KR102132731B1 - Breathable impact absorbing cushioning and constructions - Google Patents

Abstract

Disclosed herein is a breathable cushioning pad in one embodiment. The cushioning pad includes an upper layer surface, a lower layer having a lower surface, and a cushioning material disposed between the upper layer and the lower layer, and the cushioning pad has a thickness. A channel can be placed on the cushioning pad and defines the cushioning area. The channel comprises a thickness smaller than the thickness of the cushioning region. One or more vents extend through the connection of the top and bottom surfaces.

Description

Breathable Shock Absorbing Cushion and Assembly {BREATHABLE IMPACT ABSORBING CUSHIONING AND CONSTRUCTIONS}

The present disclosure relates to breathable and comfortable protective pads, articles comprising such pads, pads and methods of making and using the articles, particularly those requiring free range of motion. Protective pads with breathability and comfort for humanity.

This application is a partial succession of co-owned and co-pending application No. 13/208,229 filed on August 11, 2011, and the benefit of U.S. Provisional Application No. 61/591,902 filed on January 28, 2012. Claims, all of these applications are hereby incorporated by reference in their entirety.

Many activities, especially athletic activities, involve a potential danger to the body from impact. Elbows, knees, shoulders, ankles, buttocks and other joints may be particularly susceptible to shock damage and are still challenging to protect without limiting the range of motion and motion of the individual. Impact protection is heavy, non-breathable or limited, or otherwise does not target specific body parts accurately, or is too inconsistent.

Some shock protection systems are heavy and consist of separate rigid pads that limit motion. Rigid components can be padded with some type of soft cushion to make them comfortable for the body, which attempts to alleviate the impacts on the body, but excessive layers add only to the weight and discomfort of the pads. In addition, padding systems can become hot with wear and can also limit evaporation of moisture and sweat.

Other protective pads are made of softer materials, so the pads can bend but offer little protection against severe impacts, especially from rocks or other hard objects. These materials include standard polyether or polyester foams that are chemically foamed.

Other padding can be made of more rigid foam materials, such as cross-linked polyethylene foams or EVA foams. Such foams provide slightly greater protection, but limit the user's range of motion. Overall, such materials provide insufficient protection while limiting motion.

Attempts have also been made to use more rigid foams as pads, but the foam must be cut into strips to reduce the limitations of movement that a rigid piece of foam can cause. Unfortunately, for the wearer, the strips provide less protection than optimal protection.

The foam can also be thermoformed into curved or complex shapes and must be sewn between layers of material that hold the strips or pieces in place. Other materials that provide better shock absorption, such as d30, have also been used for padding, but these materials are also rigid.

Attempts have been made to make the materials described above less stiff for the wearer by creating thinner areas on each piece that allow for better bending. However, protective pads made in this way cannot provide a wide range of motion in the position of the padding, because the material breaks apart when bent in thinner areas. These materials also need to be buried beneath the layers of fibers because they are not durable or do not give enough aesthetic satisfaction to be exposed. The use of cover materials adds unnecessary weight to the padding and increases the cost of the pads.

There is a need for protective padding with improved breathability, particularly for areas requiring free motion, and for joints.

Disclosed herein is a breathable cushioning pad, in one embodiment. The cushioning pad includes an upper layer having an upper surface, a lower layer having a lower surface, and a cushioning material disposed between the upper layer and the lower layer. The cushioning pad has a thickness. The channel can be disposed within the cushioning pad and defines a cushioning area having a thickness. The channel comprises a thickness smaller than the thickness of the cushioning region. One or more vents extend through the upper and lower surfaces and are in fluid communication with the surfaces.

In another embodiment, the breathable cushioning pad includes grooves defined within the upper surface of the cushioning region. The groove is smaller than the thickness of the cushioning region and has a thickness greater than that of the channel.

In another embodiment, the breathable cushioning pad includes a flange and a channel adjacent the flange. The channel has a thickness greater than the thickness of the channel and less than the thickness of the cushioning region.

In other embodiments, the breathable cushioning pad includes one or more vents extending through the upper and lower surfaces of the pad and in fluid communication with the surfaces. In another embodiment, the breathable cushioning pad includes vents disposed within the channels.

In another embodiment, the breathable cushioning pad includes those disclosed herein, and in one embodiment is a breathable cushioning pad comprising a cushioning area comprising an upper surface, a lower surface, thickness and width. The cushioning region comprises a cushioning material disposed between the continuous top layer and the continuous bottom layer and continuously bonded to the layers. The channel is arranged around the cushioning area and defines the cushioning area. The channel comprises a thickness smaller than the thickness of the cushioning region. The channel further comprises a continuous top layer and a continuous bottom layer, the continuous top layer being at least partially bonded to the continuous bottom layer. One or more vents extend through the upper and lower surfaces and are in fluid communication with the surfaces.

In other embodiments, the breathable cushioning pad may include one or more vents extending through the upper and lower surfaces of the channel and in fluid communication with the surfaces.

In other embodiments, the breathable cushioning pad can include a groove defined within the upper surface of the cushioning region, the groove being smaller than the thickness of the cushioning region and greater than the thickness of the channel.

In other embodiments, the breathable cushioning pad may include a peripheral flange and peripheral channels. The peripheral flange can be spaced away from the cushioning area by the width of the peripheral channel. The peripheral flange can have a thickness greater than the thickness of the peripheral channel and less than the thickness of the cushioning region. In other embodiments, the peripheral channel can include one or more vents extending through the upper and lower surfaces of the peripheral channel and in fluid communication with the surfaces.

In certain embodiments of the cushioning pad, the continuous top and bottom layers can include polyester thermoplastic polyurethane.

In certain embodiments of the cushioning pad, the top and bottom layers can include a TPE film bonded to a layer of spandex fiber such that the TPE layers are disposed adjacent the cushioning material.

In certain embodiments of the cushioning pad, the cushioning material can include a cellular material comprising a plurality of cells with a minimum cell diameter, wherein the thickness of the cushioning material between the inner and outer layers is less than the minimum cell diameter. .

The foregoing and other features and advantages are apparent from the following more detailed description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings in which identical reference numerals are cited in the same parts throughout different drawings. Will be The drawings are not necessarily drawn to scale, but instead are emphasized when illustrating the principles of the disclosure.

