Note: Descriptions are shown in the official language in which they were submitted.
CA 02852251 2014-05-20
ATHLETE PROTECTION APPARATUS
Cross Reference to Related Applications
[0001] This application is a U.S. non-provisional utility patent
application, which claims the
benefit of co-pending U.S. provisional patent application Serial No.
61/860,019, filed on July 30,
2013 and co-pending U.S. provisional patent application Serial No. 61/985,046,
filed on April
28, 2014, both of which are incorporated by reference herein in their
entireties.
Field of the Invention
[0002] The present invention relates generally to protective gear worn by
athletes during a
sporting activity. More particularly, the invention. pertains to a wearable
apparatus constructed
for absorbing the impact of an object striking the body of player during a
sporting activity, such
as the impact of a hockey puck.
BackEround of the Invention
[0003] Many sporting activities incorporate the use of an object
intentionally thrown or
struck by a player at an extremely high rate of speed. Absent protective gear,
such objects
function as high-speed projectiles likely to cause severe bodily injury. Even
with conventional
protective gear, bodily injury is a common occurrence. An extreme example is
the game of ice
hockey, during which a hockey puck constructed from solid vulcanized rubber
can easily reach
speeds of 80-100 miles per hour. In fact, slap shots by professional hockey
players have been
known to exceed 100 miles per hour. Furthermore, sporting injuries can occur
just as readily
from the blow of another player's equipment, such as a hockey stick.
(0004] During play, it is not uncommon for a hockey player to intentionally
position body
parts in harm's way to prevent an opponent from scoring, or even advancing the
puck. With the
trend of foot and ankle injuries increasingly significantly over the past few
years, there has been
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an increasing utilization of so-called "shot blockers;" protective guards worn
about the exterior
of a player's skate to resist or dampen the blow caused by impact with a puck.
Likewise, similar
protective articles are commonly worn to protect a player's shins and knees.
[0005] Most shot blocking products are formed of a monolithic structure
molded to conform
to the shape of a player's foot or skate. For example, rigid lightweight
materials, such as
polypropylene-graphite composites, are commonly used. While such devices are
effective at
dampening the impact of a blow, they have a number of inherent limitations,
drawbacks and
disadvantages. In addition to being very costly, the rigid molded structure of
most shot blockers
tends to make them uncomfortable to wear while skating. In addition to causing
discomfort to the
wearer, they often tend to shift -- making them clunky and, in some instances,
limiting a player's
movement on the ice. Generally, conventional devices are expensive and they
lack the flexibility
necessary for a player to perform at his or her potential.
[0006] Another drawback of conventional shot blocker designs is that the
aforementioned
inflexibility limits their reuse on skates of varying shapes and sizes. For
younger hockey
players, still growing physically, this means having to continuously
repurchase such devices as
their feet grow. In particular, for youth and adolescent players whose feet
are constantly
growing, this means the purchase of new protective gear every year.
Accordingly, with each new
pair of skates, a new pair of molded guards must be purchased.
[0007] More flexible devices are known, however, because they are not
molded to conform
to the particular shape of a particular,pLayer's skate, these generic devices
tend to be clunIcy,
- resulting in a bulky skate. In the game of hockey, a bulky skate will
limit a player's turning
radius and speed, which can be very costly, in terms of the outcome of the
game. Additionally,
the known devices often require attachment using the skate shoe laces. This
can prevent a player
from cinching his skate up tight enough to be secure about his foot.
[0008] Also, most of the known devices cannot be customized to an
individual player or
team. This is particularly important when the device is designed for use in
youth sports where it
is desirable to incorporate a team logo on the device and/or identifying
indicia of an individual
player.
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[0009] Accordingly, there remains a need in the art for a protective
apparatus construction
that is adaptable for a variety of uses, including, for example, hockey skate
and pad shot
blocking devices, which is very flexible in order to comfortably readily
conform to skates of
varying sizes and shapes, be integrated with existing leg and other padding,
while still
maintaining the rigidity required to protect a player's foot and other body
parts. It would be
highly desirable to provide such an apparatus that is inexpensive and easily
customizable to an
individual team or player.
