CN103153602A - 可挠曲缓冲垫、包含这种垫的物品及其制造和使用方法 - Google Patents
可挠曲缓冲垫、包含这种垫的物品及其制造和使用方法 Download PDFInfo
- Publication number
- CN103153602A CN103153602A CN2011800483143A CN201180048314A CN103153602A CN 103153602 A CN103153602 A CN 103153602A CN 2011800483143 A CN2011800483143 A CN 2011800483143A CN 201180048314 A CN201180048314 A CN 201180048314A CN 103153602 A CN103153602 A CN 103153602A
- Authority
- CN
- China
- Prior art keywords
- pad
- thickness
- cushion pad
- passage
- lower floor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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Abstract
本文公开了一种舒适的保护垫,其可整合到诸如衣服和保护壳的物件中。在一个实施例中,示例性缓冲垫包括第一通道,第一通道包括厚度和宽度。第一通道包括连续上层和连续下层,连续上层至少部分地粘结到连续下层。缓冲区域与第一通道相邻设置,且厚度大于第一通道的厚度。缓冲区域还包括设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料。可在缓冲区域的上表面中限定沟槽,沟槽的厚度小于缓冲区域的厚度并大于第一通道的厚度。
Description
技术领域
本发明涉及舒适的保护垫、包括这种垫的物件以及制造和使用垫和物件的方法,并且本发明具体涉及用于人的需要自由移动范围的区域的舒适的保护垫。
相关案件
在此要求2010年8月11日提交的共同拥有的且共同待审查的临时申请第61/401,373号和2010年9月12日提交的临时申请第61/382,022号的优先权,两申请全文援引于此以供参考。
背景技术
许多活动、尤其是体育活动存在身体受到撞击的潜在风险。肘、膝、肩、踝、髋和其它关节会特别容易受到撞击损伤,不限制个人的运动和移动范围地对肘、膝、肩、踝、髋和其它关节进行保护仍然是有挑战性的。撞击保护件可能厚重、不透气或是限制性的,或者无法精确或一致地针对特定身体部位。
一些撞击保护系统由厚重且限制运动的分离刚性垫组成。刚性部件可衬有某种形式的软衬垫,从而使它们对于身体来说是舒适的,这试图缓冲对身体的撞击,但额外的层增加垫的重量和不舒适度。此外,衬垫系统穿起来会热,并还抑制湿气和汗水的蒸发。
其它防护垫由更软材料制成,所以它们弯曲,但几乎不提供对严重撞击的保护,尤其是对来自岩石或其它坚硬物体的撞击的保护。这些材料包括标准的化学发泡聚醚或聚酯泡沫。
其它衬垫可由更硬的泡沫材料制成,诸如交联聚乙烯泡沫或EVA泡沫。这些泡沫提供更多一点的保护,但限制使用者的运动范围。总的来说,这些材料提供不充分的保护,同时限制运动。
还已尝试将更硬的泡沫用作垫,但泡沫必须切成条以减少固体泡沫件会造成的运动限制。遗憾的是,对于穿着者来说,条提供欠佳的保护。
泡沫也可热成型成弯曲或复杂形状,并且被缝制在将条或部件保持在位的材料层之间。在衬垫中也使用过提供更好撞击吸收的其它材料诸如d30,但这些材料也是坚硬的。
已经尝试通过在每个部件中形成允许更好挠曲的较薄区域而使前述材料对穿着者呈现更低的硬度。但这样制造的保护垫不能在衬垫位置提供全范围运动,因为当较薄区域挠曲时材料断开。这些材料还需要被压埋在织物层下,因为它们不耐用或不足以美观到露出。覆盖材料的使用为衬垫增加不必要的重量,并增加垫的成本。
存在对保护衬垫进行改进的需要,尤其是对于要求运动范围的区域和关节区域。
发明内容
在一个实施例中,本公开涉及一种缓冲垫,该缓冲垫包括第一通道,该第一通道包括厚度和宽度。第一通道包括连续上层和连续下层,该连续上层至少部分地粘结到连续下层。缓冲区域与第一通道相邻设置,且具有大于第一通道的厚度的厚度。缓冲区域还包括设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料。沟槽可被限定在缓冲区域的上表面中,沟槽的厚度小于缓冲区域的厚度并大于第一通道的厚度。
在一些实施例中,缓冲垫包括与缓冲区域间隔开通道宽度的周界凸缘,该周界凸缘具有大于第一通道的厚度并小于缓冲区域的厚度的厚度。周界凸缘包括设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料。
在一些实施例中,连续上层通过设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料的多个部分在周界通道中至少部分地粘结到连续下层。
在一些实施例中,周界通道包括设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料连续层。
在另一实施例中,本发明涉及一种缓冲垫,该缓冲垫包括周界通道,该周界通道包括厚度和宽度。周界通道包括连续上层和连续下层。连续上层至少部分地粘结到连续下层。连续垫包括与周界通道相邻的缓冲区域,该缓冲区域具有大于周界通道的厚度的厚度。缓冲区域还包括设置在连续上层与连续下层之间并粘结到连续上层和连续下层的缓冲材料。周界凸缘与缓冲区域间隔开周界通道的宽度,且具有大约等于内层和外层的组合厚度的厚度。
在缓冲垫的任何实施例中,连续上层和连续下层可包括聚酯热塑性聚氨酯。
在缓冲垫的任何实施例中,连续上层和连续下层可包括粘结到氨纶织物层的TPE膜,使得TPE层与缓冲材料相邻设置。
在缓冲垫的任何实施例中,缓冲垫可包括微孔材料,该微孔材料包括具有最小孔直径的多个孔,且内层与外层之间的缓冲材料的厚度小于最小孔直径。
附图说明
从以下本公开的示例性实施例的更详细说明书中,前述和其它特征和优点会显而易见,如附图所示在附图中相同的附图标记指不同图中的相同部件。这些图不一定按比例绘制,而重点放在示出本发明的原理上。
图1A是根据本公开的一个示例性缓冲垫的俯视图,具有各种缓冲区域;
图1B是图1A所示缓冲垫的俯视图;
图1C是图1A所示缓冲垫的俯视图;
图1D是图1A所示缓冲垫的俯视图;
