WO2021090264A1

WO2021090264A1 - Protective garment and relative production method

Info

Publication number: WO2021090264A1
Application number: PCT/IB2020/060475
Authority: WO
Inventors: Paolo BONETALLI; Michelangelo MERATI; Dino MERELLI; Guglielmo BELOTTI
Original assignee: Stilo S.R.L.
Priority date: 2019-11-08
Filing date: 2020-11-06
Publication date: 2021-05-14
Also published as: EP4054368A1; IT201900020610A1

Abstract

Protective garment (1) adapted to be worn and provided with at least one protective plate (2, 30, 31, 32) adapted to cover and protect a corresponding area of the user's body; said at least one protective plate (2; 30, 31, 32) comprising a monolithic slab (4) which is provided with at least two hard and rigid portions/sectors (11, 13, 15; 41, 43) that are made of hard and rigid composite material and extend substantially for the whole thickness (d) of the monolithic slab (4); and with at least one flexible portion/sector (12, 14; 42) that is made of elastomeric material (12, 14; 42), extends substantially for the whole thickness (d) of the monolithic slab (4) or for a major part of the same thickness (d), is interposed between two or more hard and rigid portions/sectors (11, 13, 15; 41, 43), and substantially seamlessly joins the same hard and rigid portions/sectors (11, 13, 15; 41, 43) along the edge.

Description

"PROTECTIVE GARMENT AND RELATIVE PRODUCTION METHOD"

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from Italian patent application no. 102019000020610 filed on November 8, 2019, the entire disclosure of which is incorporated herein by reference.

TECHNICAL SECTOR

The present invention relates to a protective garment and the relative production method.

More in detail, the present invention relates to a protective armour or vest adapted to be worn by drivers during karting races. Use to which the following disclosure will make explicit reference without however losing in generality.

STATE OF THE PRIOR ART

As is known, while driving, go-kart drivers continually bump against the lateral sides of the seat that notoriously lacks any padding. Unfortunately, in some cases the impacts can be so violent that they cause bruises or the fracture of some bones of the rib cage with all the problems that this entails.

To overcome this drawback, in recent years go-kart drivers have begun to wear a rib protector structured to protect the trunk from the impacts against the seat.

The rib protector is usually structured so as to embrace the chest and abdomen of the driver/user from behind, and is basically made up of an adjustable harness adapted to be fitted/worn by the driver/user, and of a series of platelike protective plates that are firmly fixed on the harness so as to cover as many areas as possible of the user's trunk.

More in detail, the rib protector currently mostly used in karting races are provided with three large platelike protective plates that are arranged side by side to one another, so as to respectively cover the back and the two hips of the user.

The central protective plate has a semi-rigid structure and is adapted to be placed resting on the user's back, astride the spine. Each of the two lateral plates, on the other hand, basically consists of a thick slab of hard and rigid material that is suitably curved so as to follow the profile of the user's hip.

In the more sophisticated rib protectors, moreover, the slabs of hard and rigid material are entirely made of carbon fibre embedded in a solid polymer matrix, i.e. of composite material.

Unfortunately, being made of a highly rigid composite material, the two composite-material lateral plates are unable to flex to optimally adapt to the shape of the driver's/user's hips, with the consequent major problems of comfort.

In addition, the rib protectors described above offer limited protection in the central area of the user's back.

OBJECT OF THE INVENTION

Aim of the present invention is to provide a protective armour or vest with plates of composite material, which offers a better and more extensive protection to the driver's /user's torso and is additionally more comfortable than the rib protectors currently available on the market.

In compliance with these aims, according to the present invention there is provided a protective garment as defined in claim 1 and preferably, though not necessarily, in any one of the claims dependent thereon.

According to the present invention there is also provided a production method of a protective garment made of composite material as defined in Claim 9 and preferably, though not necessarily, in any of the claims dependent thereon.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described with reference to the accompanying drawings, which illustrate an example of non-limiting embodiment, where:

- Figure 1 is a perspective view of a protective garment realized according to the teachings of the present invention, with parts in section and parts removed for clarity's sake;

- Figure 2 is a top view of the protective garment illustrated in Figure 1, with parts in section and parts removed for clarity's sake;

- Figures 3 to 8 schematically illustrate some production steps of the protective vest illustrated in Figures 1 and 2;

- Figure 9 schematically illustrates a variant of the production method of the protective vest illustrated in Figures 1 and 2; whereas

- Figure 10 is a perspective view of a second embodiment of the protective garment illustrated in Figure 1, with parts in transparency and parts removed for clarity's sake.

PREFERRED EMBODIMENT OF THE INVENTION

With reference to Figures 1 and 2, number 1 denotes as a whole a protective garment structured to protect the wearer from impacts and/or abrasions.

More in detail, the protective garment 1 is preferably structured/shaped so as to be able to cover and protect the user's trunk/torso from impacts and/or abrasions, and is therefore particularly adapted to be used/worn by drivers of go-karts or similar vehicles to protect the trunk/torso from impacts with the seat.

In other words, the protective garment 1 is preferably a rib-protecting vest capable of protecting the rib cage of the driver/user from impacts with the seat of the vehicle.

Clearly, the protective garment 1 could also be used by motorcyclists, firefighters, civil protection personnel, and any other person who needs to protect the trunk and/or other parts of the body from impacts and abrasions.

With reference to Figures 1 and 2, the protective garment 1, or rather the rib-protecting vest, comprises: a large protective plate 2 with an oblong and platelike structure, which is preferably substantially C-bent so as to be able to embrace the user's torso from behind, and more specifically the user's chest and abdomen from behind; and preferably a support harness 3, optionally of the adjustable type, which is adapted to be fitted/worn by the user and is fixed/attached to the protective plate 2 so as to be able to stably support the same protective plate 2, keeping it adherent to the user's body.

The protective plate 2, in turn, is basically made up of, or in any case comprises a large monolithic slab 4 of adequate thickness, which is generally made of a hard and rigid composite material, and is additionally provided with one or more platelike portions or sectors that are made of elastomeric material, and extend for a prevalent/major part of the overall thickness d of the slab 4, so as to allow the monolithic slab 4 to flex locally in an elastic manner.

More in detail, the portion (s)/sector(s) of elastomeric material preferably take up at least 80% of the overall thickness d of the monolithic slab 4.

