 44 constitutes at least
part of the inner side 49 of the core 44. The zones of different
materials 48.sub.1-48.sub.Z of the core 44 of the pad 36.sub.x may
comprise three, four, five or more zones of different materials in
other examples.
[0063] In this embodiment, respective ones of the zones of
different materials 48.sub.1-48.sub.Z of the core 44 of the pad
36.sub.x differ in density.
[0064] More particularly, in this embodiment, a density of the
inner zone 48.sub.2 of the core 44 is less than a density of the
outer zone 48.sub.1 of the core 44. This may help to provide shock
absorption and comfort for the player's head. For instance, in some
embodiments, the density of the inner zone 48.sub.2 of the core 44
may be no more than 80%, in some cases no more than 50%, in some
cases no more than 20%, and in some cases an even lesser fraction
of the density of the outer zone 48.sub.1 of the core 44.
[0065] Each of the density of the outer zone 48.sub.1 of the core
44 and the density of the inner zone 48.sub.2 of the core 44 may
have any suitable value. For instance, in some embodiments, the
density of the outer zone 48.sub.1 of the core 44 may be no more
than 15 lb/ft.sup.3 (0.240 g/cm.sup.3), in some cases no more than
4 lb/ft.sup.3 (0.064 g/cm.sup.3), and in some cases no more than 2
lb/ft.sup.3 (0.032 g/cm.sup.3), and/or the density of the inner
zone 48.sub.2 of the core 44 may be no more than 15 lb/ft.sup.3
(0.240 g/cm.sup.3), in some cases no more than 8 lb/ft.sup.3 (0.128
g/cm.sup.3), and in some cases no more than 2 lb/ft.sup.3 (0.032
g/cm.sup.3).
[0066] Respective ones of the zones of different materials
48.sub.1-48.sub.Z of the core 44 may differ in one or more other
properties in addition to or instead of density.
[0067] For example, in some embodiments, a modulus of elasticity
(i.e., Young's modulus) of the inner zone 48.sub.2 of the core 44
may be less than a modulus of elasticity of the outer zone 48.sub.1
of the core 44. For instance, in some embodiments, the modulus of
elasticity of the inner zone 48.sub.2 of the core 44 may be no more
than 90%, in some cases no more than 80%, in some cases no more
than 70%, and in some cases an even lesser fraction of the modulus
of elasticity of the outer zone 48.sub.1 of the core 44. In some
cases, the modulus of elasticity may be evaluated according to ASTM
D-638 or ASTM D-412. Alternatively, in other embodiments, the
modulus of elasticity of the inner zone 48.sub.2 of the core 44 may
be greater than the modulus of elasticity of the outer zone
48.sub.1 of the core 44.
[0068] As another example, in some embodiments, a resilience of the
inner zone 48.sub.2 of the core 44 may be less than a resilience of
the outer zone 48.sub.1 of the core 44. For instance, in some
embodiments, the resilience of the inner zone 48.sub.2 of the core
44 may be no more than 80%, in some cases no more than 60%, in some
cases no more than 40%, and in some cases an even less fraction of
the resilience of the outer zone 48.sub.1 of the core 44 according
to ASTM D2632-01 which measures resilience by vertical rebound.
Alternatively, in other embodiments, the resilience of the inner
zone 48.sub.2 of the core 44 may be greater than the resilience of
the outer zone 48.sub.1 of the core 44. Each of the resilience of
the inner zone 48.sub.2 of the core 44 and the resilience of the
outer zone 48.sub.1 of the core 44 may have any suitable value.
[0069] As another example, in some embodiments, an elongation at
break of the inner zone 48.sub.2 of the core 44 may be greater than
an elongation at break of the outer zone 48.sub.1 of the core 44.
For instance, in some embodiments, the elongation at break of the
inner zone 48.sub.2 of the core 44 may be at least 110%, in some
cases at least 130%, and in some cases at least 150% of the
elongation at break of the outer zone 48.sub.1 of the core 44
according to ASTM D-638 or ASTM D-412, and in some cases even
more.
[0070] Each of the elongation at break of the inner zone 48.sub.2
of the core 44 and the elongation at break of the outer zone
48.sub.1 of the core 44 may have any suitable value. For instance,
in some embodiments, the elongation at break of the inner zone
48.sub.2 of the core 44 may be at least 20%, in some cases at least
40%, in some cases at least 60%, and in some cases even more,
and/or the elongation at break of the outer zone 48.sub.1 of the
core 44 may be at least 20%, in some cases at least 40%, in some
cases at least 60%, and in some cases even more.