1 is a top view of a cross section of one embodiment of a cushioning pad according to the present disclosure, comprising a plurality of rectangular cushioning medallions,
Figure 2 is a perspective view of the cushioning pad section shown in Figure 1,
3 is a bottom view of the cushioning pad section shown in FIG. 1,
FIG. 4 is a plan view of one of the square cushioning medallion forming portions of the cushioning pad shown in FIG. 1, showing a centrally located “vent”;
Figure 5 is a perspective view of the rectangular cushioning medallion shown in Figure 4,
Figure 6 is a cross-sectional view of the rectangular cushioning medallion shown in Figure 4,
7 is a cross-sectional view of one section of the cushioning pad section shown in FIG. 1,
8 is a top view of a cross section of another embodiment of a cushioning material according to the present disclosure, comprising a plurality of vents disposed between medallions,
9 is a bottom view of the cushioning material section shown in FIG. 8,
10 is a perspective view of a cross section of another embodiment of a cushioning material according to the present disclosure, comprising a plurality of linear vents disposed between medallions,
11 is a top view of the cushioning material section shown in FIG. 10,
12 is a bottom view of the cushioning material section shown in FIG. 10,
13 is a plan view of an alternative embodiment of the rectangular cushioning medallion shown in FIG. 4, comprising airflow channels extending fluidly from the exterior sidewalls of the medallion to the vent sidewalls,
14 is a perspective view of the cushioning medallion shown in FIG. 13,
15 is a cross-sectional view of the rectangular cushioning medallion shown in FIG. 13,
FIG. 16 is a top view of an alternate hexagonal cushioning medallion, including a central vent and airflow channels extending fluidly from the exterior sidewalls of the medallion to and from the vent sidewalls,
17 is a perspective view of the cushioning medallion shown in FIG. 16,
18 is a cross-sectional view of the rectangular cushioning medallion shown in FIG. 16,
19 is a top view of an alternate octagonal cushioning medallion, including a central vent,
FIG. 20 is a top view of an alternate octagonal cushioning medallion, including airflow channels and central vents fluidly connecting the exterior sidewalls of the medallion to the vent sidewalls,
21 is a cross-sectional view of the rectangular cushioning medallion shown in FIG. 20,
22 and 23 are top and cross-sectional views of one embodiment of an exemplary elbow pad including a plurality of vents fluidly connecting and extending the front and rear sides of the elbow pad,
24 and 25 are top and cross-sectional views of another embodiment of an exemplary elbow pad comprising a plurality of vents fluidly connecting and extending the front and rear sides of the elbow pad,
26 is a top and cross-sectional view of another embodiment of an exemplary elbow pad comprising a plurality of curved vents fluidly connecting and extending from the front and rear sides of the elbow pad,
27 is a table listing exemplary ranges for various diameters of pads according to the present disclosure.

The present disclosure relates to a protective cushioning pad with breathability and comfort, articles comprising the pads, and methods of making and using the pads.

The pads of the present invention include cushioning areas of various shapes, sizes, configurations and thicknesses. For ease of discussion, the terms “cushioning region” and “medalion” will be used interchangeably throughout the description. Various materials can be used for medallions as described below. The medallions are spaced apart by channels of various depths and configurations, defining the perimeter of the medallions and functioning as flexible “hinges”. The pads of the present invention may include one or more medallions, one or more channels, or one or more medallions and one or more vents disposed in both channels. Vents can include a variety of shapes, sizes, configurations and thicknesses. The vents allow airflow to and from the opposite sides of the pad, which not only provides ventilation characteristics to the pads and to the garments containing the pad, but also reduces the weight of the pads. Therefore, such garments allow the body's moisture and vapors to be released, thus allowing them to be used as active clothing without any discomfort or overheating.

The surface of the medallions may also include channels and/or grooves of various depths and configurations, which partially define the appearances of the medallions and provide some aeration. In some examples, a peripheral flange can be provided and spaced away from the pad periphery.

Medallions, vents, channels, grooves and flanges as well as a combination of materials forming the pads provide the pads with various functional features. For example, the channels are deeper than the grooves and are configured to provide unrestricted free motion in critical areas such as around the joints. The grooves are shallower than the hinges, while retaining some cushioning and/or impact resistance while providing flexibility. However, it should be understood that both channels and grooves function as “hinges” that increase the articulation of the pad.

The cushioning pads of the present invention can be combined with fabric and designed to have special functional properties. Such fabrics are particularly unique in their ability to provide protection against parts of the body that bend the joints. Padding can be combined with garments in a unique way, resulting in an integral padding system in which garment materials fit snugly but stretch to conform to the body or specific joint shape, better protecting other wearers from impact than other products. This is because the pad is in constant, close or direct contact with the wearer during free motion. The garments combined with the pads of the present invention provide improved protection from injuries during wear, which is a user in use when the base of the pad or the material to which the base of the pad is attached is stretched, such as a compression cloth and combined with a snugly fitted fabric. Because it can maintain direct contact with the body. The flexibility of the pads allows the pads to conform to the user's body shape, thereby allowing the pads to maintain contact with the user's body. That is, if the pads of the present invention are of some degree of flexibility, the pads will not be able to adapt to the changing body appearances of the user during motion. For ease of discussion, the term "flexibility" as used herein refers to the ability of a pad to be moved by bending, interstices, flexion and/or stretching, and the like.

By combining certain shapes, sizes, configurations, appearances and orientations of medallions, hinges, grooves and/or surrounding flanges with specific pad and fabric materials, garments can be used to maximize the user's free motion while It can be designed to protect certain target sites, especially joints. Such garments are aesthetically pleasing, have greater durability, lower cost, greater breathability and comfort and provide a significant range of motion and targeted accurate protection for the body.

Similarly, the cushioning pads of the present invention can be incorporated into other articles, such as protective cases. For example, padding can be incorporated into sleeves or cases corresponding to the shape and size of an electronic device, such as a laptop computer or media device, so that they fit snugly but also stretch to conform to the outside of the case. Cases comprising the pads of the present invention provide lightweight, flexible and impact resistant protection and dissipate heat from the devices contained within the case.

In one exemplary embodiment comprising a continuous bonded multi-layer structure, the present pads and items comprising these pads are rugged, durable, and other prone to degrade under these harsh conditions. Unlike padded clothes, it provides items that can withstand the temperatures, detergents and mechanical action used in industrial and/or commercial laundry. The presence of a continuous bond between the layers at the hinges is advantageous, which is a medallion that minimizes or prevents egress of cushioning material from the pad or alternatively minimizes or prevents ingress of materials such as fluids into the pads. (medallion) is fixed in place. Thus, the hinges stabilize the pads, especially the cushioning material, so that fluids and other materials cannot penetrate the pad, which may otherwise cause delamination. In addition, the presence of continuously bonded vents maximizes the breathability and ventilating ability of the pads without compromising the durability and washability of the pads.

1-6, when viewed together, illustrate a section 100 of cushioning material according to the present specification. For ease of discussion, section 100 may be referred to hereinafter as “pad 100 ”. As shown, the pad 100 includes a front surface 10, a rear surface 12 and a circumference 14. The pad 100 further includes a plurality of cushioning zones 20 spaced apart and interconnected by a plurality of channels 38, and one or more vents 30 disposed at the center of each of the medallions 20. do.

For ease of discussion throughout the specification, "cushioning zone(s)" will be referred to as medallion(s) below. While multiple medallions are illustrated, it should be understood that the pad may include a single medallion having one or more vents. Similarly, a vent is illustrated in each of the plurality of medallions, but it should be understood that each medallion need not include a vent. In this embodiment, the pad 100 and cushioning zone 20 are square, but any shape, size, or configuration can be obtained as the pad 100 and cushioning zone 20 are actually or desired for a particular design or application. It should be appreciated that it can. The size, shape, thickness and material composition of the pads, medallions and vents include, but are not limited to, the desired amount of flexibility of the pad, the desired amount of impact resistance, the desired amount of breathability, and the like. It may vary depending on a number of factors. In addition, the configuration of the medallions can be varied, and more than one type of medallion shape or vent shape can be used for the pads.