Summary of the Invention
[0010] The present invention overcomes the deficiencies of the known art
and the problems
that remain unsolved by providing a method and respective apparatus for
blocking the impact of
a sporting object against a foot or other body part of a user.
[0011] In accordance with one exemplary implementation, a shot blocker
apparatus is
provided comprising:
a guard having guard body and a pair of selectively securable straps extending
therefrom, the guard body including a flexible base fabric layer and a first
cover layer affixed to
said flexible base fabric layer to define a plurality of longitudinally
extending channels
therebetween; and
a relatively rigid plate and a relatively flexible plate disposed within each
of the
plurality of longitudinally extending channels.
[0012] In another aspect, the guard body includes a main guard body and
right and left guard
wings extending from the main guard body to protect the ankles of the user.
[0013] In another aspect, the first cover layer is stitched to the base
fabric layer to define the
longitudinally extending channels.
[0014] In another aspect, the first cover layer is formed from a flexible
fabric suitable for
receiving printing.
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[0015] In yet another aspect, a set of transition stitching lines are
formed between the main
guard body and the right and left guard wings to define additional channels in
the right and le-ft
guard wings independent of the channels formed in the main guard body.
[0016] In yet another aspect, the plurality of longitudinally extending
channels defines a first
set of longitudinally extending channels, and an additional second cover layer
is affixed over the
first cover layer and stitched thereto to define a second set of
longitudinally extending channels
for receipt of rigid and/or flexible plates.
[0017] In yet another aspect, the first set of longitudinally extending
channels is staggered
with respect to the second set of longitudinally extending channels.
[0018] In yet another aspect, the second set of longitudinally extending
channels includes a
gap therebetween.
[0019] In yet another aspect, there is provided a method of use, comprising
the steps of
providing a flexible shot blocker guard having a main guard body including a
plurality of longitudinally extending channels;
inserting a rigid and a flexible plate into each of the plurality of
longitudinally
extending channels within the main guard body; and
affixing the main guard body of the flexible shot blocker over laces provided
on the
skate of a user,
[0020] In another exemplary implementation, a knee pad assembly and
corretponding
method of construction is provided for protecting lateral and posterior areas
of a player's leg =
from impact-related injury.
[0021] In accordance with one implementation, the knee pad assembly
comprises:
a sleeve defining an interior pocket, the sleeve including:
a first base layer and a ribbed upper cover layer, and
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an arcuate support pad having an arcuate attachment structure and a straight
support pad having a straight support pad; and
a first layer of rigid material positioned in the interior pocket and a second
layer
of flexible material positioned in the interior pocket of said sleeve.
[0022] In an aspect, the arcuate attachment structure includes an arcuate
length of hook-and-
loop selective closure material.
[0023] In another aspect, the straight attachment structure includes a
straight length of hook
and loop closure material
[0024] In another aspect, the first base layer, the ribbed upper cover
layer, the arcuate
support pad and the straight support pad are integrally formed.
[0025] In another aspect, the first rigid layer of material is formed from
a polymer
composite.
[0026] In another aspect, the first rigid layer of material is formed as a
series of elongated
rigid plates.
[0027] In another aspect, the first rigid layer of material is formed as a
series of elongated
rigid plates having semi-spherical cross sections.
[00281 In another aspect, the second flexible layer of material is formed
from a polymer
composite.
[0029] In another aspect, the second flexible layer of material is formed
as a series of
elongated flexible plates.
[0030] In another aspect, the elongate rigid plates of the first rigid
layer of material are
positioned atop and intermediate of the individual flexible plates of the
second flexible layer of
material.
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[00311 These and other aspects, features, and advantages of the
present invention will
become more readily apparent from the attached drawings and the detailed
description of the
preferred embodiments, which follow.