图1E是图1A所示缓冲垫的俯视图;
图2是穿过线2-2的图1A的缓冲垫的示意性侧视图;
图3是穿过线3-3的图1A的缓冲垫的示意性侧视图;
图4是根据本公开的另一示例性缓冲垫的俯视图;
图5是穿过线5-5的图4的缓冲垫的示意性侧视图;
图6是穿过线6-6的图4的缓冲垫的示意性侧视图;
图7是根据本公开的另一示例性缓冲垫的俯视图;
图8是图7的缓冲垫的透视图;
图9是穿过线8-8的图7的缓冲垫的示意性侧视图;
图10是根据本发明的另一示例性缓冲垫的俯视图;
图11是图10的缓冲垫的透视图;
图12示出穿着紧身袖子的使用者的部分视图,其中整合了图7的缓冲垫,并示出肘部活动时缓冲垫对肘部的适应性;以及
图13是整合了图7的缓冲垫的紧身T恤的正视图。
具体实施方式
本发明涉及改进的舒适缓冲垫、包括该垫的物件以及制造和使用该垫的方法。
这些垫包括各种形状、尺寸、构造和厚度的缓冲区域。为了方便讨论,术语“缓冲区域”和“章部(medallion)”在整个说明书中互换使用。可对章部使用各种材料,如下文所述。章部通过具有各种深度和构造的通道间隔开,通道限定章部的周界。章部的上表面可包括各种深度和构造的沟槽,沟槽部分地限定章部的轮廓。在一些情况下,设置与垫的周界间隔开的周界凸缘。
章部、通道、沟槽和凸缘以及形成垫的材料的组合共同为垫提供各种功能特性。例如,通道比沟槽深,并构造成在诸如关节周围的关键区域提供不受限制的自由运动范围。各沟槽比铰接部浅,并提供挠性,同时保持一些缓冲和/或防撞性。但是,应当理解,通道和沟槽都用作“铰接部”,为垫提供多级铰接。
本缓冲垫可被包含在衣服中,并可被设计成具有特定的功能特性。这些衣服是独特的,其能够为身体的挠曲区域尤其是关节提供运动保护。衬垫能够以独特方式包含在服装中,使得服装材料紧贴但拉伸并符合人体或特定关节形状,形成一体式衬垫系统,该系统比其它产品更好地保护穿着者免受撞击,因为垫在全范围运动期间与穿着者持续和直接接触。包含本垫的服装在穿着时提供免受伤害的改进保护,因为垫的基部或垫的基部所附连的材料在包含到拉伸且紧贴的衣服、诸如紧身衣服中时可在使用期间保持与使用者身体的直接接触。垫的挠性允许垫符合使用者的身体形状,以便垫可保持与使用者的身体接触。即,没有本垫的柔度,垫就不能符合使用者在运动时变化的身体轮廓。为了便于讨论,本文使用的术语“可挠曲”意思是垫通过弯曲、扭曲、挠曲和/或拉伸等移动的能力。
通过将章部、铰接部、沟槽和/或周界凸缘的特定形状、尺寸、构造、轮廓和定向与特定垫和衣服材料组合,服装可被设计成使使用者的自由运动范围最大,同时保护身体的特定目标区域,尤其是关节。这些服装美观、更耐用、成本更低、更舒适并提供显著的运动范围和对身体针对性、精确的保护。
类似地,本缓冲垫可被包含到诸如保护壳的其它物件中。例如,衬垫可包含在与诸如膝上型计算机或媒体装置的电子装置的形状和尺寸对应的套管或壳中,使得它们紧贴但还拉伸并符合壳的外部。包括本垫的壳可提供轻质、可挠曲且防撞保护。
本垫和包括这种垫的构造提供坚固、耐用且能够承受在工业和/或商业洗涤中使用的温度、清洁剂和机械作用的物件,而不像其它带衬垫衣服在这种苛刻条件下会降解。
图1A-图1E和图2-图3一起示出根据本公开的一个示例性缓冲垫100。垫100具有如上所述适于肘关节轮廓的形状、尺寸和构造,且应当理解,该垫可包括实际的或特定设计或应用需要的任何形状、尺寸或构造。如图所示,垫100包括前表面10、后表面12和周界14。如图2和图3的剖视图所示,垫100包括设置在选配外层16和内层17之间的缓冲层15。
选配外层16可包括:能够提供足够弹性以当对其施力时防止撕扯和/或拉伸;具有足够结构整体性以形成预定形状;且能够承受所期望使用的环境(例如诸如扭曲、弯曲、挠曲、拉伸等的重复变形)而不显著降解的任何材料。外层16还可选择成便于层15的处理,在一些情况下外层16可包括粘结特性。因此,外层16可选择成在模制后提供相对非粘性表面和光滑表面供人触摸。
外层16可包括任何厚度,且该厚度可根据应用而变化。用于特定应用的所需厚度可由本领域的普通技术人员通过常规实验确定。外层16的厚度范围可从约0.2毫英寸(此后称为“mil”)至约60mil、更尤其从约0.5mil至约30mil且还更尤其从约1.0mil至约15mil。
在产品手感重要的情况下,发现理想的是使外层的厚度最小。因此,在该产品中,理想的会是使用尽可能最薄的外层而不有损耐用性。例如,对于相对薄的外层16的理想应用,外层16的厚度范围可从约0.2mil至约6mil、更尤其从约0.5mil至约3mil且还更尤其从约0.6mil至约2mil。
在一些情况下,理想的会是使用较厚的外层16,其与较薄外层相比可提供增强的耐用性。例如,当本材料用在振动阻尼应用中时,理想的会是外层16的厚度为约50至约60mil。替代地,当缓冲层有粘性时,较厚层会是理想的,因为如果外层16被刺穿,粘性材料会露出,使得产品难以处理。
当使用热成型工艺形成本产品时,理想的会是使用具有厚度高达1/8英寸的外层,且在需要或必要时的一些情况下甚至更厚。已经发现,能够通过在热成型工艺期间施加热量和/或真空而对具有高达6mil或更大厚度的外层保持非常软的柔韧性。
在模制工艺期间,外层16可作为材料片被施加。以片的形式,且尤其当外层相对薄时,材料会非常柔韧并可在处理期间非常容易皱起和/或折叠。因此,外层16还可包括辅助处理材料的支承层(未示出)。或者,通过使用本领域技术人员已知的各种技术外层还可在模制工艺期间或之后作为材料涂层被施加。
用于外层16的适当材料包括塑料、诸如橡胶的弹性材料、热塑弹性体(“TPE”)和/或类似物以及包括前述材料中的至少一种的组合。可用于外层的塑料的实例包括但不限于:乙烯-醋酸乙烯酯(“EVA”)、尼龙、聚酯、聚乙烯、聚烯烃、聚氨酯、聚氯乙烯(“PVC”)、聚苯乙烯、聚四氟乙烯(“PTFE”)、胶乳橡胶、硅树脂、乙烯基及其组合。
用于外层16的其它可能材料包括各种其它合成和/或非合成材料,包括但不限于纸、织物、金属、金属化塑料、塑料膜、金属箔和/或类似物,以及包括前述材料中至少一种的复合材料和/或组合。其它耐用材料也可用于外层,包括编织织物、机织织物和无纺织物、皮革、乙烯基或任何其它合适的材料。使用织物层作为外层16会是有利的,因为其可捕获和分散否则可能形成在层中或层之间的气泡,从而形成最终模制产品的更好的外观。
理想的会是对外层使用稍有弹性的材料;因此诸如氨纶织物的弹性织物会是理想的。使用弹性织物作为外层会是理想的,因为其可改进铰接部和沟槽的挠曲,并使外层形成波状形状。在一些情况下,具有更有限拉伸的加热或其它成型或预拉伸材料可改进模制工艺。