6 and 7, the pad 100 includes a cushioning layer 15 disposed between the optional outer and inner layers 16, 17. In this embodiment, the cushioning layer 15 is disposed between and surrounded by an optional outer layer 16 and an optional inner layer 17 (the outer layer 16 and the inner layer 17 herein are respectively) It may also be referred to as upper layer 16 and lower layer 16). The outer layer 16 defines the contours of the medallions, defining the top surface 34 and the outer sidewall 36 extending downward from the top surface 34 to the top surface 10 of the channel 38. Similarly, the outer layer 16 defines a vent sidewall 37 extending downward from the top surface 34 to the inner layer 17. If desired, the side walls 36, 37 can be perpendicular to the top surface 34 or can have an angled profile relative to the top surface 34. If desired, and as shown, the top surface 34 may be rounded in the transition region "TR" between the top surface and side walls 36 and 37.

As mentioned above, the plurality of medallions 20 are spaced and interconnected by a plurality of channels 38. For each discussion, "channels" may be referred to hereinafter as hinges throughout the specification. As shown in FIG. 7, the hinges 38 are the width W ₁ defined by the space between the perimeters of adjacent medallions, the space between the top surface 34 of the medallions and the top surface 10 of the pad 100. It has a depth ( "D1") and the inner and outer layer thickness (T ₁₎ which is defined by the combined thickness of the cushioning material 15 is disposed between 16,17 and the layers defined by the. The width W ₁ of the hinges 38 can vary as desired or desired, and can range from narrow, such as about 1 mil to about 1000 mils or more. In some examples, it will be desired that the width W _{1 of the} hinges is as narrow as possible to maintain the flexibility of the pads while maximizing the protection features of the medallions. These applications will include applications where maximum protection is desired or the hinge is intended to be wound around a corner. Where impact protection is desired, the width of the hinges can be designed to be narrower than the width of the object that can impact the pad. In these examples, the width W ₁ can range from about 1 mil to about 10 mils, more particularly about 3 mils to about 7 mils, and even more particularly about 5 mils.

In other examples where the protective features are less important, the width W _{1 of the} hinges may be desired to be wider in order to maximize the aesthetic characteristics of the hinges to which the colors of the medallions can be contrasted. In these examples, if desired, the width W ₁ can be in the millimeter or centimeter range or even more.

The hinges 38 may be straight or curved depending on the shape of the medallions. The depth of the hinges between the medallions can be the same or different, and the depth can vary along the hinge. Both curved or straight hinges can be used in combination with pads as in this embodiment, and can include a combination of curved and straight hinged regions.

In this embodiment, the thickness of the cushioning layer 15 disposed between the upper layer 16 and the lower layer 17 in the hinges 38 can be minimized during the manufacturing process, so that the thickness of the hinge 38 Approach 0 in the field. As a result, the cushioning material in the hinges 38 is not visible to the naked eye or is detectable using only a very sensitive thickness gauge.

Residual cushioning material 15 remaining between the layers 16 and 17, if any, assists bonding the layers 16 and 17 together in the hinges 38. Depending on the material used, the bonding between the layers 16, 17 can be at least partially chemical, thermal and/or mechanical adhesion. For example, if the material used as the cushioning layer is a resin, the residual resin in the hinges 38 can function as an adhesive to bond the layers 16, 17 together. The use of a resin as a bonding agent is advantageous, which eliminates the need for a separate adhesive in relatively thin hinge regions, maintains a consistent and evenly flexible adhesive throughout the pad, thereby improving pad durability. Order.

Alternatively, if the fiber is used as one of the layers 16, 17, the bonding between the layers at the hinges can be at least partially mechanical, and the resin is squeezed into the openings or pores in the fiber ( As a result of squeezed), the portions of the layers 16, 17 are joined during manufacture to form the islands of the bonded layers 15, 16, 17 disposed between the islands of the bonded layers 16, 17. cause.

By minimizing or removing any residual cushioning material 15 from the hinges 38, the flexibility of the hinges is maximized, so that the entire pad 100 is bent, flexed, folded in various directions ( folding and twisting are possible.

As mentioned above, the outer layer 16 and the inner layer 17 are optional, but for many reasons, especially the cushioning layer 15 is a cellular material and/or does not easily maintain its shape. This may be desired in the case of poor material.

For example, in the embodiments illustrated above, both the outer layer 16 and the inner layer 17 are continuously bonded to the cushioning layer 15 across the entire pads including hinges. Depending on the structure of the pad, the outer layer and inner layer can be bonded to the cushioning layer 15, or they can be joined to each other when the amount of material in the hinges is minimized or removed. One advantage of joining the front layer to the cushioning layer 15 is to provide a continuous uninterrupted surface above and below the cushioning layer 15, ie surrounding the cushioning layer 15 in addition to the perimeter of the pad. The continuous top layer and bottom layer strengthen the hinge and groove area, minimize breakage in the hinges and/or grooves, which can occur in different ways due to the warpage of the pad during use, which may result in hinges and/or Grooves are thinner than medallions. One or more bonded layers can be used for protection of thin hinge regions during bending. When used as the outer layer 16, the thermoplastic polyurethane film is desired to prevent cracking or destruction of the layer 17 in the hinges or grooves. In addition, the inner layer can provide strength to the hinges or grooves if bonded to the foam, or in many embodiments, both the inner layer and the outer layer are bonded to the foam. It is desired that both the inner and outer bonding layers maintain the structural integrity of the pads when the hinge thickness is very small, especially with or without cushioning material at the hinge. It is desired to use a material with substantial elasticity for the inner and outer layers, such as TPE films, spandex fibers, and the like. In some embodiments, the use of fibers with laminated film backing may be desired as an inner or outer layer. Inner layers, which are laminates of fibers and films, such as polyurethane film laminates, can be very desirable to maximize the durability of the hinges.

Optionally, as disclosed in the pending and co-owned U.S. Application No. 13/208,229, filed August 11, 2011, incorporated herein by reference in its entirety, the top surface 34 of the medallions are planar surfaces. , Can be contoured using various geometric shapes including a combination of curved and planar surfaces and solid surfaces. Alternatively, the upper surface 34 of the medallion may include a surface defined by a thickness that generally decreases radially toward the perimeter of the medallion or toward the perimeter of the pad.

These pads can be made using the techniques disclosed in U.S. Patent Nos. 7,827,704 and U.S. Publication Nos. 2008/0034614 and U.S. Publication Nos. 2009/0255625, incorporated herein by reference in their entirety. Molds for the present pads allow compression of the layers 15, 16, 17 together under conditions sufficient to minimize or eliminate foam at the hinges 38, 50, 60, for certain embodiments of the pads. It is designed to allow adhesion of layers, which can be chemical, thermal and/or mechanical adhesion.

8 and 9, when viewed together, illustrate another embodiment of an exemplary cushioning pad 200 according to the present specification. The pad 200 has a structure similar to the pad 100, and a plurality of vents 40 (hereinafter referred to as “hinge vents”) disposed in the hinges 38 between the medallions 20 is added. do. Hinged vents are a variation on medallion vents, and are another way to maximize pad ventilation and reduce pad weight as well. The hinge vents can be used alone or in addition to the medallion vents 30. In this embodiment, the hinge vents 40 are circular, but as mentioned above, any size or shape can be used.

10 to 12, when viewed together, illustrates another embodiment of an exemplary cushioning pad 300 according to the present specification. The pad 300 has a structure similar to that of the pad 100, and a plurality of vents 50 disposed in the hinges 38 between the medallions 30 are added. In this embodiment, the hinge vents 50 are straight, but as mentioned above, any size or shape can be used. Also, in this embodiment, the hinges can be relatively narrow compared to other embodiments, in particular the pad includes an optional inner layer and an outer layer, and the inner and/or outer layers are stretchy and And/or improves the flexibility of the pad if it is elasticized.

