GB2615573A

GB2615573A - Protective pad for incorporation into a garment

Info

Publication number: GB2615573A
Application number: GB2201814.7A
Authority: GB
Inventors: Nicholas Travell Geoffrey; Joseph Travell Aaron
Original assignee: Planet Knox Ltd
Current assignee: Planet Knox Ltd
Priority date: 2022-02-11
Filing date: 2022-02-11
Publication date: 2023-08-16
Also published as: GB202201814D0

Abstract

A protective pad 10 for incorporation into a garment, the pad comprising a flexible body 12 having an outer edge 14, an upper surface 16 and a lower surface 18, the body having one or more discontinuities 20 extending inwardly from the outer edge, wherein each of the one or more discontinuities is defined by opposing complementary inner edge surfaces 22a, 22b that are each inclined relative to the upper and lower surfaces from which they extend. The inclination of the edges permits further sliding or overlap of the edges than is possible with wedge-shaped discontinuities (figs. 4A-5C). The pad may also comprise a plurality of protrusions 24 separated by channels 26 which facilitate additional flexing of the pad. The pad may be added to compartments in a garment or attached directly to the garment e.g. by moulding or sewing (figs. 7A-7B).

Description

PROTECTIVE PAD FOR INCORPORATION INTO A GARMENT

[0001] This invention relates to a protective pad for incorporation into a garment. The protective pad may provide impact protection and/or other protection to the wearer of the garment.

BACKGROUND

[0002] It is known to complement certain garments with protective pads to provide impact and/or other protection to the wearer of the garment. For example, clothing worn by motorcycle users, cyclists and skiers often incorporates such protective pads. In many instances, the protective pads are provided in a plurality of pockets located in the garments to protect body parts that may be particularly vulnerable to injury should the wearer of the garment be involved in a motorcycle accident. For example, the pockets may be located in the shoulder, elbow and/or knee portions of the garments. The protective pads may be made of any suitable material that may confer a protective function. In certain known examples, the protective pad comprises a flexible elastomeric material that provides impact protection whilst permitting movement of the joints and limbs of the garment wearer. Nevertheless, being planar in shape, as the protective pads flex to conform around a moving joint of the garment wearer (e.g. a shoulder, elbow or knee), they tend to buckle and create bulges that inhibit further flexing of the protective pad and become visible through the garment and/or uncomfortable to the wearer.

[0003] Certain protective pads include slits or wedge-shaped cutouts extending from an outer edge of the pad to provide additional flexibility. However, there still remains a need for providing an improved protective pad that provides better conformity to the moving joints of the wearer of the garment in which the protective pads reside and that are less prone to buckling.

[0004] It is an object of certain embodiments of the present invention to overcome at least some of the disadvantages associated with the prior art.

BRIEF SUMMARY OF THE DISCLOSURE

[0005] In accordance with an aspect of the present invention there is provided a protective pad for incorporation into a garment, the protective pad comprising a body having an outer edge, an upper surface and a lower surface, the body having one or more discontinuities extending inwardly from the outer edge, wherein each of the one or more discontinuities is defined by opposing complementary inner edge surfaces that are each inclined relative to the upper and lower surfaces from which they extend.

[0006] In certain embodiments, the protective pad may be flexible such that the opposing inner edge surfaces are moveable relative to one another. The opposing inner edge surfaces may be slidable against one another when in contact with one another.

[0007] In certain embodiments, the body may comprise a flexible material. The flexible material may comprise an elastomeric material. In certain embodiments, the flexible material may comprise polyurethane foam. In other embodiments, the flexible material may comprise any one or more of thermoplastic polyurethane (TPU), a polyethylene (e.g. thermoplastic elastomer styrene-ethylene-butylene-styrene (TPE SEBS), low density polyethylene (LDPE), or ultra-high molecular weight polyethylene (UHMVVPE)), or fibrous materials or fibre-containing composites (e.g. containing carbon or glass fibres). In other embodiments, the flexible material may comprise thermoplastic rubber (TPR), or a non-Newtonian fluid or any material that changes its viscosity under load (wherein such fluids are subsequently set, cured or otherwise hardened).

[0008] In certain embodiments, one of the opposing complementary inner edge surfaces may be inclined relative to the upper surface by between 5° and 85° and the other of the opposing complementary inner edge surfaces may be inclined relative to the lower surface by between 5° and 85°. In preferable embodiments, the opposing complementary inner edge surface may be inclined relative to the upper surfaces by between 5° and 50°, and optionally between 20° and 29°.

