WO2005020730A2

WO2005020730A2 - Human limb/joint protective pad and method of making

Info

Publication number: WO2005020730A2
Application number: PCT/US2004/027092
Authority: WO
Inventors: James Landi; Michael Landi
Original assignee: Xo Athletic
Priority date: 2003-08-21
Filing date: 2004-08-20
Publication date: 2005-03-10
Also published as: CA2536562A1; CA2536562C; WO2005020730A3; US20050039245A1; US8353062B2; US7661148B2; US20100100995A1

Abstract

A protective pad includes a pre-tensioned resilient padded membrane resiliently suspended to a semi-rigid shell. A cavity is defined between the pretensioned padded membrane and the shell. In use, the pad is attached to the limb or joint to be protected with the tensioned membrane engaging the limb or joint to be protected. The pre-tensioned membrane and air cushion in the cavity absorb the energy of an impact transferred by the shell during a sporting event or other activity.

Description

Human Limb/Joint Protective Pad and Method of Making

Field of the Invention

[001] The invention relates generally to pads for protecting the limbs and

joints of humans. More particularly, the invention relates to protective pads

having a tensioned padded membrane bonded to a semi-rigid shell to impart a

resilient, trampoline-like dampening effect.

Description of the Prior Art

[002] Protective equipment such as, for example, shoulder pads, rib

protectors, hip pads and thigh pads are commonly worn by participants in many

types of sporting events for protection from shock resulting from contact with an

object or another participant. Such protective equipment has long been used by

athletes in such contact sports as football and hockey, as well as non-contact sports

such as baseball, basketball, equestrian events, and so forth. Protective pads such

as knee and elbow pads are commonly used during activities such as, for example,

skating, skateboarding, and cycling to protect against bodily injury during falls on

pavement or other hard surfaces.

[003] Conventional protective pads typically include a relatively hard outer

shell of a material such as plastic, leather, vulcanized fiber, and the like, as well as

an inner layer of soft padding material. The hard outer layer is provided to receive the applied force or shock of an impact, and to distribute the force over a large

area. The soft padding material, in addition to acting as a cushion for providing

comfort to the wearer, usually acts to absorb and dampen the aforementioned force

in order to protect the wearer from the shock of an impact. Some exemplary

conventional padding materials include cotton, foam rubber, foamed plastic,

sponge rubber, and expanded rubber or vinyl. Such designs rely heavily upon the

softness and resulted resilience of the padding material to absorb the applied force. [004] A common protective pad construction often provides a substantial

thickness of cushioning material attached to an interior surface of a protective

shell. In this manner the thickness of cushioning material fills a substantial

portion or the entire gap or space between the shell and a limb or joint intended to

be protected. U.S. Patent Nos. 6,401 ,245 and 6,156,000 are exemplary of this

common type of protective pad construction. The '245 patent discloses a knee cup

10 sewn to a cushioning base 29 directly engaging the knee of a wearer. The knee

cup includes an outer shell 12 having a rear indentation 32 completely filled with a

dampening insert 14, such that the insert is interposed between the shell and the

base. One drawback of this prior art protective pad is that it has a relatively

complex construction requiring several time-consuming and labor-intensive

fabrication steps. Another drawback of this type of construction is that the

stitching used to attach the_^ knee cup 10 to the cushioning base 29 results in the

transfer of impact forces to relatively minute concentrated areas along the edge of

the base 29. In fact, it is not uncommon for the concentrated forces applied along relatively small stitched areas to exceed the tensile strength of the fabric base 29 at

these areas of attachment. As a result, repetitive impacts can lead to accelerated

tearing or ripping of the fabric, and corresponding premature separation of the

base fabric from the protective shell or cup. Generally, protective pad

constructions utilizing unyielding, non-resilient attachment means, such as

stitches, rivets, glues and the like, have relatively limited durability. The U.S.

Patent 6,156,000 discloses a method for making a protective pad wherein a blank

pad 11 is cut into a shaped pad 11 ' and a rigid shield is formed directly on the

exterior surface of the shaped pad by injection molding a material such as

polyvinyl chloride. The 6,156,000 patent discloses a substantially simplified

method of construction. However, the direct bonding of the rigid shield to the

pad, without any resilient intermediate layer, results in the same susceptibility of

the article to tearing and separation between the shield and the pad. Furthermore,

in pad constructions where the cushioning material completely fills the gap or

space between the shell and the body part or joint being protected, the degree of

cushioning or dampening of an impact force is substantially limited by the

resiliency and thickness of the cushioning layer.

[005] U.S. Patent No. 6,151,714 discloses another type of protective pad 10

having a construction wherein a rigid outer shell 24 having a shielding element 12

is attached along a peripheral shell flange 28 to an underlying planar cushioning

body 16 such that a cavity 40 is formed between the shell and cushioning body.

The protective pad disclosed in the '714 patent offers some improvement with regard to impact force dampening. Particularly, upon application of a force to the

impact surface 30 of the shell 24, the shielding element 12 resists flexing as the

cushioning element 14 flexes to permit penetration of the protected joint surface

20 into the cavity. However, the peripheral shell flange is stitched to the planar

cushioning body and, therefore, suffers from the aforementioned susceptibility to

tearing and separation due to concentrated forces at these localized attachment

areas.

[006] U.S. Patent Nos. 5,451,201 ; 4,484,361; 4,494,247; 4,513,449;

5,472,413; 6,029,273; 6,098,209; 6,253,376; 6,319,219; 6,347,403 and 6,421,839

disclose examples of other protective device constructions which suffer from one

or more of the aforementioned drawbacks and limitations of the prior art.