Brief Description of the Drawings
[0032] The preferred embodiments of the invention will hereinafter be
described in
conjunction with the appended drawings provided to illustrate and not to limit
the invention, in
which:
[0033] FIG. 1 presents a bottom isometric view of a shot blocker
apparatus;
[0034] FIG. 2 presents a top isometric view of the shot blocker
apparatus, originally
introduced in FIG. 1;
[0035] FIG. 3 presents a sectional view of the shot blocker
apparatus, originally introduced
= in FIG. 1, taken along line 3-3 of FIG. 2, showing inner components;
[0036] FIG. 4 presents a top plan view of an alternative embodiment
of a shot blocker
apparatus;
[0037] FIG. 5 presents a sectional view of the alternate embodiment
shot blocker apparatus,
originally introduced in FIG. 4, taken along line 5-5 of FIG. 4;
[0038] FIG. 6 presents a top isometric view of the shot blocker
apparatus, originally
introduced in FIG. 1, being strapped to a skate;
[0039] FIG. 7 presents a top isometric view of the shot blocker
apparatus, originally
introduced in FIG. 1, strapped to the skate;
[0040] FIG. 8 presents an isometric view of an exemplary knee pad
assembly;
[0041] FIG. 9 presents a cross-sectional view of the knee pad
assembly originally introduced
in FIG. 8, wherein the section is taken along section line 9--9 of FIG. 8;
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[0042] FIG. 10 presents an end view of the knee pad assembly
originally introduced in FIG.
8;
[0043] FIG. 11 presents an isometric front view of the knee pad
assembly originally
introduced in FIG. 8, shown in a curved configuration;
[0044] FIG. 12 presents an isometric view of the knee pad assembly
originally introduced in
FIG. I and an existing hockey knee wear or leg protector, immediately prior to
assembly;
[0045] FIG. 13 presents an alternative isometric view of the knee
pad assembly and the
existing hockey leg protector originally introduced in FIG. 12; and
[0046] FIG. 14 presents an isometric view showing the knee pad
assembly and the existing
=
hockey leg protector originally introduced in FIG. 12, in an assembled
condition.
[0047] Like reference numerals refer to like parts throughout the
several views of the
drawings.
DETAILED DESCRIPTION
[0048] The following detailed description is merely exemplary in
nature and is not intended
to limit the described embodiments or the application and uses of the
described embodiments. As
used herein, the word "exemplary" or "illustrative" means "serving as an
example, instance, or
illustration." Any implementation described herein as "exemplary' or
"illustrative" is not
necessarily to be construed as preferred or advantageous over other
implementations. All of the
implementations described below are exemplary implementations provided to
enable persons
skilled in the art to make or use the embodiments of the disclosure and are
not intended to limit
the scope of the disclosure, which is defined by the claims. For purposes of
description herein,
the terms "upper", "lower", "left", "rear", "right", "front", "vertical",
"horizontal", and
derivatives thereof shall relate to the invention as oriented in FIG. 1.
Furthermore, there is no
intention to be bound by any expressed or implied theory presented in the
preceding technical
field, background, brief summary or the following detailed description. It is
also to be
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understood that the specific devices and processes illustrated in the attached
drawings, and
described in the following specification, are simply exemplary embodiments of
the inventive
concepts defmed in the appended claims. Hence, specific dimensions and other
physical
characteristics relating to the embodiments disclosed herein are not to be
considered as limiting,
unless the claims expressly state otherwise.
[0049] A first exemplary implementation of the invention, in the form of a
hockey puck shot
blocking apparatus, shown generally as reference numeral 100, is presented in
various
configurations in FIGS. 1 through 3. Referring initially to FIGS. 1 and 2, the
shot blocker .
apparatus 100 includes a guard 110, for protecting a wearer's foot from impact
With a hockey
puck, hockey stick and the like. Front and rear strap sets, 112 and 114,
respectively, are provided
for securing the shot blocker apparatus 100 to the wearer's skate as described
in more detail
hereinbelow. The guard 110 includes a main guard body 116 and right and left
guard wings 118
and 120, respectively, extending rearwardly from the main guard body 116. The
front straps 112
extends from outer side edges 122 and 124 of the main guard body 116, while
the rear strap 114
extends from rear edges 126 and 128 of the right and left guard wings 118 and
120, respectively.
[0050] The guard 110 generally includes a base fabric layer 130 and a first
cover layer 132.