13-15, when viewed together, illustrates another embodiment of an exemplary medallion 60 according to the present specification. The medallion 60 has a structure similar to that of the medallion 30, and a plurality of grooves 42 formed on the upper surface 34 of the medallion, extending from each of the outer side walls 36 to the vent side wall 37, is added . The grooves 42 are fluidly connected to the vent, which improves the flow of air into and out of the vent 30, as well as reducing the weight of the pad. In addition, grooves 42, such as hinges 38, increase the flexibility of the pad, and as the thickness of the cushioning layer 15 in the grooves 42 decreases, the grooves 42 and the pad ( The flexibility of 100) increases as in the breathability of the pad.

The width, depth, orientation, and location of the grooves 42 in the upper surfaces 34 of the medallions may vary depending on a number of factors including, but not limited to, desired direction and amount of flexibility, and the like. . However, in order to maximize breathability, a fluid connection to the vent is desired. The width, depth, orientation, and location of the grooves 42 are not limited to a number of factors including, but not limited to, the desired amount of bending for the pad and/or medallion on which the groove is formed, the desired breathability of the pads, and the like. It may change again depending on. The grooves 42 are designed to be thicker than the hinge regions at the thickest point of the medallions, but thinner than the medallions. Accordingly, the groove thickness may range from about 10% to 95% of the thickness of the medallion, about 20% to 75% of the thickness of the medallion, and even more particularly greater than about 50% of the thickness of the medallion. Further, in any pad according to the present specification, the groove 42 is designed to allow the pad to bend in the target area and provide airflow when fluidly connected to the vents.

Like the hinges 38, the grooves 42 can be curved grooves or straight grooves arranged along parallel and/or intersecting axes. Both curved and straight grooves can be used in combination, and the grooves can include both curved and straight regions. The thickness of the grooves in the pad or in the medallion can be the same or different, and the thickness can vary along the length of the groove and from groove to groove.

16 to 18 illustrate another embodiment of an exemplary medallion 70 according to the present specification when viewed together. The medallion 70 has a structure similar to that of the medallion 60, except that it has a hexagonal structure rather than a rectangular structure. The medallion 70 also includes a plurality of grooves 42 formed in the upper surface 34 of the medallions extending from each of the outer hexagonal sidewalls 36 to the vent sidewall 37.

19 illustrates another embodiment of an exemplary medallion 80 according to the present specification. The medallion 80 has a structure similar to the medallion 30, except that it has an octagonal structure rather than a rectangular structure.

20 and 21 together illustrate another embodiment of an exemplary medallion 80' according to the present specification. The medallion 80' has a structure similar to the medallion 60, 70, except that it has an octagonal structure rather than a rectangular or octagonal structure. In addition, the medallion 80 ′ includes a plurality of grooves 42 formed in the upper surface 34 of the medallions extending from each of the outer octagonal sidewalls 36 to the vent sidewall 37.

As described above, another aspect of the present specification is the incorporation of the pads described above into garments, particularly compression garments, to protect certain areas of the body. When one of the pads described above is incorporated into a compression sleeve or garment that is tightly fitting to the wearer, the hinged and/or grooved multi-layer pad structure, upon contacting the form fitting with the area to be protected In such a way that the hinged pads are retained, they are sewn, glued or otherwise attached to the spandex fiber or otherwise attached to the stretchable material. The pad can be sewn inside or outside the garment. It may be desired to have the pad cover only on a portion of the entire circumference of the sleeve, so the sleeve is still stretchable to fit the wearer. The integration of the protective pad of the compression garment provides a simple and inexpensive way to add protection for specific body areas without altering the entire garment.

When the pad is integrated into the compression sleeve, some unique features and advantages are provided compared to the method of protecting other moving joints. When integrated into the compression sleeve, the pad can be in continuous foam fitting contact with the joint to be protected, which is a flexible joint such as knees, elbows, shoulders and ankles. It may be desirable to protect them, as the selection of suitable hinges allows the protective sleeves to remain naturally in the correct position and orientation. By proper selection of the hinge and placement of the sleeve on the garment, the protective compression sleeve moves as one with the limbs, allowing a much wider range of motion than conventional padding.

When the protective sleeve is positioned in foam fitting contact with the user's body, the possibility of further injury to the user by any impact caused by the pad hitting the user is minimized. More stiffer pads may not be able to make continuous contact with the user's body area or joint with the foam fitting, since these pads are not flexible enough. Without foam fitting, the pads can be part of the impact that damages the wearer. In the sleeve configuration, the pads provide improved protection for the moving joints, since these pads can wrap around a wide radius, and in some instances provide 360° protection by wrapping the entire joint. In general, it is desired to leave some area of the compression sleeve without additional padding layers to allow the sleeve to stretch and follow the arm.

In some embodiments, it may be desired that garments are made from a wicking fabric that is designed to escape moisture from the skin layer.

In addition, the pads can be designed to improve air and/or moisture transmission, which may not be an option with other protective paddles, without significantly impairing protection. The use of vents as described above in hinges, grooves and/or medallions improves moisture and/or air permeability. Use in combination with a spacer fiber or wicking fiber as the inner layer or a TPE film layer as the inner layer also improves comfort and can wick moisture through the hinges. In addition, the use of a moisture vapor transmissive (MVT) film layer can further improve comfort. These films can function by chemical adsorption/desorption. Examples of these films are available from Omniflex under the product name Sympatex or TX1540. The use of microporous high moisture permeability films such as Gore-Tex or Porel (by Porrvair) or other similar films may also be used.

22 and 23, when viewed together, illustrate another embodiment of an exemplary elbow pad 500 that may have the same configuration and optional flanges as any of the foregoing embodiments. In this embodiment, the pad includes channels, grooves and a plurality of round vents 30 disposed on the flange.

24 and 25, when viewed together, illustrate another embodiment of an exemplary elbow pad 500 that may have the same configuration and optional flanges as any of the embodiments described above. In this embodiment, the pad includes a plurality of round vents 30 disposed in the channels and flanges. In this embodiment, the thickness of the cushioning material in the channels and flanges is minimized or eliminated.

26 illustrates another embodiment of an exemplary elbow pad 600, as disclosed in the '229 application, which also includes a plurality of curved vents 30. The curved vent shapes shown in this embodiment have improved motion and stretch in the areas of the curved vent while maintaining another “encapsulated medallion” structure provided by the bonded multi-layer configuration. Gives

In any or all of the above-described embodiments, the pads are optional peripheral flanges 40' confined to the top surface 10 (see FIGS. 22-26) to keep the medallions spaced apart from the periphery of the pad. ). The optional peripheral flange 40 ′ may include a width (“W ₂ ”) defined by the spacing between the perimeter of the outermost medallion and the perimeter 14 of the pads. The width W ₂ of the peripheral flange 40 ′ can be varied as desired. The peripheral flange 40' can be thinner than the medallion, so that the pad is an item such as clothes along the flange area using various techniques such as sewing, gluing, welding, gluing, heat sealing, etc. To be attached to the field. For example, when integrated with a compression sleeve, the pad can be sewn, glued or otherwise attached to the outside of the sleeve fabric at the flange, or the pad can be sewn or attached to the inner surface of the sleeve. And can be exposed through the corresponding opening in the sleeve.

It should be understood that the flange is not required for the pads, and the pads can be attached to the lower surface using other means, such as sewing, gluing, welding, heat sealing, adhesion, and the like.