In other words, the monolithic slab 4 is a platelike monolithic body provided with two or more rigid portions/ sectors, which are made of hard and rigid composite material and extend substantially for the whole thickness d of the monolithic slab 4; and with at least one flexible portion/ sector made of elastomeric material, which takes up at least 80% of the thickness d of the monolithic slab 4, is interposed between two or more rigid portions/sectors, and substantially seamlessly joins the immediately-adjacent rigid portions/sectors along the edge.

The portions/sectors made of hard and rigid composite material and the portion (s)/sector(s) made of elastomeric material are therefore contiguous and complementary to each other.

More in detail, each rigid portion/sector is preferably formed by one or more superimposed layers of fibres, preferably synthetic, suitably intertwined and/or overlapping each other, and embedded in a solid polymeric matrix.

Each flexible portion/sector, on the other hand, is preferably formed by a thick and homogeneous layer of elastomeric material, optionally of the thermoplastic type.

In addition, the or each flexible portion/sector preferably takes up/extends substantially for the whole thickness d of the monolithic slab 4.

In other words, the thick and homogeneous layer of elastomeric material has a thickness substantially equal to the thickness d of the monolithic slab 4.

Preferably, the monolithic slab 4 is moreover stably/ permanently substantially C-bent so as to be able to embrace the user's torso from behind, and more specifically the user's chest and abdomen.

In addition, the thickness d of slab 4 preferably ranges between 1 and 10 mm (millimetres).

With reference to Figures 1 and 2, preferably the protective plate 2 additionally comprises a shock-absorber pad or a lining 5, which is made of soft and/or elastically deformable material and is arranged to cover, preferably integrally, the inner face of the monolithic slab 4, i.e. the face turned in use towards the user's body.

Optionally, the outer face of monolithic slab 4 is moreover covered, preferably substantially entirely, by a coating layer or film 6 made of hard and flexible material.

Preferably, the coating layer or film 6 is additionally made of composite material. Clearly, the coating layer or film 6 can also be made of homogeneous polymeric material. More in detail, in the example shown, the monolithic slab 4, or rather each rigid portion or sector of monolithic slab 4, is preferably formed by at least one and, more conveniently, a plurality of overlapped layers of carbon fibres and/or glass fibres and/or aramid fibres (Kevlar) and/or polyester fibres (Vectran) and/or polyamide fibres (nylon), suitably intertwined and/or overlapping each other, and embedded in a solid polymer matrix. Preferably, the polymeric matrix is furthermore an epoxy thermosetting resin.

Alternatively, the solid polymer matrix can be a phenolic or polyester thermosetting resin.

Each flexible portion or sector of monolithic slab 4, on the other hand, preferably basically consists of a layer of vulcanized rubber or other similar elastomeric material, of adequate thickness, which joins, along the edge and seamlessly, the adjacent portions/sectors made of hard and rigid composite material.

Preferably, the layer of vulcanized rubber or other similar elastomeric material additionally has a thickness substantially equal to the overall thickness d of the monolithic slab 4.

With reference to Figures 1 and 2, in the example shown, in particular, the monolithic slab 4 is preferably divided longitudinally into a series of contiguous bands or segments, which are alternatively made of hard and rigid composite material or of elastomeric material, and which preferably also take up the whole width w of the monolithic slab 4.

Preferably, the various bands or segments made of hard and rigid composite material and the bands or segments made of elastomeric material additionally have a substantially specular arrangement with respect to the midplane M of the monolithic slab 4, or rather of the protective garment 1.

More in detail, the monolithic slab 4 is preferably provided with a large central rigid band or segment 11, which is made of hard and rigid composite material, is preferably substantially rectangular in shape, and is adapted to be placed resting on the user's back, astride the spine; with a first pair of intermediate flexible bands or segments 12, which are made of elastomeric material, are arranged on opposite sides of the central band or segment 11, take up the whole width w of the monolithic slab 4, and seamlessly join the central band or segment 11 along the edge; and with a first pair of rigid lateral bands or segments 13, which are made of hard and rigid composite material, take up the whole width w of the monolithic slab 4, are each placed adjacent to a respective intermediate band or segment 12, on the opposite side with respect to the central band or segment 11, and seamlessly join the same lateral band or segment 12 along the edge.

Clearly the two intermediate flexible bands or segments 12 take up a prevalent/major part of the overall thickness d of the slab 4.

More in detail, the two intermediate flexible bands or segments 12 preferably take up substantially the whole thickness d of monolithic slab 4.

The monolithic slab 4 is therefore able to flex/bend in elastic manner at the two intermediate bands or segments 12.

Preferably the central rigid band or segment 11 is moreover arranged astride the midplane M, and is optionally dimensioned so as to extend roughly from one axillary cavity of the user to the other.

The two intermediate flexible bands or segments 12, on the other hand, preferably have a length I₂ lower than the length t_\ of the central band or segment 11. Similarly, the two lateral rigid bands or segments 13 preferably have a length 1₃ lower than the length t_\ of the central rigid band or segment 11, and optionally even greater than the length

I₂ of the two intermediate flexible bands or segments 12. With reference to Figures 1 and 2, preferably the monolithic slab 4 is moreover provided with a second pair of intermediate flexible bands or segments 14, which are made of elastomeric material, take up the whole width w of monolithic slab 4, are arranged each adjacent to a respective lateral rigid band or segment 13, on the opposite side with respect to the intermediate band or segment 12, and seamlessly join the same lateral rigid band or segment 13 along the edge; and with a second pair of lateral rigid bands or segments 15, which are made of hard and rigid composite material, take up the whole width w of monolithic slab 4, are arranged each adjacent to a respective intermediate flexible band or segment 14, on the opposite side with respect to the lateral rigid band or segment 13, and seamlessly join the same intermediate flexible band or segment 14 along the edge.

Clearly also the two intermediate flexible bands or segments 14 take up a prevalent/major part of the overall thickness d of the slab 4.

More in detail, also the two intermediate flexible bands or segments 14 take up substantially the whole thickness d of monolithic slab 4.

The monolithic slab 4 is therefore able to flex/bend in elastic manner also at the two intermediate flexible bands or segments 14.