当外层16包括织物层时,织物可以是编织织物、机织织物、无纺织物、合成物、非合成物和包括前述中至少一种的组合,且织物层可层叠成例如TPE膜。当垫的应用需要拉伸时,则使用具有伸长性的外层可能是理想的,且当外层是层压件时,可能使层压件中的每层伸长是理想的。
如上所述,理想的会是对外层使用稍微有弹性的材料,诸如上述TPE材料。这种TPE材料还之所以理想是因为它们可用作相对低厚度的膜。可使用任何膜厚度,只要其与模制方法兼容且适于预期应用即可,但约1mil与约10mil之间的膜厚度是理想的。较厚的膜更耐用,但较薄的膜成本较低,并可提供更软的感觉。诸如当热成型更深的形状时存在选择更厚的膜的其它原因,如本文下文所述。尽管在这些应用中可使用比1mil薄或比10mil厚的膜,但使用较厚的膜可能是理想的。使用膜而非织物来作为外层可使产品易于清洁并保护缓冲材料免受损坏和污物。膜可包括约100%至约1500%的伸长率、更尤其约200%至约1000%且还更尤其约300%至约700%。
一些可能的TPE材料包括苯乙烯嵌段共聚物、聚烯烃共混物、弹性体合金、热塑性聚氨酯、热塑性共聚多酯、热塑性聚酰胺及其组合。市售的弹性体合金的实例包括可熔融处理的橡胶和热塑性硫化橡胶。合适的TPE的实例包括热塑性聚氨酯(“TPU”)。由于其耐用性、弹性、柔软性和挠性的组合,TPU膜会是理想的。一种合适的膜是可从迪尔菲尔德聚氨酯(Deerfield Urethane)、拜尔材料科学公司(Bayer MaterialScience Company)以产品名Dureflex PS5400获得的聚酯聚氨酯膜。理想的会是使用聚酯TPU膜,而不是聚醚TPU膜,因为聚酯TPU膜除了与聚醚TPU膜相比具有改善的耐磨性外,还在诸如运动服和商业洗涤中的高湿度条件下出乎意料地运行良好。
此外,可用垫的不同部分上的织物和膜制造垫和服装,以允许全范围运动和来自两种材料的进一步保护。理想的会是外层是织物和膜的复合物,从而膜在挠曲期间辅助保护铰接部,并还可用作缓冲材料的保护屏障。
内层17可包括与外层16相同的材料。当内层17包括织物层时,织物可以是编织织物、机织织物、无纺织物、合成物、非合成物和包括前述中至少一种的组合,且织物层可层叠成例如TPE膜。当垫的应用需要拉伸时,则使用具有伸长性的内层可能是理想的,且当内层是层压件时,可能使层压件中的每层伸长是理想的。使用织物层作为内层17会是有利的,因为其可捕获和分散否则可能形成在层中或层之间的气泡,从而形成最终模制产品的更好的外观。
在内层、外层和/或缓冲层中的一个或更多个中使用活性剂会是理想的。例如,银基或铜基活性剂的添加可为材料提供抗微生物剂或抗真菌特性。在内层或外层或泡沫本身中使用活性物质会是理想的,诸如添加银基或铜基的活性物质作为抗微生物剂或抗真菌剂。
内层16和外层17中的一层或两层还可包括颜色、图形和/或包括文字在内的标记。设置在该层上的颜色、图形和/或标记可在其它层由无色和/或透明材料形成时通过其它层透出,出于外观和成本原因,这会是理想的。此外,如果需要,内层16和外层17中的一层或两层还可以是可透流体的。本文使用的“可透流体”意思是形成该层的材料对于流体材料的通过或进入是开放的。
继续参照图1A-图1E和图2-图3,垫100包括设置在上表面10中的至少一个缓冲区域。在本示例性实施例中,垫100包括中心圆形章部18。第一上部月牙形章部20被设置成与章部18相邻并在章部18上方与其间隔开,且上部半圆形章部22被设置成与上部月牙区域20相邻并在上部月牙区域20上方与其间隔开。第二下部月牙形章部24被设置成相邻于中心区域18并在中心区域18下方与其间隔开、与上部月牙区域20相对并间隔开。大致梯形章部26被设置成相邻于下部月牙形章部24并在下部月牙形章部24下方与其间隔开;且第二下部大致半圆形章部28被设置成相邻于梯形区域26并在梯形区域26下方与其间隔开。相对的大致梯形章部30、32设置在中心区域18的左侧和右侧、与上部月牙区域20和下部月牙区域24相邻并间隔开。
如图1C、图2和图3中最清楚示出的,前述章部18、30、32中的每个均包括上表面34和向下延伸至垫100的上表面10的侧壁36。侧壁36可垂直于上表面34,或具有相对于上表面34的倾斜轮廓、到达铰接部或沟槽底部的点。因此,在一些实施例中,铰接部和/或沟槽可具有锯齿形或具有倾斜壁,这使铰接部露出得最少。
章部的尺寸、形状、厚度和材料成分可根据多个因素变化,多个因素包括但不限于垫的所需挠性量。此外,章部的构造可变化,且可在垫中使用一种以上类型的章部形状。
缓冲层15可包括一层或更多层任何材料或材料组合,该材料具有通过诸如模制形成预定形状的足够结构整体性,且能够承受它们预期使用的环境而没有明显降解。
材料类型和成分可选择成提供具有预定材料特性的物件和/或物件区域,其可用于定制用于诸如缓冲、防撞、耐磨等特定应用的垫。适当材料的实例包括聚合材料、复合材料等。合适聚合材料的实例包括但不限于热固性聚合材料、弹性体聚合材料、包括热塑弹性体材料在内的热塑性材料、包括前述至少一种的组合。一些可能的聚合材料包括但不限于:聚氨酯、硅树脂和/或类似物以及包括前述材料中至少一种的组合。
在一些情况下,对于垫来说理想的可能是具有缓冲特性以在诸如用于与身体接触时提供柔软,柔韧和舒适的感觉。在这些情况下,已经发现一些聚合胶可能是合适的。合适聚合胶的一个实例是硬度范围从约0.01肖氏00至小于或等于约70肖氏A、更尤其小于70肖氏00、还更尤其小于60肖氏00的聚氨酯胶。该材料可包括范围从约30肖氏000至约88肖氏D的硬度。聚合物的硬度可由本领域的普通技术人员使用诸如硬度计或针穿硬度计来确定。胶的形成可通过本领域的技术人员已知的各种方法来进行。例如,聚氨酯凝胶的形成可包括在存在催化剂的情况下使适当的预聚合先体(precursor)材料反应、例如使多元醇与异氰酸酯反应。
在一些情况下,可能理想的是垫是轻质的,且在这些情况下,缓冲材料15可包括诸如低密度泡沫材料的泡沫材料。合适低密度泡沫的实例包括聚酯和聚醚聚氨酯泡沫。
在一些情况下,可能理想的是垫能够提供防撞性。在这些情况下,已经发现各种类型的撞击吸收材料适用于缓冲材料,尤其是能量吸收泡沫。对于这些应用,理想的会是这些泡沫的密度范围从约5至约35磅/立方英尺(pcf)、更尤其从约10至约30pcf、且还更尤其从约15至约25pcf。合适的速率依赖型泡沫是可以从罗格斯公司(RogersCorporation)以品牌和购得的开孔微孔聚氨酯泡沫。