The first cover layer 132 defines a first set of longitudinally extending
pockets or channels 134.
The base fabric layer 130 and the first cover layer 132 are formed from a
shock-absorbing
material similar to that used in forming shoulder pads and other protective
garments.
Additionally, the first cover layer 132 is formed from a material that can be
colored and readily
accepts printing. This allows the first cover layer 132 to be printed upon
with images and indicia
relating to a team color, team name and logo, and the like. Furthermore, it
allows the first cover
layer 132 to be easily customized to an individual by incorporating the
individual's player
number or other identification, such as, for example, a player's name, on the
first cover layer 132.
[0051] Referring particularly to FIG. 3, the first set of channels 134 are
formed by securing
= or adhering the first cover layer 132 to a second cover layer 170,
described in more detail
hereinbelow, along longitudinally extending lines of attaclunent 136, such as,
for example, lines
of attachment 136a and 136b. The first cover layer 132 may be affixed to the
second cover layer
170 using any of myriad means of attachment, including stitching, chemical
adhesive, welding,
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heat sealing, securely bonding the first cover layer 132 to the second cover
layer 170. In a
preferred embodiment, the first cover layer 132 is affixed to the second cover
layer 170 by
stitching in lines of attachment 136a, 136b, etc. to form and define the
channels 134.
[0052] As best shown in FIG. 2, the front strap 112 includes a right front
segment 138 and a
left front segment 140. Likewise the rear strap 114 includes a right rear
segment 142 and a left
rear segment 144. The right- front segment 138 extends from the outer side
edge 122 of the main
guard body 116 and the left front segment 140 extends from the outer side edge
124 of the main
guard body 116. The right rear segment 142 extends from the rear edge 126 of
the right guard
wing 118 and the left rear segment 144 extends from the rear edge 128 of the
left guard wing
120.
[0053] The right front segment 138 of the front strap 112 preferably
includes attachment
structure, such as, a strip of securing material 146 at a free end 148 of the
right front segment
138, which cooperates with a complimentary strip of material (not shown) on a
free end 150 of
the left front segment 140. Similarly, the right rear segment 142 of the rear
strap 114 includes a
strip of securing material 152 at a free end 154, which cooperates with a
corresponding strip of
securing material (not shown) at a free end 156 of the left rear segment 144.
The strips of
securing material 146 and 152 may be formed from a variety of securing
structures and
materials, such as, for example hook-and-loop material, snaps, adhesive strips
and the like. In a
preferred embodiment, the strips of securing material 146 and 152 are formed
from hook-and
loop-fastener system to providing greater adjustment flexibility.
[0054] The channels 134 may have equal or varying lengths. For example, the
channels
134a-134e adjacent the outer side edge 124 of the main guard body 116 and the
channels 134p -
134t adjacent the outer side edge 122 of the main guard body 116 may have
varying lengths,
while the channels 134f-134o of the main guard body 116 have equal lengths.
The lengths and
shapes of each of the channels 134a-134o define the shape, or peripheral edge,
of the guard 110.
In the exemplary implementation, as best illustrated in FIG. 2, the shape of
the guard 110 is
defined by a trapezoidal main guard body 116 with right and left guard wings
118 and 120
extending rearwardly from the main guard body 116. It is understood that the
guard 110 may be
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implemented in a multitude of shapes and geometries, which allow the guard 110
to conform to
the shape of a skate 200, without departing from the scope of the invention.
[0055] A first transition line 158 can be provided between the main guard
body 116 and the
right guard wing 118, and a second transition line 160 can be provided between
the main guard
body 116 and the left guard wing 120. Preferably, the transition lines 158 and
160 are formed by
stitching and provide a greater range of movement and flexibility between the
main guard body
116 and the right and left guard wings 118 and 120, respectively. This also
results separate sets
of right guard channels 162 and a left guard channels 164, which are
independent of the channels
134 of the main guard body 116.
