PROTECTION DEVICE AND PROCESS OF MAKING THE SAME

Abstract

A wearable protection device including an inflatable element having a plurality of side-by-side segments and configurable between a deflated condition and an inflated condition. The protection device includes a case defining a compartment in which the plurality of segments is housed. The case includes a first and a second cover in sheet material, at least partially opposite to each other.

Claims

1. A wearable protection device comprising: an inflatable element comprising a plurality of side-by-side segments each extending along a respective extension trajectory, wherein each of the side-by-side segments comprises at least one wall in sheet material delimiting an internal volume and having a first and second portion facing each other, wherein each of the side-by-side segments further comprises one or more peripheral engagement portions, wherein the inflatable element is configurable between: a deflated condition in which the first and second portions of at least one wall of each of the side-by-side segments, for a predominant portion of a surface extension, are close together and at least partially in contact with each other, an inflated condition in which the first and second portions of the at least one wall of each of the side-by-side segments, for a preponderant portion of its surface extension, are spaced apart, wherein said at least one wall, in the inflated condition, defines an internal volume greater than the internal volume defined by the same wall in the deflated condition, a case defining a compartment in which the plurality of the side-by-side segments is housed, wherein the case comprises a first and a second cover in sheet material, at least partially opposite to each other, wherein each segment is interposed between said first and second covers, wherein at least one peripheral engagement portion of at least one segment of the inflatable element is fixed to, or in proximity of, at least one of said first and second covers.

2. The wearable protection device according to claim 1, wherein the inflatable element comprises at least two peripheral engagement portions opposite to each other with respect to the internal volume of the respective segment, wherein at least one of said segment is fixed, at opposite peripheral engagement portions with respect to the internal volume of the respective segment, to the first and second covers.

3. The wearable protection device according to claim 1, wherein the at least one wall of each segment comprises a first wall and a second wall in sheet material, wherein the first wall has a respective central zone defining said first portion of the atleast one wall of the inflatable element, wherein the second wall has a respective central zone, which defines said second portion of the at least one wall of the inflatable element, wherein the first and second walls of each segment are engaged with each other at a peripheral edge to define the peripheral engagement portion of the inflatable element.

4. The wearable protection device according to claim 3, wherein each segment is fixed, at peripheral edge portions positioned opposite each other with respect to the internal volume of the respective segment, to the first and second covers.

5. The wearable protection device according to claim 3, wherein the peripheral edge of each segment comprising a first tract and a second tract opposite each other and joined at respective end portions by at least one connection tract, wherein the first and second tracts of the peripheral edge extend substantially along the extension trajectory of the respective segment, wherein each segment is fixed to the first and second cover at the first and second tract of the peripheral edge.

6. The wearable protection device according to claim 5, wherein each segment is sewn to the first and second covers exclusively at at least one of said peripheral engagement portions.

7. The wearable protection device according to claim 5, wherein each of the side-by-side segments is fixed by a seam to: the first cover at the first tract of the peripheral edge along at least 70% of the total longitudinal extension of said first tract, substantially defined along the extension trajectory of the respective segment, and the second cover at the second tract of the peripheral edge along at least 70% of the total longitudinal extension of said second tract, substantially defined along the extension trajectory of the respective segment.

8. The wearable protection device according to claim 1, wherein at least a peripheral portion of the first and second cover of the case is fixed to each other by sewing, wherein each of the side-by-side segments of the inflatable element is sewn to the first and second cover spaced from the seams joining the first and second covers.

9. The wearable protection device according to claim 1, wherein the case comprises a plurality of auxiliary covers arranged in the compartment, wherein each auxiliary cover being made of sheet material and defining a sub-chamber in which at least one segment of the inflatable element is housed, wherein each auxiliary cover is fixed to at least one of: at least a peripheral engagement portion of the segment housed in the auxiliary cover, the first cover of the case, or the second cover of the case.

10. The wearable protection device according to claim 9, wherein at least 70% of each segment is contained within the sub-chamber of a respective auxiliary cover.

11. The wearable protection device according to claim 1, further comprising: an activator configured to activate the actuator to allow the inflatable element to pass from the deflated to the inflated condition, a control unit operatively connected to the activator, wherein the control unit is configured to send a command signal to the activator for the activation of the actuator, and at least one sensor configured to emit a signal representative of a user condition, wherein the control unit is configured to: receive the signal from the sensor, compare the received signal with at least one threshold value of a control parameter, determine, based on the comparison, the presence of an accident condition for the user and, if the accident condition is determined, send the command signal to the activator to detect an occurrence of the accident condition.

12. A wearable protection device comprising: an inflatable element comprising a plurality of side-by-side segments each extending along a respective extension trajectory, wherein each segment comprises at least one wall in sheet material delimiting an internal volume and having a first and second portion facing each other, wherein the inflatable element is configurable between: a deflated condition in which the first and second portions of at least one wall of each segment, for a preponderant part of its surface extension, are close together and at least partially in contact with each other, an inflated condition in which the first and second portions of the at least one wall of each segment, for a preponderant portion of its surface extension, are spaced apart, wherein said at least one wall, in the inflated condition, defines an internal volume greater than the internal volume defined by the same wall in the deflated condition, a case defining a compartment in which the plurality of segments is housed, wherein the case comprises a first and a second cover in sheet material, at least partially opposite to each other, wherein each segment is interposed between said first and second covers, wherein two immediately adjacent segments of the inflatable element-in cooperation with at least one of the first or second cover, in the inflated condition and in a cross-section orthogonal to the extension trajectory of at least one of said segments-delimit at least one empty zone.