[007] Accordingly, there is a well-established need for a protective pad

having a construction overcoming the drawbacks and limitations of the prior art.

In particular, it would be desirable to provide a protective pad having improved

dampening characteristics and enhanced durability. Furthermore, the protective

pad should be comfortable to wear and have a relatively simple construction

lending itself to efficient, cost-effective and non labor-intensive manufacturing.

Summary of the Invention

[008] The invention is directed to protective pads for protecting the elbows,

knees, shoulders or other joints or limbs or the genital area or breasts of a person

during a sporting event or other activity. The protective pads are comfortable to wear and have a construction providing a trampoline-like resilient quality that

enhances the protective capability of the pads in the event that the wearer is struck

in the region in which the pad is worn. An efficient, cost-effective and non labor-

intensive method is provided for making the protective pads.

[009] In one general aspect of the present invention, a protective pad is

provided comprising: a shell having a concave interior surface and a convex outer surface

adjoined by a perimeter edge; a pre-tensioned resilient padded membrane; and an

elastic suspension arrangement adjoining the pre-tensioned resilient padded

membrane about the perimeter edge of said shell to define a cavity between the

shell and the tensioned resilient padded membrane.

[010] In a further aspect of the present invention, a central aperture may be

provided extending through the tensioned resilient padded membrane for engaging

the joint being protected.

[011] In another aspect of the present invention, the edge of the shell may

be formed to define a flanged region attached to the pre-tensioned padded

membrane with a resilient bonding material.

[012] In a still further aspect of the present invention, the resilient bonding

material may extend to or substantially cover the entire exterior surface of the

tensioned padded membrane. [013] In another aspect of the present invention, the resilient bonding

shell.

[014] In yet a further aspect of the present invention, the protective pad

defines an elbow pad.

[015] Still another aspect of the present invention provides a helmet.

[016] Yet another aspect of the present invention provides a shoulder pad.

[017] A still further aspect of the present invention provides a protective

pad for protecting the genitals or breasts.

[018] In a still further aspect of the present invention, a method of

fabricating a protective pad is provided wherein a resilient padded membrane is

stretched into a tensioned configuration, a shell is brought into engagement with

the tensioned padded membrane, and a resilient bonding material is introduced

between the edge of the shell and the tensioned padded membrane so as to form an

elastic suspension arrangement therebetween.

[019] These and other aspects, features, and advantages of the present

invention will become more readily apparent from the attached drawings and the

detailed description of the preferred embodiments, which follow.

Brief Description Of The Drawings

[020] The preferred embodiments of the invention will hereinafter be

described in conjunction with the appended drawings provided to illustrate and not

to limit the invention, where like designations denote like elements, and in which:

[021] FIG. 1 is a top view of a knee pad embodiment of the protective pads

of the present invention;

[022] FIG. 2 is a longitudinal cross-sectional view of the protective pad of

the invention illustrated in FIG. 1 ;

[023] FIG. 3 is a longitudinal cross-sectional view of a knee pad

embodiment of the protective pads of the present invention, wherein the knee pad

includes a joint-engaging aperture extending through the padded membrane, with

the knee pad shown on the knee of a wearer in application of the invention;

[024] FIG. 3A is a longitudinal cross-sectional view of still another

embodiment of the protective pad, with a flange formed along the periphery of the

pad body or shell and bonded to the tensioned padded membrane;

[025] FIG. 4 is a longitudinal sectional view of yet another embodiment of

the protective pad, wherein the bonding material extends from the exterior surface

of the tensioned padded membrane to an outer area of engagement between the

shell and the padded membrane, and is further formed at an inner area of

engagement between the tensioned padded membrane and the shell;

[026] FIG. 5 is a longitudinal sectional view of yet another embodiment of

the protective pad wherein the resilient bonding material encapsulates the outer surface of the tensioned padded membrane and extends to the exterior area of

engagement between the shell and the tensioned membrane;

[027] FIG. 6 is a longitudinal sectional view of another embodiment of the

protective pad wherein the entire exterior surface of the shell is encapsulated by

the elastic bonding material;

[028] FIG. 7 is a longitudinal sectional view of still another embodiment of

the knee pad, wherein the resilient bonding material is disposed between the

tensioned membrane and a flange formed along the periphery of the shell;

[029] Fig. 7A is a longitudinal sectional view of a still further embodiment

of the knee pad, wherein the resilient bonding material is disposed between the

tensioned membrane and the flange and further extending to the outer periphery of

the shell;

[030] FIG. 8A is a top view of an injection-molding apparatus, illustrating

the positioning of a padded membrane in the mold in a first step for fabricating a

protective pad in accordance with the present invention;

[031] FIG. 8B is a top view of the injection mold of FIG. 8A, showing

stretching of the padded membrane in multiple directions into a tensioned state or

configuration, and subsequent positioning of the shell in an open injection mold in

a second fabrication step;

[032] FIG. 8C is a top view of the injection-molding apparatus, showing a

bonding material mold positioned over the shell, and the subsequent injection molding of an elastic bonding material between the shell and the tensioned padded

membrane along the outer surface of the shell in a third fabrication step;

[033] FIG. 8D is a top view of the injection mold, showing lifting of the

bonding mold from the shell on the injection mold;

[034] FIG. 8E is a top view of the injection mold, showing cutting or

excising of excess padded membrane material from the shell;

[035] FIG. 8F is a top view of the protective joint pad of FIG. 1 , fabricated

using the steps of FIGS. 8A-8E;

[036] FIGS. 9A-9C are longitudinal sectional views of FIG. 8A-8C,

respectively;

