EP3075274A1

EP3075274A1 - Protection device and method for manufacturing such protection device

Info

Publication number: EP3075274A1
Application number: EP16162494.5A
Authority: EP
Inventors: Fanny Boria
Original assignee: Dainese SpA
Current assignee: Dainese SpA
Priority date: 2015-03-30
Filing date: 2016-03-25
Publication date: 2016-10-05

Abstract

A method for manufacturing a protection device and a respective protection device are described. The method envisages designing a lattice body comprising a plurality of cells (15) or internally hollow units or units having a cavity. The method envisages increasing the energy absorption capacity of one or more zones of said lattice body (12) by subdividing one or more cells (15) of said one or more zones of the lattice body (12) into two or more cell fractions, or filling at least a part of the cavity (16) of one or more of said cells (15) of said one or more zones of the lattice body (12).

Description

The present disclosure relates in general to a protection device for protecting the human body during the course of dynamic sports, namely a protection device of the type suitable for being used during sports activities for protecting a user against knock, falls and impacts in general. The present disclosure also relates to an article which can be worn for practising dynamic sports and which includes said protection device.
It is well-known that sports activities such as motorcycling, but also skiing, skating, cycling and in any case sports which involve high-speed movements, may easily result in falling of the person who is practising the activity; during these falls numerous zones of the person's body are particularly exposed to the risk of injury. Knees, wrists, elbows, shoulders, neck and back are often the parts which are most affected by falls during these activities, both because normally they are the parts which first make contact with the ground, and because they do not have any or a limited layer of muscular or fatty tissue which is able to absorb energy and sufficiently dampen the knocks.
In order to diminish the effects of falls or impacts in general, protection devices are generally available, these being arranged opposite the parts of the body which are exposed to impact during the practice of dynamic or extreme sports activities.
One category of products suitable for this purpose envisages the use of a substantially plate-like element with an energy absorption capacity, which is fixed, for example, onto a garment in the region of the zone to be protected. It is possible to adjust and choose different materials and forms of the protection element in order to improve the resistance of the latter and increase its capacity to dissipate the impact energy. Depending on the material and the form, protection devices which have a particularly rigid consistency, or a softer consistency, are obtained. These protection devices, although advantageous from many points of view, have a number of drawbacks.
One drawback consists, for example, in the difficulty of designing the protection device, based on the numerous options available in terms of materials and forms, in order to obtain suitable protection and in that often it is required to vary the rigidity of the material depending on the zone of the protection device. In fact, in some zones of the protection device, it is necessary to have a greater rigidity which allows greater protection, while in other zones of the protection device it is necessary to ensure that the protection device is softer and more flexible so as to adapt better to the shape of the human body and follow correctly each movement.
The technical problem forming the basis of the present disclosure is therefore that of providing a method for manufacturing a protection device which is adapted to protect the human body, for example in dynamic sports, and a respective protection device obtained by means of this method, and to also provide further advantages.
This problem is solved by a method and a protection device according to the respective independent claims. Further secondary characteristics are defined in the respective dependent claims and in the following description.
In particular the present disclosure is based on the solution idea that it is possible to design a protection device or protector, based on a basic pattern or geometrical object, which may correspond to an internally hollow body, such as a tubular body, a sleeve-like body, a ring-like body or similar closed-ring and hollow body of given cross-section, which has a similar repeating pattern so as to form a lattice in which, in order to obtain a greater rigidity of the lattice or adjust locally the rigidity of the lattice, each geometrical object is subdivided into fractions, the sum of which corresponds to the basic geometrical object. The subdivision may be performed by providing crosspieces, bridge elements, transverse walls or similar stiffening or reinforcing elements which connect in a "bridge-like" manner two parts or zones of the side wall which defines the aforementioned tubular body or internally hollow body, or by filling at least partially the cavity of the geometrical object. Basically, a protection device according to the present disclosure is based on the idea that it is possible to adjust the rigidity of a lattice body by repeating in a lattice body a basic geometrical object, and to reinforce or stiffen locally as required each basic geometrical object by modifying the basic geometrical object.
Based on this solution idea, a method for manufacturing a protection device is provided, wherein the method envisages:

designing a lattice body comprising a plurality of cells, or internally hollow units, or units having a cavity, such as a plurality of tubular bodies, sleeve-like bodies, or ring-like bodies arranged adjacent to each other so as to define the lattice;
varying the capacity of energy absorption, a consistency or configuration of said lattice body, or varying a mesh opening of each cell of said lattice body, by subdividing one or more cells into two or more fractions, or by filling at least a part of the cavity of one or more of said cells.