13. The wearable protection device according to claim 12, wherein the empty zone extends along at least 80% of the total longitudinal extension of said segments defined along the respective extension trajectories.

14. The wearable protection device according to claim 12, wherein the empty zone, in the inflated condition and at a longitudinal centreline between two adjacent segments delimiting said empty zone, has a predetermined area, wherein a ratio between said predetermined area and a cross-sectional area of one of the segments delimiting said empty zonein the inflated condition, in a cross-section along a plane orthogonal to the extension trajectory of the respective segment, at a longitudinal centreline zone of said segmentis between 0.05 and 0.3.

15. The wearable protection device according to claim 12, wherein the at least one empty zone comprising: a first empty zone delimited between two immediately adjacent segments of the inflatable element and the first cover, a second empty zone delimited between two immediately adjacent segments of the inflatable element and the second cover.

16. The wearable protection device according to claim 12, wherein the at least one empty zone, in cross-section, being substantially triangular in shape.

17. The wearable protection device according to claim 12, wherein each segment further comprises one or more peripheral engagement portions, wherein the peripheral edge of each segment has a first and second tract opposite to each other with respect to the internal volume defined by the same segment and joined at respective end portions by at least one connection tract, wherein the first and second tracts of the peripheral edge develop substantially along the extension trajectory of the respective segment, and wherein each segment is sewn to the first and second cover at the first and second tract of the peripheral edge.

18. The wearable protection device according to claim 17, wherein two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element, in the inflated condition of said segments, are placed at a predetermined distance, wherein two second tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element, in the inflated condition of said segments, are placed at a predetermined distance, wherein the ratio between said minimum distance and the predetermined distance between two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element in the inflated condition of said segments, is equal to or greater than 1, and wherein the ratio between said minimum distance and the predetermined distance between two second tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element, in the inflated condition of said segments, is equal to or greater than 1.

19. The wearable protection device according to claim 12, wherein the inflatable element is made of deformable material, wherein the wall of the inflatable element has a gas impermeable structure, and wherein the case is at least partially made of perforated and gas-permeable material.

20. The wearable protection device according to claim 12, wherein the first and second covers of the case, in the deflated condition of the inflatable element and in the area where said segments are fixed to the case, are spaced from each other up to a maximum distance, wherein said first and second covers, in the inflated condition of the inflatable element and in the area where said segments are fixed to the case, are arranged at an operating distance less than said maximum distance, and wherein the ratio between the maximum distance and the operating distance between the first and second cover is equal to or greater than 1.1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Certain embodiments and aspects of the invention will be described below with reference to the accompanying drawings, which are provided for illustrative purposes only and are therefore not limiting, wherein:

[0069] FIGS. 1 and 2 are schematic views of a garment comprising a protection device according to the present invention;

[0070] FIG. 3 is a perspective view of a protection device according to the present invention, for example usable on the garment of FIGS. 1 and 2;

[0071] FIGS. 4 and 5 are schematic views of a further garment comprising a protection device according to the present invention;

[0072] FIG. 6 is a perspective view of an inflatable element usable in a protection device;

[0073] FIG. 7 is a sectional view of a protection device according to a first embodiment, in a deflated condition;

[0074] FIG. 8 is a sectional view of the protection device of FIG. 7, in an inflated condition;

[0075] FIGS. 9 and 10 are perspective views of a protection device according to a second embodiment, in a deflated condition and an inflated condition, respectively;

[0076] FIGS. 11 and 12 are sectional views of the protection device of FIGS. 9 and 10, in a deflated condition and an inflated condition, respectively.

CONVENTIONS AND DEFINITIONS

[0077] In the present detailed description, corresponding parts illustrated in the various figures are indicated by the same numerical references. The figures may illustrate the subject-matter of the invention by means of representations that are not to scale; therefore, parts and components illustrated in the figures may relate only to schematic representations.

[0078] The term sheet material refers to a structure with two dimensions (e.g., length and width) strongly overriding a third dimension (the thickness). The sheet material extends in thickness between a first and a second main surface and may be a single-layer or multi-layer.

[0079] For example, as will be better described below, the protection device object of the present invention comprises at least one inflatable element, which may be made of sheet material. In particular, the inflatable element may comprise at least one wall, optionally a first and a second wall, made of sheet material, capable of substantially defining a fluid-tight bag. The inflatable element may have a first and second walls joined in a fluid-tight way to define substantially a bag.

[0080] The sheet (or foil) material of at least one wall, optionally of the first and second wall, of the inflatable element may be monolayer or multilayer. In the case of a monolayer sheet, this may substantially comprise a plastic film, in particular a material that is substantially impermeable to gases. In detail, the first and second walls may be of a heat-sealable type to allow said walls to be welded together; in particular, the first and second walls may be engaged with each other by means of heat pressing, high frequency welding or ultrasonic welding.