[037] FIG. 9D is a longitudinal sectional view of FIG. 8D, with the bonding

mold shown in side view;

[038] FIGS. 9E-9F are longitudinal sectional views of FIGS. 8E-8F,

respectively;

[039] FIG. 10A is a top view of an injection mold, illustrating positioning

of the padded membrane in the mold in a first step for fabricating a second

embodiment of the protective pad in accordance with the present invention;

[040] FIG. 10B is a top view of the injection mold of FIG. 10A, showing

stretching of the padded membrane in multiple directions and positioning of the

shell in the injection mold in a second fabrication step; [041] FIG. IOC is a top view of the injection mold, showing a bonding

mold positioned over the shell and injection-molding of the bonding material

between the shell and the padded membrane material in a third fabrication step;

[042] FIG. 10D is a top view of the injection mold, showing lifting of the

bonding mold from the shell on the injection mold;

[043] FIG. 10E is a top view of the injection mold, showing cutting of

excess padded membrane material from the shell;

[044] FIG. 10F is a top view of the protective joint pad of FIG. 3, fabricated

using the steps of FIGS. 10A-10E;

[045] FIG. 10G is a top view of an injection mold, with the protective joint

pad of FIGS. 3 and 10F placed in a inverted position in the injection mold;

[046] FIG. 1 OH is a top view of the injection mold of FIG. 10G, illustrating

injection molding of the bonding material on the underside of the padded

membrane in the regions where the shell contacts the padded membrane;

[047] FIG. 101 is a bottom view of the protective joint pad of FIG. 4,

fabricated according to the steps of FIGS. 10G and 10H;

[048] FIGS. 11A-11H are longitudinal sectional views of FIGS. 10A-10H

respectively;

[049] FIG. I ll illustrates removal of the protective joint pad of FIG. 101

from the injection mold;

[050] FIG. 12 is a top view of an elbow pad embodiment of the protective

pads of the present invention; [051] FIG. 13 is a longitudinal sectional view taken along cutting plane 13-

13 in FIG. 12;

[052] FIG. 14 is a transverse sectional view taken along cutting plane 14-14

in FIG. 13;

[053] FIG. 15 is a longitudinal sectional view taken along cutting plane 15-

15 in FIG. 12;

[054] FIG. 16 is a transverse sectional taken along cutting plane 16-16 in

FIG. 15;

[055] FIG. 17 is a longitudinal sectional view taken along cutting plane 17-

17 in FIG. 12;

[056] FIG. 18 is a transverse sectional view taken along cutting plane 18-18

in FIG. 17;

[057] FIG. 19 is a top view of a protective helmet embodiment of the

present invention; and

[058] FIG. 20 is a side view of the protective helmet embodiment shown in

FIG. 19;

[059] FIG. 21 is a longitudinal sectional view taken along cutting plane 21-

21 in FIG. 19 and showing the protective helmet prior to being positioned on a

head of a user;

[060] FIG. 22 is a transverse sectional view taken along cutting plane 22-22

in FIG. 20 and showing the helmet being positioned on the head of the user; [061] FIG. 23 is a top view of a shoulder pad embodiment of the protective

pads of the present invention;

[062] FIG. 24 is a front view of the shoulder pad embodiment of the

protective pad shown in FIG. 23; and

[063] FIG. 25 is a transverse sectional view taken along cutting plane 25-25

in FIG. 24.

Detailed Description Of The Preferred Embodiments [064] Shown throughout the figures, the present invention is generally

directed to protective pads for human joints or limbs, and methods for making the

pads. The pads incorporate a tensioned resilient padding membrane which is

connected to a semi-rigid shell by means of an elastic suspension arrangement

utilizing an elastic bonding material in order to achieve a trampoline-like quality

providing comfort to the wearer, enhanced dampening, and improved durability

vis-a-vis existing protective pad designs. The protective pads of the present

invention have a simple construction complemented by an efficient, high-speed,

cost-effective and non labor-intensive method of production.

[065] Referring initially to FIGS. 1 and 2, in which a first embodiment of

the present invention a protective knee pad is generally indicated by reference

numeral 1. The protective pad includes a unitary pad body or shell 2, preferably

molded or otherwise formed from a rigid or semi-rigid material such as

polypropylene or similar thermoplastic resins. The shell 2 has a convex outer surface 3 and a concave inner surface 4 adjoined by a continuous peripheral edge

5. Preferably, one or more vent openings 6 are provided extending through the

shell 2. The shell 2 is directly fused about its periphery to a resilient padded

membrane, indicated generally by reference numeral 7. This is accomplished

through the formation of the elastic suspension arrangement in the form of an

elastic or resilient bonding material 8.

[066] Significantly, the resilient padded membrane is stretched into a

tensioned state, or configuration, prior to having the shell 2 bonded thereto. The

significance of attaching the resilient padded membrane 7 in such a tensioned state

will become apparent from the following description. Preferably, padded

membrane 7 is fabricated from a synthetic rubber or like material providing the

necessary resiliency. By way of example, the applicant has been successful using

neoprene, a polymerized chloroprene that, in addition to being resilient, is highly

resistant to ozone, weathering, various chemicals, oil and flame. Preferably, the

elastic suspension arrangement in the form of resilient or semi-resilient bonding

material 8 comprises a soft elastomer, such as kraton and the like, characterized by

the ability to stretch under low stress conditions and, upon release of the stress,

return with force to its approximate original configuration.