In any or all of the above-described embodiments, the environment in which the buffering action layer 15 has sufficient structural integrity to be formed into predetermined shapes, such as by molding, and is intended to be used without significant degradation It may include one or more layers of any material or combination of materials that can withstand.

The material type and composition can be selected to provide articles and/or zones of articles that have predetermined material properties that can be used to fit pads to a particular application, such as cushioning, impact resistance, abrasion resistance, and the like. Examples of suitable materials include polymer materials, composite materials, and the like. Suitable polymeric materials include, but are not limited to, thermosetting polymeric materials, elastomeric polymeric materials, thermoplastic materials including thermoplastic elastic materials, and combinations comprising one or more of the foregoing. Some possible polymeric materials include, but are not limited to, polyurethanes, silicones, and the like, and combinations comprising one or more of the foregoing materials.

In some cases, it may be desirable for the pad to have cushioning properties to provide a soft, supple, and comfortable feel, such as when used in contact with the body. In these cases, it has been found that some polymerizable gels may be suitable. One example of a suitable polymerizable gel comprises a hardness tester ranging from about 0.01 Shore 00 to about 70 Shore A or less, more specifically less than 70 Shore 00, and even more specifically less than 60 Shore 00 It is a polyurethane gel. The material may include a hardness tester ranging from about 30 shore 000 to about 88 shore D. The hardness meter of the polymer can be determined by one of skill in the art using tools such as hardness meters or penetrometers. The formation of the gel can be accomplished by various methods known to those skilled in the art. For example, the formation of a polyurethane gel may include reaction with a suitable pre-polymeric precussor material, eg, with isocyanates and polyols in the presence of a catalyst.

In some cases, it may be desirable for the pad to be lightweight and in such cases, the cushioning material 15 may include a foam material such as a low density foam material. Examples of suitable low density foams include polyester and polyether polyurethane foams.

In some cases, it may be desirable for the pad to provide impact resistance. In these cases, various types of shock absorbing materials have been found to be suitable for cushioning materials, especially energy absorbing foams. For such applications, these foams range from about 5 to about 35 pounds per cubic foot (pcf), more specifically from about 10 to about 30 pcf, and even more specifically from about 15 to about 25 pcf. It may be desirable for the branch to include a density. Suitable rate dependent foams are available from Rogers Corporation under the trade names of open cells, micro polyurethane foams PORON® and PORON XRD®.

In all of the above-described embodiments, when the force is applied to the optional outer layer, the optional outer layer 16 has sufficient elasticity, sufficient structural integrity to be formed in predetermined shapes to prevent tearing and/or stretching; And any material capable of providing being able to withstand environments that are intended to be used without significant degradation (eg, repetitive deformations such as twisting, bending, flexing, stretching, etc.). The outer layer 16 can also be selected to facilitate handling of the layer 15, which in some cases can include adhesive properties. Thus, the outer layer 16 can be selected to provide a relatively non-tacky surface and a smooth surface for human contact after molding.

The outer layer 16 can include any thickness, and the thickness can be varied depending on the application. The desired thickness for a particular application can be determined using routine experimentation by those skilled in the art. The outer layer 16 can be from about 0.2 milli-inch (hereinafter “mil”) to about 60 mils, more specifically from about 0.5 mils to about 30 mils, even more specifically from about 1.0 mils To about 15 mils.

It has been found that in cases where hand-feel of the products is important, it is desirable to minimize the thickness of the outer layer. Therefore, it may be desirable to use the thinnest outer layer possible without sacrificing durability in such products. For example, for applications where a relatively thin outer layer 16 is desired, from about 0.2 mil to about 6 mil, more specifically from about 0.5 mil to about 3 mil, and even more specifically from about 0.6 mil to about 2 It may include a thickness having a range of mil.

In some cases, it may be desirable to use a thicker outer layer 16 that can provide increased durability compared to thinner outer layers. For example, when current materials are used in vibration damping applications, it may be desirable for the thickness of the outer layer 16 to be about 50 mils to 60 mils. Alternatively, thinner layers may be desirable when the buffer layer is adhered, which makes the material difficult to handle because the outer layer 16 can be punched to expose the adhesive material.

When the products are formed using a thermoforming process, it may be desirable to use an outer layer that has a thickness of up to about 1/2 inch, and in some cases even thicker when desired or necessary. It has been found that by applying heat and/or vacuum during the thermoforming process, it is possible for the outer layer having a thickness of 6 mils or more to maintain very soft flexibility.

The outer layer 16 may also include a support layer (not shown) that assists in the handling of the material. Alternatively, the outer layer can also be applied as a coating of material during or after the molding process, using various techniques known to those skilled in the art.

Suitable materials for the outer layer 16 include elastomeric materials such as plastics, rubber, thermoplastic elastomers (“TPE”), and the like, and combinations comprising one or more of the materials described above. Materials of plastics that can be used for the outer layer are ethylene-vinyl acetate ("EVA"), nylon, polyester, polyethylene, polyolefin, polyurethane, polyvinyl chloride ("PVC"), plystyrenes, polytetrafluoro Roethylene ("PTFE"), latex rubber, silicone, vinyl, and combinations thereof.

Other possible materials for the outer layer 16 include paper, fabric, spacer fibers, metal, metallized plastic, plastic film, metal foil, etc., as well as composites and/or one or more of the foregoing. Various other synthetic and/or non-synthetic materials, including but not limited to combinations. Other durable materials can be used for the outer layer, including knit, woven and nonwoven, leather, vinyl or any other suitable material. The use of spacer fibers as the outer layer can maximize airflow.

It may be desirable to use some elastic materials for the outer layer; Accordingly, stretchable fibers such as spandex fabrics may be desirable. The use of stretchable fibers as the outer layer may be desirable, since the stretchable fibers can improve the bending of the hinges and grooves, and the shaping of the outer layer into a contoured shape. In some cases, pre-stretch materials with heating or otherwise molded or more limited stretch can improve the final product.

When the outer layer 16 comprises a fibrous layer, the fibers can be knitted, woven, nonwoven, synthetic, non-composite and combinations comprising one or more of the foregoing, the fibrous layer being, for example, TPE It can be laminated into a film. If stretchability is desired in pad applications, an outer layer that is stretched may be desirable, and when the outer layer is a stack, it is preferred that each layer in the stack is stretched.

As mentioned above, it may be desirable to use a slightly elastic material for the outer layer, such as the TPE materials mentioned above. Such TPE materials may also be desirable, since TPE materials are available as films of relatively small thickness. If suitable for the intended application and compatible with the method of molding, any film thickness may be used, but film thicknesses of about 1 mil to about 10 mils may be desirable. The thicker the film, the greater the durability, but the thinner the film, the more expensive it can provide a softer feel. There are other reasons for selecting thicker films, such as when thermoforming deeper shapes to improve the molding process. The use of a non-fiber film as the outer layer can easily manufacture the product to clean and protect the cushioning material from damage and dust. Films can include an elongation of about 100 percent (%) to about 1500 percent, more specifically about 200 percent to about 1000 percent, and even more specifically about 300 percent to about 700 percent.