[0009] In certain embodiments, the body may comprise a plurality of protrusions separated by a plurality of channels, wherein the channels facilitate flexing of the protective pad. The plurality of protrusions may comprise a tessellation of shapes each separated by the plurality of channels. In certain embodiments, the shapes may comprise hexagonal columns.

[0010] The plurality of protrusions may or may not extend onto the opposing inner edge surfaces.

[0011] The body may comprise a unitary component or an assembly of components.

[0012] In accordance with another aspect of the present invention there is provided a garment comprising one or more protective pads described above. The garment may comprise one or more enclosed compartments, wherein each of the one or more enclosed compartments may house one of the one or more protective pads. The protective pads may be located at one or more of a knee region, a shoulder region, or an elbow region, of the garment.

[0013] In accordance with another aspect of the present invention there is provided a method of manufacturing the above-described protective pad, the method comprising using hot forming, cold forming, injection moulding, or additive manufacturing (i.e. 3D printing) to produce the protective pad.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which: Figure 1 is a top-down view of a protective pad according to an embodiment of the present invention; Figure 2 is a perspective view of the protective pad of Figure 1; Figure 3 is a further perspective view of the protective pad of Figure 1; Figure 4A is a schematic top-down view of a part of a protective pad in accordance with the prior art, wherein the protective pad is in a first configuration; Figure 4B is a schematic top-down view of a part of the prior art protective pad of Figure 4A in a second configuration; Figure 4C is a schematic side-view of a part of the prior art protective pad of Figure 4A in the second configuration; Figure 5A is a schematic top-down view of a part of the protective pad of Figures 1-3, wherein the protective pad is in a first configuration; Figure 5B is a schematic top-down view of a part of the protective pad of Figures 1-3 in a second configuration; Figure 5C is a schematic side-view of a part of the protective pad of Figures 1-3 in the second configuration; Figure 6 is a schematic side-view of a part of the protective pad of Figures 1-3 in the first configuration; Figure 7A shows an upper body garment in accordance with an aspect of the present invention; and Figure 7B shows a lower body garment in accordance with an aspect of the present 25 invention.

DETAILED DESCRIPTION

[0015] Figure 1 is a top-down view of a protective pad 10 according to an embodiment of the present invention.

[0016] The protective pad 10 is configured for incorporation into a garment to provide the wearer of the garment a degree of protection. As is described in more detail below, the protective pad may be incorporated into a garment by manufacturing the protective pad separately to the garment and subsequently inserting or otherwise fixing the protective pad on or in the garment, or the protective pad may be incorporated into a garment by forming the protective pad directly into or on the garment. The protective pad 10 is preferentially positioned in the garment in regions of the garment that are adjacent to joints of the wearer of the garment.

For example, the protective pad 10 may be positioned in the garment in or around a shoulder region, an elbow region and/or a knee region of the garment.

[0017] The protective pad 10 may provide the wearer of the garment with protection that includes, but is not limited to, impact protection, frictional protection and puncture protection from sharp objects. As an example, protective pads 10 according to embodiments of the present invention may be worn by a motorcycle user to provide protection to the motorcycle user in the event of a motorcycle accident. Other examples of relevant users include, but are not limited to, skiers and cyclists. Of course, users of the present invention are not limited to such users, and any user requiring similar protection may advantageously make use of the protective pads 10.

[0018] The protective pad 10 comprises a body 12. In the embodiment shown in the Figures, the body 12 comprises a unitary component (i.e. a component that is formed as a single piece and remains so). In alternative embodiments, however, the body 12 may comprise multiple components that are assembled together during manufacture. The body 12 may comprise a flexible material. For example, the flexible material may be an elastomeric material. In certain embodiments, the flexible material may comprise any one or more of a polyurethane (e.g. polyurethane, polyurethane foam, or thermoplastic polyurethane (TPU)), a polyethylene (e.g. thermoplastic elastomer styrene-ethylene-butylene-styrene (TPE SEES), low density polyethylene (LDPE), or ultra-high molecular weight polyethylene (UHMWPE)), or fibrous materials or fibre-containing composites (e.g. containing carbon or glass fibres). In other embodiments, the flexible material may comprise thermoplastic rubber (TPR), or a non-Newtonian fluid or any material that changes its viscosity under load (wherein such fluids are subsequently set, cured or otherwise hardened).