[067] An air-filled space or cavity 9 is defined between the tensioned

padded membrane 7 and the concave inner surface 4 of the shell 2. As shown in

FIG. 2, in one aspect of the invention the resilient bonding material 8 provided

along the periphery of the shell, and generally about an outer area of engagement of the shell and the padded membrane 7, extends completely over the upper

convex surface 3 of the shell 2 to provide additional enhanced dampening of the

force of an impact to the shell 2. Openings 8a are provided through the layer of

bonding material 8 in communication with corresponding vent openings 6 in the

shell 2. Preferably, the bonding material layer openings 8a are slightly larger than

the corresponding openings 6 in underlying shell 2.

[068] Referring now to FIG. 3, in another aspect of the present invention,

the protective pad 11 is provided having an aperture 7a extending through the

tensioned padded membrane 7 in communication with cavity 9. The padded

membrane aperture 7a is preferably sized and shaped for frictionally engaging and

at least partially conforming to the patella, or knee 20a, of the leg 20 of a wearer.

The padded membrane 7 engages the user's leg 20, and the aperture 7a enhances

positional stability of the padded membrane 7 on the leg 20. Preferably, the

protective pad is held in place by straps (not shown) or other fastening means

known by those skilled in the art. As is further illustrated in FIG. 3, the elastic or

resilient bonding material 8 can be provided disposed about both inner and outer

areas of engagement of the periphery of the shell 2 and the upper surface of the

tensioned padded membrane 7.

[069] The construction of the protective pads of the present invention form

a unique trampoline-like arrangement that provides significantly enhanced impact

protection to the joints or other body parts being shielded vis-a-vis prior art

protective pad constructions. Particularly, the tensioned padded membrane 7 is suspended about the periphery of the shell 2 by the elastic suspension arrangement

or the elastic or resilient bonding material 8 in a manner similar to that when a

resilient sheet is attached by resilient cords or springs to the frame of a trampoline.

During the tensioning process, the resilient padded membrane 7 stores kinetic

energy that tends to return it to the initial unstressed condition. Accordingly, as

best illustrated in FIG. 3, upon application of a force against the exterior shell

surface 3, the resilient padded membrane 7 overlying the joint surface 20a

temporarily stretches or flexes into the cavity 9 such that the impact energy or

force against the shell is transferred to, and substantially absorbed by, both the

elasticity of the bonding material 8 and the resiliency of the padded membrane 7.

Subsequently, the padded membrane 7 returns to its pre-impact tensioned

configuration. In this manner, the tensioned pre-stressed padded membrane's

resistance to subsequent compression or deformation combined with the elasticity

of the bonding material during an impact provides efficient protection to the

wearer.

[070] Additional impact energy dampening is achieved as a result of air

trapped within the cavity 9. In other words, because the rate of egress of air from

the cavity 9 during an impact is restricted to the pathways defined by the shell

apertures 6, the trapped air acts as an additional cushioning mechanism. The

elasticity of the bonding material 8 combined with its relatively large engagement

or contact area between the shell 2 and padded membrane 7 by means of the

resilient bonding material 8 substantially minimizes the occurrence of padded membrane tearing or ripping. Accordingly, the trampoline-type arrangement of

the present invention avoids or minimizes undesirable separation of the shell 2

from the padded membrane 7, leading to appreciably improved pad durability over

the prior art.

[071] Referring briefly to FIG. 3 A, in a further aspect of the present

invention, a protective pad 21 is provided with a shell 22 having an outwardly-

extending perimeter flange 25 contacting the tensioned padded membrane 7. The

elastic bonding material 8 preferably covers the extended engagement area of the

flange 25 at the exterior of the shell 22, as well as at the inner surface 4 of the shell

22 adjacent to the flange 25. An aperture 7a may be provided extending through

the padded membrane 7, as heretofore described with respect to the protective pad

11 of FIG. 3.

[072] Referring briefly to FIG. 4, in another aspect of the present invention,

a protective pad 31 is provided having the elastic or resilient bonding material 8

virtually surrounding the area of junction between the shell 22 and the membrane

7. In this manner, the resilient connecting arrangement 8 extends from a lower

surface of the stretched padded membrane 7, around a peripheral edge of the

padded membrane, to the outer area of engagement between the shell 2 and the

padded membrane 7. The elastic suspension arrangement or bonding material 8 is

further formed at the inner area of engagement between the shell 2 and the padded

membrane 7. An aperture 7a is typically provided in the padded membrane 7. [073] Referring briefly to FIG. 5, in yet another aspect of the present

invention, a protective pad 41 is provided having a thin layer of the bonding

material 8 coating the lower exterior surface of the stretched padded membrane 7

and extending to the exterior area of engagement between the edge 5 of the shell 2

and the padded membrane 7. The thin layer of bonding material 8 on the padded

membrane 7 contacts the skin of the user's leg 20 (see FIG. 3) during use and

further contributes to the elasticity of the padded membrane 7, absorbing impact

energy during use.

[074] Referring briefly to FIG. 6, in still another aspect of the present

invention, a protective pad 51 is provided having the bonding material 8

encapsulating the entire convex outer surface 3 of the shell 2. The bonding

material 8 further extends along the exterior and interior areas of engagement of

the shell 2 with the stretched padded membrane 7, and may further extend around

a peripheral edge of the padded membrane 7 to the lower exterior surface thereof.

In this manner the elastic or resilient bonding material forms the elastic suspension

arrangement which actually surrounds the entire area of junction between the

membrane and the shell. An opening 8a is preferably provided through the

bonding material 8 in communication with, and corresponding to, the air opening

6 of the shell 2.

[075] Referring briefly to FIG. 7, in yet another aspect of the present

invention, a protective pad 61 is provided having a shell 62 including an outwardly

extending peripheral flange 65. The bonding material 8 is preferably provided disposed between the underside of the flange 65 and the corresponding area of the

stretched padded membrane 7. In this manner the elastic suspension arrangement

8 is sandwiched between the flange 65 and the membrane 7.