Some possible TPE materials include styrene block copolymers, polyolefin mixtures, elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, and combinations thereof. Examples of commercially available elastomeric alloys include melt-processable rubbers and thermoplastic vulcanizates. Examples of suitable TPEs include thermoplastic polyurethanes (“TPU”). TPU films may be desirable because of the combination of durability, elasticity, ductility and flexibility. One suitable film is a polyester polyurethane film available from the Bayer Material Science Company, Deerfield Urethane under the Dureflex PS5400 product name. It may be desirable to use a polyester TPU film that is not a polyether TPU film, in addition to having improved abrasion resistance compared to the polyether TPU film, the polyester TPU film can also be used in functional sportswear and commercial laundry, This is because it has a fairly good performance under high humidity conditions.

Additionally, pads and garments can be made of both fiber and film on different parts of the pad, allowing wide movement and additional protection from the use of both materials. The outer layer is a composite of the fibrous film so that the film helps to protect the hinge during bending and also serves as a protective barrier for the cushioning material.

In any or all of the above-described embodiments, inner layer 17 may include the same materials as outer layer 16. When the inner layer 17 comprises a fibrous layer, the fibers can be knitted, woven, nonwoven, synthetic, non-composite, and combinations comprising one or more of the foregoing, the fibrous layer being, for example, TPE It can be laminated to a film. If the pad application requires elasticity, the use of an elongated inner layer may be desirable, and if the inner layer is a laminate, it may be desirable for each layer in the laminate to elongate. The use of the fiber layer as the inner layer 17 can be advantageous because the fiber layer can trap and scatter air bubbles (otherwise bubbles can be formed between or within the layers), resulting in final molded products Resulting in an improved appearance to the field.

The use of active agents in one or more of the inner layer, outer layer and/or buffering layer may be preferred. For example, the addition of silver or copper based activators can provide materials with antimicrobial or antifungal properties. The use of active agents in the inner or outer layer or the foam itself may be desirable, such as the addition of silver or copper based active agents to act as antibacterial or antifungal agents.

One or both of the inner and outer layers 16, 17 may also include indicia including color, artwork and/or text. The color, artwork and/or markings placed on these layers can be transferred through the outer layers when the outer layers are formed of colorless and/or transparent materials that may be desirable for aesthetic and cost reasons. Further, if desired, one or both of the inner and outer layers 16, 17 can also be fluid permeable. As used herein, “fluid-permeable” means that the material from which the layer is formed is open to passage or inflow of the fluid material.

The size, shape, configuration, orientation and dimensions of the pad, medallions, medallion contours, hinges, grooves and flanges can be varied as desired to achieve the desired properties for the pad design. All of the above-mentioned features are designed to facilitate the flexibility of the pad to match inward or outwardly to the user's body during movement alone or in combination. However, it should be understood that in each of the foregoing embodiments and in any pad according to the present disclosure, all of the above-described measurements may vary depending on the pad's desired properties and design. For example, pads are designed to provide various properties such as cushioning, breathability, breathability, vibration dampening and/or shock absorption, but are not limited thereto. The properties of the pad change the thickness and/or material type of the cushioning layer 15 in the medallions, change the size, shape, number and location of the vents, and determine the spacing between the medallions (ie, the width of the hinges). And/or by changing the contours of the medallions and the like. For example, the use of a gel for the cushioning layer 15 provides cushioning and vibration damping properties to the pad, the use of foam reduces the weight of the pad, and the use of ratio dependent or shock absorbing foam impacts the pad. Increase absorption; Etc. Generally, an increase in the thickness of the buffering layer 15 in the medallion generally increases the properties described above, and the use of a combination of materials for the buffering layer 15 can provide a combination of properties.

In any or all of the above-described embodiments, and in any pad according to the present disclosure, hinges are designed that provide flexibility for the pad in target areas where flexibility is desired or desired. The use of curved parallel and/or intersecting hinges allows the flexibility of the pad to be tailored to certain functions, such as protective joints during movement. The width, depth, orientation and position of the hinges can vary depending on a number of factors including, but not limited to, the desired amount and flexibility location for the pad.

The flexibility of the hinges can be changed by changing the thickness of the material of the hinge zones. For example, a decrease in the thickness of the material in the hinges increases the flexibility of the pad, and an increase in the thickness of the material in the hinge regions decreases the flexibility. In some embodiments, including one or both of the inner and outer layers 16, 17, "squeeze" the buffering layer 15 in the hinges to minimize or remove the amount of material in the hinge region. "It is possible. In such embodiments, flexibility can be maximized or improved by minimizing the thickness of the buffering layer 15 at the hinges or when the pad is molded without the buffering layer 15 at the hinges 38. . For example, when using the inner and outer layers 16, 17 with a thickness of about 4 mil, the buffering material 15 is removed from the hinge region as much as possible during the molding process to reach 8 mils or the inner and outer It is possible to achieve hinge thicknesses reaching the combined thickness of the layers 16 and 17.

To maximize the flexibility of the layered structures, it is recommended to use a hinge depth of less than about 20% of the thickness of the medallion, more specifically less than about 10% of the thickness of the medallion, and even more specifically less than about 5% of the thickness of the medallion. It may be desirable. The continuous portion consists of hinge depths of 0.020", 0.040" and up to 0.080".

When the pad is molded with pads with optional inner and/or outer layers, or both layers, when the hinge thickness corresponds approximately to the combined thickness of the layer(s) but not to the layer 15 or the buffering layer ( The maximum pad flexibility can be achieved when the thickness of 15) is minimized or approaching zero.

Deep hinges can also have some foam thickness and still provide great fluidity. As described below, one feature of the present protection pads can prevent the outer and/or inner layers from breaking the buffering layer in relatively thin hinge regions during repeated bending, so that the foam is the inner layer and the outer The foam thickness is not limited by the foam flexural strength as long as it adheres to either or both layers.

In each of the above-described embodiments, and in any pad according to the present disclosure, the width of the hinges, or the spacing between the medallions, is designed to allow the pads to bend as much as possible while still maintaining the protective properties of the medallions. Thus, the spacing between the medallions can be determined by the amount of distance required to have a flexible hinge without exposing too much of the spacing between the medallions, thus causing damage when the gap between the medallions is impacted will be. Thus, maximum protection can be achieved using a hinge width of less than about 20% of the medallion thickness, more specifically less than about 10% of the medallion thickness, and even more specifically less than about 5% of the medallion thickness. As described above, the use of angled or serrated hinges and/or grooves (not illustrated) can also reduce the amount of unprotected surface exposed.

In any or all of the foregoing embodiments, the pads can be formed such that the foam has a generally uniform density across the pad. Specifically, it may be desirable in some examples to minimize the compression of the foam in grooves or hinges during molding or molding, which increases the density of the foam, which reduces the range of motion and eliminates the foam. This is because they tend to provide non-uniform padding levels. Variations in contoured medallions and foam thickness not only provide an aesthetically pleasing pad, they also maximize protection where this pad is most needed and reduce protection where this pad is less demanded Provide the ability. By using a uniform foam density and changing the thickness if necessary, the weight of the pad is reduced and the range of motion is increased. Using thermoforming or compression to take the foam and compress the zones into shape increases the density within these zones and creates additional weight, creating non-uniform protection and less motion range.

The present cushioning materials offer advantages over other materials. The present breathable cushioning materials can be used to make breathable, low profile, suitable protective padding and clothing for athletes. These pads and clothing are breathable and allow for the increase of sweat and air. Moreover, in some embodiments, individual cells of padding may move independently of each other.