[0071] As another example, in some embodiments, a hardness (e.g.,
Shore OO hardness) of the inner zone 48.sub.2 of the core 44 may be
less than a hardness of the outer zone 48.sub.1 of the core 44. For
instance, in some embodiments, on a Shore OO hardness scale, a
ratio of the hardness of the inner zone 48.sub.2 of the core 44
over the hardness of the outer zone 48.sub.1 may be no more than
0.9, in some cases no more than 0.5, in some cases no more than
0.3, and in some cases an even lesser ratio. In some cases, the
hardness may be evaluated according to ASTM D2240. Alternatively,
in other embodiments, the hardness of the inner zone 48.sub.2 of
the core 44 may be greater than the hardness of the outer zone
48.sub.1 of the core 44.
[0072] As another example, in some embodiments, an indentation
force deflection (IFD) of the inner zone 48.sub.2 of the core 44
may be less than an IFD of the outer zone 48.sub.1 of the core 44.
For instance, in some embodiments, the IFD of the inner zone
48.sub.2 of the core 44 may be no more than 95%, in some cases no
more than 80%, in some cases no more than 60%, and in some cases an
even less fraction of the IFD of the outer zone 48.sub.1 of the
core 44 according to ASTM D3574 which measures the force required
to compress a foam material 25% of its thickness. Alternatively, in
other embodiments, the IFD of the inner zone 48.sub.2 of the core
44 may be greater than the IFD of the outer zone 48.sub.1 of the
core 44.
[0073] Each of the IFD of the inner zone 48.sub.2 of the core 44
and the IFD of the outer zone 48.sub.1 of the core 44 may have any
suitable value. For instance, in some embodiments, the IFD of the
inner zone 48.sub.2 of the core 44 may be no more than 15
pound-force per square inch (psi), in some cases no more than 10
psi, and in some cases no more than 6 psi according to ASTM D3574,
and/or the IFD of the outer zone 48.sub.1 of the core 44 may be no
more than 20 psi, in some cases no more than 16 psi, and in some
cases no more than 12 psi according to ASTM D3574.
[0074] The zones of different materials 48.sub.1-48.sub.Z of the
core 44 of the pad 36.sub.x may include any suitable materials.
[0075] In this embodiment, with additional reference to FIG. 18,
each of the outer zone 48.sub.1 and the inner zone 48.sub.2 of the
core 44 is a zone of expanded microspheres 60.sub.1-60.sub.M. That
is, each of the outer zone 48.sub.1 and the inner zone 48.sub.2 of
the core 44 is at least mainly (i.e., mainly or entirely) made of
expanded microspheres 60.sub.1-60.sub.M. Each expanded microsphere
60.sub.x comprises a polymeric shell 62 expanded by a fluid
encapsulated in an interior of the polymeric shell. In this
example, the polymeric shell 62 of the expanded microsphere
60.sub.x is a thermoplastic shell. The fluid encapsulated in the
polymeric shell 62 is a liquid or gas (in this case a gas) able to
expand the expanded microsphere 60.sub.x when heated during
manufacturing of the pad 36.sub.x. In some embodiments, the
expandable microspheres 60.sub.1-60.sub.M may be Expancel.TM.
microspheres commercialized by Akzo Nobel. In other embodiments,
the expandable microspheres 60.sub.1-60.sub.M may be Dualite
microspheres commercialized by Henkel; Advancell microspheres
commercialized by Sekisui; Matsumoto Microsphere microspheres
commercialized by Matsumoto Yushi Seiyaku Co; or KUREHA Microsphere
microspheres commercialized by Kureha. Various other types of
expanded microspheres may be used in other embodiments.
[0076] The expanded microspheres 60.sub.1-60.sub.M may be provided
in any suitable form during manufacturing of the pad 36.sub.x. For
example, in some embodiments, the expanded microspheres
60.sub.1-60.sub.M may include dry unexpanded, dry expanded, wet
unexpanded, wet expanded, and/or partially-expanded dry and/or wet
microspheres.
[0077] As discussed above, in this embodiment, the inner zone
48.sub.2 of expanded microspheres of the core 44 is less dense than
the outer zone 48.sub.1 of expanded microspheres of the core
44.
[0078] In this embodiment, each of the outer zone 48.sub.1 of
expanded microspheres of the core 44 and the inner zone 48.sub.2 of
expanded microspheres of the core 44 constitutes at least a
substantial part (i.e., a substantial part or an entirety) of the
core 44. More particularly, in this embodiment, each of the outer
zone 48.sub.1 of expanded microspheres of the core 44 and the inner
zone 48.sub.2 of expanded microspheres of the core 44 constitutes
at least one-quarter of the core 44 by weight, in some cases at
least one-third of the core 44 by weight, and in some cases at
least half of the core 44 by weight. Specifically, in this case,
the outer zone 48.sub.1 of expanded microspheres of the core 44 is
larger than the inner zone 48.sub.2 of expanded microspheres of the
core 44, with the outer zone 48.sub.1 of expanded microspheres of
the core 44 constituting about 70% of the core 44 by weight and the
inner zone 48.sub.2 of expanded microspheres of the core 44
constituting about 30% of the core 44 by weight.
