Padding Material for Protective Equipment
20250221476 ยท 2025-07-10
Inventors
Cpc classification
International classification
Abstract
A padding material for protective equipment is provided. The padding material is formed from a single, integral piece of material with a cellular structure. The size and/or shape of the cellular structure is non-uniform to provide support and reduce pressure in chosen areas. One embodiment of the protective equipment includes knee pad with a shell, padding disposed in front of the knee of the wearer, the padding including a non-uniform stiffness.
Claims
1. A knee pad comprising: an upper support configured to couple to a leg of a user above a knee; a lower support configured to couple to the leg of the user below the knee; a shell coupled to the upper support and the lower support and positioned between the upper support and the lower support; and a single, integral padding layer comprising: an outer surface interfacing against the shell; an inner surface; and a plurality of cells, each of the plurality of cells extending between the outer surface and the inner surface, each of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis extending along the channel; and a cell wall enclosing the channel, the cell wall comprising a plurality of segments angled relative the longitudinal axis.
2. The knee pad of claim 1, wherein a portion of plurality of segments are angled inward, toward the channel and a portion of the plurality of segments are angled outward, away from the channel.
3. The knee pad of claim 2, wherein half of the plurality of segments are angled inward and half of the plurality of segments are angled outward.
4. The knee pad of claim 1, wherein a thickness of the padding layer is defined between the outer surface and the inner surface, and wherein the thickness is less than 40 mm.
5. The knee pad of claim 4, wherein the thickness is less than 25 mm.
6. The knee pad of claim 1, wherein the shell further comprises: a front wall; and a pair of lateral walls, each lateral wall extending from an opposing side of the front wall.
7. The knee pad of claim 6, wherein the padding layer further comprises: a central section positioned against the front wall of the shell; and side sections positioned against the pair of lateral walls of the shell.
8. The knee pad of claim 7, wherein the plurality of cells in the central section have a first dimension and the plurality of cells in the side sections have a second dimension, and wherein the first dimension is greater than the second dimension.
9. A knee pad comprising: an upper support; a lower support; a shell coupled to the upper support and the lower support, the shell positioned between the upper support and the lower support; and a single, integral padding layer comprising: an outer surface positioned along the shell; an inner surface; and a plurality of cells, each of the plurality of cells extending between the outer surface and the inner surface, each of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis; and a cell wall enclosing the channel, the cell wall comprising: an inward angled segment; and an outward angled segment; wherein the inward angled segment and the outward angled segment are each angled relative the longitudinal axis.
10. The knee pad of claim 9, wherein the inward angled segment is angled inward, toward an opposing portion of the cell wall and wherein the outward angled segment is angled outward, away from the opposing cell well.
11. The knee pad of claim 9, wherein the cell wall comprises two inward angled segments and two outward angled segments.
12. The knee pad of claim 9, wherein an interior surface of the inward angled segment is at a 30 degree angle relative to an axial axis of the cell.
13. The knee pad of claim 9, wherein each cell wall a thickness defined between an exterior surface of the cell wall and an interior surface of the cell wall, wherein the thickness is 2 mm.
14. The knee pad of claim 13, wherein a padding layer thickness is less than 25 mm.
15. The knee pad of claim 9, wherein each cell has a height defined between the outer surface and the inner surface of the padding layer, and wherein the height is about 17.5 mm.
16. A knee pad comprising: an upper support; a lower support; a shell coupled to the upper support and the lower support, the shell positioned between the upper support and the lower support; and a single, integral padding layer comprising: an outer surface positioned along the shell; an inner surface; and a plurality of cells, each of the plurality of cells extending between the outer surface and the inner surface, each of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis; and a cell wall surrounding the channel, the cell wall comprising: a pair of inward angled segments; and a pair of outward angled segments; wherein the pair of inward angled segments and the pair of outward angled segments are each angled relative the longitudinal axis.