继续参照图1A-图1E和图2-图3,在上表面10中限定一个或更多个通道,以将章部18、30、32保持为间隔关系。如图2所示,通道38具有由相邻章部周界之间的间距限定的宽度“W1”、由章部的上表面34与垫100的上表面100之间的间距限定的深度“D1”、以及由内层16和外层17以及设置在两层之间的缓冲材料15的组合厚度限定的厚度“T1”。对于所有讨论,“通道”此后将在说明书中称为铰接部,而不意图限制沟槽也用作铰接元件的事实。
铰接部的宽度W1可根据要求或需要改变,且范围可从窄至约1mil至约1000mil或更多。在一些情况下,对于铰接部的宽度“W1”来说理想的会是尽可能窄,从而使章部的保护特征最大,同时保持垫的铰接能力。这些应用包括需要最大保护的应用,或者铰接部用于围绕角部包裹的应用。在需要撞击保护的情况下,铰接部的宽度可设计成比撞击垫的物体的宽度窄。在这些情况下,宽度W1范围可从约1mil至约10mil、更尤其从约3mil至约7mil、且还更尤其约5mil。
在保护特征较不重要的其它情况下,理想的会是铰接部的宽度“W1”宽得多,从而使铰接部最具美观特征,铰接部可做成与章部的颜色形成对比。在这些情况下,如果需要,宽度W1可以是毫米或厘米范围或者甚至更大。
铰接部38可以是沿平行和/或相交轴线设置的线型通道,如图1C所示。如本实施例所示,铰接部38可沿平行轴线“A1”和“A2”大致对准。铰接部38也可弯曲,如曲线“A3”和“A4”所示。章部之间铰接部的深度可相同或不同,且该深度可沿铰接部变化。弯曲和线型铰接部都可如本实施例中那样与垫组合使用,并可包括弯曲和线型铰接区域的组合。
如图1B最清楚示出的,选配周界凸缘40(此后称为“凸缘”)可被限定在上表面10中,以保持章部相对于垫的周界间隔开。在本实施例中,选配周界凸缘40具有由最外部章部的周界与垫100的周界14之间的间距限定的宽度“W2”。周界凸缘40的宽度W2可根据需要变化。如下文将更详细描述的,周界凸缘40比章部薄,通过使用诸如缝制、胶粘、粘接等的各种技术允许垫沿凸缘区域附连到诸如衣服的物件。当例如整合有紧身袖子时,垫可缝制、胶粘或以其它方式附连到袖子织物的外部,或垫可缝制或附连到袖子的内表面,并通过袖子上的相应开口露出。
可选地,章部的上表面34可使用各种几何形状形成轮廓,包括平坦表面、弯曲表面以及平坦和弯曲表面的组合。如图3所示,在本实施例中,章部26的上表面34包括平放于平面“P1”中的平坦部分34a,平面“P1”大致平行于平面“P2”,P2与垫100的上表面10共面。章部26的上表面34还包括平放于平面P3中的另一部分34b,平面P3与平面P1和P2相交。部分34b的厚度大致朝向章部26的周界径向减小。或者,章部的上表面34可包括由朝向章部周界或朝向垫的周界大致径向减小的厚度限定的表面。
如图1C和图3最清楚示出的,一个或更多个沟槽42可选择性地形成在章部的上表面34中。像铰接部38一样,沟槽42增加垫的挠性,且随着沟槽42中缓冲层15的厚度减小,沟槽42和垫100的挠性增加。章部的上表面34中的沟槽42的宽度、深度、定向和位置可根据多个因素变化,多个因素包括但不限于所要求的方向和挠性量等。
像铰接部38一样,沟槽42可以是弯曲沟槽,或沿平行和/或相交轴线设置的线型沟槽。弯曲和线型沟槽都可组合使用,且沟槽可包括弯曲和线型区域。如图1E所示,在本实施例中,左梯形章部30包括具有与中心章部18相交的轴线“A4”的第一线型沟槽42x和具有与轴线A4相交的轴线“A5”的第二线型沟槽42y。如图所示,两轴线大致在中心章部18的中心处相交并从中心章部18朝向垫100的周界14径向延伸,但应当理解,沟槽的轴线不必须在垫的中心处相交。类似地,相邻章部20包括具有轴线“A6”的第三线型沟槽42z,轴线A6与轴线A4和A5相交。垫或章部中的沟槽的厚度可相同或不同,且该厚度可沿沟槽的轴线或长度且在沟槽之间变化。
图4-图6在共同看时,示出根据本公开的示例性缓冲垫200的另一实施例。垫200具有与垫100类似的结构,包括前表面10、后表面12和外部边缘/周界14,缓冲层15设置在选配外层16和内层17之间。垫200包括与垫100中相同的章部。可选地,一个或更多个沟槽42可形成在章部的上表面34中。
此外,如前述实施例中那样,铰接部38被限定在垫200中,从而以间隔开的关系保持章部,并为垫提供挠性。铰接部38具有由相邻章部周界之间的间距限定的宽度“W1”、由章部的上表面34与垫200的上表面10之间的间距限定的深度“D1”以及由内层16和外层17以及设置在两层之间的可能存在的缓冲材料15的组合厚度限定的厚度“T2”。
垫200还包括附加的周界铰接部50,该附加的周界铰接部50与垫的周界的形状对应。像铰接部38一样,周界铰接部50具有由相邻章部周界与周界凸缘40之间的间距限定的宽度“W1”、由章部的上表面34与垫200的上表面10之间的间距限定的深度“D1”以及由内层16和外层17以及设置在两层之间的可能存在的缓冲材料15的组合厚度限定的厚度“T2”。
在本实施例中,使设置在铰接部38、50中的上层16与下层17之间的缓冲层15的厚度在制造过程期间最小,使得其厚度在铰接部38、50中接近零。于是,铰接部38、50中的缓冲材料可能肉眼不可见,或仅可使用非常敏感的厚度计来检测。
保留在层16、17之间的残留缓冲材料有助于将两层16、17在铰接部38、50中粘结在一起。根据所使用的材料,层16、17之间的粘结可至少部分地为化学、热和/或机械粘结。例如,如果用作缓冲层的材料是树脂,则铰接部38、50中的残留树脂可用作将层16、17粘结在一起的粘合剂。使用树脂作为粘结剂是有利的,因为其消除了在非常薄的铰接区域中对单独的粘合剂的需要,且其保持粘结在整个垫中一致且同程度地挠曲,由此增强垫的耐用性。
替代地,如果使用织物作为层16、17之一,则铰接部中两层之间的粘结可至少部分为机械的,由于树脂被挤进织物中的开口或孔中,使得制造期间层16、17的各部分粘结,形成设置在粘结层16、17的孤岛之间的粘结层15、16、17的“孤岛”。
通过使铰接部38、50中的缓冲层15最小或将其消除,可使铰接部的挠性最大,使得整个垫200能够沿各方向弯曲、挠曲、折叠和扭曲。例如,如图5所示垫200沿铰接部38、50在箭头“A”的方向上弯曲或挠曲多达180度。沿相反方向“B”,挠性仅由章部的厚度和间距限制。
在本实施例中,铰接部38、50中的内层16和外层17之间的连续粘结的存在是有利的,因为其将章部“锁定”就位,使缓冲材料从垫的移出最少或防止该移出,或者替代地使诸如流体的材料进入垫的移入最小或防止该移入。因此,铰接部38、50使垫、尤其是缓冲材料稳定,使得流体或其它材料不能穿透垫,这种穿透否则可能会导致脱层。