[0019] As shown in Figures 2 and 3, the body may have a generally curved profile in an unflexed and natural configuration. In other embodiments, the body 12 may be formed to take on another shape in its unflexed and natural configuration.

[0020] The body 12 may be formed by any suitable manufacturing method. In certain non-limiting examples, the body 12 is formed by moulding. The moulding may comprise cold casting wherein one or more materials are poured into a mould which is subsequently closed, and the constituent materials react to create a foam that expands to conform and to the shape defined by the mould and solidify. In other embodiments, the moulding may comprise hot forming, wherein one or more materials are poured into a mould and allowed to solidify therein. The materials may already be in a foamed state prior to entry into the mould. Polyurethane may be a particularly preferable material for use in either cold casting or hot forming methods, although the present invention is not limited to such. In other embodiments, the body 12 may be formed by injection moulding, e.g. using any of the materials listed above. In alternative embodiments, the body 12 may be formed by additive manufacturing (i.e. 3D printing).

[0021] The body 12 has an outer edge 14 that delimits the body 12, an upper surface 16 and a lower surface 18 opposite the upper surface 16. The body 12 additionally comprises a plurality of discontinuities 20 that comprise breaks in the material forming the body 12. Each of the plurality of discontinuities 20 extends inwardly from the outer edge 14 and terminates before reaching another portion of the outer edge 14 (as otherwise the discontinuities 20 would removably separate a portion of the body 12).

[0022] Each of the plurality of discontinuities 20 is defined by opposing complementary inner edge surfaces 22a, 22b that are each inclined relative to the upper surface 16 and lower surface 18 from which they extend. Only one inner edge surface 22b is shown in Figures 1 and 2, whereas both inner edge surfaces 22a, 22b are visible in Figure 3. The inner edge surfaces 22a, 22b are moveable relative to one another providing a degree of freedom to the body 12. The advantages afforded by the discontinuities 20 of embodiments of the present invention are described below (together with reference to prior art arrangements for contrast).

[0023] Figures 4A, 4B and 40 show schematic views of a part of a protective pad 110 according to the prior art. Figure 4A shows a schematic top-down view of the protective pad 110 in a first configuration and Figure 4B shows a schematic top-down view of the protective pad 110 in a second configuration. Figure 40 shows a side view of the protective pad 110 in the second configuration. The protective pad 110 includes a discontinuity 120 in the form of a wedge-shaped cut out having opposing inner edge surfaces 122a, 122b. The inner edge surfaces 122a, 122b each extend perpendicularly relative to an upper surface 116 and a lower surface 118 of the protective pad 110. In the first configuration shown in Figure 4A, the inner edge surfaces 122a, 122b are not urged towards one another and so are separated from one another. In the second configuration shown in Figures 4B and 40, the inner edge surfaces 122a, 122b are urged against one another so that they abut one another. This may occur, for example, if the protective pad 110 is flexing around a joint (e.g. shoulder, elbow or knee) of a wearer of a garment containing the protective pad 110. As seen by comparing Figure 4A with Figures 4B and 4C, the inner edge surfaces 122a, 122b must travel a reasonable distance before they contact one another, and once they do contact one another, abutment between them prevents any further relative movement along the directions they were previously travelling. Therefore, either a gap exists between the inner edge surfaces 122a, 122b (as in the first configuration) or the inner edge surfaces 122a, 122b are in contact with one another (as in the second configuration) and no further relative movement is permitted therebetween without re-opening the gap. In reality, even in the second configuration, due to the wedge-shaped nature of the discontinuity 120, the inner edge surfaces 122a, 122b may not contact one another over the entire length of the discontinuity 120. Consequently, any gap existing between the inner edge surfaces 122a, 122b On either of the first or second configurations) results in a weak point in the protective pad 110, since the protective pad 110 provides less or no protective function in that region.

[0024] Figures 5A, 5B and 50 show schematic views of a part of the previously described protective pad 10 according to an embodiment of the present invention. Figure 5A shows a schematic top-down view of the protective pad 10 in a first configuration and Figure 5B shows a schematic top-down view of the protective pad 10 in a second configuration in which inner edge surfaces 22a, 22b have been urged further towards one another. Figure 5C shows a side view of the protective pad 10 in the second configuration.