The method also comprises a manufacturing step, for example for moulding the lattice body.
It is be understood that the scope of the present disclosure includes a dual design of the protection device with respect to that indicated here, whereby it is possible to vary an energy absorption capacity, a consistency or a configuration of said lattice body, or vary a mesh opening of each cell of said lattice, freeing one or more cells in a selective manner from filling or stiffening elements arranged inside the respective cells. In other words, the variation in the cell configuration may be viewed as a selective removal from the cell of filling or stiffening elements. Basically, it is possible to determine, at the design stage, the configuration of the lattice, namely its appearance, a mesh opening of each cell and/or a greater or less consistency of the lattice, defining which zones of the lattice require said variation in the configuration or variation of energy absorption capacity, and providing suitable filling elements, or crosspieces, bridge elements, transverse walls, or similar filling, stiffening and/or connecting elements which connect in a "bridge-like" manner two parts or zones of the cells or close and fill at least partially said cell.
This therefore gives rise to a design method which is greatly simplified since, based on a basic structure or framework of the cells which form the lattice, it is possible to adjust the configuration, reducing or increasing the cavities of the cells by adding or removing the aforementioned filling, stiffening and/or connecting elements.
In one embodiment, the protection device is a single body made of a material having a consistency which is soft and flexible to the touch and formed in the manner of the aforementioned lattice. Therefore said filling, stiffening and/or connecting elements are formed as one piece with said tubular bodies. In a preferred embodiment, the material is for example rubber, even more preferably it is a nitrile rubber such as polynorbornene processed by means of moulding, in particular injection-moulding.
Consequently, by providing a lattice body made of flexible material with a suitable resistance suitable for energy absorption such as a rubber, a foamed material, a so-called honeycomb material, it is possible to vary the rigidity of the lattice body and obtain zones which offer a greater or lesser degree of protection by means of variation of the way in which the cells or the tubular bodies are filled with said elements arranged inside the cells.
The cavity of each cell may be a through-cavity and therefore the cells may be tubular cells with a through-cavity. As a result, in this case, the cross-section of the cavity corresponds to a basic mesh opening of the lattice. Also, as a result, by means of a systematic subdivision of such a cavity it is possible to reduce the mesh opening and obtain a smaller mesh opening.
Alternatively, the cells may be hollow bodies with a bottom wall shaped substantially in the manner of small cups.
In one embodiment of the present disclosure, the protection device has a strip or band-shaped portion formed as one piece with the lattice body and located in a perimetral zone of the lattice body. This strip or band-shaped portion may be continuous along the perimeter of the tubular body or along sections.
This strip or band-shaped portion has a height smaller than a height of the cells which define the lattice body and is a portion suitable for being pierced by means of needles in order to receive stitching threads and allow fixing of the protection devices to a garment or to another device. In particular, the protection device may be inserted in a pocket of a garment or fixed on an inner side of the garment and stitched there along the perimeter.
It is also possible for portions with a lower height to be provided in other zones of the protection device which are also distant from the perimetral zone and where the device must be stitched to a remaining part of a garment or of another device.
The protection device may be shaped so as to ergonomically match the form of the articulation for which it is intended, for example it may have a cup or shell-like configuration, so that it can be arranged opposite an elbow, shoulder or knee.
In accordance with further embodiments of the present disclosure, the protection device may be a back shield suitable for protecting the back of a user. It therefore consists of an independent protection accessory, which, like an insert, is adapted to be inserted in a garment for dynamic sports, preferably in combination with other energy absorption structures, so as to provide more effective protection of the back, or may be configured to be worn on its own by a user, for example by means of straps.
The lattice body may be associated with other energy absorption layers for ensuring a suitable energy absorption and compliance with the existing standards. Further characteristic features and modes of use forming the subject of the present disclosure will become clear from the following detailed description of preferred examples of embodiment thereof, provided by way of a non-limiting example.
It is evident, however, that each example of embodiment may have one or more of the advantages listed above; in any case it is not required that each embodiment should have simultaneously all the advantages listed.
It should also be understood that the scope of the present disclosure includes all the possible combinations of embodiments indicated above and those described with reference to the following detailed description.
Reference will be made to the figures of the accompanying drawings in which:

Figure 1 shows a plan view of a protection device according to an embodiment of the present disclosure;
Figure 2 shows a plan view of the protection device according to Figure 1, as though flattened in a plane;
Figure 3 shows a cross-sectional view along the sectioning line III-III of Figure 2;
Figure 3a shows the sequence of a progressive subdivision of a basic geometrical element or pattern according to the present disclosure;
Figure 4 shows a perspective view from one side of the protection device according to Figure 1;
Figure 5 shows a perspective view from another side of the protection device according to Figure 1;
Figure 6 shows a plan view of a variation of embodiment of a protection device according to the present disclosure;
Figure 7 shows a plan view of the protection device according to Figure 6, as though flattened in a plane;
Figure 8 shows the sequence of a progressive subdivision of a basic geometrical element or pattern according to the present disclosure for the protection device shown in Figure 6;
Figure 9 shows a perspective view from one side of the protection device according to Figure 6;
Figure 10 shows a perspective view from another side of the protection device according to Figure 6;
Figure 11 shows a garment including a plurality of protection devices according to respective embodiments of the present disclosure.

With reference to the accompanying figures, the reference numbers 10, 100 indicate a number of embodiments of a protection device for dynamic sports or for other activities according to the present disclosure, in which this device is adapted to provide effective protection against knocks or impacts during the practice of dynamic sports, or extreme sports in general, or other activities. "Protection device" is understood as meaning in particular that the device is a protector suitable for being worn (directly or fitted to a garment) by a user who is practising a dynamic sport or other activity, in order to protect the user's body from possible knocks or impacts which may occur during the course of this activity. These protection devices are particularly suitable for protecting articulation zones of the user's body such as the elbows, knees, shoulders, hips, etc.
The protection devices 10, 100 shown in the accompanying figures may differ in terms of their form and overall configuration depending on the articulation with which they are associated.
In particular the protection device 10 shown in Figures 1-5 is a device suitable for protection of the shoulders and the protection device 100 shown in Figures 6-10 is intended for protection of the knees and the elbows. The two devices differ in particular owing to their form which is shorter and wider for protection of the shoulders, and longer for protection of the knees and elbows.
It is to be understood that the protection devices 10, 100 according to the two embodiments are based on the same common principles illustrated in the present disclosure and will therefore be described together in relation to these common characteristics.
In particular, the protection device 10, 100 is made of a flexible material and comprises, preferably formed as one piece, a lattice body 12 having a first side 13 and a second side 14 opposite to the first side 13. The lattice body 12 is in the example a layer or sheet of flexible material with a substantially plate-like form. For example, the protection device 10 is manufactured by means of moulding, so as to obtain easily a single lattice body 12.
Even more precisely, in the example, the flexible material from which the lattice body 12 is made is a rubber, even more preferably it is a nitrile rubber, for example polynorbornene, having a Shore A hardness value of between 30 and 40 and a springback elasticity of between 0 and 10%. It is possible to use other materials such as rubbers, expanded polymers, polymeric honeycomb structures or metals. The lattice body 12 has a plurality of cells 15 or tubular bodies arranged alongside each other so that the side walls of a tubular body are common to the side walls of adjacent tubular bodies or cells 15.
The cells 15 have been indicated by means of bold lines in Figures 2, 3a, 7 and 8. In the example of embodiment shown in the figures, the cells have a polygonal form, such as a hexagonal form.
Even more particularly, in the embodiment shown in the figures, the cells 15 have through-cavities 16 which extend between the first side 13 and the second side 14 of the lattice body 12. The through-cavities 16 of the cells define a mesh opening of the lattice.
According to an aspect of the present disclosure, in order to vary a configuration of the protection device 10, 100, it is envisaged subdividing each cell 15 into increasingly smaller fractions or segments so as to obtain a lattice having a smaller lattice mesh opening, and preferably in the specific case, a greater rigidity of the protection device.
The reduction in size of the lattice mesh opening may be achieved by providing crosspieces 17 or bridge-like connectors which connect zones of the side wall of a same single cell 15. In the embodiment shown, the crosspieces 17 connect vertices of the polygon, such as the aforementioned hexagon, which results in the internal geometric subdivision thereof so as to provide geometric forms such as a rhombus and triangle.
Even more particularly, as can be seen in Figures 3a to 8, starting with a cell 15 without crosspieces as shown on the right in these figures, it is possible to provide a first bent stiffening crosspiece 17 which connects two vertices of the hexagon separated by an intermediate vertex of the hexagon. In order to obtain a greater rigidity, it is possible to provide a further stiffening crosspiece 17 which connects the first stiffening crosspiece 17 to another vertex of the hexagon which is adjacent and consecutive to one of the two aforementioned vertices so as form a crosspiece 17 which is substantially Y-shaped. In order to obtain an even greater rigidity, it is possible to provide a further stiffening crosspiece which connects the Y-shaped stiffening crosspiece to another vertex of the hexagon which is adjacent and consecutive to the other of the two aforementioned vertices so as to form a crosspiece 17 substantially in the form of an X, leaving free only two opposite vertices of the hexagon. In order to obtain a maximum rigidity, it is possible to envisage a further stiffening crosspiece which passes through the X in the central zone and connects the two vertices of the hexagon left free so as to form a star-like stiffening member inside the cell 15. In particular, the subdivision of the geometry of the basic cell results in a varied segmentation of the hexagon so as to produce rhombuses and triangles which are in all cases inscribed within the hexagonal basic cell.