[0081] In detail, the at least one wall, optionally the first and second wall, of the inflatable element may be made of at least one of the following material: polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The thickness of the single plastic film may be between 0,05 mm and 0,4 mm, optionally 0,1 mm and 0,25 mm.

[0082] In the case of a multilayer sheet, this may comprise at least a first gas barrier layer coupled with a second layer configured to increase the sheet's mechanical properties.

[0083] The first gas barrier layer may comprise a plastic film, e.g., polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The first layer is coupled with the second layer, e.g., by means of glue. As mentioned above, the second layer substantially defines the structural element of the multilayer sheet configured to increase the mechanical properties of the sheet with respect to a sheet having the same thickness made solely of the material of the first layer. The second layer may be made of woven material, e.g., nylon or polyester.

[0084] In this way, the first layer of the multilayer sheet ensures gas impermeability, while the second layer ensures resistance during inflation. In the case of an inflatable element with a first and second wall, these are placed in contact with each other on the side of the first layer in such a way that said first and second walls may be welded together in a fluid-tight manner, e.g., by hot pressing, high-frequency welding or ultrasonic welding.

[0085] When engaged with each other, the first and second walls of multilayer material substantially define a bag wherein the first layer defines the inner surface while the second layer defines an outer surface of said bag.

[0086] The term impermeable refers to the ability of a body or material to prevent the passage of fluids. The wall, optionally the first and second wall, of the inflatable element is substantially impermeable to gas, i.e., it does not allow a gas (optionally air or nitrogen) to pass through the thickness of the sheet material.

[0087] The term breathable indicates the permeability of a body or material to a gas, e.g., air.

[0088] The term actuator refers to any device capable of causing a movement on a body, e.g., upon command from the control unit (reception by the actuator of a command sent by the control unit). The actuator may comprise a gas generator, such as a pressure vessel.

[0089] The protection device may comprises/use at least one control unit for controlling the operating conditions of the protection device. The control unit may be a single unit or consist of several separate control units, depending on the design choices and operational requirements.

[0090] By control unit is meant a component of electronic type, which may comprise at least one of: a digital processor (CPU), an analogue type circuit, or a combination of one or more digital processors with one or more analogue type circuits. The control unit may be configured or programmed to perform certain steps: this may be achieved in practice by any means that allows the control unit to be configured or programmed. For example, in the case of a control unit comprises one or more CPUs and one or more memories, one or more programs may be stored in appropriate memory banks attached to the CPU(s); the program(s) contain instructions which, when executed by the CPU(s), program or configure the control unit to perform the operations described in relation to the control unit. Alternatively, if the control unit is or comprises analogue type circuitry, then the circuitry of the control unit may be designed to include circuitry configured, in use, to process electrical signals to perform the steps related to the control unit.

[0091] At least part of the operation of the protection device described may be performed by a data processing unit, or control unit, technically substitutable for one or more computers designed to execute a portion of a software programme or firmware loaded onto a storage medium. Such a software programme may be written in any known programming language.

[0092] The data processing unit, or control unit, may be a general purpose processor configured to perform one or more of the steps of the operating process identified in this disclosure through the software or firmware programme, or be an ASIC or dedicated processor or FPGA, specifically programmed to perform at least part of the operations of the operating process.

[0093] The memory medium may be non-transitory and may be internal or external to the processor, or control unit, or data processing unit. The memory medium may also be physically divided into several portions.

DETAILED DESCRIPTION

Protection Device

[0094] Reference 1 indicates a wearable protection device configured to protect a user's body from impact, e.g., in the event of an accident. For example, the protection device 1 may be used in the sport field and may be inserted or engaged in technical clothing, such as jackets, gilet, tracksuits for the motorcycling and motorsport fields. In fact, as will be better described below, the protection device 1 of the present invention may be insertable/coupled to a garment or be an integral part of a garment; further, the protection device 1 may be used as a stand-alone protection, for example a knee pad, a back protector, a head, neck and chest protector of a user. As will be better described below, the protection device 1 is configured to inflate by means of pressurised gas to define a kind of bag configured to absorb shocks.

[0095] The protection device 1 comprises a case 3 made of sheet material, defining a compartment V, which, as will be further described below, is configured to house at least one inflatable element 2. The case 3 is made of a deformable material, e.g., it is at least partly made of at least one of the following materials: polyester, nylon, cotton. In fact, the case 3 is configured to be arranged in a stretched or taut configuration, depending on the stresses/strains applied to the material. Additionally, the case may be made at least in part, optionally entirely, of gas-permeable sheet material. In particular, the material itself or the case structure may be gas permeable. For example, in a non-limiting way, the sheet material from which the case 3 is made may be of a woven type which, due to its structure, may provide a certain breathability in itself; further, the sheet material from which the case 3 is made may have a perforated structure. In fact, gas permeability may be achieved due to the type of material used and/or the presence of openings through the thickness of the sheet that allow gas to pass through.

[0096] The case 3 with a perforated woven structure was illustrated in the accompanying figures. Such a configuration ensures the passage of air through the case 3 and thus a certain breathability.