[0079] Thus, in this embodiment, the expanded microspheres
60.sub.1-60.sub.M of the inner and outer zones 48.sub.1, 48.sub.2
of the core 44 constitute a substantial part (i.e., a substantial
part or an entirety) of the core 44 by weight. More particularly,
in this embodiment, the expanded microspheres 60.sub.1-60.sub.M of
the inner and outer zones 48.sub.1, 48.sub.2 of the core 44
constitute at least one-quarter of the core 44 by weight, in some
cases at least one-third of the core 44 by weight, and in some
cases at least a majority of the core by weight. Specifically, in
this example, the expanded microspheres 60.sub.1-60.sub.M of the
inner and outer zones 48.sub.1, 48.sub.2 of the core 44 constitute
at least 80%, in this case, substantially the entirety of the core
44.
[0080] The zones of different materials 48.sub.1-48.sub.Z of the
core 44 of the pad 36.sub.x may be arranged in any suitable way and
have any suitable size and configuration.
[0081] In this embodiment, each of a thickness T.sub.1 of the outer
zone 48.sub.1 of the core 44 and a thickness T.sub.2 of the inner
zone 48.sub.2 of the core 44 corresponds to a significant part of a
thickness T.sub.C of the core 44. More particularly, in this
embodiment, each of the thickness T.sub.1 of the outer zone
48.sub.1 of the core 44 and the thickness T.sub.2 of the inner zone
48.sub.2 of the core 44 corresponds to at least one-quarter, in
some cases at least one-third, and in some cases at least a
majority of the thickness T.sub.C of the core 44. Specifically, in
this example, each of the thickness T.sub.1 of the outer zone
48.sub.1 of the core 44 and the thickness T.sub.2 of the inner zone
48.sub.2 of the core 44 corresponds to more than half of the
thickness T.sub.C of the core 44.
[0082] Also, in this embodiment, the outer zone 48.sub.1 of the
core 44 and the inner zone 48.sub.2 of the core 44 may be
interlocked. For instance, in this embodiment, a given one of the
outer and inner zones 48.sub.1, 48.sub.2 of the core 44 and an
adjacent one of the outer and inner zones 48.sub.1, 48.sub.2 of the
core 44 are interlocked by an interlocking part 61 of the given one
of the outer and inner zones 48.sub.1, 48.sub.2 of the core 44
extending into an interlocking void 63 of the adjacent one of the
outer and inner zones 48.sub.1, 48.sub.2 of the core 44. This may
be done to facilitate manufacturing (e.g., molding) of the outer
and inner zones 48.sub.1, 48.sub.2 of the core 44) and/or to help
secure them.
[0083] In this embodiment, the inner zone 48.sub.2 of the core 44
comprises projections 64.sub.1-64.sub.6 projecting from an adjacent
part 65 of the inner side 49 of the core 44 and spaced from one
another. The projections 64.sub.1-64.sub.6 may provide areas of
increased cushioning and may facilitate air circulations
thereabout.
[0084] The covering 46 of the pad 36.sub.x covers at least a
substantial part (i.e., a substantial part or an entirety) of the
core 44 of the of the pad 36.sub.x. This may help to retain
integrity of the core 44. For example, in this embodiment, this may
help to retain the zones of different materials 48.sub.1-48.sub.Z
of the core 44 together. Also, in this embodiment in which the core
44 includes expanded microspheres, the covering 46 may help to
protect the outer and inner zones 48.sub.1, 48.sub.2 of expanded
microspheres against chipping, crumbling or cracking in use, as
their expanded microspheres may otherwise be friable.
[0085] In this embodiment, the covering 46 covers at least part of
the inner side 49 of the core 44 and at least part of the outer
side 47 of the core 44. More particularly, in this embodiment, the
covering 46 covers at least a majority of the periphery 67 of the
core 44. In this example, the covering 46 covers at least a
majority, in this case all, of the inner side 49 of the core 44 and
at least a majority, in this case all, of the outer side 47 of the
core 44. Specifically, in this example, the covering 46 envelopes
the core 44 (i.e., completely encloses the core 44). This may help
to maximize an effect of the covering 46 in retaining integrity of
the core 44.