一起看时,图7-图9中示出根据本发明的另一示例性缓冲垫300。垫300在结构上类似于垫200,且还包括设置在章部32a、32b之间的铰接部60。像铰接部38、50一样,增加铰接部60增加了垫300沿各方向弯曲、挠曲、折叠和扭曲的能力。
一起看时,图10-图11中示出根据本公开的另一示例性缓冲垫400。垫400在结构上类似于垫300,并还包括限定围绕中心章部18a设置的同心章部18a、18c的两个同心铰接部38a、38b。像铰接部38、50、60一样,增加同心铰接部38a、38b增加了垫300沿各方向、尤其在肘关节区域中弯曲、挠曲、折叠和扭曲的能力。
垫、章部、章部轮廓、铰接部、沟槽和凸缘的尺寸、形状、构造、定向和面积可根据需要变换,以便实现垫设计的所需特性。所有前述特征单独或组合地设计成便于垫向内或向外挠曲以在运动期间符合使用者的身体。但是,应当理解,在每个前述实施例中,且在根据本公开的任何垫中,所有前述措施可根据垫的所需特性和设计而变化。例如,垫被设计成提供各种特性,诸如但不限于缓冲、减震和/或撞击吸收等。垫的特性可通过改变章部中缓冲层15的厚度和/或材料类型、改变章部之间的间距(即铰接部的宽度)、和/或改变章部的轮廓等而变化。例如,对缓冲层15使用胶为垫提供缓冲和减震性能;使用泡沫减轻垫的重量;使用速率依赖型或撞击吸收泡沫增加垫的撞击吸收;等。总地来说,增加章部中缓冲层15的厚度通常增加了前述特性;且使用用于缓冲层15的材料的组合可提供各性能的组合。
在每个前述实施例中,且在根据本公开的任何垫中,铰接部设计成为垫在要求或需要挠性的目标区域中提供挠性。使用弯曲、平行和/或相交的铰接部允将许垫的挠性定制成特定功能,诸如在运动期间保护关节。铰接部的宽度、深度、定向和位置可根据多个因素变化,多个因素包括但不限于垫的所需挠性量和挠性位置。
铰接部的挠性可通过改变铰接区域中材料的厚度而变化。例如,减小铰接部中材料的厚度增加了垫的挠性,而增加铰接区域中材料的厚度降低该挠性。在包括内层16和外层17中一层或两层的一些实施例中,能够“挤压”在铰接部中的缓冲层15以使铰接区域中的材料量最少或消除该材料量。在该实施例中,当铰接部中的缓冲层15的厚度接近零时或当将垫模制成在铰接部38中没有缓冲层15时可实现最大挠性。例如,当使用厚度约4mil的内层16和外层17时,通过模制过程期间从铰接区域移除尽可能多的缓冲材料15能够实现接近8mil或接近内层16和外层17的组合厚度的铰接部厚度。
因此,可使用小于章部厚度的约20%、更尤其小于章部厚度的约10%、且还更尤其小于章部厚度的约5%的铰接部深度来实现最大保护。成功部分已经被制成具有0.020"、0.040"和高达0.080"的铰接部深度。
当垫模制成具有前层、后层或两层时,当铰接部厚度大致与除了层15的各层的组合厚度对应时或者当缓冲层15的厚度接近零时可实现最大的垫挠性。
深铰接部还可具有一定的泡沫厚度,且仍提供良好的移动性。如下文所述,本保护性垫的一个特征是外层和/或内层可保护缓冲垫在重复挠曲期间在相对薄的铰接区域不断裂,从而泡沫厚度不受泡沫挠曲强度的限制,只要泡沫粘结到内层或外层中的一个或两者即可。
在每个前述实施例中,在根据本公开的任何垫中,铰接部的宽度或章部之间的间距设计成允许垫尽可能弯曲,同时仍保持章部的保护特性。因此,章部之间的间距可通过需要具有可挠曲铰接部的距离量来确定,而不在章部之间露出太多空间,使得当章部之间的间隙被撞击时会发生伤害。因此,可使用小于章部厚度的约20%、更尤其小于章部厚度的约10%、且还更尤其小于章部厚度的约5%的铰接部宽度来实现最大保护。如上文指出的,使用成角度或锯齿形铰接部和/或沟槽(未示出)还可降低露出的不受保护表面的量。
在每个前述实施例中,且在根据本公开的任何垫中,沟槽42被设计成允许垫在目标区域中弯曲。沟槽42的宽度、深度、定向和位置可同样根据多个因素变化,多个因素包括但不限于垫和/或其中形成沟槽的章部所需的弯曲量。沟槽42设计成比铰接区域厚,但比章部的最厚点薄。因此,沟槽厚度范围可从章部厚度的约10%至95%、章部厚度的约20%至约75%且仍更尤其为章部厚度的约50%。
如上文指出的,外层16和内层17是选配的,但出于多种原因它们可能是理想的,尤其是当缓冲层15是微孔材料和/或是不易于保持其形状的材料时。
例如,在上述实施例中,外层16和内层17都跨越整个垫、包括在铰接部中连续粘结到缓冲层15。根据垫的构造,当铰接部中的材料量最少或消除时,外层和内层可粘结到缓冲层15,或者它们可彼此粘结。将前层粘结到缓冲层15的一个显著优点是在缓冲层15上方和下方除了垫的周界处提供连续不间断的表面,即封装缓冲层15。连续上层和连续下层加固铰接部和沟槽区域,使铰接部和/或沟槽中的断裂最小化,否则因为铰接部和/或沟槽比章部薄,由于使用期间垫的挠曲可能发生这种断裂。可使用至少一个粘结层以在挠曲期间保护薄铰接区域。热塑性聚氨酯膜在用作外层16时,尤其利于防止铰接部或沟槽中内层17的破裂或断裂。如果粘结到泡沫,内层还可为铰接部或沟槽提供强度,或在多个实施例中,内层和外层都粘结到泡沫。在铰接部厚度非常小的情况下,尤其在铰接部中几乎没有或完全没有膜时,内部粘结层和外部粘结层对于保持垫的结构整体性都是理想的。理想的是对内层和外层使用具有显著弹性的材料,诸如TPE膜、氨纶织物等。在一些实施例中,使用具有层叠膜背衬的织物作为内层或外层可能是理想的。作为织物和膜的层压件的诸如聚氨酯膜层压件的内层对于使铰接部的耐用性最大化会是非常理想的。
如上文所述,本公开的另一方面是将上述垫整合到服装中,尤其是紧身服装中以保护身体的特定区域。当前述垫之一整合到紧密贴合穿着者的紧身袖子或服装中时,带铰接部和/或带沟槽的多层垫结构被缝合、粘结或以其它方式附连到氨纶织物或其它可拉伸材料,使得带铰接部的垫与所要保护的区域保持贴身接触。该垫可缝合到服装的内侧或外侧。可能理想的是垫仅覆盖袖子的整个周边的一部分,从而袖子仍可显著拉伸以配合穿着者。独特铰接的保护垫与紧身服装的整合在不改变整个服装的情况下通过形成将显著撞击吸收垫添加到特定身体区域的简单方式来提供特别的协同作用。
图12示出包括附连到袖子500的本体64的缓冲垫300的紧身袖子500。如图所示,垫300通过将周界凸缘40缝合到袖子500的本体64而附连到袖子500,使得使用时,中心章部18的位置对应于使用者的肘部。使用时,当使用者的臂弯曲时,可挠曲铰接部38和沟槽42的组合允许垫与使用者臂的弯曲构造符合,同时保持中心章部18相对于肘部的位置。