[0056] Referring now specifically to FIG. 3, a partial cross-section of a
portion of the main
guard body 116 of the guard 110 is shown illustrating some of the channels 134
such as, for
example, the channels 134f-134h. In order to provide protection against the
impact of hard
structures, such as hockey pucks, the channels 134 contain longitudinally
extending rigid plates
166. The rigid 'plates 166 may be generally rectangular and formed from a
lightweight
composite. Additionally, to provide cushioning from the impact of a fast
moving hockey puck,
the channels 134 additionally include longitudinally extending flexible plates
168. The flexible
plates 168 are also preferably rectangular and formed from a lightweight
composite. The flexible
plates 168 are located adjacent the second cover layer 170, while the rigid
plates 166 are
positioned over the flexible plates 168 and adjacent the first cover layer
132. The rigid plates 166
and the flexible plates 168 may be formed from a variety of materials, such as
various polymer
composites, including but not limited to Kevlar (ID and plastic, having the
required rigidity and/or
flexible/resilient characteristics.
[0057] While the disclosed embodiment illustrates a single rigid plate 166
and a single
flexible plate 168 within each of the channels 134, it is contemplated that a
combination of three
or more stacked plates may be provided within each of the channels 134.
[0058] The second cover layer 170 is affixed to the base fabric layer 130
along a second set
alines of attachment 172 to define a second set of channels 174, such as, for
example, channels
174f-174i, to receive additional rigid and flexible plates 166 and 168,
respectively. As shown,
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the flexible plates 168 are positioned adjacent the base fabric layer 130
while the rigid plates166
are positioned above the flexible plates 168 and beneath the lines of
attachment 136 between
channels 134. This provides greater protection to a wearer's foot while
maintaining a high degree
of flexibility of the guard 110. As shown, the second set of attachment lines
172 are affixed
intermediate the first attachment lines 136. This positions and offsets the
rigid and the flexible
plates, 166 and 168, contained in the first set of channels 134, from the
rigid and the flexible
plates, 166 and 168, contained in the second set of channels 174. Thus, the
area at the junction of
the second set of lines of attachment 172 with base fabric layer 130 is
further protected with the
rigid and the flexible plates 166 and 168 contained in the channels 174 to
prevent injury to the
user.
[0059] Turning now to FIGS. 4-5, in a further exemplary implementation a
modified
structure of the shot blocker apparatus is shown generally as reference
numeral 200. Shot block
apparatus 200 includes a guard 210 for absorbing the impact of a blocked puck,
thereby
substantially reducing the corresponding impact of the shot transferred to the
player's foot. In
this implementation, f3r the purpose of clarity, like features of the shot
guard apparatus 200 and
shot guard apparatus 100 are numbered the same, with the exception that, where
possible,
similar/corresponding components are preceded by a "2" in place of a "1" when
referring to
apparatus 200.
[0060] In a similar fashion to guard 110 previously described, guard 210
preferably
incorporates a base fabric layer 230 and a first, outermost, cover layer 232
defining a first set of
longitudinally extending channels 234. Rigid and flexible plates 266 and 268,
respectively, are
positioned, preferably stacked as shown, within the first set of channels 234,
as illustrated in a
select subset of channels 234i through 234k (FIG. 5). As should be apparent to
those skilled in
the art there is some significance to providing the rigid plates 266 above the
flexible plates. For
example, the rigid plates function to absorb a substantial degree of the blow
caused by impact
with the puck, which impact is distributed over the area of the rigid plate
and further dampened
upon transfer of the resulting force to the underlying flexible plate.
[0061] The guard 21.0 additionally includes a second cover layer 270, which
is affixed
directly to the base fabric layer 230 along lines of attachment 272 and
defines a second set of
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longitudinally extending channels 274 (shown are the channels 274f-274i). As
with the first set
of channels 234, rigid and flexible plates 266 and 268, respectively, are
positioned within the
second set of channels 274.
[0062] Unlike the prior embodiment, in this embodiment, the first cover
layer 232 is affixed
to the second cover layer along two separate lines of attachment 236 and 238
between the
adjacent channels 234. This creates a staggered configuration for the channels
234 leaving a gap
280 between adjacent channels 234, for example, the adjacent channels 234i and
234j. The gap
280 permits a thinner overall cross-section of the guard 210 for increased
flexibility and comfort.