Padding and garments made of the present breathable cushioning material are washable, durable and have improved breathability compared to these paddings that are not ventilated. In addition, the protection capacity of the present padding is increased compared to comparable structures that do not include vents, because ventilated medallions and padding can absorb more energy due to the ability of movement, as well as folding walls. . When rate dependent materials are used to shape the padding, the ventilated structure provides increased area for impact or energy transfer to the rate dependent material.

When the inner and outer film layers are used on the pad, the pad structure allows the manufacturer to reduce the width of the space between the cushioning regions, since it is not necessary to use a cloth to place and position the pad. It also allows the manufacturer to design the angles of these grooves and hinges to cover and protect the user during a full range of motion while remaining in place during stretching, fitting and activity.

In contrast to a pocket enclosed pad, the ability to create an exposed or exoskeleton protection pad provides the advantage of wearing individually supportive or corrective braces, such as knee braces, ankle supports, back supports, and the like. Thus, the pads can be attached or adhered to mechanical supports to protect adaptive athletic athletes from themselves and other athletes by similar braces. Similarly, the design of the pads according to the present disclosure can be fitted and adhered to braces worn by conventional athletes. This provides protection to both the wearer of the brace but also other athletes who come into contact with the correcting brace. One example of such a brace is padding on knee braces used in professional football.

The pads can also be used on shin guards worn by young, adult and professional soccer players. The properties of the shock absorbing foam padding in combination with foam fitting garments provide a unique and high accuracy protection of targeted body parts. Accordingly, one embodiment of the present disclosure is flexible, foam fitting breathable shank and ankle guards for soccer players. These shank and ankle guards provide greater protection against football players due to the closer feet of the foam, moisture wicking materials used in the assembly, more comfort from ventilation and perforation, and for example by straps or by the user It provides a more durable product than non-breathable rigid plastic pads that are held in place by the friction of the socks.

Foam padding and other layers can be designed to have perforations through the material as previously mentioned, or with minimal or no degradation of impact protection within the grooves or hinge regions. The fact that all the layers of the pad are adhered together in succession allows in some embodiments the vaporization of water vapor through predetermined paths rather than being absorbed into the pad. Once the humidity is transported to the fiber layer, it can be channeled out through the pads because the surfaces are glued. In contrast, other pads can have one or more layers without floating, which makes them more uncomfortable to wear.

In certain embodiments, the fact that the outer surface (fiber or film) is the actual outer surface of the garment or sleeve (in some embodiments) is an important difference. Pads covering the padding, with unadhered fibers or stitched covering over the outside, allow the outer layer to slip over the padding upon impact, which affects the precision of the impact protection. When wearing current garments according to the present disclosure, the wearer has a pad on the outside of the foam-fitted garment, which provides more accurate protection of a particular body area or joint. Having the exposed outer layer of the pad of the present disclosure (as shown in FIGS. 12 and 13) as the outer layer of the garment or sleeve also allows for improved humidity or air flow management, which can peel off in any form. It is improved to cut the foam pieces with the cover. Precise vents and air channels minimize heat and humidity production. Moreover, embodiments in which the outer surface of the pad is exposed allow the inner side of the foam fitting garment to lie flat against the user's skin because the inner surface of the pad is generally flat. When attached to the outside of the elastic fiber, the user can have a continuous layer of elastic fiber or other material relative to the skin. This also allows the pad to hold the skin surface closely, and also a more seamless inner surface that causes less friction or irritations to the skin.

Using pads exposed on the surface also provides an improved ability to make the hinges or grooves tighter and/or smaller, which is otherwise flexible by filling the hinge spaces and hindering the movement of the hinges. Because it can prevent. Grooves and hinges can also be angled and shaped with specific designs to more precisely cover and protect the object. The creation of specific and more aerodynamic shapes can also be made on the garment surface using the present pads. In combination with protection, aerodynamic surfaces can be advantageous in sports such as ski racing, where the wearer has less reinforced wind resistance and can be protected from collisions with gates, for example. Other sports, such as bike racing, can benefit from improved aerodynamics.

The use of the present shock absorbing pads allows the shock absorbing foam to react more quickly when exposed on the surface of the garment since it eliminates the layer(s) between the pad and the shock. It is used when using “rate dependent” shock absorbing foams such as Poron XRD, or other such materials that are hard to impact, and only on exposed surfaces with a single layer of adhesive film or other material between the foams. This can be a desirable feature, and the object hitting the pad allows the foams to react better and faster.

In some embodiments, the use of a film, especially a polyester polyurethane film, as the outer layer of the pad attached to the sleeve or garment creates a durable and washable pad system. The outer surface to which the film is exposed may be durable and resistant to contamination. As a top layer, sewn or otherwise attached, the fibers can be torn, torn or dirty, and can be difficult to wash. Fibers and/or films that are continuously bonded to the hinge regions as an inner or outer layer or to the cushioning material of the medallions are more durable than the unadhered stitched fibers used in many pads, where the torn outer garment is worn by the wearer. The pad, which is intended to protect the body, must be exposed and removed or removed from the garment. In embodiments of the present disclosure using a fiber layer as an inner or outer layer, the film layer inside the fiber can also minimize and/or prevent contaminants or liquids from seeping or penetrating the foam.

The fact that in many embodiments the pads are molded with a uniform density of foam padding (i.e., not a foam compressed to a higher density) the protection of a more precise design than the varying densities caused by compression, and a greater range Allows motion.

The present pads, clothing and manufacturing methods are advantageous for many reasons. For example, a single continuous pad with many elements provides an economical advantage over traditional pad construction techniques by eliminating the labor intensive cutting, scoring or thermoforming that would otherwise be required for end garment construction. do.

Some embodiments have a hinge of almost zero areas, while others are 0.010" (10 mils), 0.020" (20 mils) or even 0.080" (80 mils) or 0.120" (120 mils).

The use of a bonded inner layer with elasticity and a bonded outer layer with elasticity is also preferred in embodiments where stretch is required, such as when the cushioning pad is attached to the stretchable garment.

The fact that in the hinge zones where the thickness of the hinge zones is close to zero, or in thin hinge zones (foams less than 0.100" (1 mil)), the fact that the entire pad has a successively bonded inner or outer layer (or both) is used to create space. Maintains and prevents separation of unprotected areas, as opposed to the pads where separate cut pieces are used to create the pad, which cut pieces can be separated under stress or force and the user is exposed. Permitted, possibly injured.

In some embodiments, using a narrow hinge space has proven desirable to prevent areas exposed when the joint bends in certain ways. The present disclosure allows very narrow hinges, or very narrow spaces between medallions, and minimizes the risk of hinge separation during use.

The pads are lightweight and can be made to provide better protection for certain body zones, which is particularly advantageous for athletes and active individuals.

One advantage of the present protective pads is that the entire bend area can be protected by one pad or several pads specially designed for a particular part of the body, rather than smaller cut pads or strips that are sewn to the garment. Is there. The continuously bonded large pad is more economical and also prevents the movement of the cuts or strips of the pads, which will cause gaps in protection. In addition to providing improved and more accurate protection than current products, these protection pads allow the entire durable pad to be exposed, which is an aesthetic advantage while saving weight and better humidity or air delivery. You can make a more comfortable pad.

One skilled in the art will recognize that other methods of attachment can be used, but it has been found that sewing provides certain advantages. In contrast to heat sealing or welding, sewing cushioning pads in place along the periphery flange has been found to prevent or minimize pads from being separated from the garment, which may peel off within the garment (i.e., retain the pads). It is advantageous compared to pads attached by means of loosening in designed pockets), stitching, gluing, welding, heat sealing, etc.