Furthermore, similarly to the intermediate flexible bands or segments 12, the two intermediate flexible bands or segments 14 preferably have a length £4 lower than the length

£i of the central band or segment 11. Preferably the length

£4 of the two intermediate flexible bands or segments 14 is moreover lower than the length £₃ of the lateral rigid bands or segments 13 and/or than the length £2 of the intermediate flexible bands or segments 12. Similarly, the two lateral rigid bands or segments 15 preferably have a length £5 lower than the length £1 of the central rigid band or segment 11. Preferably the length £5 of the two lateral rigid bands or segments 15 is furthermore greater than the length £3 of the lateral rigid bands or segments 13 and/or than the length £4 of the intermediate flexible bands or segments 14 and/or than the length £2 of the intermediate flexible bands or segments 12.

The coating layer or film 6, on the other hand, has a nominal thickness preferably lower than or equal to 10% of the overall thickness of monolithic slab 4, and is preferably made of a composite material formed by one or more overlapped layers of fabric of carbon fibre and/or glass fibres and/or aramid fibres (Kevlar) and/or polyester fibres (Vectran) and/or polyamide fibres (nylon) appropriately intertwined and/or overlapping each other, embedded in a solid polymeric matrix.

Clearly, the thickness of the coating layer or film 6 must be sufficiently reduced so not to hinder the flexion of monolithic slab 4 at the intermediate bands or segments 12 and 14.

In addition, the coating layer or film 6 must be made of a composite material chemically compatible with the composite material forming the various bands or segments of hard and rigid composite material 11, 13 and 15 of the monolithic slab 4.

With reference to Figures 1 and 2, the support harness 3, on the other hand, preferably comprises a pair of shoulder straps 20 which connect the central band or segment 11 of the monolithic slab 4 directly to the two lateral bands or segments 15, and/or a front strap 21 which connects the two lateral bands or segments 15 to one another and allows the monolithic slab 4 to be tightened on the user's trunk/torso. Operation of protective garment 1, or rather of the rib-protecting vest, is easily inferable from what described above and does not require further explanations.

As regards the protective plate 2, the production of protective plate 2 envisages making the monolithic slab 4, and then applying/fixing, preferably by gluing, the shock- absorber pad or a lining 5 on the inner face of the monolithic slab 4.

Alternatively, the shock-absorber pad or a lining 5 can be fixed on the monolithic slab 4 by means of screws, rivets or other mechanical anchoring members.

Furthermore, in the example shown, the coating layer or film 6 is preferably made directly on the monolithic slab 4, during the production of the same slab.

More in detail, the monolithic slab 4 is made with the following production method that allows to realize a plate like monolithic body provided with a plurality of portions/ sectors of hard and rigid composite material and with one or more portions/sectors of elastically-deformable elastomeric material, contiguous and complementary to each other.

Clearly, the portions/sectors of hard and rigid composite material and the portions/sectors of elastomeric material seamlessly join to one another along the edge. The portions/sectors of hard and rigid composite material, moreover, substantially extend for the whole thickness of the platelike monolithic body, whereas the portions/sectors of elastomeric material extend substantially for the whole thickness of the platelike monolithic body or for a major/ prevalent part of the same thickness.

The production method of monolithic slab 4 will be described assuming that a mould 100 is already available with a cavity that copies in negative the shape of the monolithic slab 4 to be produced, and that it is desired to produce a monolithic slab 4 made of hard and rigid composite material, which is provided with the bands or segments of elastomeric material 12 and 14, and in which the bands or segments of elastomeric material 12 and 14 take up the whole thickness d of monolithic slab 4.

With reference to Figure 3, the production method of monolithic slab 4 firstly provides for placing/laying, on the inner surface of the mould 100, at least one sheet of pre-impregnated fabric 101, i.e. a sheet formed by one or more pieces of fabric which are embedded in the preferably thermosetting, semi-fluid resin, while leaving uncovered the areas of the mould 100 corresponding to the flexible portions /sectors of monolithic slab 4 to be made, i.e. the areas corresponding to the bands or segments of elastomeric material 12 and 14.

In the example shown, in particular, the sheet of pre impregnated fabric 101 is preferably divided into a series of substantially rectangular parts/pieces/squares, separated and distinct from one another, which are placed/laid on the inner surface of the mould 100, each at a respective rigid portion/sector of the monolithic slab 4 to be made, i.e. at a respective band or segment of composite material 11, 13, 15.

In the example shown, moreover, the sheet of pre impregnated fabric 101 has a thickness preferably ranging between 0,5 and 5 mm (millimetres), and is preferably formed by one or more pieces of synthetic fabric suitably overlapped and/or intertwined to one another and embedded in a preferably epoxy, thermosetting resin.

Preferably, the piece(s) of synthetic fabric are also made of carbon fibre and/or glass fibre and/or kevlar or other aramid fibres and/or of Vectran or other polyester fibres.

Alternatively, the thermosetting resin could be also a phenolic or polyester resin.

More in detail, in the example shown, the sheet of pre impregnated fabric 101 is preferably formed by one or more pieces of high-strength carbon fibre fabric, embedded in a thermosetting epoxy resin having a polymerisation/ reticulation temperature preferably ranging between 100°C and 140°C.

With reference to Figure 4, after having placed the sheet of pre-impregnated fabric 101 in the cavity of the mould 100, the production method of monolithic slab 4 provides for placing/laying a film of thermoplastic elasto meric material 102 on the inner surface of the mould 100, in the area corresponding to each flexible portion/sector of the monolithic slab 4 to be made, or rather corresponding to each portion of elastomeric material 12, 14 to be made, preferably by at least partially overlapping the edge of the film of thermoplastic elastomeric material 102 to the edge of the sheet of pre-impregnated fabric 101.

In other words, the film of thermoplastic elastomeric material 102 takes up an area slightly higher than the area of the mould 100 corresponding to the portion of elastomeric material 12, 14 to be made.

In the example shown, in particular, the film of thermoplastic elastomeric material 102 has a thickness preferably lower than 0,1 mm (millimetres), and is preferably made of a thermoplastic polyurethane polymer (TPU).

More in detail, the film of thermoplastic elastomeric material 102 is preferably made of an ether-based thermo plastic polyurethane resin.

Alternatively, the film of thermoplastic elastomeric material 102 could also be made of an ester-based thermo plastic polyurethane resin.

Preferably, the film of thermoplastic elastomeric material 102 moreover has a melting/softening temperature close to the polymerisation/reticulation temperature of the thermosetting resin of the sheet of pre-impregnated fabric 101.