当垫与紧身袖子整合时,与保护移动关节的其它方法相比提供一些独特特性和优点。当整合到紧身袖子中时,垫可与所保护的关节连续紧密接触,当保护诸如膝盖、肘部、肩部和踝部的挠曲关节时这可能是理想的,因为适当设计的铰接部允许保护性袖子自然地保持在正确位置和定向中。当铰接部设计得当时,保护性紧身袖子作为一体与臂一起移动,从而允许比常规衬垫更宽的运动范围。
此外,由于保护性袖子与关节和皮肤紧密接触,所以在来自外部物体的撞击之后没有垫碰撞皮肤或关节造成的附加撞击。更硬的垫可能不能与特定身体区域或关节连续接触,因为它们不可挠曲或不合身。如果不合身,垫可变成伤害穿着者的撞击的一部分。袖子构造中的垫尤其能够更好地保护运动关节,因为他们可围绕宽半径包络,且在一些情况下通过包络整个关节提供360度保护。一般而言,理想的是使紧身袖子的一些区域没有附加衬垫层,以允许袖子拉伸并更好地符合臂。
图13示出包括附连到衬衫600的本体80的缓冲垫300的紧身衬衫600。如图所示,垫300通过将周界凸缘40缝合到衬衫600的本体80而附连到衬衫600,使得中心章部18的位置对应于使用者的胸部中心。使用时,可挠曲铰接部38和沟槽42的组合允许垫300符合使用者的胸部区域,从而保持垫300紧密靠近使用者身体,由此当使用者在经受胸部区域中的撞击时使垫300的撞击吸收能力最大化。
服装还可由设计成将湿气从皮肤层移走的芯吸织物制成。
本垫还可设计成提高空气和/或湿气的传输,而不显著影响保护,这不是其它保护衬垫的选择。铰接部、沟槽和/或章部可包括穿孔(未示出),这提高湿气或空气传输率。使用芯吸织物作为内层或结合TPE膜层作为内层可增强舒适性并通过铰接部芯吸湿气。此外,使用高湿气蒸发传输(“MVT”)膜层可进一步提高舒适性。这些膜可通过化学吸收/解吸来作用。这些膜的实例可从奥米尼弗莱克斯公司(Omniflex)以商品名Sympatex或TX1540购得。也可使用诸如Goretex或Porelle(出自Porvair)的微孔高MVT膜,或类似膜。
在一些实施例中,垫可形成为使得泡沫在整个垫具有大致均匀的密度。具体地,在一些情形中,可能理想的是在模制或成型期间不将泡沫压缩到沟槽或铰接部中,因为压缩增加泡沫的密度,这趋向于通过消除泡沫而缩小运动范围并提供不均匀的衬垫水平。有轮廓的章部和泡沫厚度的变化不仅提供美观的垫,而且它们还在最需要保护的地方提供最大保护,且在较不需要的地方提供较少保护。通过在需要的地方使用均匀泡沫密度和变化的厚度,减轻垫的重量,并增加运动范围。使用热成型或压缩而使泡沫和压缩区域成形可增加这些区域的密度并形成附加重量、不均匀的保护和更小的运动范围。
可使用美国专利7,827,704和美国公开US2008/0034614和US2009/0255625公开的技术制造本垫,其全文援引于此以供参考。对于垫的某些实施例,用于本垫的模具被设计成允许层15、16、17在足以使铰接部38、50、60中的泡沫最少或消除泡沫的条件下压缩在一起,同时允许各层粘结在一起,粘结可以是化学、热和/或机械粘结。
垫结构与内部膜层和外部膜层允许制造商使垫的各部分之间的间隙更小,因为不必使用织物来对垫进行定位和安置。这还允许制造商以最适当的方式使这些沟槽和铰接部倾斜和成型以完全覆盖和保护穿着者同时在活动期间拉伸、配合并保持在位。
与被在袋中、被封闭在织物或柔性膜中的垫相反,形成露出的保护性泡沫垫的能力提供对穿着支承或矫正护件(brace)诸如护膝、脚踝支承件、背部支承件等的个人提供保护的独特和关键能力。因此,垫可附连或粘结到机械支承件以保护适应性移动运动员免受自身和具有类似护件的其它运动员的伤害。类似地,根据本公开的垫的设计可定制并可粘结到由常规移动运动员穿着的护件。这为护件的穿着者以及与矫正护件接触的其它运动员提供保护。这种护件的一个实例是在专业足球中使用的护膝上的衬垫。
本垫也可用在由年轻人、成年人和专业足球运动员穿着的护胫上。撞击吸收泡沫衬垫的特性与合身服装结合提供对目标身体部分的独特和高精度保护。因此,本公开的一个实施例是用于足球运动员的可挠曲、合身、透气的护胫和护踝。显著地,这种护胫和护踝由于泡沫的更紧密配合、来自芯吸材料的更舒适性、结构中使用的通气部和穿孔而为足球运动员提供更多保护,并提供比例如用使用者的袜带或袜子的摩擦保持在位的不透气的硬质塑料垫更耐用的产品。
如先前指出的泡沫衬垫和其它层可设计成具有穿过材料或在沟槽或铰接区域内的穿孔,而不显著影响保护。在一些实施例中,垫的所有层连续粘结在一起的事实允许水蒸汽的蒸发更容易地穿过预形成的路径。一旦湿气被芯吸到织物层中,该湿气可因为表面被粘结而通过垫排出。这是与其它垫的显著区别,其它垫的一层或更多层自由浮动,使得它们不适于穿着。
包括粘结到章部、铰接部和沟槽中的缓冲层15的连续内层和连续外层的垫提供自由运动范围和耐用垫,因为其允许垫随着身体的特定区域一起挠曲和铰接而不会劣化。垫具有连续内表面、连续外表面或两者的情况保持铰接部的定向和位置以及间距。本垫与其中以分离件切割、刻划或模制泡沫以形成铰接部的垫和服装相反,所述垫和服装可造成垫之间过多的拉伸并造成对使用者的伤害。本保护性垫允许垫的固定定向。该特征可能对于不保护显著移动关节区域的应用来说较不理想,且仅形成一般的衬衫和裤子衬垫。
将垫整合到紧身或合身服装中允许对身体的包括关节在内的特定区域进行保护;该保护不仅针对外部撞击。使用具有本垫的这种紧身或合身服装防止垫在撞击之前与皮肤分离,这可能对身体造成二次撞击。
在某些实施例中,外侧表面(织物或膜)(在一些实施例中)是服装或袖子的实际外侧表面的事实是重要区别。具有跨越外部缝合、覆盖衬垫的未粘结织物或其它覆盖件的垫允许在撞击时外层跨越衬垫滑动,这影响撞击保护的精度。当穿着当前服装时,穿着者具有在合身服装外部的垫,并享受特定身体区域或关节的更精确保护。使本公开垫的露出的外层作为服装或袖子的外层(如图12和图13所示)还允许改进的湿气和空气流动管理,这优于具有任何形式的松散覆盖件的切割泡沫片。在一些实施例中精确的空气通道和穿孔允许更少的热量和湿气积累。此外,使垫的外表面露出的实施例允许合身服装的内侧抵靠使用者的皮肤平放,因为垫的内表面可通常是平坦的。当附连到弹性织物的外侧时,使用者可具有抵靠皮肤的不间断弹性织物层或其它材料。这允许垫紧密地包围皮肤表面并还具有较不易于对皮肤造成擦伤或刺激的更无缝的内表面。
使用在表面上露出的垫还更能够使铰接部或沟槽更紧和/或更小,因为否则附加的外部材料会通过填充在铰接空间中和与铰接部的运动干涉而阻碍适当的铰接。在具体设计中沟槽和铰接部还可倾斜或成型为更精确地覆盖和保护目标。也可使用本垫在服装表面上形成特定的和更符合空气动力学的形状。空气动力学表面与保护结合在诸如滑冰的运动中会是有利的,在滑冰运动中穿着者会例如得到免受与门撞击的保护,同时改进地降低风阻。诸如自行车比赛的其它运动也可受益于改进的空气动力学性能。