[0097] As mentioned above, the case 3 is made of deformable sheet material. For example, the woven structure ensures a certain deformability of the sheet material capable of moving according to applied stresses. The thickness of the sheet material forming the case 3 may be between 0,05 mm and 2,5 mm, optionally between 0,1 mm and 1 mm.

[0098] The case 3 may comprise a first and second cover 4, 5 made of sheet material at least partially facing each other so as to delimitate, in interposition between said covers 4, 5, a compartment V which, as will be better described below, is configured to house at least one inflatable element 2. The first and second covers 4, 5 may have respective peripheral portions 3c fixed to each other, for example by means of sewing (FIG. 3), to substantially define one at least partially closed bag. The first and second covers may be fixed (e.g., sewn), in a non-limiting way, for substantially the entire extension of the peripheral portion 3c to define substantially a fully closed pouch (FIG. 3). The type of engagement between the first and second covers may depend on the type of material used for the case 3; for example, if a woven material is used, the first and second covers may be fixed by means of a seam. The possibility of joining covers 4, 5 by means of glue or a heat-sealing process is not excluded. In a different embodiment, the first and second covers 4, 5 faces each other but are spaced to substantially define an open type compartment V.

[0099] In fact, in a first embodiment, the case 3 consists only of the first and second covers 4, 5 which may be joined at peripheral portions 3c or, as mentioned above, may be two entirely unattached layers.

[0100] FIGS. 7 and 8 show a different embodiment of the case 3 which further includes, in a non-limiting way, a plurality of auxiliary covers 30 arranged in the compartment V in interposition between the first and second covers 4, 5; each auxiliary cover 30 defines within it a sub-chamber C, in which the inflatable element 2 is housed, in particular at least one segment of the inflatable element (a component better described below). Each auxiliary cover 30 comprises at least one wall made of sheet material, which may be made of the same material as the first and second covers 4, 5. Each auxiliary cover 30 may be directly fixed to at least one of: the inflatable element (optionally directly to the segment of the inflatable element housed in the respective auxiliary cover 30), the first cover 4, the second cover 5.

[0101] In further detail, each auxiliary cover 30 comprises one or more peripheral engagement portions fixed to, or in proximity to, at least one of said first and second covers 4, 5. In still greater detail, each auxiliary cover 30 is fixed at its peripheral engagement portion to: the inflatable element 2 (optionally directly to the segment of the inflatable element 2 housed in the respective auxiliary cover 30), to the first cover 4, to the second cover 5. In fact, each auxiliary cover 30 comprises at least two peripheral engagement portions opposite each other with respect to the internal volume defined by the sub-chamber C of the respective auxiliary cover 30; each auxiliary cover is therefore fixed at opposing peripheral engagement portions of the inflatable element and/or to the first and second cover 4, 5.

[0102] The peripheral engagement portion of an auxiliary cover 30 may be defined by a protruding band in sheet material; depending on the material used, this portion may be sewn, glued or heat-sealed to at least one of: the first cover, the second cover, the inflatable element.

[0103] FIGS. 7 and 8 show a case 3 having, in a non-limiting way, two auxiliary covers 30 fixed to both the first cover 4 and the second cover 5. The at least one wall of each auxiliary cover 30 comprises a first wall 30a and a second wall 30b in sheet material facing each other and movable with respect to each other due to the deformable structure thereof. The first and second walls of each auxiliary cover 30 delimits a respective sub-chamber C configured to house one or more segments of the inflatable element.

[0104] Each auxiliary cover 30 extends longitudinally along an extension trajectory to define a length of said auxiliary cover. The length may be between 50 and 350 mm, optionally between 100 and 300 mm, and be defined substantially according to the structure and size of the inflatable element 2. For example, each auxiliary cover 30 may cover only a portion of the length of a segment or wrap around the segment entirely. Further, each of said first and second walls 30a, 30b of an auxiliary cover extends, orthogonally to the extension trajectory, between a first and second longitudinal portions (see references 30a, 30a, 30b, 30b in FIGS. 7 and 8) opposite to each other to substantially define a wall height. A non-limiting configuration of the case 3 is shown in the attached figures where the first longitudinal portions 30a, 30b of the first and second walls 30a, 30b are both fixed, optionally sewn, to a same portion of the first cover 4 while the second longitudinal portions 30a, 30b of the first and second walls 30a, 30b are both fixed, optionally sewn, to a same portion of the second cover 5.

[0105] As mentioned above, the protection device 1 further comprises at least one inflatable element 2 comprising a plurality of side-by-side segments each extending along a respective extension trajectory. As mentioned above, the inflatable element 2 is housed in the compartment V of the case, in particular interposed between the first and second covers 4, 5. The inflatable element 2 is made of deformable sheet material, for example it is at least partly made of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber. In fact, the inflatable element 2 is configured to arrange itself in a stretched or taut configuration depending on the stresses/strains applied to the material. Further, the inflatable element 2 has a gas-tight structure such that the same element may switch from a deflated condition (relaxed condition of the inflatable element) to an inflated condition where the sheet material of the inflatable element is substantially stretched (in tension).