[0086] More particularly, in this embodiment, the covering 46 is
molded to conform to the core 44. That is, the covering 46 is
shaped by molding equipment including one or more molds in order to
conform to the core 44 during a molding process for making the pad
36.sub.x, as further discussed later. This allows the covering 46
to closely follow and match the periphery 67 of the core 44. Also,
the covering 46 is affixed to the core 44. In this case, the
covering 46 is bonded to the core 44 during the molding
process.
[0087] In this example of implementation, the covering 46 comprises
a layer of polymeric material 70 molded to conform to the core 44.
In this embodiment, the layer of polymeric material 70 is a layer
of polyurethane (e.g., thermoplastic polyurethane). The layer of
polymeric material 70 may include any other suitable polymeric
material in other embodiments (e.g. polyester, nylon fabric,
etc.).
[0088] In this embodiment, the covering 46 comprises an outer
covering member 51 that covers the outer side 47 of the core 44 and
an inner covering member 53 that covers the inner side 49 of the
core 44. More particularly, in this embodiment, the outer and inner
covering members 51, 53 comprise respective parts of the layer of
polymeric material 70 and meet at a junction 55. The outer and
inner covering members 51, 53 may be formed separately during
manufacturing of the pad 36.sub.x, as discussed later.
[0089] The covering 46 is significantly thinner than the core 44.
For example, in some embodiments, a thickness T.sub.E of the
covering 46 corresponds to no more than 10%, in some cases no more
than 5%, and in some cases no more than 2% of the thickness T.sub.C
of the core 44. For instance, in some embodiments, the thickness
T.sub.E of the covering 46 may be no more than 2 mm, in some cases
no more than 0.5 mm, in some cases no more than 0.2 mm, and in some
cases even less.
[0090] In this embodiment, the covering 46 may be used to enhance
an appearance of the pad 36.sub.x. For example, in this embodiment,
the covering 46 displays a decoration 72 that includes an
arrangement of a plurality of different colors. This may be useful
as the 36.sub.1-36.sub.C occupy a significant area within the
helmet 10.
[0091] More particularly, in this embodiment, the decoration 72 is
defined by the layer of polymeric material 70 and includes four
different colors. In this example, the decoration 72 includes areas
of contrasting colors and lines in one color which are spaced apart
by gaps having another color and which cross other lines.
[0092] The decoration 72 of the covering 46 may take on any other
suitable configuration in other embodiments. For instance, in some
embodiments, the decoration 72 may include a graphical
representation of: one or more alphanumeric characters that may
form text (e.g., a word, a message, etc.); one or more symbols
(e.g., a logo, a sign, an emblem, etc.); one or more shapes or
patterns; and/or one or more real or imaginary objects (e.g., a
person, an animal, a vehicle, an imaginary or fictional character,
or any other real or imaginary thing). For example, in some
embodiments, the arrangement of colors of the decoration 72 may
represent colors and/or a logo of a sports team for which the
player plays.
[0093] The decoration 72 may be provided in any suitable way. For
example, in this embodiment, the decoration 72 may be provided by
silk-screening. In other embodiments, the decoration 72 may be
provided by sublimation, roller printing, pad printing, or any
other suitable technique.
[0094] The covering 46 may be implemented in various other ways in
other embodiments. For example, in some embodiments, the covering
46 may comprise a fabric layer, such as a non-woven fabric layer or
a woven fabric layer (e.g., of spandex, nylon, polyester,
polypropylene, or any other suitable fabric material). As another
example, in some embodiments, the covering 46 may comprise a
plurality of layers of different materials. For instance, in some
embodiments, the inner covering member 53 that covers the inner
side 49 of the core 44 may include the layer of polymeric material
70 (e.g., polyurethane), while the outer covering member 51 that
covers the outer side 47 of the core 44 may include a fabric layer.
As yet another example, in some embodiments, the covering 46 may
comprise a plurality of layers that are stacked.
[0095] In this embodiment, the pad 36.sub.x comprises a plurality
of ventilation holes 80.sub.1, 80.sub.2. In this example, the
ventilation holes 80.sub.1, 80.sub.2 are aligned with ventilation
holes 82.sub.1, 80.sub.2 of the outer shell 11. Each ventilation
hole 80.sub.x of the pad 36.sub.x extends through the core 44 and
is defined by an interior surface 90 of the core 44, and the
covering 46 covers at least part, in this case all, of the internal
surface 90 of the core 44.
[0096] The pad 36.sub.x may be manufactured in various ways. In
this embodiment, the pad 36.sub.x is made by a molding process in
which its core 44 is molded into shape and its covering 46 is
molded to conform to the core 44. The molding process uses molding
equipment including one or more molds to shape the core 44 and the
covering 46.