[0063] Turning now to FIGS. 5 and 6, the use and application of the shot
guard 100 to an
underlying skate 300 will now be described. The skate 300 generally includes a
foot or body
portion 310 and a blade 312 extending from an underside 314 of the body
portion 310. The body
portion 310 includes a central foot pocket 316, a heel pocket 318 and a toe
pocket 320. The body
portion 310 additionally includes an ankle portion 322 and a flexible tongue
324 extending up
through the central foot pocket 316. A rear portion or shin riser 326 supports
the shin of the user
while laces 328 are provided to cinch the central foot pocket 316 tight about
the foot of the user
for maximum support.
[0064] In use, a user inserts a foot (not shown) into the body portion 310
of the skate 300 and
the laces 328 are tightened to secure the foot within the skate 300.
Thereafter, the shot blocker
apparatus 100 is applied to the skate 300 by initially overlaying the central
foot pocket 316 of the
skate 300 with the main guard body 116 of the shot blocker 100. As noted
above, the free end
148 of the right front half 138 of the front strap 112 includes the strip of
securing material 146
and the free end 154 of the right rear half 142 of the rear strap 114 includes
the strip of securing
material 152.
[0065] After the shot blocker 100 is placed over the central foot pocket
316, a mating strip of
securing material 176 on the free end 150 of the left front half 140 of the
front strap 112 is
wrapped around the foot pocket 316 and is secured to the strip of securing
material 146 on the
right front half 138 of the front strap 112. Likewise, a mating strip of
securing material 178
provided on the free end 156 of the left rear half 144 is secured around the
heel pocket 218 of the
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=
skate 300 to the strip of securing material 152 on the right rear half 142 to
thereby secure the
shot blocker 100 to the skate 300. The right and left guard wings 118 and 120
of the guard 110
protect the ankle portions 322 of the skate 300 while the main guard body 116
protects the
central foot pocket 316 of the skate 300.
[0066] It should be noted that, the shot blocker 100 is applied after the
laces 328 of the skate
have been cinched up and in no way interferes with the tightening of the
central foot pocket 316
about the foot of a user. It is understood that the apparatus and method of
the present invention is
not limited to a foot guard. The invention can be implemented as a wrist guard
or knee guard, for
example, to protect any number of body parts that may be injured during a
sporting game.
[0067] As will be apparent to those skilled in the art, the unique
construction of the invention
lends itself to a host of sports-related equipment utilized in a variety of
sports. Accordingly,
while the exemplary implementations described and shown herein deal primarily
with hockey-
related applications, the application is not intended to be so limiting. For
example, body
protection devices, padding and the like, are used in baseball, lacrosse and a
host of other sports.
[0068] In that regard, in another implementation the invention is shown and
described
incorporated or integrated into a hockey knee pad assembly 400, along with an
exemplary
method of construction, in FIGS. 8 through 14. Referring initially to FIGS. 8
and 9, the knee pad
assembly, shown generally as reference numeral 400, is provided to protect the
sides and the
popliteal or rear area of the leg located behind the knee of a user. The knee
pad assembly 400
includes a generally "D" shaped sleeve 410 defining an interior pocket 412,
and having a flat
base layer 414 beneath a ribbed upper cover layer 416. The sleeve 410 has an
arcuate first edge
418, an opposite straight second edge 420 and first and second side edges, 422
and 424,
respectively, extending between the arcuate first edge 418 and the straight
second edge 420. The
first and second side edges 422 and 424 include first and second upper side
edges 426 and 428
on the ribbed upper cover layer 416 and first and second lower side edges 430
and 432 on the fiat
base layer 414.
[0069] The knee pad assembly 400 additionally includes an arcuate support
pad 434
extending from the arcuate first edge 418 and a straight support pad 436
extending from the
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straight second edge 420. The arcuate support pad 434 and the straight support
pad 436 are
provided to support and retain respective arcuate and straight attachment
structures 438 and 440
for use in connecting the knee pad assembly 400 to other protective gear of a
player, as described
in more detail below. The arcuate and straight attachment structures 438 and
440 may include
adhesive strips, buckles, snap closures or any other commonly available
fastener structure. In the
disclosed embodiment, the arcuate and straight attachment structures 438 and
440 include
respective arcuate and straight lengths of hook-and-loop closure material 442
and 444 affixed to
upper surfaces 446 and 448 of the arcuate and straight support pads 434 and
436.