[076] Referring now to Fig. 7A, in still a further aspect of the present

invention, a protective pad is formed having a shell 62 with the outwardly

extending peripheral flange 65 which is formed with a channel 63 facing the

stretched membrane 7 and extending through the length of the flange. During the

fabrication the liquefied bonding material 8 is distributed at a high temperature

and pressure from a supply mechanism to a molding tip 67 and is initially injected

into the channel 63. Upon passing through the length of the flange 65, a barrier or

bonding material formation is developed at the interior of the shell in the vicinity

of the padded membrane 7. Upon further application of the liquefied bonding

material, the flange 65 and the entire shell 62 are spaced from the membrane 7, so

that a layer of resilient bonding material 8 is formed therebetween. Upon further

application, the bonding material 8 extends around a peripheral edge of the flange

65 to the exterior surface of the shell 62.

[077] Referring now primarily to FIGS. 8A-9F, the protective pad 1

heretofore described with respect to FIGS. 1 and 2 is preferably fabricated in the

following manner. As shown in FIGS. 8A and 9A, a sheet of the resilient padded

membrane 7, which may be formed having substantially rectangular configuration,

is initially attached to the respective padded membrane receiving members or

clamps 72 provided at a base 71 of an open injection mold 70. The clamps 72 are typically attached to the outer periphery or the longitudinal and transverse edges of

the padded membrane 7. Significantly, in the next operational step, as shown in

FIGS. 8B and 9B, to accumulate the required kinetic energy the padded membrane

7 is stretched in multiple directions into a tensioned state or configuration by

retracting the fabric clamps 72 outwardly. In this operational step the required

kinetic energy is generated and stored within the stretched padded membrane.

Alternatively, the resilient padded membrane 7 can be precut and then loaded into

the injection mold 70 either manually or automatically. Subsequently, the shell 2

is placed, with its concave surface facing downward, onto the stretched padded

membrane 7. After that, as shown in FIGS. 8C and 9C, a bonding mold 73 is

positioned over the shell 2. The bonding mold 73 has a concave configuration

complementary to the desired configuration of the bonding material 8 to be

deposited on the shell 2, as well as concave surfaces or grooves 73a extending

along the perimeter thereof. A gap 75 is defined between the bonding mold 73

and the shell 2. Multiple bonding material inlet tubes 74 extend through

respective openings (not shown) in the bonding mold 73, and communicate with

the gap 75. The bonding material inlet tubes 74 are connected to a suitable pump

and supply mechanism (not shown) for dispensing the resilient bonding material 8

in a melted, liquid state. Accordingly, the liquefied bonding material 8 is

distributed at high heat and pressure from the pump and supply mechanism,

through the inlet tubes 74, and injected into the gap 75, wherein the bonding

material 8 fills the gap 75 and the spaces defined by the concave surfaces 73a extending along the perimeter of the shell 2 retaining its elasticity. As shown in

FIGS. 8D and 9D, after the bonding material 8 solidifies, the elastic suspension

arrangement is formed, and the bonding mold 73 is lifted from the shell 2. Next,

as shown in FIGS. 8E and 9E, a suitable excising device 76 is used to cut the

excess padded membrane material 7b from the padded membrane 7. In some

instances, the excess fabric padded membrane material 7b may extend a

substantial distance outwardly from the boundaries of the shell 2. In that case, the

excess padded membrane material 7b may be cut to define straps (not shown) to

be used in attachment of the protective pad 1 to the body of a user (not shown),

and a hook-and-loop type fastener system, such as VELCRO, may be provided on

the straps for attachment purposes. Finally, the fabricated protective pad 1 is

removed from the mold 70, as shown in FIGS. 8F and 9F.

[078] In this manner, an engaging surface is defined by a pre-tensioned

padded membrane 7 elastically suspended in a transverse plane from an essentially

rigid, or sometimes resilient, outer periphery of the shell 2, with the padded

membrane adjoined to the shell by means of the elastic bonding material 8 acting

as an elastic suspension arrangement. It will be apparent to those skilled in the art

that the fabrication method for the protective pad 1 heretofore described represents

only one possible fabrication method and the protective pad 1 may be fabricated

according to other techniques.

[079] Referring next to FIGS. 10A-11F, the protective pad 11 heretofore

described with respect to FIG. 3 is preferably fabricated in the following manner. As shown in FIGS. 10A and 11 A, a sheet of the padded membrane 7, which can

be formed having substantially rectangular configuration, is initially attached or

clamped to respective receiving members or clamps 82 provided at a base 81 of an

injection mold 80. The base 81 includes a base opening 81a extending centrally

therethrough. The clamps 82 are typically attached to both the longitudinal and

transverse edges of the padded membrane 7. Next, as shown in FIGS. 10B and

1 IB, to accumulate and store the required kinetic energy the padded membrane 7

is stretched in multiple directions, by retracting the fabric clamps 82 outwardly,

into a tensioned state or configuration. As shown in FIGS. 10C and 1 IC, the shell