[0025] As previously described and as is visible in Figure 50, the inner edge surfaces 22a, 22b are each inclined relative to the upper surface 16 and lower surface 18 from which they extend. Additionally, they extend such that they overlap with one another along an axis that is perpendicular to the upper surface 16 and the lower surface 18. Consequently, when viewed along this axis (e.g. such as the top-down views of Figures 5A and 5B), no gap exists in a direction parallel to the top surface 16 (or bottom surface 18) between the inner edge surfaces 22a, 22b in either of the first and second configurations. That is, whether or not flexing of the protective pad 10 is causing the inner edge surfaces 22a, 22b to be urged towards one another, the ability of the protective pad 10 to provide its protective function across all of its areas is not compromised in spite of the presence of the discontinuities 20. Moreover, the inclined configuration of the inner edge surface 22a, 22b permits them to slide against one another when in contact with one another. Thus, further relative movement between the inner edge surfaces 22a, 22b is possible when the inner edge surfaces 22a, 22b are in contact with one another, thereby further enhancing the flexibility of the protective pad 10 without giving rise to deformations such as buckling or bulging.

[0026] Indeed, the presence of the discontinuities 20 themselves improves the ability of the protective pad 10 to conform to non-planar surfaces (e.g. joints) without wrinkling or buckling. Consequently, the protective pad 10 may dynamically flex around a moving joint as required without buckling and without the features enabling such flexing compromising the protective properties of the protective pad 10. Protective pads 10 according to embodiments of the present invention may therefore avoid the disadvantages associated with prior art protective pads relating to buckling and bulging within a garment containing the pads. Garments containing protective pads 10 according to embodiments of the present invention may therefore permit the protective pads 10 to provide their protective functions without buckling or bulging which negatively affect the aesthetics or comfort of the garments.

[0027] Figure 6 shows a further schematic side view of a part of the protective pad 10, but in the first configuration. As mentioned above and as is clearly shown in Figure 6, any notional line running perpendicular to either of the upper surface 16 and the lower surface 18 within the bounds of the outer edge 14 and in the vicinity of the discontinuity 20 passes through the body 12. Put more simply, the inner edge surfaces 22a, 22b overlap one another.

[0028] As shown in Figure 6, the inner edge surface 22a is inclined relative to the lower surface 18 by an angle Si. Similarly, the inner edge surface 22b is inclined relative to the upper surface 18 by an angle 02. Since the inner edge surfaces 22a, 22b are opposing and complementary relative to one another, ei is substantially equal to 92. By virtue of being inclined relative to the respective lower and upper surfaces 18, 16, neither 91 nor 92 is equal to 00 or 900 (i.e. the inner edge surfaces 22a, 22b are neither parallel or perpendicular to the respective lower and upper surfaces 18, 16). In certain preferable embodiments, both 81 and 82 are between 5° and 500, and preferably between 200 and 29° (inclusive), as such arrangements permit particularly effective engagement and relative sliding of the inner edge surfaces 22a, 22b against one another. However, in other embodiments, 91 and 02 may be any value between 5° and 85° and still benefit from certain advantages of the present invention.

[0029] Figures 7A and 7B each show a garment that may incorporate one or more protective pads 10 in accordance with embodiments of the present invention. In particular, Figure 7A shows an upper body garment 30a, such as a jacket, having a pair of shoulder regions 32, and a pair of elbow regions 34. At each of the shoulder regions 32 and elbow regions 34, the garment 30a comprises an enclosed compartment 38 that is suitable for receiving and housing one of the above-described protective pads 10. Each enclosed compartment 38 may include an opening that may be opened and closed with a temporary closing means capable of retaining the protective pad 10 therein. Alternatively, each enclosed compartment 38 may receive the protective pad 10 (e.g. during manufacture of the garment 30a) and be closed in a manner such that the enclosed compartment is not re-openable without damaging the enclosed compartment 38 or garment 30a. For example, the protective pads 10 may be sewn or otherwise sealed in the enclosed compartments.

[0030] Figure 7B shows a lower body garment 30b, such as a pair of trousers, that includes a pair of knee regions 36. At each knee region 36, the garment 30b also comprises an enclosed compartment 38 that is suitable for receiving one of the above-described protective pads 10. 30 The enclosed compartments 38 may be as described above with reference to Figure 7A.

[0031] In alternative embodiments, the one or more protective pads may be incorporated into a garment by means other than insertion. In particular, the one or more protective pads may be formed directly in or on a part of a garment according to any of the manufacturing methods described above. For example, such forming may include, but is not limited to, directly moulding the one or more protective pads onto a fabric or fibrous material which may be part of a garment or sewn, or otherwise integrated into or fixed onto the garment. The term garment may be taken to mean any wearable item such that protective pads according to embodiments of the present invention having straps, a sleeve or other fixing means capable of allowing a wearer to wear the protective pad may be considered to be such a garment. Indeed, the protective pad may be formed separately and later assembled to the straps, sleeve or other fixing means (which may be a fabric or other suitable material) or the protective pad may be formed directly onto or into the straps or other fixing means.