使用本撞击吸收垫,当露出在服装表面上时,允许撞击吸收泡沫反应更快,因为在泡沫与撞击物之间没有不必要的层。当使用诸如Poron XRD或其它这种材料的“速率依赖型”撞击吸收泡沫时,这会是理想的。这些材料在撞击时变硬,且在暴露表面上仅使用泡沫与撞击垫的物体之间的单层粘结膜或其它材料允许泡沫反应更好且更快。
在一些实施例中,使用膜、尤其是聚酯聚氨酯膜作为附连到袖子或服装的垫的外层形成耐用且更可清洁的垫系统。露出膜的外表面会既耐用又防污。作为顶层的织物,无论是缝合或以其它方式附连,都会撕开和撕裂或变脏,且在这些复杂服装中,会难以清洁。作为内层或外层共同连续粘结到铰接区域中或粘结到章部中的缓冲材料的织物和/或膜会比许多垫中所使用的未粘结缝制织物更耐用,其中撕破的外部服装使垫暴露意味着防止穿着者与服装错位或脱离。在使用织物层作为内层或外层的本公开的实施例中,织物内的膜层还可最小化和/或防止灰尘或液体渗透或穿透泡沫。
多个实施例模制成具有均匀密度的泡沫衬垫的事实(即,不是较高密度的压缩泡沫)允许保护的更精确设计以及比压缩造成的变化密度更大的运动范围。
本垫、衣服和制造方法由于多种原因是有利的。例如,具有多个元件的单个连续垫通过消除否则在最终服装结构中所需要的劳动密集的切割、刻划或热成型而提供优于常规垫结构技术的经济优点。
对于缓冲层15使用厚度接近零的粘结铰接部是非常独特的。在这种几乎零厚度的铰接区域中,外层的顶表面仍在整个铰接部粘结到内层,这可允许显著地改进在特定选择区域的运动范围。如所指出的,铰接区域可以是几乎零厚度(小于0.001"(1mil)的泡沫)或高得多的任何地方,只要小于缓冲材料的更厚区域即可。一些实施例具有接近零的铰接区域,而其它实施例为0.010"(10mil)、0.020"(20mil)或者甚至0.080"(80mil)或0.120"(120mil)。铰接区域和沟槽区域以多种取向的组合允许形成在需要的地方组合全范围运动的垫,而不是形成在需要较少挠曲的其它区域中的保护性衬垫。
诸如当缓冲垫附连到拉伸服装时,在需要拉伸的实施例中使用具有弹性的粘结内层和具有弹性的粘结外层也是理想的。
在铰接区域厚度接近零附近的位置处或在薄铰接区域(小于0.100"(1mil)泡沫)中,整个垫具有连续粘结内层或外层(或两者)的事实保持间距并防止未受保护区域的分离。这与其中使用分离的切割件来形成垫的垫不同,因为切割件可在强迫下分开,并使使用者暴露且可能受到伤害。
在一些实施例中,已经证实使用窄铰接间距对于当关节以某些方式挠曲时防止露出是理想的。本公开允许非常窄的铰接部,或章部之间非常窄的间距,而在使用时没有铰接部分离的危险。
为关节设计的一些实施例包括被同心铰接部围绕的中心章部(例如中心圆形章部、靶心章部、多边形章部等)。中心章部可用于适当地定位并放置垫,使得中心章部位于关节(例如肘骨)上方。
保护性衬垫的可挠曲特性、耐用性和双膜层结构适于对穿着支承和矫正护件的个人提供保护,支承和矫正护件包括但不限于护膝、护踝和背部支承件。
在一些实施例中使用具有多种取向的多级铰接部和沟槽既是理想的又是独特的。
本垫可制造成为特定身体区域提供更好保护同时是轻质的,这对于运动员和活动人员是显著有利的。
本保护性垫的一个优点在于整个挠曲区域可由为身体的特定部分专门设计的一个大垫或几个大垫而不是缝合到服装中的较小切割垫或条保护。整体式大垫不仅更经济,而且防止垫的切割件或条造成保护间隙的移位。除了比当前产品提供更好且更精确的保护之外,本保护垫还允许露出整个更耐用的垫,这既美观又节省重量,并可使垫更舒适,具有更好的湿气和空气传输。露出,意思是不必将垫放入袋中,或将垫缝合到袋中,其中它们会在袋中保持松弛。而是,本垫通过缝合直接附连到下方材料。
本领域的普通技术人员会认识到可使用其它附连方法,但已经发现缝合提供某些优点。与热密封或焊接不同,已经发现沿周界凸缘将缓冲垫缝合到位防止或最小化垫与服装的分离,这与在服装内松弛(即,在被设计成包含垫的袋中被松弛地保持)或通过焊接、热密封等附连的垫相比是有利的。
此外,可根据本公开制造格外耐用的缓冲垫,缓冲垫包括内膜层和外膜层,在膜层有缓冲材料,该缓冲垫由具有内层与外层之间“接近零”厚度的缓冲材料的铰接部限定,并终止于外部边缘,该外部边缘具有与周界凸缘相邻的接近零的周界铰接部以及设置在内层与外层之间相对低厚度的缓冲材料的组合。前述垫是格外耐用的,并可承受反复的商业洗涤。在这些垫中,在包含在服装中时,理论上周界凸缘的厚度(例如约20mil)提供用于缝合的坚固区域,该区域如果不被20mil周界凸缘支承否则会磨损和撕裂而没有缓冲材料。此外,周界凸缘形成更有吸引力的产品,该产品具有比在缓冲垫的周界处以膜终止可能更软的边缘。
还考虑到整个垫中的接近零铰接部允许垫在洗涤循环期间有助于垫的耐用性,因为铰接部中的泡沫材料非常薄,从而不再存在微孔结构。因此,缝合的周界凸缘防止或最小化垫在反复洗涤中揭开,即锁定缓冲垫的周界。
此外,内膜和外膜连续粘结到章部区域中的缓冲材料或在铰接部内彼此粘结防止或最小化流体或其它材料进入垫以及缓冲材料从垫跑出的几率。两特征组合地增强严格条件下多个垫的耐用性,完全消除或防止其它产品中发生的层的层离。认为周界凸缘和相邻的接近零铰接部防止或最小化流体和/或颗粒渗透垫超过周界凸缘,因为泡沫已经几乎完全从铰接区域去除,且没有在铰接区域中的泡沫的微孔结构,流体和/或颗粒不能移过周界凸缘。因此,周界凸缘用作流体和/或颗粒渗透到垫中的缓冲件。
类似地,铰接部的贯穿缓冲垫的“网络”,尤其是当铰接部是“接近零”铰接部时,进一步改进垫的耐用性,因为消除和/或最少化铰接区域中的泡沫或其它缓冲材料,所以增加了铰接部中的粘结强度。粘结强度在铰接区域增加是因为铰接区域中的其余缓冲材料不足以支承泡沫结构(在泡沫的情况下)。如果泡沫保持在铰接部中,粘结强度可限于泡沫撕裂强度。因此,当泡沫或其它缓冲材料的厚度最小时,铰接部中的粘结增加,因为没有薄泡沫孔壁被撕裂。即,铰接部中没有多孔泡沫结构,且没有用于使流体和/或颗粒渗透超过周界凸缘的空间。于是,如果损坏或损害单个章部或铰接部,则对整个垫的损坏最小或被隔离,因为该损坏仅波及相邻的垫和/或铰接部。
本垫的另一优点在于深铰接部与较深的沟槽的组合或多级铰接部为保护性服装提供改进的保护,同时在被保护区域保持显著的运动范围。使用连接的顶部、底部或两层允许更精确地使用铰接部和沟槽,并防止各个章部相对于彼此移动。此外,与可拉伸合身服装材料的整合产生对所保护区域的主要包络并使外部垫与身体的特定区域连续接触。