2 is then placed on the tensioned padded membrane 7, after which a bonding mold

83 is positioned over the shell 2. The bonding mold 83 has a concave

configuration which is complementary to the configuration for the bonding

material 8 to be deposited on the shell 2. The mold 83 also contains concave

surfaces or grooves 83a along the perimeter thereof. Multiple exterior bonding

material inlet tubes 84 extend through respective openings (not shown) in the

bonding mold 83. Furthermore, a pair of interior bonding material inlet tubes 85

extend through the central base opening 81a of the base 81. The exterior bonding

material inlet tubes 84 and the interior bonding material inlet tubes 85 are

connected to a suitable pump and supply mechanism (not shown) for dispending

the liquefied bonding material 8. Accordingly, the liquefied bonding material 8 is

distributed from the pump and supply mechanism, through the exterior bonding

material inlet tubes 84, into the spaces defined by the concave surfaces 83a. This occurs in such a manner that the bonding material 8 conforms to the configuration

of the concave surfaces 83a extending along the outer perimeter of the shell 2 at

the junction thereof with the padded membrane 7. The interior bonding material

in the tubes 85 are utilized to deliver the liquefied bonding material, so as to form

the required bond between the inner perimeter of the shell 2 and the stretched

fabric of the padded membrane 7. As shown in FIGS. 10D and 11D, after the

bonding material 8 at least partially cures, so as to form the elastic suspension

arrangement, the bonding mold 83 is lifted from the shell 2. Next, as shown in

FIGS. 10E and 1 IE, a suitable excising device 76 is used to cut the excess padded

membrane material 7b from the padded membrane 7. Finally, the fabricated

protective pad 11 is removed from the injection mold 80, as shown in FIGS. 10F

and 1 IF. It is understood that the fabrication method for the protective pad 11

heretofore described represents only one possible fabrication method. Thus, the

protective pad 11 may be fabricated according to other techniques according to the

knowledge of those skilled in the art.

[080] Referring next to FIGS. 10G-11I, the protective pad 31 heretofore

described with respect to FIG. 4 is preferably fabricated in the following manner.

As shown in FIGS. 10G and 11G, the protective pad 11 previously fabricated

typically according to the steps of FIGS. 10D-11F is placed in an inverted

configuration of an injection mold 90. The mold 90 is usually formed having a

base 91 that holds a concave bonding mold 93 including a concave surface or

groove 93a extending around the perimeter thereof. As shown in FIGS. 10H and 1 IH, a lid 92, having a concave surface or groove 92a (FIG. 1 II), is then placed over the pad 11. Multiple bonding material inlet tubes 94 extend through

^ recptctive openings (not shown) in the lid 92, and communicate with the concave surface 92a. The bonding material inlet tubes 94 are connected to a suitable pump and supply mechanism (not shown) for the liquefied bonding material 8. Accordingly, the liquefied bonding material 8 is distributed from the pump and supply mechanism, through the inlet tubes 94 and into the space defined by the concave surface 92a, wherein the bonding material 8 conforms to the configuration of the concave surface 92a of the lid 92 and the concave surfaces 93a extending along the perimeter of the bonding mold 93. Thus, the elastic suspension arrangement is formed virtually surrounding the entire area of engagement between the shell and the padded membrane. Finally, as shown in FIGS. 101 and 1 II, after the bonding material 8 is at least partially cured, and the elastic suspension arrangement formed, the fabricated protective pad 31 is removed from the bonding mold 93 of the injection mold 90. It is understood that the fabrication method for the protective pad 31 heretofore described represents only one possible fabrication method, and the protective pad 31 may be fabricated according to other techniques according to the knowledge of those skilled in the art.

[081] Referring now to FIGS. 12-14, illustrating an elbow protective pad 101 fabricated according to the principles of the invention. The elbow pad 101 includes an elongated, semi-rigid, generally elliptical pad body or shell 102. The outer periphery of the shell 102 may generally define the shape of the numeral "8"

when viewed from the front, as shown in FIG. 12, and includes concave side edges

102a. As further shown in FIG. 13, the shell 102 has a convex outer surface 103,

a concave inner surface 104 and a continuous edge 105. Preferably, one or more

vent openings 106 are provided extending through the shell 102. During the

manufactured process a resilient padded membrane 107, fabricated from a resilient

material such as neoprene, prior to being connected to the shell 102 is stretched in

multiple directions, so as to be placed into a pre-tensioned state or configuration.

After that it is bonded to the edge 105 at the outer area of engagement of the shell

102. In this manner the elastic suspension arrangement is formed using an elastic

or resilient bonding material 108 such as previously described with respect to prior

embodiments of the invention. The elastic or resilient bonding material 108

preferably may extend to or cover a substantial portion or the entire outer surface

103 of the shell 102, as shown in FIG. 13. However, it should be noted that the

bond between the shell 102 and the padded membrane 107 can be also formed in a

manner previously described with respect to the embodiments of Figs. 3, 3a, 4, 5,

6 and 7. An air-containing cavity 109 is defined between the shell 102 and the

tensioned padded membrane 107. When viewed in longitudinal cross-section, as

shown in FIG. 13, the tensioned padded membrane 107 typically protrudes into the

cavity 109 in the center region of the protective pad 101 at a protrusion 107a. In

use, the protective pad 101 is strapped to the user's arm (not shown) using straps

(not shown), for example, with the user's elbow contacting the padded membrane 107. During the force of an impact, the shell 102, tensioned padded membrane

107, the elastic suspension arrangement utilizing resilient boding material and air-

filled cavity 109 absorb the impact energy in the same manner as previously

described with respect to the knee pad embodiment of FIGS. 1-7.

[082] Referring now to FIGS. 12, 15 and 16, in another aspect of the

present invention, a protective elbow elastic pad, indicated generally by reference

numeral 111, includes bonding material 108 forming the suspension arrangement

provided along both the outer and inner areas of engagement of the shell 102 with

the tensioned padded membrane 107. One or more apertures 107b are preferably

provided extending through the tensioned padded membrane 107.