[0106] The sheet material of the inflatable element 2 may be, for example, a monolayer plastic film, which is gas-tight and deformable. In the case of monolayer plastic film, this may define an elastically deformable inflatable element structure. Alternatively, the sheet material of the inflatable element 2 may be a multi-layered material; for example, the sheet material defining the inflatable element may comprises: a first layer in plastic film, and a second woven layer coupled with the first layer, optionally fixed by glue or heat-sealing.

[0107] The first layer may be of a gas impermeable layer and define a gas barrier layer such that the inflatable element 2 can be inflated; for example, the first layer may comprise a plastic film, e.g., polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The second layer may substantially define the structural element of the multilayer sheet, e.g., configured to prevent the inflatable element from bursting during its transition from a deflated to an inflated (operational) condition; for example, the second layer may be made of woven material, e.g., nylon or polyester. In the case of multilayer sheet material, this may be deformable but substantially non-elastically deformable.

[0108] Each segment may have an elongated conformation, optionally extending along the extension trajectory T (see FIG. 6). Two immediately side-by-side segments may present substantially the same length, which is measured along their respective extension trajectories. For example, each segment may have a length measured along the extension trajectory of greater than 50 mm, optionally between 100 and 350 mm. Further, the at least one wall of each segment, according to a section along a plane orthogonal to the extension trajectory of the respective segment and at the peripheral engagement portion, substantially defines a closed perimeter edge having a predetermined length (or extension), which may be between 45 mm and 345 mm, optionally between 70 mm and 300 mm. In fact, the length of a segment measured along the extension trajectory is greater than the length of the closed perimeter edge of the same segment; in particular, the ratio between the length of a segment, measured along the extension trajectory, and the length of the closed perimeter edge of the same segment may be greater than 1,1, optionally between 1,2 and 1,6.

[0109] As described above, the inflatable element 2 and thus each segment is of a deformable type and may deform elastically. In a non-limiting way, the ratio between the length of the perimeter edge of each segment, in the inflated condition of the inflatable element 2, and the length of the same perimeter edge in the deflated condition of the inflatable element 2 is equal to or greater than 1, optionally being between 1 and 1,4 including extremes. In particular, it is possible to obtain an elastic deformation of the inflatable element by means of the engagement of a monolayer sheet material made of plastic film, for example polyurethane, while it is possible to obtain a change of shape of the inflatable element without, a plastic or elastic deformations by means of the engagement of a multilayer sheet material (reinforced sheet), for example made of nylon and polyurethane.

[0110] As mentioned above, the inflatable element 2 comprises a plurality of segments. Each segment comprises at least one wall in sheet material delimiting an internal volume and having a first and second portion facing each other; the inflatable element 2 is configurable between: a deflated condition (see, for example, FIGS. 7, 9 and 11) where the first and second portions of at least one wall of each segment, for a preponderant part of their surface extension, are close together and at least partially in contact with each other, and an inflated condition (see, for example, FIGS. 8, 10 and 12) where the first and second portions of at least one wall of each segment, for a predominant part of its surface extension, are spaced apart.

[0111] Each segment, in the inflated condition, defines an internal volume greater than the internal volume defined by the same segment when placed in the deflated condition. Further, in the inflated condition, the segments present substantially parallel extension trajectories. In each case, the first and second covers 4, 5 of the case 3, in the inflated condition and in the deflated condition, are maintained at a distance, for a preponderant portion of the surface extension of said covers (e.g., at least 70%, optionally at least 80%, of the surface extent of said covers 4, 5) by interposition of the plurality of segments.

[0112] FIGS. 7 and 11 show the portions of the at least one wall that are substantially separated in the inflated condition. These portions have been presented separately from each other for the sake of simplicity and to allow a better identification of the same in the attached figures; however, these walls are, in the deflated condition in contact with each other, also at a central area of these portions.

[0113] At least one of said segments, optionally all segments, further comprises one or more peripheral engagement portions 2c fixed to, or in proximity to, at least one of said first and second covers 4, 5, e.g., by one or more seams.

[0114] In detail, the at least one wall of each segment comprises a first wall 2a and a second wall 2b in sheet material: the first wall 2a has a central area, which defines said first portion of the at least one wall whereas the second wall 2b has a respective central area, which defines said second portion of the at least one wall. The first and second walls 2a, 2b of each segment are engaged with each other at a peripheral edge 2c to define a single peripheral engagement portion. The peripheral engagement portion substantially defines a fluid-tight band of union between the walls 2a, 2b which are also engaged to the case 3. Depending on the sheet material of the walls, these may be joined together to define the peripheral edge 2c by at least one of: glue, weld, seam. In an embodiment, the first and second walls 2a, 2b of the inflatable element 2 are fixed to each other by at least one of the following processes: hot pressing, high frequency welding, ultrasonic welding.

[0115] As shown in FIG. 3, each of said segments of the inflatable element 2 is fixed to the first and/or second covers 4, 5 at a distance from the joined peripheral portions 3c of said first and second covers 4, 5: in fact, each of said segments of the inflatable element 2 is sewn to the first and second covers 4, 5 at a distance from the seams joining the first and second covers 4, 5.