[0097] The zones of different materials 48.sub.1-48.sub.Z are
provided. In this embodiment, each of the outer and inner zones
48.sub.1, 48.sub.2 of the core 44 is provided separately. More
particularly, in this embodiment, each of the outer and inner zones
48.sub.1, 48.sub.2 of the core 44 is molded into shape by the
molding equipment. For instance, as the outer and inner zones
48.sub.1, 48.sub.2 of the core 44 have different shapes, a mold
having a cavity corresponding to a three-dimensional shape of the
outer zone 48.sub.1 of the core 44 may be used to form the outer
48.sub.1 of the core 44, whereas another mold having a cavity
corresponding to a three-dimensional shape of the inner zone
48.sub.2 of the core 44 may be used to form the inner zone 48.sub.1
of the core 44.
[0098] In this embodiment, as it is a zone of expanded microspheres
60.sub.1-60.sub.M, each of the outer and inner zones 48.sub.1,
48.sub.2 of the core 44 is formed by placing an amount of
microspheres in the cavity of the mold in which it is to be formed.
In some examples, the microspheres placed into the mold may include
unexpanded microspheres (e.g., dry unexpanded microspheres in a
loose powder, wet unexpanded microspheres in a paste-like form).
Alternatively or additionally, in some examples, the microspheres
placed into the mold may include pre-expanded microspheres that
have been previously heated to pre-expand them (e.g., either
partially or fully expand them). Also, in some examples, any other
minor constituent of the outer and inner zones 48.sub.1, 48.sub.2
of the core 44 (e.g., a color pigment substance) may be placed into
the mold with the microspheres.
[0099] Each of the outer and inner zones 48.sub.1, 48.sub.2 of the
core 44 is separately molded in the mold in which is to be formed
by applying heat. As part of the molding process, microspheres
provided in the mold expand. The molding process may then include a
cold molding phase in which the temperature is lowered. Temperature
and pressure of the molding process cause bonding of adjacent ones
of the expanded microspheres.
[0100] The covering 46 is molded to conform to the core 44. In this
embodiment, each of the outer and inner covering members 51, 53 of
the covering 46 is provided separately. More particularly, in this
embodiment, each of the outer and inner covering members 51, 53 is
molded into shape by the molding equipment to respectively conform
to the outer and inner sides 47, 49 of the core 44. For instance,
in some embodiments, a mold comprising a cavity that includes a
surface corresponding to a three-dimensional shape of the outer
covering member 51 and that of the outer side 47 of the core 44 may
be used to form the outer covering member 51, and another mold
comprising a cavity that includes a surface corresponding to a
three-dimensional shape of the inner covering member 53 and that of
the inner side 49 of the core 44 may be used to form the inner
covering member 53.
[0101] In some embodiments, a precursor of each of the outer and
inner covering members 51, 53 is prepared for placement into the
mold in which it is to be formed in order to conform to the core
44. More particularly, in this embodiment, the precursor of each of
the outer and inner covering members 51, 53 includes a sheet (e.g.,
which may have been previously cut from a larger sheet). In this
example, the sheet comprises part of the layer of polymeric
material 70. In some cases, the sheet may include the decoration
72.
[0102] Molding of the sheet of each of the outer and inner covering
members 51, 53 into the mold in which it is to be formed in order
to conform to the core 44 may be achieved in any suitable way. In
this embodiment, at least part of the covering 46 is vacuum-formed
to conform to the core 44. For example, in this embodiment, the
sheet to form the inner covering member 53 is vacuum-formed in the
mold for shaping the inner covering member 53. The inner zone
48.sub.2 of the core 44 is then placed on the inner covering member
53, which has been vacuum-formed. The outer zone 48.sub.1 of the
core 44 is then placed on the inner zone 48.sub.2 of the core 44.
The sheet to form the outer covering member 51 is then placed on
the outer zone 48.sub.1 of the core 44 in the mold in which it is
to be formed to conform to the outer zone 48.sub.1 of the core 44.
For instance, in some embodiments, the sheet to form the outer
covering member 51 may be vacuum-formed in the mold, which is then
closed. Alternatively, in some embodiments, the sheet to form the
inner covering member 53 may be shaped to conform to the outer zone
48.sub.1 of the core 44 when the mold is closed and it is pressed
against the outer zone 48.sub.1 of the core 44.
[0103] The covering 46 is bonded to the core 44 during the molding
process. More particularly, in this embodiment, the outer and inner
covering members 51, 53 are respectively bonded to the outer and
inner sides 47, 49 of the core 44. In some embodiments, a hot-melt
adhesive film or another adhesive may be associated with one or
both of the outer and inner covering members 51, 53 to enhance
bonding to the core 44. In this example, the outer and inner
covering members 51, 53 meet at their junction 55 where they are
joined, thereby enveloping the core 44. The molding process may
then include a cold molding phase in which the temperature is
lowered.