More in detail, the film of thermoplastic elastomeric material 102 has a melting/softening temperature preferably ranging between 120°C and 160°C.

Even more in detail, in the example shown, the film of thermoplastic elastomeric material 102 is preferably a film marketed by the company FAIT PLAST SPA from Cellatica (BS) under the name "FAITGOM E/4 crystral".

With reference to Figure 5, after having placed the film of thermoplastic elastomeric material 102 in the cavity of mould 100, the production method of monolithic slab 4 provides for placing/laying a sheet of non-vulcanized rubber 103 on the film of thermoplastic elastomeric material 102, in the area corresponding to each flexible portion/sector of the monolithic slab 4 to be made, or rather corresponding to each portion of elastomeric material 12, 14 to be made.

Preferably, the sheet of non-vulcanized rubber 103 is further shaped so as to remain within the perimeter of the corresponding film of thermoplastic elastomeric material 102.

In other words, the sheet of non-vulcanized rubber 103 does not protrude outside the perimeter of the corresponding film of thermoplastic elastomeric material 102.

Clearly, the sheet of non-vulcanized rubber 103 could also be shaped so as to protrude outside the perimeter of the corresponding film of thermoplastic elastomeric material 102.

In addition, the sheet of non-vulcanized rubber 103 has a nominal thickness preferably greater than that of the sheet of pre-impregnated fabric 101, and preferably substantially equal to the thickness of the monolithic slab 4 to be made.

In the example shown, in particular, the sheet of non- vulcanized rubber 103 has a thickness preferably ranging between 1 and 10 mm (millimetres), and is preferably made of a non-reticulated synthetic rubber with a vulcanisation temperature preferably ranging between 120°C and 160°C. That is, with a vulcanisation temperature substantially equal to the polymerisation/reticulation temperature of the thermo setting resin of the sheet of pre-impregnated fabric 101.

More in detail, the sheet of non-vulcanized rubber 103 is preferably made of EPDM rubber, and has a vulcanisation temperature preferably equal to about 140°C.

Even more in detail, in the example shown, the sheet of non-vulcanized rubber 103 is preferably made of the synthetic rubber marketed by the company GUMMIWERK KRAIBURG GMBH & Co.KG from Waldkraiburg under the name "KRAIBON".

With reference to Figure 6, after having placed the sheet of non-vulcanized rubber 103 in the cavity of mould 100, the production method of monolithic slab 4 preferably, though not necessarily, provides for placing/laying, over the sheet of pre-impregnated fabric 101, a second sheet of pre-impregnated fabric 104, i.e. a sheet formed by one or more pieces of fabric embedded in the thermosetting semi fluid resin, while leaving uncovered the areas of the mould 100 corresponding to the flexible portions/sectors of the monolithic slab 4 to be made, or rather to the portions of elastomeric material 12 and 14 to be made.

Preferably, moreover the edge of the second sheet of pre-impregnated fabric 104 at least partially overlaps the edge of each sheet of non-vulcanized rubber 103.

In addition, the sheet of pre-impregnated fabric 104 has a thickness preferably ranging between 0,2 and 5 mm (millimetres), and is preferably formed by one or more pieces of synthetic fabric suitably overlapped to one another and embedded in a preferably epoxy, thermosetting resin. Preferably, the piece(s) of synthetic fabric are furthermore made of carbon fibre and/or glass fibre and/or kevlar or other aramid fibres and/or of Vectran or other polyester fibres.

More in detail, in the example shown, the sheet of pre impregnated fabric 104 is preferably made of the same material as the sheet of pre-impregnated fabric 101. Preferably, the sum of the thicknesses of the sheets of pre-impregnated fabric 101 and 104 is , moreover, substan tially equal to the thickness of the sheet of non-vulcanized rubber 103. Obviously in absence of the sheet of pre impregnated fabric 104, the thickness of the sheet of non- vulcanized rubber 103 is substantially equal to the thickness of the sheet of pre-impregnated fabric 101.

With reference to Figure 7, after having placed the sheet of non-vulcanized rubber 103 or, if provided, the sheet of non-vulcanized rubber 104 in the cavity of mould 100, the production method of the monolithic slab 4 preferably, though not necessarily, provides for placing/laying, over the sheet of non-vulcanized rubber 103, at least a piece of reinforcing synthetic fabric 105, with high strength yarns. Preferably, the piece of reinforcing synthetic fabric 105 moreover extends at least partially over the sheet of pre-impregnated fabric 101 or, if any, over the sheet of pre-impregnated fabric 104.

More in detail, in the example shown the piece of synthetic fabric 105 is preferably made of Kevlar or other aramidic fibre. Alternatively, the piece of synthetic fabric 105 could also be made of polyester fibres such as, for example, mono-oriented polyester-polyarylate (commercially known as VECTRAN).

Obviously, the production method of monolithic slab 4 can provided for placing/laying the piece of synthetic fabric 105 over even just a single sheet of non-vulcanized rubber 103, i.e. over the sheet of non-vulcanized rubber 103 corresponding to a single portion in elastomeric material 12, 14 to be made.

With reference to Figure 8, after having placed the sheet of non-vulcanized rubber 103 and, if provided, the sheet of non-vulcanized rubber 104 and/or the piece of synthetic fabric 105 in the cavity of mould 100, the production method of monolithic slab 4 provides for placing/ laying, over the piece of synthetic fabric 105 or the sheet of pre-impregnated fabric 104 and in any case over the sheet of non-vulcanized rubber 103, a second film of thermoplastic elastomeric material 106, so as to completely cover the area of the mould corresponding to each flexible portion/sector of the monolithic slab 4 to be made, or rather to each portion of elastomeric material 12, 14 to be made, preferably at least partially overlapping the edge of the film of thermoplastic elastomeric material 106 to the edge of the sheet of pre-impregnated fabric 101 or 104 and/or to the edge of the film of thermoplastic elastomeric material 102.

In other words, at each flexible portion/sector of the monolithic slab 4 to be made, the sheet of non-vulcanized rubber 103 is enclosed between the film of thermoplastic elastomeric material 102 and the film of thermoplastic elastomeric material 106, optionally together with the edge of the second sheet of pre-impregnated fabric 104 and/or the piece of synthetic fabric 105.