It is pointed out that preferably the walls of the cells and the crosspieces which form the lattice are always arranged perpendicularly with respect to the normal of the surface, this constructional methodology ensuring a maximum performance in terms of impact energy absorption in any direction of origin of the external force, owing to the perpendicularity of the walls which produce the impact absorption effect.
It can be seen that the protection devices 10, 100 have central zones of the lattice with a smaller lattice mesh opening and/or a greater rigidity in the central region of the lattice 12. Therefore, the protection device 10, 100 is designed to envisage a subdivision of the cells gradually increasing from a peripheral zone towards a central zone of the protection device 10, 100.
Some cells 15 have been highlighted in Figure 2 and Figure 7 in order to show how the cells have a mesh opening which is much smaller in the centre of the base element 12 where maximum protection is required, and a much larger mesh opening in a perimetral zone where less rigidity and a greater capacity of the protection device to adapt ergonomically to the anatomy of the articulation of the user's body is required.
It is to be understood that the lattice body 12 may not be formed solely by the hexagonal shaped cells 15 and that these cells represent only some of the cells which form the lattice body. It is pointed out that, in the embodiment shown in the drawings, the general optical effect is always based on a hexagonal shaped cell, but in reality on some occasions one side of the hexagon wall is opened so as to obtain a more linear and homogeneous increase in the actual rigidity, with a corresponding effect in visual terms.
With this arrangement of parts a protection device 10, 100 with a high degree of flexibility in terms of performance is obtained, ensuring satisfactory breathability and lightness owing to the through-cavities 16, satisfactory protective capacity owing to the presence of the cells 15 and the respective stiffening crosspieces 17, and satisfactory flexibility and mobility owing to cells which do not have crosspieces or have fewer of them towards the outermost areas.
It is pointed out moreover that, in accordance with the variation in protective capacity, the base element 12 has a greater height H1 in a central zone corresponding to a maximum zone of curvature and maximum degree of protection required, and a smaller height H2 in a perimetral zone, where a smaller degree of protection is required. For example, H1 is equal to 9 mm and H2 is equal to 5 mm. Moreover, as can be seen from the drawings, the lattice body 12 has a strip or band-shaped portion 25 or a flat portion which extends along the perimeter and more preferably along the entire perimeter. This strip-shaped portion 25 has a height much smaller than H2 and forms a weakened zone which is sufficiently weak for it to be pierced by a sewing needle. It therefore consists of a zone which may be pierced by a needle. In this way, the protection device may be fastened to a garment by means of stitching, for example it may be stitched onto an inner side of a garment 20. A stitch 23 is indicated by means of a broken line in Figures 4, 5 and 10.
With reference to Figure 11, this shows a garment 20, more precisely a motorcyclist's suit.
The garment 20 shown in Figure 11 includes a plurality of protection devices 10, 100, each intended to be arranged opposite a respective articulation of the body of the user who is wearing the garment 20, such as the shoulders, hips, elbows and knees.
In the example shown, the protection device 10, 100 is fixed perimetrally onto the garment 20 by means of stitching and is covered, for example, by an external barrier, such as an external layer, for example a soft cushion layer or a leather portion. The protection device 10, 100 may therefore be arranged between the user and the external barrier. Basically, the protection device 10 is enclosed within the garment 20 by the external barrier 20.
The protection device 10, 100 could also be inserted inside a pocket of the garment 20.
Similar articles may be made so as to protect other parts of the body of a user practising dynamic sports, such as an elbow protector, knee protector, neck protector, or shoulder-blade protector, with the possibility of wearing the protection device also externally.
It should be noted that, in the examples, the protection devices 10, 110 have been shown with an elliptical and elongated form, having a curved and rounded profile. It is understood that the scope of the present disclosure includes also protection devices with different forms and profiles likewise suitable for being associated with the user's body so as to ensure adequate protection.
The subject-matter of the present disclosure has been described hitherto with reference to preferred embodiments thereof. It is to be understood that there may be other embodiments which relate to the same inventive idea, all falling within the scope of protection of the claims attached here below, such as protection devices for the back, knuckles, flanks, shinbone, etc., and that the protection device could be developed so as to provide complete coverage of extensive parts of the body, such as the limbs, creating a protective exoskeleton with varied functions depending on the area which the protector is intended to cover.