[0104] The pad 36.sub.x, with its core 44 shaped and its covering
62 molded to conform to its core 44, is removed from the molding
equipment and may be finished by one or more post-molding
operations. For example, in some embodiments, a trimming operation
may be performed to remove excess material from the covering 46
that extends beyond the core 44 (e.g., at the junction 55 of the
outer and inner covering members 51, 53).
[0105] Various other manufacturing techniques may be used to make
the pad 36.sub.x in other embodiments.
[0106] The pad 36.sub.x, including its core 44 and its covering 46,
may be implemented in various other ways in other embodiments.
[0107] For example, in some embodiments, as shown in FIG. 20, a
state of the inner zone 48.sub.2 of expanded microspheres of the
core 44 may be different from a state of the outer zone 48.sub.1 of
expanded microspheres of the core 44. That is, the expanded
microspheres 60.sub.1-60.sub.M of the inner zone 48.sub.2 of the
core 44 may be in a different state from those of the outer zone
48.sub.1 of the core 44.
[0108] More particularly, in this embodiment, the outer zone
48.sub.1 of expanded microspheres of the core 44 is consolidated,
i.e., its expanded microspheres 60.sub.1-60.sub.M are consolidated
such that the outer zone 48.sub.1 is substantially solid, while the
inner zone 48.sub.2 of expanded microspheres of the core 44 is
unconsolidated, i.e., its expanded microspheres 60.sub.1-60.sub.M
are unconsolidated such that the inner zone 48.sub.2 is softer and
more malleable than the outer zone 48.sub.1. For instance, in some
embodiments, the unconsolidated expanded microspheres
60.sub.1-60.sub.M of the inner zone 48.sub.2 of the core 44 may be
in a paste-like form. The unconsolidated state (e.g., paste-like
form) of the expanded microspheres 60.sub.1-60.sub.M of the inner
zone 48.sub.2 may be achieved by encapsulating the inner zone
48.sub.2 with the inner covering member 53 while it is
vacuum-formed, wherein the vacuum molding process is performed at a
temperature lower than the consolidation temperature of the
expanded microspheres 60.sub.1-60.sub.M This may help to enhance a
cushioning effect of the inner zone 48.sub.2 of the core 44.
[0109] As another example, in some embodiments, as shown in FIG.
21A, one or more of the zones of different materials
48.sub.1-48.sub.Z of the core 44 of the pad 36.sub.x may not be a
zone of expanded microspheres (i.e., not be mainly or entirely made
of expanded microspheres, but may rather be a zone at least mainly
made of material other than expanded microspheres). For instance,
in this embodiment, the inner zone 48.sub.2 of the core 44 is a
zone of foam 85, i.e., a zone at least mainly (i.e., mainly or
entirely) made of foam 85, while the outer zone 48.sub.1 of the
core 44 is a zone of expanded microspheres as discussed above. The
foam 85 may help to enhance comfort for the player's head. This may
also be useful to provide better impact absorption or other
protection against linear and rotational impacts.
[0110] In this embodiment, the foam 85 includes polyurethane foam
(e.g., PORON XRD foam commercialized by Rogers Corporation, or any
other suitable polyurethane foam). The foam 85 may include any
other suitable foam in other embodiments (e.g., polyvinyl chloride
(PVC) foam, vinyl nitrile foam, etc.).
[0111] More particularly, in this embodiment, as shown in FIG. 21B,
before being molded, the foam 85 of the inner zone 48.sub.2 of the
core 44 of the pad 36.sub.x includes: a foam layer 86 (e.g., which
may include one or more foam plies) that forms a "base" which
extends over at least a majority, in this case all, of the inner
side 49 of the core 44 to be molded; a foam layer of foam 87 that
is smaller than and overlies the foam layer 86 in a specific region
of the inner zone 48.sub.2 (e.g., in this case a region located
underneath the projection 64.sub.1); and respective portions of a
foam layer 89 for forming each of the projections 64.sub.1-64.sub.6
projecting from the adjacent part 65 of the inner side 49 of the
core 44 and spaced from one another.
[0112] In this embodiment, the outer zone 48.sub.1 of the core 44
may be formed by placing an amount of microspheres in the cavity of
the mold in which it is to be formed by applying heat as described
earlier, and the inner zone 48.sub.2 of the core 44 may be formed
by placing the foam layers 86, 87, 89 of the foam 85 into the
cavity in which it is to be formed (e.g., on the outer zone
48.sub.1 of the core 44) so that after molding the foam layers 86,
87, 89 of the foam 85 amalgamate into the inner zone 48.sub.2 of
the core 44.