实例1
模制缓冲垫以形成根据图1所示设计的肘垫。所使用的材料对于缓冲垫15(亮黄色)是PORON、对于厚度约19mil的内层17为可拉伸织物(黑色)、以及对于厚度约4mil的层16为透明聚氨酯TPE膜。模制之后,对横截面中的组合厚度进行测量,如以下表A所示。
表A
在该实例中,该模具未设计成在模制期间压缩各层以从铰接区域去除泡沫。对垫的视觉观察表明,如所预期的如果泡沫保持在铰接区域中,垫的前部是均匀的亮黄色。形成的铰接部可挠曲,但不能太过挠曲而变得“松软”。
实例2
模制缓冲垫以使用实例1中所用的相同材料形成根据图7所示设计的肘垫。模制之后,对横截面中的组合厚度进行测量,如以下表B所示。
表B
在该中,模具设计成在模制期间压缩铰接区域中的材料以从铰接区域消除(缓冲层15中的)泡沫量或使泡沫量最少。对垫的视觉观察显示,如预期的如果泡沫保留在这些区域中,章部和凸缘是均匀的亮黄色,如所预期的如果在制造期间从铰接区域去除或挤出尽可能多的泡沫,铰接部是均匀的黑色。形成的铰接部极具柔性,以至于垫在铰接部处是“松软”的,并在铰接部处可折叠约180度。总地来说,在本公开与任何现有技术之间有多个重要区别,但某些重要区别如下:
应注意,本文中的术语“第一”、“第二”等不表示任何顺序或重要性,而是用于区分一个元件和另一个元件,并且术语“一”、“一个”不表示对数量的限制,而是表示存在至少一个所提及的物品。相似地,应注意,本文中使用的术语“底部”和“顶部”除非另加说明,否则仅用于便于说明,并且不限于任何一个位置或空间定向。另外,与数量一起使用的修饰语“约”包括定值并且具有上下文所指示的意义(即,包括与具体的数量的测量相关的误差度)。
在本文中使用标准术语描述化合物。例如,不被所示的基替代的任何位置被理解成具有其被所示的化学键所填充的化合价,或氢原子。不在两个字母或符号之间的破折号(“-”)被用于表示附接取代基的点。例如,-CHO通过羰基的碳被附接。除非在本文中另外限定,否则本文中的所有百分数意味着重量百分数(“wt.%”)。此外,在本文中公开的所有范围是包括性的并且是可组合的(例如,范围“至多约25wt.%,其中期望约5wt.%至约20wt.%,并且更期望约10wt.%至约15wt.%”包括该范围的端点和所有中间值,例如,“月5wt.%至约25wt.%、约5wt.%至约15wt.%”,等)。符号“+/-10%”意味着所示的测量值可以从定值减10%的值到定值加10%的值。
最后,除非以其它方式进行限定,否则本文所使用的技术和专用术语具有与本公开所属领域的普通技术人员通常所理解的意思相同的意思。
尽管已参照其示例实施例描述了本公开,但本领域技术人员应当理解,可在不偏离本公开范围的条件下进行各种改变并且可用等同元件来替换本公开的元件。此外,可作出许多变型以使特定情形或材料适应本公开的教导,而不脱离本公开的实质范围。因此,本公开并不局限于为实施本公开而被考虑作为最佳模式所披露的具体实施例,而本公开会包括落入所附权利要求范围内的所有实施例。
Claims (19)
1.一种缓冲垫,包括:
第一通道,所述第一通道具有厚度和宽度,所述第一通道包括连续上层和连续下层,所述连续上层至少部分地粘结到所述连续下层;
与所述第一通道相邻的缓冲区域,所述缓冲区域的厚度大于所述第一通道的厚度,所述缓冲区域还包括设置在所述连续上层与所述连续下层之间并粘结到所述连续上层和所述连续下层的缓冲材料;以及
沟槽,所述沟槽被限定在所述缓冲区域的上表面中,所述沟槽的厚度小于所述缓冲区域的厚度并大于所述第一通道的厚度。
2.根据权利要求1所述的缓冲垫,还包括周界凸缘和周界通道,所述周界通道与所述缓冲区域间隔开所述周界通道的宽度,所述周界凸缘的厚度大于所述周界通道的厚度,并小于所述缓冲区域的厚度。
3.根据权利要求1所述的缓冲垫,其中,所述周界凸缘包括设置在所述连续上层与所述连续下层之间并粘结到所述连续上层和所述连续下层的至少一部分所述缓冲材料。
4.根据权利要求1所述的缓冲垫,其中,所述连续上层通过设置在所述连续上层与所述连续下层之间并粘结到所述连续上层和所述连续下层的缓冲材料的多个部分来在所述第一通道中至少部分地粘结到所述连续下层。
5.根据权利要求1所述的缓冲垫,其中,所述第一通道包括设置在所述连续上层与所述连续下层之间并粘结到所述连续上层和所述连续下层的缓冲材料的连续层。
6.根据权利要求1所述的缓冲垫,其中,所述第一通道的宽度在从约1mil至约10mil的范围内。
7.根据权利要求1所述的缓冲垫,其中,所述周界通道的宽度在从约1mil至约10mil的范围内。
8.根据权利要求1所述的缓冲垫,其中,所述周界通道的厚度在从约1mil至约10mil的范围内。
9.根据权利要求1所述的缓冲垫,其中,所述周界通道的厚度在从约5mil至约8mil的范围内。
10.根据权利要求1所述的缓冲垫,其中,所述缓冲材料的密度在从约10磅每立方英尺至30磅每立方英尺的范围内。
11.根据权利要求1所述的缓冲垫,其中,所述缓冲材料的密度在从约15磅每立方英尺至25磅每立方英尺的范围内。
12.根据权利要求1所述的缓冲垫,其中,所述缓冲材料是速率依赖型泡沫。
13.根据权利要求1所述的缓冲垫,还包括服装,其中所述缓冲垫缝合连接到所述服装。
14.根据权利要求13所述的缓冲垫,其中,所述服装是紧身袖子,且缓冲章部被构造成对应于肘关节。
15.根据权利要求13所述的缓冲垫,其中,所述服装是紧身裤腿,且缓冲章部被构造成对应于膝关节。
16.根据权利要求1所述的缓冲垫,其中,所述连续上层和所述连续下层是聚酯热塑性聚氨酯。
17.根据权利要求1所述的缓冲垫,其中,所述连续上层和所述连续下层是粘结到氨纶织物层的TPE膜,且TPE层与所述缓冲材料相邻设置。
18.根据权利要求1所述的缓冲垫,其中,所述缓冲材料是多孔材料,所述多孔材料包括具有最小孔直径的多个孔,且所述内层与所述外层之间的所述缓冲材料的所述厚度小于所述最小孔直径。
19.一种缓冲垫,包括:
周界通道,所述周界通道具有厚度和宽度,所述周界通道包括连续上层和连续下层,所述连续上层至少部分地粘结到所述连续下层;
与所述周界通道相邻的缓冲区域,所述缓冲区域的厚度大于所述周界通道的厚度,所述缓冲区域还包括设置所述连续上层与所述连续下层之间并粘结到所述连续上层和所述连续下层的缓冲材料;以及
周界凸缘,所述周界凸缘与所述缓冲区域间隔开所述周界通道的宽度,所述周界凸缘的厚度大约等于所述内层和所述外层的组合厚度。
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