[083] Referring now to FIGS. 12, 17 and 18, in yet another elbow pad

embodiment of the protective pads, indicated by reference numeral 121, the

bonding material 108 forming the elastic suspension arrangement is provided

along both the inner and outer areas of engagement of the shell 102 with the

padded membrane 107, and also extending to or covering the exterior surface of

the padded membrane 107 with a layer of the bonding material 108. Accordingly,

the layer of the elastic bonding material 108 of the suspension arrangement, in

addition to the resilient padded membrane 107, the shell 102 and the air contained

in the cavity 109, absorbs impact energy upon striking of an object or person

against the shell 102.

[084] Referring now to FIGS. 19-22, in another embodiment of the present

invention, a protective helmet 131 is provided having a generally semi-spherical, semi-rigid shell 132. The shell 132 includes a convex outer surface 133 and a

concave inner surface 134 adjoined by a continuous edge 135, as shown in FIG.

21. One or more vent openings 136 preferably extend through the shell 132. An

elastic bonding material 138 is provided along the areas of engagement of the shell

132 with a pre-tensioned resilient padded membrane 137 forming an elastic or

resilient suspension arrangement. As illustrated in Fig. 21 , the resilient padded

membrane is stretched into a tensioned state prior to having the shell 132 bonded

thereto. During the tensioning process, the padded membrane 137 stores kinetic

energy that tends to return it to the initial unstressed condition. The bonding

material 108 may extend or cover the convex outer surface 133 of the shell 132, as

best shown in FIG. 21. A cavity 139 is defined between the tensioned padded

membrane 137 and the shell 132. Preferably, one or more vent openings 138a are

provided extending through the resilient bonding material 138 in communication

with the corresponding vent openings 136 extending through the shell 132. As

illustrated in Fig. 22, upon being positioned on the head of a user the tensioned

padded membrane 137 forms a concave middle portion 137a. Thus, upon

application of a force against the exterior of the helmet 131, the resilient padded

membrane 137 overlying the head of a user temporarily stretches or flexes into the

inner cavity 139. In this manner, the impact energy of force against the shell 132

is transferred to and absorbed by the elasticity of the suspension arrangement

including the bonding material 138 and the resiliency of the padded membrane 137. The protective helmet 131 is preferably fastened to the user's head using

conventional straps (not shown).

[085] Referring now to FIGS. 23-25, in yet another embodiment of the

present invention, a shoulder pad 141 is provided having a semi-rigid pad body or

shell 142 including a convex outer surface 143 and a concave inner surface 144

adjoined by a continuous edge 145, as shown in FIG. 25. The shell 142 further

includes a chest cover portion 150 which, in use, extends over a portion of the

chest (not shown) of a wearer, and back cover portion 151 which extends over a

portion of the back (not shown) of the wearer. A neck notch 152 defined between

the chest cover portion 150 and the back cover portion 151 is configured for

receiving the neck (not shown) of the wearer. The elastic suspension

arrangement including the resilient bonding material 148 suspends a pre-tensioned

resilient padded membrane 147 within the shell 142, and preferably covers the

exterior areas of engagement of the padded membrane 147 with the shell 142, as

well as the convex outer surface 143 of the shell 142. The pre-tensioned padded

membrane 147 preferably includes a concave portion 147a that extends into the

curvature defined by the concave shell 142. The elastic bonding material 148

may further extend partially along the outer surface of the tensioned padded

membrane 147, as further shown in FIG. 25. A cavity 149 is defined between the

pre-tensioned padded membrane 147 and the concave inner surface 144 of the

shell 142. The protective pad 141 is shown configured to be worn on the right

shoulder of a wearer. Accordingly, a protective pad (not shown) designed to be worn on the left shoulder of the wearer would be substantially identical in design

to the protective pad 141 shown in FIGS. 23-25, but would comprise a mirror

image of the protective pad 141.

[086] Since many modifications, variations, and changes in detail can be

made to the described preferred embodiments of the invention, it is intended that

all matters in the foregoing description and shown in the accompanying drawings

be inteφreted as illustrative and not in a limiting sense. Thus, the scope of the

invention should be determined by the appended claims and their legal

equivalence.

Claims

What is claimed is: 1. A protective pad comprising: a shell having a concave interior surface and a convex outer surface

adjoined by a perimeter edge; a pre-tensioned resilient padded membrane; and an elastic suspension arrangement adjoining said pre-tensioned resilient

padded membrane about the perimeter edge of said shell to define a cavity

between said shell and said pre-tensioned resilient padded membrane.

2. A protective pad as recited in claim 1, wherein said pre-tensioned

resilient padded membrane being stretched in multiple directions prior to being

elastically suspended at said shell, and said elastic suspension arrangement further

comprising a resilient bonding material, so that a trampoline-type unit is formed

by said shell, pre-tensioned resilient padded membrane and elastic suspension

arrangement.

3. A protective pad as recited in claim 2, wherein said resilient bonding

material is provided at an outer area of engagement between said shell and said

pre-tensioned resilient padded membrane.

4. A protective pad as recited in claim 2, wherein said resilient bonding

material extends to or substantially covers an exterior of said shell.

5. A protective pad as recited in claim 4, wherein said resilient bonding

material is provided at an outer area of engagement of said shell with said pre-

tensioned resilient padded membrane.

6. A protective pad as recited in claim 2, wherein said resilient bonding

material extends to or substantially covers said tensioned resilient padded

membrane.

7. A protective pad as recited in claim 6, wherein said resilient bonding

tensioned resilient padded membrane.

8. A protective pad as recited in claim 3, wherein said resilient bonding

material is provided at an inner area of engagement of said shell with said pre-

tensioned resilient padded membrane.