[0116] In detail, the peripheral edge 2c of each segment substantially has a first and a second tract 2c, 2c opposite to each other with respect to the internal volume defined by the segment itself and joined at the end portions by at least one connection tract 2c (see, for example, FIG. 11). The first and second tracts 2c, 2c of the peripheral edge extend substantially along the extension trajectory of the respective segment whereas the connecting edge 2c substantially defines a section extending transversely to the extension trajectory T of the respective segment. Each segment may define a distinct component and thus a kind of single fluid-tight bag closed at opposite longitudinal end portions; in such a configuration, each segment comprises the first and second tracts 2c, 2 joined at two end portions by two respective connection tracts 2c. FIG. 3, on the other hand, illustrates an inflatable element 2 having a plurality of segments which protrude transversally (optionally orthogonally) from a connection section 20 of the inflatable element 2; the plurality of segments emerges from the same side of the connection section 20 and are placed in fluid communication with each other by said connection section 20. Also in such a configuration, each segment substantially has the first and second segments 2c, 2c joined at a longitudinal end opposite to the connection section 20 by means of a single connecting segment 2c of the peripheral edge 2c.

[0117] The connection section 20 is part of the inflatable element 2 and is also housed in the compartment V of the case 3: the connection section may be also fixed to at least one of said first and second covers 4, 5. The connection section 20 may be a single tubular element joined to a plurality of segments, or it may have substantially the same double-wall structure as the segments, and thus move from an inflated to a deflated condition.

[0118] At least one of the first and second tracts 2c, 2c of the peripheral edge 2c of each segment may be fixed to at least one of the first and second covers 4, 5. In more detail, in a non-limiting way, at least a part of the first tract 2c of a segment is fixed to the first cover 4, whereas at least a part of the second tract 2c of the same segment is fixed to the second cover 5; in this way, each segment is substantially fixed, e.g., sewn, to the case 3 at two opposing tracts with respect to the internal volume defined by the same segment. In greater detail, each segment may be fixed: to the first cover 4 at the first tract 2c for at least 50%, optionally 70%, of a total longitudinal extension of said first tract 2c, substantially defined along the extension trajectory of the respective segment, and to the second cover 5 at the second tract 2c of the peripheral edge for at least 50%, optionally 70%, of a total longitudinal extension of said second tract, substantially defined along the extension trajectory of the respective segment.

[0119] The peripheral edge 2c of each segment fixed, optionally sewn, to case 3 may define a single continuous tractor define two or more discrete portions.

[0120] In dimensional terms, two first tracts 2c of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element 2, in the inflated condition of said segments, are placed at a predetermined distance D1, which may be equal to or greater than 25 mm, optionally between 30 mm and 80 mm; similarly, two second tracts 2c of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element 2, in the inflated condition of said segments, are placed at a predetermined distance D2 (see FIGS. 8 and 12), which may be equal to or greater than 25 mm, optionally between 30 mm and 80 mm. In fact, the predetermined distance D1 between two first tracts 2c may be substantially equal to the predetermined distance D2 between two second tracts 2c.

[0121] Further, the first and second tracts 2c, 2c of the peripheral edge 2c of a segment are placed, in the inflated condition of the inflatable element 2, at a minimum distance Dm, which may be equal to or greater than 25 mm, optionally between 30 mm and 120 mm, even more optionally between 40 mm and 80 mm. In detail, the ratio between the minimum distance Dm of a segment and the distance D1 between the first tract 2c of the same segment and a tract 2c of an immediately adjacent segment is equal to or greater than 1, optionally it is between 1 and 1,5. Similarly, the ratio of the minimum distance Dm between the first and second tracts of the peripheral edge of a segment and the distance D2 between the second tract 2c of the peripheral edge of the same segment and a second tract of an immediately adjacent segment is equal to or greater than 1, optionally it is between 1 and 1,5.

[0122] The distances D1, D2 and Dm may be defined based on the size, in terms of perimeter edge, of the segments of the inflatable element 2. In fact, as mentioned above, each segment has a perimeter edge having a predetermined length; the ratio between the minimum distance Dm between the first and second tracts 2c and 2c of a segment and the length of the perimeter edge of the same segment is equal to or less than 1, optionally it is between 0,75 and 0,95. The length of the perimeter edge of a segment may further be related to the distances D1 and D2. In fact, the ratio between the distance D1 (between the first tract 2c of a first segment and a first tract 2c of a second immediately adjacent segment) and the length of the perimeter edge of the first segment is equal to or less than 0,9, optionally between 0,45 and 0,75. Similarly, the ratio of the distance D2 (between the second tract 2c of a first segment and a second tract 2c of a second immediately adjacent segment) and the length of the perimeter edge of the first segment is equal to or less than 0,9, optionally between 0,45 and 0,75.

[0123] Similar relations may be defined between the peripheral engagement portions of the walls 30a, 30b of each auxiliary cover 30 which, as schematically shown in the accompanying figures, is substantially countershaped to the segment of the inflatable element 2 housed in the respective auxiliary cover 30. As mentioned above, each auxiliary cover 30 is configured to contain the expansion of a segment, for example to prevent it from bursting, during the transition of the inflatable element from the deflated condition to the inflated condition. Therefore, in the inflated condition the auxiliary cover 30 when fixed to the peripheral edge 2c of a segment defines, in the inflated condition, a kind of cover adhered to the wall of the segment; therefore, said auxiliary cover 30, when joined to the peripheral edge 2c of a segment substantially shares the same dimensions and ratios between the various distances D1, D2 and Dm.