In the example shown, in particular, the film of thermoplastic elastomeric material 106 has a thickness preferably lower than 0,5 mm (millimetres), and is preferably made of the same material as the film of thermoplastic elastomeric material 102.

With reference to Figures 3 to 8, before placing/laying the sheet of pre-impregnated fabric 101 on the inner surface of the mould 100, the production method of monolithic slab 4 optionally also provides for placing/laying, on the whole inner surface of the mould 100 corresponding to the outer face of the monolithic slab 4 to be made, a thin sheet of pre-impregnated fabric 111, i.e. a sheet formed by one or more fabric pieces embedded in the preferably thermosetting semi-fluid resin.

The sheet of pre-impregnated fabric 101, therefore, overlaps the sheet of pre-impregnated fabric 111, if any.

The sheet of pre-impregnated fabric 111 forms the coating layer 6 of the monolithic slab 4.

Clearly, the sheet of pre-impregnated fabric 111 has a nominal thickness much lower than that of the sheet of pre impregnated fabric 101 and/or 104.

In the example shown, in particular, the sheet of pre impregnated fabric 111 is preferably made of the same composite material as the sheet of pre-impregnated fabric 101, and preferably has a nominal thickness lower than or equal to 10% of the nominal thickness of the sheet of the pre-impregnated fabric 101.

Finally, after having placed the film of thermoplastic elastomeric material 106 in the cavity of the mould 100, the production method of monolithic slab 4 provides for extracting the air from the mould 100 and then subjecting the mould 100 and all its contents to a thermal baking cycle which simultaneously causes the vulcanization of the sheet of non-vulcanized rubber 103, and the polymerisation/ reticulation and hardening of the resin of the sheet of pre impregnated fabric 101 and, if any, of the sheet of pre impregnated fabric 104.

More in detail, the production method of monolithic slab 4 preferably provides for placing the mould 100 and all its contents inside an autoclave oven (not shown) of known type, and then subjecting the mould 100 and all its content to a thermal baking cycle which envisages bringing and maintaining the mould 100 and its content for a predetermined time interval at a temperature preferably higher than 110°C, and sufficient to cause and complete the vulcanization of the sheet of non-vulcanized rubber 103, the adhesion of the films of thermoplastic elastomeric material 102 and 106 to the sheet of non-vulcanized rubber 103, and the complete hardening of the thermosetting resin of the sheets of pre impregnated fabric 101 and, if any, of the sheet of pre impregnated fabric 104.

Clearly, the complete hardening of the thermosetting resin of the sheet of pre-impregnated fabric 111, if any, also takes place in the same thermal cycle.

In the example shown, in particular, the thermal baking cycle preferably envisages bringing the mould 100 and all its contents to a temperature ranging between 120°C and 140°C, for a time interval preferably ranging between 5 and 30 minutes.

At the end of the thermal baking cycle, a monolithic body is formed inside the mould 100 which has the shape of monolithic slab 4, and has a series of areas/zones of rigid composite material and a series of areas/zones of flexible elastomeric material, contiguous and complementary to each other.

Obviously, the parts/zones of rigid composite material correspond to the rigid portions/sectors of the monolithic slab 4, i.e. to the bands or segments 11, 13 and 15 of hard and rigid composite material; whereas the parts/zones of elastomeric material correspond to the flexible portions/ sectors of monolithic slab 4, i.e. to the intermediate bands or segments 12 and 14 of monolithic slab 4.

Finally, at the end of the thermal baking cycle, the production method of monolithic slab 4 provides for extracting the resulting monolithic slab 4 from the mould 100.

As an alternative to the use of the autoclave oven, the production method of monolithic slab 4 can envisage placing the mould 100 and all its contents inside a press for moulding composite-material articles of known type, which is capable of extracting the air from the mould 100 and from its contents, and simultaneously subjecting the mould 100 and all its contents to the aforementioned thermal baking cycle that simultaneously causes the vulcanization of the sheet of non-vulcanized rubber 103, and the polymerisation/ reticulation and hardening of the resin of the sheet of pre impregnated fabric 101 and, if any, of the sheet of pre- impregnated fabric 104.

In other words, in the case of the press, the extraction of the air from the mould 100 and the thermal baking cycle are carried out more or less simultaneously.

Clearly, the production method described above makes it possible to also make a monolithic slab 4 provided with only one portion/sector of elastomeric material.

Once the monolithic slab 4 has been made, the production of protective plate 2 preferably continues with the fixing of the shock-absorber pad or a lining 5 on the inner face of the monolithic slab 4, i.e. on the face of the slab 4 turned in use towards the user's body.

Once the protective plate 2 has been completed, the production of protective garment 1 preferably continues with the fixing of the support harness 3 to the protective plate 2, or rather to the monolithic slab 4.

The advantages deriving from the particular structure of protective plate 2 of protective garment 1, or rather of the rib-protecting vest, are noteworthy.

Firstly, although the monolithic slab 4 is a monolithic body made mainly of hard and rigid composite material, the bands/portions of elastomeric material 12 and 14 still allow the protective plate 2 to bend and adapt optimally to the shape of the driver's/user's hips.

The protective garment 1, or rather the rib-protecting vest, is therefore more comfortable to wear than similar products currently on the market.

In addition, the extensive use of composite material makes it possible to produce a protective garment 1, or rather a the rib-protecting vest, with reduced weight.

Finally, it is clear that changes and variants can be made to the protective garment 1, or rather to the rib- protecting vest, and/or to the protective plate 2 and/or to the monolithic slab 4 and/or to the production method thereof without thereby departing from the scope of the present invention.

For example, the sheet of pre-impregnated fabric 111 could be replaced by a sheet of thermoplastic polymeric material.

In addition, the sheet of polymeric material could also be fixed/applied to the outer face of monolithic slab 4 after the extraction from the mould 100, preferably by gluing.

Furthermore, the film of thermoplastic elastomeric material 102 could be placed/applied on the inner surface of the mould 100, in the area corresponding to the or each flexible portion/sector of the monolithic slab 4 to be made, or rather in the area corresponding to each portion of elastomeric material 12, 14 to be made, before the sheet of pre-impregnated fabric 101.

More in detail, with reference to Figure 9, alterna tively the production method of monolithic slab 4 can provide for placing/laying, on the inner surface of mould 100 and in the area corresponding to the or each flexible portion/sector of the monolithic slab 4 to be made, or rather corresponding to each portion of elastomeric material 12, 14 to be made, a film of thermoplastic elastomeric material 102.