[0113] As another example, in some embodiments, as shown in FIGS.
22 to 24, the zones of different materials 48.sub.1-48.sub.Z of the
core 44 of the pad 36.sub.x may be more than two in number, such as
three, four or more zones. For instance, in this embodiment, the
outer zone 48.sub.1 of the core 44 is a zone of expanded
microspheres and the inner zone 48.sub.2 of the core 44 is a zone
of foam as discussed above, while there is another inner zone
48.sub.3 of foam 88 different from the foam 85 of the inner zone
48.sub.2. In this case, the inner zone 48.sub.3 of the core 44
comprises the projections 64.sub.1-64.sub.6 projecting from the
adjacent part 65 of the inner side 49 of the core 44 and spaced
from one another.
[0114] In this embodiment, the foam 88 includes polyurethane foam
(e.g., PORON XRD foam commercialized by Rogers Corporation, or any
other suitable polyurethane foam). The foam 85 may include any
other suitable foam in other embodiments (e.g., polyvinyl chloride
(PVC) foam, vinyl nitrile foam, etc.).
[0115] More particularly, in this embodiment, the density of the
foam 85 is different from the density of the foam 88. In this
example, the density of the foam 88 is less than the density of the
foam 85. For instance, in some embodiments, the density of the foam
88 may be no more than 90%, in some cases no more than 80% and in
some cases no more than 70% of the density of the foam 85.
Alternatively, in other embodiments, the foam 88 may be denser than
the foam 85.
[0116] As another example, in some embodiments, as shown in FIG.
25, the inner zone 48.sub.2 of the core 44 of the pad 36.sub.x may
be perforated such that it comprises a plurality of apertures
91.sub.1-91.sub.A. This may be useful to enhance ventilation and
provide sweat management to the player.
[0117] As another example, in some embodiments, the covering 46 of
the pad 36.sub.x may cover less than the entirety of the core 44 of
the pad 36.sub.x. For example, in some embodiments, certain regions
of the inner side 49 and/or certain regions of the outer side 47 of
the core 44 may not be covered by the covering 46 but may rather be
exposed.
[0118] Although in this embodiment the article of protective
athletic gear 10 is the helmet 10, in other embodiments, the
article of protective athletic gear 10 may be any other article of
protective athletic gear comprising one or more cushioning
components constructed using principles described herein in respect
of the cushioning components 12.sub.1-12.sub.C.
[0119] For example, in some embodiments, as shown in FIG. 26, the
article of protective athletic gear 10 may be an arm guard (e.g.,
an elbow pad) for protecting an arm (e.g., an elbow) of a user, in
which the arm guard 10 comprises a cushioning component 212
constructed using principles described herein in respect of
cushioning components 12.sub.1-12.sub.C and constituting a pad 236
of the arm guard 10.
[0120] As another example, in some embodiments, as shown in FIG.
27, the article of protective athletic gear 10 may be shoulder pads
for protecting an upper torso (e.g., shoulders and a chest) of a
user, in which the shoulder pads 10 comprise a cushioning component
312 constructed using principles described herein in respect of the
cushioning components 12.sub.1-12.sub.C and constituting a pad 336
of the shoulder pads 10.
[0121] As another example, in some embodiments, as shown in FIG.
28, the article of protective athletic gear 10 may be a leg guard
for protecting a leg of a user, in which the leg guard 10 comprises
a cushioning component 412 constructed using principles described
herein in respect of the cushioning components 12.sub.1-12.sub.C
and constituting a pad 436 of the leg guard 10.
[0122] As another example, in some embodiments, as shown in FIG.
29, the article of protective athletic gear 10 may be a chest
protector for a goalie or baseball catcher for protecting his/her
chest, in which the chest protector 10 comprises a cushioning
component 712 constructed using principles described herein in
respect of the cushioning components 12.sub.1-12.sub.C and
constituting any portion of the chest protector 10 (e.g., a chest
portion, an abdominal portion, an arm portion if present,
etc.).
[0123] As another example, in some embodiments, as shown in FIG.
30, the article of protective athletic gear 10 may be a glove for
protecting a user's hand, in which the glove 10 comprises a
cushioning component 812 constructed using principles described
herein in respect of the cushioning components 12.sub.1-12.sub.C.
For example, in this case, the glove 10 is a blocker glove for a
goalie and the cushioning component 812 constitutes a board portion
of the blocker glove 10 to deflect pucks or balls.
[0124] In some embodiments, the article of athletic gear 10 may be
used for purposes other than protection.