[0070] The sleeve 410 may be formed from a variety of relatively flexible
materials such as,
for example, polymers, fabrics and foams, to name just a few. The ribbed
contour of the upper
cover layer 416 is most easily maintained by forming the sleeve 410, or at
least the ribbed upper
cover layer 416, of a foam or polymeric material. Additionally, in an
exemplary implementation,
the arcuate support pad 434 and the straight support pad 436 are formed
integrally with the
sleeve 410. Thus, the use of a foam or polymeric material for the arcuate and
straight support
pads 434 and 436 provide a solid base for the arcuate and straight attachment
structures 438 and
440.
[0071] Referring now specifically to FIG. 9, in order to protect the user
against impact
injury, the knee pad assembly 400 includes a first rigid layer 450 which may
be constructed
from, for example, a strong and rigid polymer composite material and a second
flexible layer
452, constructed from a strong, but relatively flexible, polymer composite
material. The first
rigid layer 450 and the second flexible layer 452 are positioned within the
interior pocket 412 of
the sleeve 410. The first rigid layer 450 is positioned adjacent to and
beneath the ribbed upper
cover layer 416 while the second flexible layer 452 is positioned between the
first rigid layer 450
and the flat base layer 414. By positioning the first rigid layer 450 above
the second flexible
layer 450, any impact against the lame pad assembly is initially absorbed by
the first rigid layer
450, and any additional impact energy cushioned and absorbed by the second
flexible layer 452
to prevent injury to the user.
[0072] In an exemplary embodiment, the first rigid layer 450 consists of a
series of
longitudinally extending rigid plates 454, such as rigid plates 454a-454j,
which are semi-
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spherical in cross section, and the second flexible layer 452 consists of a
series of longitudinally
extending flexible plates 456, such as flexible plates 456a-456k, which are
also semi-spherical in
cross section. Each of the rigid plates 454 is positioned above and between
adjoining flexible
plates 456. For example, the rigid plate 454i is positioned above and between
or intermediate of
the adjoining flexible plates 456i and 456j located below the rigid plate
454i. By positioning and
constructing the knee pad assembly 400 with the rigid plates 454 between the
adjoining areas of
the flexible plates 456, the flexibility of the knee pad assembly 400 is
enhanced. As shown, the
ribbed upper cover layer 416 defmes a series of longitudinally extending
pockets or channels 458
which receive and overlie the semi-circular rigid plates 454.
[0073] While not specifically shown, in an alternative embodiment, an
intermediate support
layer may be positioned between the rigid plates 454 and 456 and extend across
the interior
pocket 412 in the sleeve 410 to better separate and cushion the impact
transferred from the rigid
plates 454 to the flexible plates 456. Additionally, the longitudinally
extending pockets 458,
formed beneath the ribbed upper cover layer 416 may be constructed by
stitching or otherwise
securing the ribbed upper cover layer 416 to the intermediate layer along
longitudinally
extending lines of attachment to form individual pockets or channels for
receipt of the individual
rigid plates 454a-454i.
[0074] In a still further alternative implementation, the individual rigid
plates 454a-454i may
be integrally formed and joined together along their edges by living hinges.
Similarly, the
individual flexible plates 456a-456j may be integrally formed and joined along
their adjacent
edges by living hinges. This enhances the structural integrity of the first
rigid layer 450 and
second flexible layer 452 while maintaining flexibility between individual,
adjoining plates.
[0075] Turning now to FIGS. 10 and 11, as shown, in an exemplary
embodiment, the knee
pad assembly 400 is formed with a pre-curved shape to better conf-orm to the
leg of the user and
facilitate attachment to another protective structure as described in more
detail herein below.
Thus, the relatively flat base layer 414 has an arcuate or concave shape and
the ribbed upper
cover layer 416 also has an arcuate shape.