Preferably, the film of thermoplastic elastomeric material 102 moreover takes up an area slightly greater than the area of the mould 100 corresponding to the portion of elastomeric material 12, 14 to be made.

After having placed the film(s) of thermoplastic elastomeric material 102, the production method of monolithic slab 4 provides for placing/laying, on the inner surface of the mould 100 and over the or each film of thermoplastic elastomeric material 102, a sheet of non- vulcanized rubber 103 that substantially copies the shape of the flexible portion/sector of the monolithic slab 4 to be made, or rather of the portion of elastomeric material 12, 14 to be made. Preferably, the sheet of non-vulcanized rubber 103 is furthermore shaped so as to remain within the perimeter of the film of thermoplastic elastomeric material 102.

In other words, the sheet of non-vulcanized rubber 103 does not protrude outside the perimeter of the thermoplastic elastomeric film 102.

After having placed the sheet of non-vulcanized rubber 103 over the film of thermoplastic elastomeric material 102, the production method of monolithic slab 4 provides for placing/laying, on the inner surface of the mould 100, a sheet of non-vulcanized rubber 101, leaving uncovered the area(s) of the mould 100 where the sheet (s) of non-vulcanized rubber 103 is/are located.

In other words, the sheet of pre-impregnated fabric 101 is laid on the mould 100, leaving uncovered the areas of the mould 100 corresponding to the flexible portions/sectors of the monolithic slab 4 to be made, i.e. the areas correspon ding to the bands or segments of elastomeric material 12 and 14.

Preferably, the edge of the sheet of pre-impregnated fabric 101 moreover surmounts and at least partially covers the edge of the sheet of non-vulcanized rubber 103.

With reference to Figure 9, after having placed the sheet of pre-impregnated fabric 101 inside the mould 100, the production method of monolithic slab 4 preferably provides for placing/laying, over the sheet of non- vulcanized rubber 103, a second sheet of non-vulcanized rubber 203 which preferably substantially copies the shape of the sheet of non-vulcanized rubber 103 and/or of the flexible portion/sector of the monolithic slab 4 to be made, or rather of the portion in elastomeric material 12, 14 to be made.

Preferably, the sheet of non-vulcanized rubber 203 is moreover shaped so as to overlap, along the perimeter edge, the sheet of pre-impregnated fabric 101.

In other words, the edge of the sheet of non-vulcanized rubber 203 preferably surmounts and covers the edge of the sheet of pre-impregnated fabric 101.

Clearly, the sum of the thicknesses of the sheets of non-vulcanized rubber 103 and 203 is substantially equal to the thickness d of the monolithic slab 4 to be made.

After having placed the sheet of non-vulcanized rubber 203 over the sheet of non-vulcanized rubber 103, the production method of monolithic slab 4 preferably provides for placing/laying, over the sheet of non-vulcanized rubber 101, a second sheet of pre-impregnated fabric 104, while leaving uncovered the area(s) of the mould 100 where the sheet (s) of non-vulcanized rubber 203 is/are located.

In other words, similarly to the sheet of pre impregnated fabric 101, also the sheet of pre-impregnated fabric 104 is laid inside the mould 100 so as to leave uncovered the areas of the mould 100 corresponding to the flexible portions/sectors of the monolithic slab 4 to be made, i.e. the areas corresponding to the bands or segments of elastomeric material 12 and 14.

Preferably, the edge of the sheet of pre-impregnated fabric 104 moreover surmounts and at least partially covers the edge of the sheet of non-vulcanized rubber 203.

After having placed the sheet of pre-impregnated fabric 104 inside the mould 101, the production method of monolithic slab 4 provides for placing/laying, over the sheet of non- vulcanized rubber 103 or 203 and over the sheet of pre impregnated fabric 104, a second film of thermoplastic elastomeric material 106 so as to entirely cover the sheet of non-vulcanized rubber 103 or 203 and the perimeter edge of the sheet of pre-impregnated fabric 104, i.e. the area of the mould corresponding to the or to each flexible portion/ sector of the monolithic slab 4 to be made, or rather to the or to each portion of elastomeric material 12, 14 to be made.

In other words, the edge of the film of thermoplastic elastomeric material 106 surmounts and covers the edge of the sheet of pre-impregnated fabric 104.

Similarly to the sheet of non-vulcanized rubber 103, also the sheet of non-vulcanized rubber 203 is preferably shaped so as to remain within the perimeter of the overlying film of thermoplastic elastomeric material 106.

With reference to Figure 9, after having placed the film of thermoplastic elastomeric material 106 over the sheet of non-vulcanized rubber 103 or 203 and over the sheet of pre-impregnated fabric 104, the production method of monolithic slab 4 optionally also provides for placing/ laying, over the layer of pre-impregnated fabric 104, a third sheet of pre-impregnated fabric 204, while leaving substan tially uncovered the area(s) of the mould 100 where the film(s) of thermoplastic elastomeric material 106 is/are located.

Preferably, the edge of the sheet of pre-impregnated fabric 204 furthermore surmounts and covers the edge of the film of thermoplastic elastomeric material 106.

In other words, similarly to the sheets of pre impregnated fabric 101 and 104, the sheet of pre-impregnated fabric 204 is also laid inside the mould 100 so as to leave uncovered the areas of the mould 100 corresponding to the flexible portions/sectors of the monolithic slab 4 to be made, i.e. the areas corresponding to the bands or segments of elastomeric material 12 and 14.

Preferably, the sheet of pre-impregnated fabric 204 moreover has a nominal thickness much lower than that of the sheet of pre-impregnated fabric 101 and/or 104.

In the example shown, in particular, the sheet of pre impregnated fabric 204 is preferably made of the same composite material as the sheet of pre-impregnated fabric 101 and/or 104, and preferably has a nominal thickness lower than or equal to 50% of the nominal thickness of the sheet of pre-impregnated fabric 101 and/or 104.

With reference to Figure 9, before placing/laying the film(s) of thermoplastic elastomeric material 102 inside the mould 100, the production method of monolithic slab 4 optionally also provides for placing/laying, on the whole inner surface of the mould 100 corresponding to the outer face of the monolithic slab 4 to be made, the sheet of pre impregnated fabric 111. The sheet of pre-impregnated fabric 101, therefore, overlaps the sheet of pre-impregnated fabric 111, if any.