[0125] For instance, in some embodiments, with additional reference
to FIGS. 31 to 33, the article of athletic gear 10 may be a sports
implement for handling by a user, in which the sports implement 10
comprises a cushioning component 612 constructed using principles
described herein in respect of the cushioning components
12.sub.1-12.sub.C. For example, in some embodiments, a core 644 of
the cushioning component 612 may be constructed using principles
described herein in respect of the core 44 of each of the
cushioning components 12.sub.1-12.sub.C in order to provide shock
absorbance, while a covering 646 of the cushioning component 612
may be constructed using principles described herein in respect of
the covering 46 of each of the cushioning components
12.sub.1-12.sub.C but comprise rigid material 670 that imparts
strength and rigidity (e.g., that forms a wall of the sports
implement 10). In some embodiments, the rigid material 670 may
comprise fiber-reinforced polymeric material (e.g.,
carbon-fiber-reinforced polymeric material or
glass-fiber-reinforced polymeric material) or any other composite
material that is provided (e.g., wrapped as pre-impregnated fiber
tape) about the core 644.
[0126] For example, in some embodiments, as shown in FIG. 31, the
sports implement 10 may be a hockey stick. The hockey stick 10
comprises a shaft 620, a handle 622 disposed at a proximal end
portion of the shaft 620, and a blade 624 disposed adjacent a
distal end portion of the shaft 620. In this embodiment, the blade
624 of the hockey stick 10 comprises the cushioning component 612.
In other embodiments, the handle 622 of the hockey stick 10 may
comprise the cushioning component 612 or another cushioning
component similar to the cushioning component 612. In yet other
embodiments, the blade 624 of the hockey stick 10 may comprise the
cushioning component 612, while the handle 622 of the hockey stick
10 may comprise another cushioning component similar to the
cushioning component 612.
[0127] As another example, with additional reference to FIG. 32,
the sports implement 10 may be a lacrosse stick. The lacrosse stick
10 comprises a shaft 650, a handle 652 disposed at a proximal end
portion of the shaft 650, and a lacrosse head 654 disposed adjacent
a distal end portion of the shaft 650. In this example, the handle
652 of the lacrosse stick 10 comprises the cushioning component
612.
[0128] As another example, with additional reference to FIG. 33,
the sports implement 10 may be a ball bat, such as a baseball bat
or a softball bat. The ball bat 10 comprises a handle 752, a barrel
754, and a tapered transition 755 between the handle 752 and the
barrel 754. In this example, the barrel 754 comprises the
cushioning component 612.
[0129] As another example, in some embodiments, as shown in FIG.
34, the article of athletic gear 10 may be an article of footwear
comprising a cushioning component 512 constructed using principles
described herein in respect of the cushioning components
12.sub.1-12.sub.C. In this embodiment, the article of footwear 10
is a skate. For example, in this case, the skate 10 is a hockey
skate for a hockey player. The skate 10 comprises a boot 525, a
blade holder 547 and a blade 549. In this example, the cushioning
component 512 constitutes a portion of the boot 525. More
particularly, in this example, the cushioning component 512
constitutes a sole portion of the boot 525). The article of
footwear 10 may be any other type of footwear (e.g., shoes) in
other embodiments.
[0130] Although in embodiments considered above the article of
athletic gear 10 is hockey, lacrosse, or baseball/softball gear, in
other embodiments, the article of athletic gear 10 may be any other
article of athletic gear usable by a player playing another type of
contact sport (e.g., a "full-contact" sport) in which there are
significant impact forces on the player due to player-to-player
and/or player-to-object contact or any other type of sports,
including athletic activities other than contact sports. For
example, in other embodiments, the article of athletic gear 10 may
be an article of football gear for a football player, an article of
soccer gear for a soccer player, etc.
[0131] In other embodiments, a device comprising one or more
cushioning components constructed using principles described herein
in respect of the cushioning components 12.sub.1-12.sub.C may be
anything other than an article of athletic gear and may thus be
designed for any suitable purpose. For example, this may include
blunt trauma personal protective equipment (PPE), automotive
interior components, chair cushioning components, bed
cushioning/mattresses, etc.
[0132] Certain additional elements that may be needed for operation
of some embodiments have not been described or illustrated as they
are assumed to be within the purview of those of ordinary skill in
the art. Moreover, certain embodiments may be free of, may lack
and/or may function without any element that is not specifically
disclosed herein.
[0133] Any feature of any embodiment discussed herein may be
combined with any feature of any other embodiment discussed herein
in some examples of implementation.
[0134] In case of any discrepancy, inconsistency, or other
difference between terms used herein and terms used in any document
incorporated by reference herein, meanings of the terms used herein
are to prevail and be used.
[0135] Although various embodiments and examples have been
presented, this was for purposes of description but this should not
be limiting. Various modifications and enhancements will become
apparent to those of ordinary skill in the art.
* * * * *