Claims

Method for manufacturing a protection device, wherein the method includes the steps of
a) designing a lattice body comprising a plurality of cells (15), or internally hollow units, or units having a cavity (16);

b) varying the capacity of energy absorption of one or more zones of said lattice body (12), a consistency or configuration of said lattice body, and/or a mesh opening of each cell (15) of said lattice body, by subdividing one or more cells (15) of said one or more zones of said lattice body (12) into two or more cell fractions (15), or by filling at least a part of a cavity (16) of one or more of said cells (15) of said one or more zones of the lattice body (12),
manufacturing the lattice body in accordance with steps a) and b).
Method according to claim 1, wherein the cell (15) has a fixed size or mesh opening.
Method according to claim 1 or 2, wherein said cell (15) is a tubular body, a sleeve-like body, a ring-like body or a similar closed and hollow body of given cross-section, which has a repeating pattern in the lattice body (12) so as to form the lattice.
Method according to any one of the preceding claims, wherein subdivision of the cells (15) is performed by providing crosspieces, bridge elements, transverse walls, or similar stiffening or filling elements which connect two parts or zones of a side wall which defines the cell (15).
Method according to any one of the preceding claims, wherein the lattice body (12) is shaped as a cup or shell and is configured so as to be associated with an articulation zone of a user's body, such as a shoulder, a knee, and/or an elbow.
Method according to any one of the preceding claims, wherein the lattice body (12) is manufactured so that the cells (15), which are subdivided into fractions, are located in a central zone of the lattice body (12).
Method according to any one of the preceding claims, wherein said cavity is a through-cavity (16).
Protection device (10, 110), said protection device (10, 110) comprising a lattice body (12) comprising a plurality of cells (15), or internally hollow units, or units having a cavity, wherein the cells (15) are repeated in said lattice body (12); wherein, in one or more zones of said lattice body, one or more cells (15) is/are subdivided into two or more cell fractions, or at least a part of a cavity (16) of one or more of said cells (15) is partially occupied by stiffening elements, connectors and/or filling elements.
Protection device (10, 110), said protection device (10, 110) comprising a lattice body (12) comprising a plurality of cells (15), or internally hollow units, or units having a cavity, which are repeated in said lattice body (12); wherein said lattice body (12) comprises at least a first zone in which one or more cells (15) define(s) a first mesh opening of the lattice and a second zone in which one or more cells (15) is/are partially occupied by stiffening elements, connectors and/or filling elements and/or has a second mesh opening or aperture smaller than the first mesh opening.
Protection device (10, 110) according to claim 8 or claim 9, wherein said cell (15) is a tubular body, a sleeve-like body, a ring-like body or a similar closed and hollow body of given cross-section, which has a repeating pattern in the lattice body (12) so as to form the lattice.
Protection device (10, 110) according to claim 8, claim 9 or claim 10, wherein said stiffening elements, connectors and/or filling elements include crosspieces, bridge elements, transverse walls, or similar stiffening elements connecting in a "bridge-like" manner two parts or zones of a side wall which defines the cell (15).
Protection device (10, 110) according to any one of the preceding claims 8 to 11, wherein the lattice body (12) is shaped as a cup or shell and is configured to be associated with an articulation zone of a user's body, such as a shoulder, a knee and/or an elbow.
Protection device (10, 110) according to any one of the preceding claims 8 to 12, wherein said first zone is a perimetral zone of the lattice body (12) and said second zone is a zone of the lattice body (12) more central than the first zone.
Protection device (10, 110) according to any one of the preceding claims 8 to 13, wherein the lattice body (12) comprises a portion (25) having a height lower than a cell height, said portion with a lower height being configured to be pierced by a sewing needle.
Protection device (10, 110) according to claim 14, wherein the portion with a lower height is a strip or band-shaped portion made as one piece with the lattice body (12) and located in a perimetral zone of the lattice body.
Protection device according to any one of the preceding claims 8 to 15, wherein the cell (15) has a fixed size or mesh opening.
Garment including a protection device (10, 100) according to any one of claims 8 to 16.