The aforementioned pads are exceptionally durable and can withstand repeated commercial laundry. It has been theorized that when these pads are incorporated into garments, the thickness of the peripheral flange (eg, about 20 mils) provides a solid area for stitching, which is otherwise cushioned if not supported by the 20 mil peripheral flange. It will break and tear without material. In addition, the peripheral flange makes the product more attractive with a softer edge than is possible by ending with a film at the periphery of the cushioning pad.

Hinges close to zero across the pad are also believed to contribute to the pad's durability during the wash cycle, because the foam material in the hinges is too thin, so that the cell-like structure is no longer present. Thus, the stitched peripheral flange prevents or minimizes the pad from falling out of repeated washing, ie restrains the periphery of the cushioning pad.

In addition, the continuous adhesion of the inner and outer films to the cushioning material of the medallion regions or to each other at the hinges prevents the opportunity for fluid or other materials to enter the pad, and the chance for the cushioning material to escape from the pads, or Minimize. When combined, both features reinforce the durability of many pads under stringent conditions, and completely eliminate or prevent peeling of the layers as occurs in other products. The peripheral flange and adjacent zero-hinged hinges are believed to prevent or minimize fluids and/or particles from permeating the pads beyond the peripheral flanges, where the foam has been almost completely removed from the hinge region, and the cellular structure of the foam within the hinge region. Without, the fluid and/or particles cannot move past the surrounding flange. Thus, the peripheral hinge acts as a buffer for the infiltration of fluid and/or particles into the pad.

Similarly, the “network” of hinges across cushioning pads further improves the durability of the pads, especially when the hinges are “close to zero” hinges, which eliminates/or eliminates foam, or other cushioning material in the hinge region. This is because minimizing increases the adhesion strength at the hinges. The adhesion strength is increased in the hinge zones because the cushioning material remaining in the hinge zones is insufficient to support the foam structure (foam in this case). If the foam remains on the hinges, the adhesive strength can be limited to the foam tear strength. Thus, when the thickness of the foam or other cushioning material is minimized, the adhesion of the hinges increases because there are no thin foam cell walls to tear. That is, without the cellular foam structure at the hinges, there is no space for fluid and/or particle penetration beyond the surrounding flange. As a result, even if a single medallion or hinge is damaged or compromised, damage to the entire pad is minimized or compartmentalized, since the damage only extends to adjacent pads and/or hinges.

Another advantage of the present pads is that they provide a combination of deep hinges and less deep grooves, or a protective garment with improved protection while maintaining a significant range of motion in the area where the multi-level hinge is protected. Using connected top, bottom, or both layers allows for more precise use of hinges and grooves, and prevents individual medallions from moving relative to each other. In addition, integration with the stretchable foam fitting garment material results in significant wrapping of the protected area and allows the outer pads to continue to contact certain areas of the body.

The terms “first”, “second”, etc., do not denote any order or importance herein, but rather are used to distinguish one element from another, and singular expressions herein do not denote a quantity limit, rather are referred to It should be noted that it indicates the presence of one or more of the items. Similarly, it should be noted that the terms “bottom portion” and “top portion” are used herein for convenience of explanation only and are not limited to any one location or spatial orientation unless otherwise indicated. In addition, the qualifier "about" used in connection with quantity encompasses the stated value and has the meaning written by context (eg, including the degree of error associated with the measurement of a particular quantity).

Compounds are described herein using standard nomenclature. For example, any position not replaced by the indicated group is understood to have its valence filled by an adhesive or by hydrogen atom A as indicated, or a dash ("-" not between two letters or symbols) ) Is used to indicate the point of attachment for a substituent. For example, -CHO is attached over the carbon of the carbonyl group. Unless otherwise specified herein, all percentages herein refer to weight percent ("wt.%"). In addition, all ranges disclosed herein are inclusive and combinable (eg, up to about 25 weight percent (wt.%), preferably from about 5 wt.% to about 20 wt.%, and more preferably from about 10 wt. % To about 15 wt.%" are all intermediate values of the last values and ranges "about 5 wt.% to about 25 wt.%, about 5 wt.% to about 15 wt.%", etc. are inclusive). The notation “± 10%” means that the displayed measurement can range from an amount of minus 10% to an amount that is plus 10% of the stated value.

Finally, unless otherwise specified, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

Although the present disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for the elements without departing from the scope of the present disclosure. Moreover, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope of the disclosure. Accordingly, the present disclosure is not limited to the particular embodiments disclosed as the optimal mode contemplated for carrying out the present disclosure, and the disclosure is intended to include all embodiments falling within the scope of the appended claims.

Claims (10)

As a breathable cushioning pad,
A cushioning pad having a thickness, comprising an upper layer having an upper surface, a lower layer having a lower surface, and a cushioning material disposed between the upper layer and the lower layer,
A channel disposed within the cushioning pad and defining a cushioning area having a thickness, the channel comprising a thickness smaller than the thickness of the cushioning area,
One or more vents extending through the upper and lower surfaces and in fluid communication with these surfaces, and
Including peripheral flanges and peripheral channels,
The peripheral flange is spaced from the cushioning area by the width of the peripheral channel, and the peripheral flange includes a thickness greater than the thickness of the peripheral channel and less than the thickness of the cushioning area,
The peripheral flange allows the cushioning pad to be attached to the garment along the peripheral flange,
Breathable cushioning pad.
According to claim 1,
Further comprising a groove defined in the upper surface of the cushioning region, the groove comprising a thickness smaller than the thickness of the cushioning region and greater than the thickness of the channel,
Breathable cushioning pad.
delete According to claim 1,
The pad further comprises one or more vents extending through the upper and lower surfaces of the pad and in fluid communication with these surfaces,
Breathable cushioning pad.
The method of claim 4,
The vent is disposed in the channel,
Breathable cushioning pad.
As a breathable cushioning pad,
A cushioning region comprising an upper surface, a lower surface, a thickness and a width, and comprising a cushioning material disposed between a continuous top layer and a continuous bottom layer and continuously bonded to these layers,
It is disposed around the cushioning region and defines the cushioning region, comprises a thickness smaller than the thickness of the cushioning region, further comprising a continuous top layer and a continuous bottom layer, the continuous top layer being at least partially continuous bottom Channels, which are glued to the layers,
One or more vents extending through the upper and lower surfaces and in fluid communication with these surfaces, and
Including peripheral flanges and peripheral channels,
The peripheral flange is spaced from the cushioning area by the width of the peripheral channel, and the peripheral flange includes a thickness greater than the thickness of the peripheral channel and less than the thickness of the cushioning area,
The peripheral flange allows the cushioning pad to be attached to the garment along the peripheral flange,
Breathable cushioning pad.
The method of claim 6,
Further comprising one or more vents extending through the upper and lower surfaces of the channel and in fluid communication with the surfaces,
Breathable cushioning pad.
The method of claim 6,
Defined in the upper surface of the cushioning region, further comprising a groove smaller than the thickness of the cushioning region and comprising a thickness greater than the thickness of the channel,
Breathable cushioning pad.
delete The method of claim 6,
The peripheral channel further comprises one or more vents extending through the upper and lower surfaces of the peripheral channel and in fluid communication with the surfaces,
Breathable cushioning pad.

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