[0124] As described above, the case 3 has the first and second covers 4, 5 to which the segments of the inflatable element are fixed. This configuration allows the first and second covers 4, 5 to substantially act as a cover for the segments of the inflatable element 2 but also defines a constrained shape configured to guide the correct inflation of the protection device 1 during the transition of the inflatable element between the deflated and inflated condition. Additionally, the presence of the case 3 allows an optimised overall shape of the protection device 1 to be defined, a condition that maximises its effectiveness.

[0125] For example, the first and second covers 4, 5 of the case 3, in the deflated condition of the inflatable element 2 and in the area where said segments are fixed to the case 3, are spaced apart from each other up to a maximum distance DM; the first and second covers 4, 5, in the inflated condition of the inflatable element 2 and always in the area where said segments are fixed to the case 3, are instead arranged at an operating distance Dp, which is less than said maximum distance DM. In detail, the ratio between the maximum distance DM and the operating distance Dp between the first and second covers 4, 5 is equal to or greater than 1, optionally between 1,1, and 1,8.

[0126] As shown in FIGS. 8 and 12, the configuration of the case 3 and the inflatable element 2 defines, in the inflated condition of inflatable element 2, one or more empty zones. In fact, the inflatable element 2, in the inflated condition, is configured to occupy a prefixed volume which is lower than the internal volume of the compartment V definable by the case 3; for example, the ratio between the internal volume of the compartment V and the prefixed volume defined by the inflatable element 2, in the inflated condition, may be equal to greater than 1,1, optionally between 1,2 and 1,5.

[0127] In detail, the structure of the inflatable element 2 and the attachment structure between said inflatable element 2 and the case 3 allows defining between two immediately adjacent segments of the inflatable element 2, in cooperation with at least one of the first cover 4 and the second cover 5, in the inflated condition and according to a section orthogonal to the extension trajectory of at least one of said segments, at least one empty zone. The empty zone may be present for a preponderant part (optionally at least 80%, even more optionally 90%) of the overall longitudinal extension of said segments. In greater detail, such empty zone is present at least in the portions wherein the segments are fixed to the case 3.

[0128] In greater detail still, the empty zone has a predefined area; the ratio between said area and the area of one of the segments delimiting said empty zonein the inflated condition, in section along a plane orthogonal to the extension trajectory of the respective segment at a longitudinal centreline of said segment-is between 0,05 and 0,3, optionally between 0,06 and 0,1. As visible, for example, in FIGS. 8 and 12, the at least one empty zone comprises: a first empty zone E1 delimited between two immediately adjacent segments of the inflatable element 2 and the first cover 4, a second empty zone E2 delimited between two immediately adjacent segments of the inflatable element 2 and the second cover 5.

[0129] Each of said first and second empty zones E1, E2 has, in cross-section along a plane orthogonal to the extension trajectory of a segment delimiting said empty zone, a substantially triangular outline. These zones are opposite to each other and define a sort of bridge between two segments, a condition which allows the first and second covers 4, 5 to stretch and thus define an auxiliary zone of protection for the user.

[0130] Further, such a structure allows the first and second covers 4, 5 at least between two peripheral edges 2c of two immediately adjacent segments to define a substantially flat surface. This condition maximizes the width extension of the protection device to provide maximum protection to the user.

[0131] As mentioned above, the inflatable element 2 comprises a plurality of segments. In particular, the inflatable element 2 may comprise a number of segments equal to or greater than 2, optionally between 2 and 20 including extremes. The segments of said plurality of segments may all be placed side-by-side to substantially define a single group of segments. Alternatively, as shown in FIGS. 3 to 5, the inflatable element 2 may comprise: at least a first series of segments comprises two or more segments placed side-by-side, or at least a second series of segments comprises two or more segments placed side-by-side.

[0132] FIGS. 4 and 5 show an inflatable element 2 presenting two series of segments. A first series used to define a protection device for a user's chest and a second series used to protect the user's back. The two series are placed in fluid communication with each other by means of a sort of manifold 40. The manifold may, for example, be placed in direct fluid communication with the connection sections 20 of the two series. FIG. 3, on the other hand, illustrates, in a non-limiting way, a protection device with three series of segments. Also in such a configuration, two manifolds are configured to place the connection sections of the various series in fluid communication.

[0133] The segments of each series, in the inflated condition, have substantially parallel extension trajectories T; as can be seen, the segments of the different series, at least in the inflated condition, are spaced apart.

[0134] The protection device 1 may further comprise at least one actuator 15 configured to be placed in fluid communication with the inflatable element 2 to allow it to switch from the deflated to the inflated condition. The actuator 15 may comprise a pressure vessel. The protection device 1 may further comprise: an activator including, for example, a pyrotechnic charge and/or a perforator configured to activate the actuator 15 to allow the inflatable element to switch from the deflated to the inflated condition, and a control unit connected to and active on the activator, wherein the control unit is configured to send a command signal to the activator for activation (e.g., opening) of the actuator 15.