Also in this case, the sheet of pre-impregnated fabric 111 forms the coating layer 6 of the monolithic slab 4.

Finally, after having placed the film of thermoplastic elastomeric material 106 and optionally also the sheet of pre-impregnated fabric 204 inside the mould 100, the production method of monolithic slab 4 provides for extracting the air from the mould 100 and subjecting the mould 100 and all its contents to a thermal baking cycle that simultaneously causes the vulcanization and union of the two sheets of non-vulcanized rubber 103 and 203, and the polymerisation/reticulation and hardening of the resin of the sheets pre-impregnated fabric 101, 104 and, if any, 204.

Clearly, the thermal baking cycle can be carried out indifferently inside an autoclave oven or inside a press for moulding composite-material articles.

On the other hand, as regards the protective garment 1, in a different embodiment the protective plate 2, instead of being fixed to the support harness 3, could be housed inside a pocket or compartment specially made in an item of clothing.

In other words, the support harness 3 could be replaced by a jacket or other item of clothing.

With reference to Figure 10, in a less sophisticated embodiment, moreover, the protective garment 1, or rather the rib-protecting vest, is provided with a series of platelike protective plates, separate and distinct from one another, which are fixed on the support harness 3 so as to cover and protect as many areas as possible of the user's trunk.

At least one of these platelike protective plates moreover includes a monolithic slab of adequate thickness, which is made predominantly of a hard and rigid composite material, and is additionally provided with one or more portions or sectors which are made of elastomeric material, and extend substantially for the whole thickness of the slab so as to allow the monolithic slab to flex locally in elastic manner.

More in detail, in this embodiment variant, it is preferably provided with three platelike protective plates, which are fixed on the support harness 3 one next to the other, so as to cover, respectively, the back and the two hips of the user.

In other words, the protective garment 1, or rather the rib-protecting vest, is preferably provided with a substantially flat, central protective plate 30 which is adapted to be placed resting on the user's back, astride the spine; and with two lateral protective plates 31 and 32, which are placed on opposite sides of the central protective plate 30, and are preferably substantially C-bent so as to cover and remain close to the user's hips.

The central protective plate 30 preferably has a semi rigid structure.

Both lateral protective plates 31 and 32, on the other hand, include a monolithic slab 4 made of composite material, which is preferably stably/permanently substantially C-bent so as to remain close to the user's hip, is overall made of a hard and rigid composite material, and is additionally provided with one or more platelike portions or sectors which are made of elastomeric material, and extend substantially for the whole thickness of the slab 4 so as to allow the monolithic slab 4 to flex locally in elastic manner.

More in detail, with reference to Figure 10, in this embodiment each monolithic slab 4 is preferably provided with a central band or segment 41 which is made of hard and rigid composite material and takes up the whole width w of the monolithic slab 4; with a first pair of intermediate bands or segments 42 made of elastomeric material, which are arranged on opposite sides of the central band or segment 41, take up the whole width w of the monolithic slab 4, and seamlessly join the central band or segment 41 along the edge; and with a pair of lateral bands or segments 43 in hard and rigid composite material, which take up the whole width w of the monolithic slab 4, are each placed adjacent to a respective intermediate band or segment 42, on the opposite side with respect to the central band or segment 41, and seamlessly join the same lateral band or segment 42 along the edge.

Clearly, the two intermediate bands or segments 42 made of elastomeric material substantially take up the whole thickness of monolithic slab 4.

Each monolithic slab 4 is therefore capable of flexing/ bending in elastic manner at the two intermediate bands or segments 42.

Preferably, the lateral protective plates 31 and 32 additionally also comprise a shock-absorber pad or a lining 5, which is made of soft and elastically deformable material and is arranged to cover, preferably integrally, the inner face of the monolithic slab 4, i.e. of the face turned in use towards the user's body.

Optionally, the outer face of the monolithic slab 4 is moreover covered, preferably substantially entirely, by a coating layer or film 6 made of hard and flexible material.

Clearly, instead of being fixed to the support harness 3, the protective plates 30, 31 and 32 could be accommodated inside pockets or compartments specially made in a generic item of clothing.

Finally, in a more sophisticated and not illustrated embodiment, the protective garment 1 could be provided, preferably in addition to the protective plate 2 or the protective plates 30, 31 and 32, with further protective plates preferably with a platelike structure, which are placed on the support harness 3 so as to cover and protect the shoulders and/or the arms and/or the sternal area of the chest and/or other areas of the trunk of the user from impacts and/or abrasions.

Clearly, instead of being fixed to the support harness 3, the further protective plates could also be accommodated inside pockets or compartments specially made in a generic item of clothing.

One or more of these further protective plates may include a monolithic slab 4 made of composite material, which has a platelike structure, and is provided with two or more hard and rigid portions/sectors that are made of hard and rigid composite material and extend substantially for the whole thickness of the monolithic slab; and with at least one flexible portion/sector, which is made of elastomeric material, extends substantially for the whole thickness of the monolithic slab 4 or for a prevalent/major part of the same thickness, is interposed between two or more hard and rigid portions/sectors, and substantially seamlessly join the same hard and rigid portions/sectors along the edge.

In other words, the protective garment 1 can be a protective armour capable of protecting the trunk and/or the arms and/or other parts of the body from impacts and abrasions.

In this case, the protective garment 1 could also be used by public security officers, military personnel, American football players and by any other person who needs to protect the trunk and other parts of the body from impacts and abrasions.

Clearly, some of these additional protective plates could include a monolithic slab made entirely of hard and rigid composite material, or made entirely of hard and rigid plastic, metal or ceramic material.

Claims

1. A protective garment (1) adapted to be worn by a person and provided with at least one protective plate (2, 30, 31, 32) adapted to cover and protect a corresponding area of the user's body; the protective garment (1) being characterised in that said at least one protective plate (2; 30, 31, 32) comprises a monolithic slab (4) which is provided with at least two hard and rigid portions/sectors (11, 13, 15; 41, 43) that are made of hard and rigid composite material and extend substantially for the whole thickness (d) of the monolithic slab (4); and with at least one flexible portion/sector (12, 14; 42) which is made of elastomeric material (12, 14; 42), extends substantially for the whole thickness (d) of the monolithic slab (4) or for a major part of the same thickness (d), is interposed between two or more hard and rigid portions/sectors (11, 13, 15; 41, 43), and substantially seamlessly joins the same hard and rigid portion/sectors (11, 13, 15; 41, 43) along the edge.