17. The knee pad of claim 16, wherein one of the pair of outward angled segments is positioned between the pair of inward angled segments.
18. The knee pad of claim 16, wherein the shell further comprises: a front wall; and a pair of lateral walls, each lateral wall extending from an opposing side of the front wall; and wherein the padding layer further comprises: a central section positioned against the front wall of the shell; and side sections positioned against the pair of lateral walls of the shell.
19. The knee pad of claim 18, wherein the plurality of cells in the central section have a first dimension and the plurality of cells in the side sections have a second dimension, and wherein the first dimension is greater than the second dimension.
20. The knee pad of claim 16, wherein the padding layer is formed from a thermoplastic elastomer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:
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DETAILED DESCRIPTION
[0035] Referring generally to the figures, one or more embodiments of protective clothing or safety equipment with a padding layer are described herein. Various types of safety equipment and protective clothing (e.g., knee pads, helmets, gloves, etc.) include padding to provide protection and/or support. For example, as discussed herein, various embodiments of a knee pad including a padding layer with a non-uniform stiffness and/or cellular structure are described.
[0036] In various embodiments, the padding layer may be formed from a single, integral piece of polymer material with a plurality of cells. In general, the compression/stiffness properties may be adjusted by controlling the geometry of the cells and the size of the cells. In specific embodiments, the cells of the padding layer have different sizes, dimensions, and/or shapes in different regions of the padding layer. Applicant has found these differences in structure provide for chosen compression or stiffness properties in key regions of the safety equipment. Further, Applicant has found that altering the cellular structure can create padding layers that exhibit relatively linear load deflection responses within specific regions of the padding layer. In this manner, the padding material may be designed to minimize high pressure zones (e.g., areas around the knee cap for a knee pad) and to distribute pressure across more evenly across the padding material. In a specific embodiment, the cell walls of the padding layer are formed from a material having a zig-zag cell profile with larger area cells located in central areas that correspond to the knee cap of the wearer. Further, as will be described in greater detail below a method of manufacturing padding layers for protective layers is discussed herein.
[0037] Referring to
[0038] Knee pad 110 includes padding layer 140 coupled to an interior surface 181 of shell 180. In various embodiments, padding layer is coupled to shell 180 by fasteners, protrusions, etc. Padding layer 140 is coupled to shell 180 between the interior surface 181 of shell 180 and the knee of the user. In various embodiments, padding layer 140 extends from one lateral wall 184 to the opposing lateral wall 184 such that padding layer 140 is adjacent to and/or coupled to front wall 182 between the lateral walls 184. Lateral walls 184 extend from opposing sides of front wall 182 of shell 180. In other words, a first lateral wall 184 extends rearward, away from a first side of the front wall 182 and a second lateral wall 184 extends rearward from a second side of the front wall 182 opposing the first side of the front wall 182. In various specific embodiments, the lateral walls 184 extend past or beyond an anterior or rear edge of the padding layer 140 such that each one of the lateral walls 184 provides a supporting force against a side (medial and lateral sides) of the knee when a user is kneeling. In various embodiments, the supporting force is applied inward, against a side of the knee when the user is kneeling.
[0039] In various embodiments, padding layer 140 is formed from a single, integral piece of polymer material. In a specific embodiment, padding layer 140 is formed from a thermoplastic elastomer. In various embodiment, padding layer 140 has a cellular structure. In such embodiments, padding layer 140 has different sized cells at different locations to provide different compression/stiffness properties at chosen locations or portions of the padding based on the expected loading of the padding in those locations or regions of the knee pad 110. As will be discussed in greater detail below, in various embodiments the padding layer 140 is designed such that the padding layer 140 exhibits relatively linear load deflection responses within locations or regions. Applicant believes such a design minimizes high pressure zones (e.g., areas around the knee cap) and distribute pressure across more evenly across the padding layer 140.