[0135] The protection device 1 may additionally comprise at least one sensor configured to emit a signal representative of a user condition.

[0136] The control unit is configured to: receive the signal from the sensor, compare the received signal with at least one threshold value of a control parameter, determine, based on the comparison, the presence of an accident condition for the user, and if the accident condition is determined, send the command signal to the activator to determine the inflated condition of the inflatable element 2.

[0137] At least one sensor may comprise at least one of: a gyroscope, an accelerometer, a GPS.

Making Process

[0138] It is also an object of the present invention a process of making a protection device 1 according to the attached claims. The process comprises a step of arranging the inflatable element 2 having said one or more peripheral engagement portions, arranged in the deflated condition. The step of arranging the inflatable element 2 comprises the sub-phases of: preparing a first sheet, overlapping a second sheet on the first sheet, and fluid-tight joining the first and second sheets at a peripheral area to define said inflatable element 2.

[0139] The first and second sheets may in a single piece to define a single semi-finished product or they may be two separate elements. The first and second sheets have substantially the same shape and size so that when overlapped the perimeter edge of the first sheet substantially coincides with the perimeter edge of the second sheet. The first and second sheets have a gas impermeable structure; for example, the first and second sheets are made at least in part of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene. Instead, the step of joining the first and second sheet may comprise at least one of the following processes: gluing, seam, welding; in particular, the welding sub-step may comprise at least one of the following processes: hot pressing, high frequency welding, ultrasonic welding. The joining of the first and second sheets defines the entire inflatable element 2, comprising at least the plurality of segments each comprising the first and second walls 2a, 2b joined together at the peripheral edge 2c. Depending on the shape of the first and second sheets, following the overlapping and joining steps, said first and second sheets may further define one or more connection sections 20.

[0140] The process further comprises a step of fixing the inflatable element 2 to the case 3. The step of fixing the inflatable element to the case 3 comprises the following sub-steps: spreading a semi-finished product in sheet material on a single plane, and fixing and wrapping said semi-finished product to the inflatable element 2 in such a way that said semi-finished product may define the case 3.

[0141] The phase of fixing the semi-finished product may be carried out following the formation of the inflatable element 2 or at the same time as this phase. For example, in a first embodiment, the process may comprise forming the inflatable element and then overlapping the semi-finished product; following the overlapping step, the process may comprise the step of fixing said semi-finished product to the peripheral edge 2c of the inflatable element, for example by means of a seam.

[0142] Alternatively, the semi-finished product may be joined, e.g., by seam, during the formation phase of the inflatable element 2, to at least one of said first and second sheets. In this way, case 3 and inflatable element 2 are formed simultaneously.

[0143] The semi-finished product may comprise at least one sheet of gas-permeable material, e.g., a mono-layer sheet. In further detail, the semi-finished product may be made at least in part, optionally entirely, of optionally perforated woven material. In still further detail, the semi-finished product may be made at least in part, optionally entirely, from at least one of the following materials: polyester, nylon, cotton.

Use of the Protection Device

[0144] It is also an object of the present invention to use protection device 1 to protect parts of a user's body. The protection device 1 may be directly used as a garment, e.g., as an integral part of a suit (see, for example, FIGS. 1 and FIG. 2), a jacket or a gilet (FIGS. 4 and FIG. 5), or it may be an integral part of an accessory for the protection of a user's body (optionally at least one of: a back protector, a chest protector, a shoulder protector, a neck protector, a head protector, a pelvis protector, a leg protector).

[0145] Alternatively, the protection device 1 may be of the type that can be coupled (fixed or detachable) to a garment or a protection device for a user.

Advantages

[0146] The present invention has important advantages over the state of the art. In fact, the attachment (e.g., the seams) of the segments to the first and/or cover 4, 5 of the case 3 allows the inflatable element to be attached and to be kept in the correct position in the compartment V of the case 3, for example during the use of the protection device 1 as an integral part or accessory of a garment 100; in this way, the protection of the user is ensured and problems of breakage of the inflatable element 2 due to incorrect positioning are avoided.

[0147] Additionally, the fixed (e.g., sewn) structure of the inflatable element 2 and the case 3 greatly simplifies the manufacturing process of the same. For example, the protection device 1 of the present invention eliminates the complex and delicate operation of inserting the inflatable element into the already formed case 3. For example, the fact of providing segments of the inflatable element sewn to the case 3 facilitates the positioning of the inflatable element 2 itself, solving possible positioning problems.

[0148] Additionally, the way the inflatable element is engaged to the case allows, in the deflated condition of the inflatable element, improves air passage, thus ensuring the provision of highly breathable clothing.

[0149] Furthermore, the way the inflatable element is engaged to the case 3 makes it possible, in the inflated condition, to obtain a protection device presenting extensive planar surfaces that allow for the adequate protection of a user's body, a condition to which is added the additional protection guaranteed by the empty zones between two immediately consecutive segments and the case 3, which allow the case and the segments to deform sufficiently to absorb shocks adequately and thus effectively protect a user's body.

[0150] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both, unless the disclosure states otherwise. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.