2. Protective garment according to Claim 1, wherein each rigid portion/sector (11, 13, 15; 41, 43) is formed by one or more superimposed layers of synthetic fibres appropriately intertwined and/or overlapping each other, and embedded in a solid polymeric matrix.

3. Protective garment according to Claim 1 or 2, wherein each flexible portion/sector (12, 14; 42) is formed by a single thick and homogenous layer of elastomeric material.

4. Protective garment according to Claim 1, 2 or 3, wherein the monolithic slab (4) has a thickness (d) ranging between 1 and 10 mm.

5. Protective garment according to any one of the preceding claims, wherein the monolithic slab (4) is permanently substantially C-bent.

6. Protective garment according to Claim 5, wherein the monolithic slab (4) is substantially C-bent so as to be able to embrace the user's torso from behind.

7 . Protective garment according to any one of the preceding claims, wherein said protective plate (2; 30, 31, 32) additionally comprises a shock-absorber pad or a lining (5) which is made of soft and/or elastically deformable material and is arranged to cover the inner face of the monolithic slab (4).

8. Protective garment according to any one of the preceding claims, wherein said protective plate (2; 30, 31, 32) additionally comprises a coating layer or film (6) made of hard and flexible material, which covers the outer face of the monolithic slab (4); said coating layer or film (6) being preferably made of composite material or of homogenous polymeric material.

9. A production method of the protective plate (2, 30, 31,

32) of a garment (1) adapted to be worn by a person to cover and protect his/her body from impacts and/or abrasions; said protective plate (2, 30, 31, 32) comprising a monolithic slab (4) which is provided with two or more rigid portions/ sectors (11, 13, 15; 41, 43) that are made of hard and rigid composite material and extend substantially for the whole thickness (d) of the monolithic slab (4); and with at least one flexible portion/sector (12, 14; 42) which is made of elastomeric material, extends substantially for the whole thickness (d) of the monolithic slab (4) or for a major part of the same thickness (d), and substantially seamlessly joins the adjacent rigid portions/sectors (11, 13, 15; 41, 43) along the edge; said production method being characterised by comprising the steps of

— placing/lying at least a first sheet of pre impregnated fabric (101) on the surface of the mould (100) that copies in negative the shape of the monolithic slab (4) to be produced, leaving uncovered the area of the mould (100) corresponding to said at least one flexible portion/ sector (12, 14; 42) to be made;

— placing/laying a first film of thermoplastic elastomeric material (102) on the surface of the mould (100), in the area of the mould (100) corresponding to the flexible portion/sector (12, 14; 42) to be made;

— placing/laying at least one sheet of non-vulcanized rubber (103, 203) over said first film of thermoplastic elastomeric material (102), in the area of the mould (100) corresponding to the flexible portion/sector (12, 14; 42) to be made;

— placing/laying a second film of thermoplastic elastomeric material (106) over said at least one sheet of non-vulcanized rubber (103, 203), so as to cover said at least one sheet of non-vulcanized rubber (103, 203); and lastly

— extracting the air from the mould (100) and subjecting the mould (100) and all its content to a thermal baking cycle that simultaneously causes the vulcanization of the sheet of non-vulcanized rubber (103, 203), and the polymerisation/reticulation and hardening of the thermosetting resin of said first sheet of pre impregnated fabric (101).

10. Production method according to Claim 9, wherein the edge of the first film of thermoplastic elastomeric material (102) superimposes the edge of the first sheet of pre impregnated fabric (101) or vice versa.

11. Production method according to Claim 9 or 10, wherein the first film of thermoplastic elastomeric material (102) is placed inside the mould (100) after the first sheet of pre-impregnated fabric (101).

12. Production method according to Claim 9, 10 or 11, wherein said sheet of non-vulcanized rubber (103, 203) is shaped so as to remain within the perimeter of said first film of thermoplastic elastomeric material (102) and/or said second film of thermoplastic elastomeric material (106).

13. Production method according to any one of Claims from 9 to 12, characterised by additionally comprising the step of placing/laying, over said first sheet of pre-impregnated fabric (101) and beneath said second film of thermoplastic elastomeric material (106), a second sheet of pre impregnated fabric (104), leaving uncovered the area of the mould (100) corresponding to the flexible portion/sector (12, 14; 42) to be made.

14. Production method according to Claim 13, wherein the edge of said second sheet of pre-impregnated fabric (104) at least partially superimposes the edge of said sheet of non- vulcanized rubber (103, 203).

15. Production method according to any one of Claims 9 to

14, wherein the edge of said second film of thermoplastic elastomeric material (106) superimposes the edge of said first film of thermoplastic elastomeric material (102) and/or the edge of said second sheet of pre-impregnated fabric (101) and/or the edge of said second sheet of pre impregnated fabric (104).

16. Production method according to any one of Claims 9 to

15, characterised by additionally comprising the step of placing/laying, over said first sheet of pre-impregnated fabric (101) and beneath said second film of thermoplastic elastomeric material (106), at least a piece of reinforcing synthetic fabric (105) that also extends over the sheet of non-vulcanized rubber (103).

17. Production method according to any one of Claims 9 to

16, wherein said first sheet of pre-impregnated fabric (101) is formed by one or more pieces of synthetic fabric suitably overlapped to one another and embedded in a preferably epoxy, thermosetting resin.

18. Production method according to any one of Claims 9 to

17, wherein said first film of thermoplastic elastomeric material (102) and/or said second film of thermoplastic elastomeric material (106) is/are made of a thermoplastic polyurethane polymer (TPU).

19. Production method according to any one of Claims 9 to 18, wherein said at least one sheet of non-vulcanized rubber (103, 203) is made of a non-reticulated synthetic rubber with a vulcanisation temperature substantially equal to the polymerisation/reticulation temperature of the thermosetting resin of said first sheet of pre-impregnated fabric (101).

20. Production method according to Claim 19, wherein the thickness of said at least one sheet of non-vulcanized rubber

(103, 203) is substantially equal to the thickness (d) of the monolithic slab (4) that is desired to make.