[0040] Referring to
[0041] In various embodiments, padding layer 140 is made of a material that allows padding layer 140 to be a reduced thickness compared to other padding structures for knee pads (e.g., foam padding, etc.). In various embodiments, the padding layer 140 has a thickness less than a maximum thickness of 40 mm. In specific embodiments, padding layer has a thickness less than 35 mm, specifically less than 30 mm and more specifically less than 25 mm. In a specific embodiment, padding layer 140 has a thickness of 19 mm.
[0042] In various embodiments, the cells 142 of the padding layer 140 have a non-uniform size. In other words, the dimensions of the cells 142 are different in various locations within the padding layer 140. As will be discussed in greater detail below, the size of the cells 142 is determined by a packing algorithm. In various embodiments, the cell 142 size of padding layer 140 in the central section 152 is greater than the cell 142 size in the side sections 154. The central section 152 of the padding layer 140 is positioned against and/or adjacent the front 182 wall of shell 180 when knee pad 110 is assembled. The side sections 154 of padding layer 140 are positioned against and/or adjacent to lateral walls 184 of shell 180 when knee pad 110 is assembled.
[0043] Referring to
[0044] In various embodiments, a portion of the wall segments 156 are walls angled inward 158 (i.e., toward channel 148 and opposing cell wall 150) and a portion of the wall segments 156 are walls angled outward 160 (i.e., away from channel 148 and opposing cell wall 150). In a specific embodiment, each cell 142 has four wall segments 156 including two walls angled inward 158 and two walls angled outward 160. In other embodiments, the number of wall segments 156 is different (e.g., 3, 5, 6, etc.). Each wall angled inward 158 has an inner surface 164 facing the channel 148 and each wall angled outward 160 has an inner surface 162 facing channel 148. In a specific embodiment, the wall angled inward 158 and specifically inner surface 164 is at about a 30 degree angle (e.g., 30 degrees plus or minus 10 degrees) relative to an axial axis 166 of cell 142.
[0045] In a specific embodiment, the cell wall 150 has a thickness, T, of 2 mm. In a specific embodiment, cell 142 has a height, H, Defined between the outer surface 144 and the inner surface 146. In a specific embodiment, H is about 17.5 mm (e.g., 17.5 mm plus or minus 5 mm). Cell 142 has an effective radius defined as a distance from the center of the cell to the cell wall 150. In a specific embodiment, cell 142 has an effective radius R of 10 mm.
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[0054] In a second step, a user input such as a smoothed pressure map 504 of a knee pressure taken of an individual kneeling. In other embodiments, the user input can be based on other user data (e.g., scan), position of bones, known impact points, etc. Pressure map 504 is customizable. In the illustrated embodiment, colors or gray scale are sued to define different zones. Pressure map 504 includes a first, outer zone 506, a second zone 508, a third zone 510, a fourth zone 512, and a middle or central zone 514. A border 516 is defined between second zone 508 and first outer zone 506. Cells formed to the left of border 516 will have a smaller size and/or dimension that the cells formed to the right of the border 516.
[0055] In a third step, an algorithm is used to convert the pressure map 504 into a defined map or group 520 of a plurality of cells. In a specific embodiment, a Flat Voronoi packing algorithm is used with the pressure map of
[0056] In a fourth step, the geometry of the wall 524 is chosen. For example, an angled or zig-zag wall (see e.g.,
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[0061] The method 500 of manufacturing a padding layer for protective equipment can similarly be used for padding layer 614 and 714. Further, the method can be used for additional types of protective equipment and/or layers such as elbow guards, padded sleeves, shoe insoles, shoe outsoles, etc. As will be generally understood, different types of protective equipment will each have their own design target or geometry 502.
[0062] It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
[0063] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.
[0064] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article a is intended to include one or more component or element, and is not intended to be construed as meaning only one.
[0065] For purposes of this disclosure, the term coupled means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. As used herein, rigidly coupled refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.
[0066] While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.
[0067] In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.