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CA 02852251 2014-05-20
=
[0076] Referring generally to FIGS. 12-14, and initially primarily to FIG.
12, the knee pad
assembly 400 is designed to used with an existing protective structure such
as, for example, an
existing knee wear or leg protector 500. It should be noted that the knee pad
assembly 400 and
its method of construction is suitable for use alone with the addition of a
securing strap (not
shown) which can be connected to the arcuate and straight attachment
structures 438 and 440 to
protect a limb or joint of a user.
[0077] In general, existing leg protector 500 includes molded, forward
facing, elongate pad
502 having a lower section 504 to protect a shin of a user, a center section
506 to protect the
anterior side of the knee of the user and an upper section 508 to protect a
lower portion of a thigh
immediately adjacent the knee of the user. A tab 510 projects from an upper
edge 512 of the
upper section 508 to aid the user in attaching the existing leg protector 500
to the user's leg. The
existing leg protector 500 further includes upper and lower securing straps
514 and 516, formed
as connectable strap halves 514a, 514b and 516a and 516b, to secure the
existing leg protector
500 to the leg of the user.
[0078] When used in conjunction with the knee pad assembly 400, the
existing leg protector
500 additionally includes a first knee wear strap or securing structure 518
extending rearwardly
from a first edge 520 of the center section 508 of the existing leg protector
and a second knee
wear strap or securing structure 522 extending rearwardly from a second edge
524 of the center
section 508. In the embodiment of the knee pad assembly 400 where the arcuate
and straight
attachment structures 438 and 440 consist of the arcuate and straight lengths
of hook and loop
closure materials 442 and 444, the first and second securing structures 518
and 522 of the -
existing leg protector 500 include complimentary first and second lengths of
hook and loop
closure materials 526 and 528. It should be noted that where the arcuate and
straight attachment
structures 438 and 440 of the knee pad assembly 400 are other than hook and
loop closure
material, the first and second securing structures 518 and 522 will include
complimentary
structures.
[0079] Referring now primarily to FIGS. 13 and 14, the assembly of the knee
pad assembly
400 to the existing leg protector 500 will now be described. While not
specifically shown,
initially, the existing leg protector 500 is positioned on a front of a users
leg with the center
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CA 02852251 2014-05-20
section 506 located over the anterior area of the knee of the user. The
existing leg protector 500
is then secured to the leg of a user by use of the upper and lower securing
straps 514 and 516.
Thereafter, the knee pad assembly 400 is positioned adjacent a posterior
aspect or popliteal area
of the knee of the user and the knee pad assembly 400 is affixed to the
existing leg protector 500.
[0080] Specifically, the straight length of hook and loop closure material
442 of the straight
attachment structure 440 is connected and affixed to the first length of hook
and loop closure
material 526 on the existing leg protector 500 and the knee pad assembly 400
wrapped around
the posterior area of the knee of the user. Thereafter, the arcuate attachment
structure 438 of the
knee pad assembly 400, and specifically the arcuate length of hook and loop
closure material
442, is affixed to the second length of hook and loop closure material 528 on
the second securing
structure 522 of the existing leg protector 500.
[0081] Alternatively, the arcuate length of hook and loop closure material
442 on the knee
pad assembly 400 may be first attached to the second securing structure 522 on
the existing leg
protector 500 and subsequently the straight length of hook and loop closure
material 444
attached to the first securing structure 518.
[0082] In this manner, the knee pad assembly 400, including its method of
construction,
provides a simple and useful device to protect the posterior or popliteal area
of the knee of a
user. Additionally, the knee pad assembly 400 provides an auxiliary protective
device for use
with the existing leg protector. 500.
[0083] The above-described embodiments are merely exemplary illustrations
of
implementations set forth for a clear understanding of the principles of the
invention. Many
variations, combinations, modifications or equivalents may be substituted for
elements thereof
without departing from the scope of the invention. Therefore, it is intended
that the invention not
be limited to the particular embodiments disclosed as the best mode
contemplated for carrying
out this invention, but that the invention will include all the embodiments
falling within the
scope of the appended claims.
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