9. A protective pad as recited in claim 8, wherein said resilient bonding

material extends to an exterior of said shell.

3θ

10. A protective pad as recited in claim 2, wherein said shell further

comprising an integral shell flange outwardly extending from an outer periphery

thereof and configured for engaging said resilient bonding material.

11. A protective pad as recited in claim 10, wherein said resilient

bonding material is provided at inner and outer areas of engagement of said flange

with said tensioned resilient padded membrane.

12. A protective pad as recited in claim 10, wherein said resilient

bonding material is sandwiched between said flange and said pre-tensioned

resilient padded membrane.

13. A protective pad as recited in claim 8, wherein the resilient bonding

material provided at said outer area of engagement of said shell and said padded

membrane extends completely around an edge of said pre-tensioned resilient

padded membrane.

14. A protective pad as recited in claim 8, wherein said padded

membrane has an opening extending therethrough and configured for engaging a

human joint.

15. A pad for protecting a joint of a human limb, comprising: a shell having a convex outer surface, a concave inner surface having a

contour complementing the joint of said human limb, and an outer edge adjoining

said inner and outer surfaces; a pre-tensioned resilient padded membrane; and an elastic suspension arrangement adjoining said pre-tensioned resilient

padded membrane about the edge of said shell to define a cavity between said

shell and said pre-tensioned resilient padded membrane.

16. A joint pad as recited in claim 15, wherein a said tensioned resilient

padded membrane being stretched in multiple directions prior to being suspended

at said shell, said elastic suspension arrangement further comprises a resilient

bonding material, so that a trampoline-type unit is formed by said shell, pre-

tensioned resilient padded membrane and elastic suspension arrangement.

17. A joint pad as recited in claim 16, wherein said resilient bonding

tensioned resilient padded membrane.

18. A joint pad as recited in claim 16, wherein said resilient bonding

tensioned resilient padded membrane.

19. A joint pad as recited in claim 18, wherein said resilient bonding

tensioned resilient padded membrane.

20. A joint pad as recited in claim 17, wherein said resilient bonding

material extends to the convex outer surface of said shell.

21. A joint pad as recited in claim 19, wherein said resilient bonding

material extends to or covers the convex outer surface of said shell.

22. A joint pad as recited in claim 19, wherein said resilient bonding

material substantially covers said tensioned resilient padded membrane.

23. A helmet comprising: a generally hemispherical shell having a convex outer surface and a

concave inner surface adjoined by an edge; a pre-tensioned resilient padded membrane; and an elastic suspension arrangement adjoining said pre-tensioned resilient

padded membrane about the edge of said shell to define a cavity between said

shell and said pre-tensioned resilient padded membrane.

32>

24. A helmet as recited in claim 23, wherein said elastic suspension

means further comprises a resilient bonding material.

25. A helmet as recited in claim 24, wherein said resilient bonding

material extends to or substantially covers said convex outer surface.

26. A shoulder pad comprising: a shell having a convex outer surface, a concave inner surface and an edge

defining a chest cover portion, a back cover portion and a neck notch between said

chest cover portion and said back cover portion; a pre-tensioned resilient padded membrane; and an elastic suspension means adjoining said pre-tensioned resilient padded

membrane about the edge of said shell to define a cavity between said shell and

said pre-tensioned resilient padded membrane.

27. A shoulder pad as recited in claim 26, wherein said elastic

suspension arrangement further comprises a resilient bonding material.

28. A shoulder pad as recited in claim 27, wherein said resilient bonding

material extends to or substantially covers said convex outer surface of said shell.

29. A method for fabricating a protective pad, comprising the steps of: providing a resilient padded membrane; stretching said resilient padded membrane into a tensioned state; tensionally suspending said stretched resilient padded membrane in a

transverse plane; positioning a shell over said tensionally suspended resilient padded

membrane; and adjoining said shell to said tensioned padded membrane by an elastic

suspension arrangement such that a cavity is formed between said shell and said

tensionally-suspended resilient padded membrane.

30. A method as recited in claim 29, wherein in said step of stretching

said padded membrane is stretched in multiple directions, and said elastic

suspension means further comprises resilient bonding material, so that a

trampoline-type unit is formed by said shell, pre-tensioned resilient padded

membrane and elastic suspension arrangement.

31. A method as recited in claim 30, wherein said tensionally-suspended

resilient padded membrane engages said shell, the method further comprising in

the formation of said elastic suspension arrangement said resilient bonding

material is provided at an outer area of engagement of said tensionally-suspended

resilient padded membrane with said shell.

32. A method as recited in claim 31, wherein the step of adjoining further comprising providing and resilient bonding material at an inner area of engagement of said tensionally-suspended resilient padded membrane with said shell.

33. A method as recited in claim 32, wherein said tensionally-suspended resilient padded membrane has an outer surface, the method further comprising the step of providing said resilient bonding material on said outer surface.

34. A protective pad comprising: a shell having a concave interior surface and a convex outer surface adjoined by a perimeter edge; a pre-tensioned resilient padded membrane; and an elastic suspension arrangement adjoining the pre-tensioned resilient padded membrane about the concave interior surface of the shell including the perimeter edge of the shell to fill the cavity between the shell and the pre-tensioned resilient padded membrane.

35. A protective pad comprising: a shell having a concave interior surface and a convex outer surface adjoined by a perimeter edge; a pre-tensioned resilient padded membrane; and an elastic suspension arrangement adjoining the pre-tensioned resilient padded membrane about the perimeter edge of the shell between the shell and the pre- tensioned resilient padded membrane.