Aspects herein are directed to systems, methods, and articles for producing a patterned film and using the patterned film to form a pattern of discrete overlay film structures on a substrate material. A uniform thickness of a film material is deposited on to a first surface of a run of carrier sheets, where each carrier sheet includes one or more holes extending there through. A first carrier sheet is extracted from the run of carrier sheets, and a second surface of the carrier sheet is positioned on a substrate material. Heat and/or pressure is applied to the film material to cause the film material to transfer to the substrate material through the one or more holes in the carrier sheet forming a pattern of discrete overlay film structures on the substrate material. The carrier sheet along with remaining portions of the film material is removed from the substrate material.

A headband is provided which has a fabric layer defining pockets, padding layers positioned circumferentially around the headband in the pockets, and an impact panel. The impact panel is positioned to be proximate to the forehead of a wearer of the headband. One of the padding layers is positioned behind the impact panel, such that the padding layer is positioned between the impact panel and the forehead of a wearer.

A pad for protective garments comprises an outer layer of heat and flame resistant material, and inner layer of heat and flame resistant material, and a cushioning layer disposed therebetween. The cushioning layer is produced from a non-newtonian material. A pad assembly may be formed using the pad along with a piece of flexible material attached thereto. The pad, or the pad assembly including the pad, may be used with protective garments such as firefighter turnout gear.

Aspects herein are directed to an article of apparel having a vent opening formed by overlapping the edges of a first panel and a second panel. A plurality of discrete overlay film structures are applied to the second panel adjacent to the vent opening. When the article of apparel is exposed to an external stimulus, the film structures undergo a reversible increase in dimension in at least the z-direction which cause the second panel of material to undergo a reversible decrease in dimension in the direction of a longitudinal axis of the vent opening thereby causing the vent opening to dynamically transition from a closed state to an open state.

A body limb protection system includes an outer layer, an inner layer, and a force dampening and defusing structure. The outer layer includes a first material composition and has an exterior surface that includes a substantially planer area. The inner layer includes a second material composition and has a shape corresponding to a body limb portion. The force dampening and defusing structure is positioned between the inner layer and the outer layer. The force dampening and defusing structure has a shape corresponding to a difference between the shapes of the inner and outer layers. The force dampening and defusing structure includes a plurality of components arranged to reduce pressure on the body limb portion when a force is applied to the substantially planer area.

There is provided an elastomeric sheet with a thickness of from 5 mm to 20 mm the elastomeric sheet having with a first side and a second side, where the first side has a plurality of deformable support members where the support members have a cavity with an opening towards the second side of the elastomeric sheet, and where the hardness of the sheet is from 40 Shore A to 80 Shore A.

Energy distribution structures provide architectural flexibility in various configurations, materials, and scalability, which enables a vast number of applications. An energy distribution structure or array thereof may include a three-dimensional outer component and a three-dimensional inner component within the outer component. The outer component absorbs and redirects initial energy from an applied energy event, and the inner component absorbs and redirects residual energy from the applied energy event. Such an applied energy event may be caused by a ballistic or non-ballistic impact, an instantaneous or prolonged impact such as atmospheric pressure or decompression, explosive overpressure (shockwave), low-velocity contact, and blunt force trauma. Energy distribution structures can increase the strength, resilience or survivability of such events, and reduce the injury or damage to target objects such as people, vehicles, structures, vessels and surfaces by shielding same from such events.

A cushioning and impact absorbing pad with a surface layer of thickness t, and an elastomeric sub-surface-structure of height h. The sub-surface structure comprises an array of elastomeric columns wherein each column has a frustoconical column wall surrounding a central void. The frustoconical column walls have a zone that is a more compressible, relatively collapsible zone in a region at an end of the column opposite the surface layer and a zone that is a relatively less compressible zone in a region at the end of the column abutting the surface layer. Column walls are tapered with draft angles in the range of greater than 6 degrees and less than 10 degrees.

Custom fitting protective athletic equipment composed of larger compressive chambers to generally surround a body part as well a plurality of smaller compressive chambers, which can be shaped to absorb rotational impact forces, outside the larger compressive chambers. A hard or yielding shell positioned either outside the chambers or between them can provide additional impact dampening and protection. Both the larger and smaller compressible chambers preferably contain compressible fluid, such as air, another gas, gel or liquid. Valves are preferably provided in the chambers so that the fluid can be controlled when an impact is received. A method is also disclosed to use three-dimensional scanning techniques and three-dimensional 3D printer manufacturing techniques to produce the protective athletic equipment of the present invention.

A back protection device for the practice of sporting activities includes a plate covering at least partially the surface of the back and in the thickness of which recesses are made intended to ensure the flexibility of the plate. The plate comprises a longitudinal ridge, the axis of which is intended to extend along the spine by delimiting, on either side, two right and left parts, each composed of an upper zone and a lower zone. The four zones are movable relative to each other, each being provided with recesses in the form of slots opening onto at least one face of the plate and being oriented with an inclination angle that is variable relative to the axis of the longitudinal ridge, so as to dissociate the flexibility of said zones.