[0032] Returning to Figures 1 to 3, the body 12 additionally comprises a plurality of protrusions 24 separated from one another by a plurality of channels 26. The channels 26 facilitate additional flexing of the protective pad 10 whilst the presence of the plurality of protrusions maintains the protective properties of the protective pad 10 in both flexed and unflexed configurations. In certain embodiments, the flexibility of the protective pad 10 may be provided by a combination of comprising an inherently flexible material and comprising the plurality of protrusions 24 and plurality of channels 26. In other embodiments, the flexibility of the protective pad 10 may be provided by comprising only one of an inherently flexible material, and the plurality of protrusions 24 and plurality of channels 26.

[0033] In certain embodiments, the plurality of protrusions 24 may comprise a tessellation of shapes each separated by the plurality of channels 26. In the non-limiting embodiment shown in Figures 1 to 3, the shapes comprise hexagonal columns, although any suitable shape may be used. In certain embodiments, such as the non-limiting embodiment shown in Figures 1 to 3, the plurality of protrusions 24 do not extend onto the opposing inner edge surfaces 22a, 22b. In doing so, the inner edge surfaces 22a, 22b remain pattern-free and smooth, thereby facilitating smooth engagement and sliding therebetween. Furthermore, in certain embodiments, such as the non-limiting embodiment shown in Figures 1 to 3, the plurality of protrusions 24 may include a combination of non-hollow protrusions 24a and hollow protrusions 24b, wherein the hollow protrusions 24b comprise channels that pass through from the upper surface 16 to the lower surface 18 and permit additional flexing of the protective pad 10. In other embodiments, the plurality of protrusions 24 may exclusively comprise either non-hollow protrusions 24a or hollow protrusions 24b.

[0034] Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0035] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0036] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS1. A protective pad for incorporation into a garment, the protective pad comprising a body having an outer edge, an upper surface and a lower surface, the body having one or more discontinuities extending inwardly from the outer edge, wherein each of the one or more discontinuities is defined by opposing complementary inner edge surfaces that are each inclined relative to the upper and lower surfaces from which they extend.
2. A protective pad according to claim 1, wherein the protective pad is flexible such that the opposing inner edge surfaces are moveable relative to one another.
3. A protective pad according to claim 2, wherein the opposing inner edge surfaces are slidable against one another when in contact with one another.
4. A protective pad according to any preceding claim, wherein the body comprises a flexible material.
5. A protective pad according to claim 4, wherein the flexible material comprises an elastomeric material. 20
6. A protective pad according to claim 4 or 5, wherein the flexible material comprises polyurethane foam.
7. A protective pad according to any preceding claim, wherein one of the opposing complementary inner edge surfaces is inclined relative to the upper surface by between 5° and 85° and the other of the opposing complementary inner edge surfaces is inclined relative to the lower surface by between 5° and 85°.
8. A protective pad according to claim 7, wherein the opposing complementary inner edge surface are inclined relative to the upper surfaces by between 200 and 29°.
A protective pad according to any preceding claim, wherein the body comprises a plurality of protrusions separated by a plurality of channels, wherein the channels facilitate flexing of the protective pad.
10. A protective pad according to claim 9, wherein the plurality of protrusions comprises a tessellation of shapes each separated by the plurality of channels.
11 A protective pad according to claim 10, wherein the shapes comprise hexagonal columns.
12. A protective pad according to any of claims 9 to 11, wherein the plurality of protrusions do not extend onto the opposing inner edge surfaces.
13. A protective pad according to any preceding claim, wherein the body comprises a unitary component.
14. A protective pad according to any of claims 1 to 12, wherein the body comprises an assembly of components.
A garment comprising one or more protective pads according to any preceding claim
16. A garment according to claim 15, comprising one or more enclosed compartments, wherein each of the one or more enclosed compartments houses one of the one or more protective pads.
17. A garment according to claim 15 or 16, wherein the protective pads are located at one or more of: a knee region, a shoulder region, or an elbow region, of the garment.
18. A method of manufacturing a protective pad according to any of claims 1 to 14, comprising using hot forming, cold forming, injection moulding, or additive manufacturing to produce the protective pad.