Abstract:
A protective garment is provided for use in conjunction with an exoskeletal upper body pad system for a sport, such as American football. The protective garment includes a shirt formed of air-permeable, moisture-wicking fabric that stretches in all directions. A number of independent protective pad segments are integrated within the shirt and are arranged to enable flexible motion by the wearer of the shirt. The independent protective pad segments are positioned and dimensioned to enable the protective garment to be worn between the body of the wearer and the exoskeletal upper body pad system. A conventional exoskeletal shoulder pad system may be easily retrofit for use with the protective garment by attaching a pair of sub pad assemblies to the main arches of the system in order to provide localized compressible padding.

Description:
TECHNICAL FIELD  
       [0001]     This invention relates generally to protective sports equipment. More particularly, this invention relates to shoulder pads for the sports of football, lacrosse and hockey.  
       BACKGROUND OF THE INVENTION  
       [0002]     Improvements are desired in the construction of football, lacrosse and hockey shoulder pads. In particular, improvements are desired in the dissipation of body heat and moisture of the wearer as well as the sanitary cleaning aspects of the pad component of football, lacrosse and hockey shoulder pad systems.  
         [0003]     The soft pad component of the conventional shoulder pad system is the element of the football, lacrosse and hockey shoulder pad system that is immediately in contact with the wearer&#39;s body. The typical football, lacrosse or hockey shoulder pad system is comprised of a hard exoskeletal system and a soft pad component. The “soft pad component” is defined herein as the compressible padding that provides cushioning. The soft pad component is distinguishable from the rigid elements of the exeskeletal system. The soft pad component in the typical shoulder pad system is mechanically attached to the exoskeletal system so as to be positioned between the wearer&#39;s torso and upper body and the exoskeletal system. The construction of conventional shoulder pad systems undesirably traps moisture and body heat between the soft pad component and the wearer&#39;s body. Additionally, the soft pad component of the conventional shoulder pad system cannot be laundered in a conventional fashion, thus leading to unsanitary conditions of the soft pad component.  
       SUMMARY OF THE INVENTION  
       [0004]     The present invention relates to an improved shoulder pad system that enables improved heat and moisture transfer away from the wearer&#39;s body. Shoulder pads according to the invention would also enable frequent and conventional laundering of the pad component.  
         [0005]     With regard to the foregoing, the present invention is directed to a pad system for a shoulder pad. In the preferred embodiment, the system includes a protective garment component having multiple protective pad segments. The protective pad segments are positioned and dimensioned to take the place of the soft pad component of a conventional shoulder pad system. Thus, at least the major portion of the compressible padding is separate from the exoskeletal system.  
         [0006]     In another aspect, the invention relates to a shoulder pad system that includes a sub pad assembly configured for installation on each arch member, wherein the sub pad assembly is further configured to underlie an epaulette system and is independent of the protective garment. By attaching a sub pad assembly to each arch member of a conventional shoulder pad system, the conventional system is quickly retrofit for use with the protective garment. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]      FIG. 1A  is a frontal perspective view of an illustrated embodiment of a shoulder pad system in accordance with a preferred embodiment thereof.  
         [0008]      FIG. 1B  is a rear perspective view thereof.  
         [0009]      FIG. 2  is an exploded perspective view of the protective garment assembly of the shoulder pad system of  FIGS. 1A and 1B .  
         [0010]      FIGS. 3A and 3B  are top and bottom plan views, respectively, of a sub pad assembly of the shoulder pad system of  FIGS. 1A and 1B .  
         [0011]      FIG. 4  is an exploded perspective view of an exoskeletal assembly of the shoulder pad system of  FIGS. 1A and 1B .  
         [0012]      FIG. 5  is a perspective view of the position and attachment of a sub pad assembly of  FIGS. 3A and 3B  to an exoskeletal system of  FIG. 4   
     
    
     DETAILED DESCRIPTION  
       [0013]     With initial reference to  FIGS. 1A and 1B , the invention relates to a shoulder pad system including an exoskeletal assembly  40 , a pair of sub pad assemblies  20  and  30 , and a protective garment assembly  10 .  
         [0000]     Protective Garment Assembly  
         [0014]     With reference to  FIG. 2 , the protective garment assembly preferably includes anterior and posterior fabric panels  220  and  230 , respectively. Using techniques known in the art, such as stitching, the fabric panels are joined together to form a garment that covers the upper torso of the wearer. In a preferred embodiment of the invention, the garment includes apertures at both sides for receiving the wearer&#39;s arms, and an aperture at the center of the top of the protective garment assembly for receiving the wearer&#39;s neck and head. Further comprising the protective garment assembly are multiple, independent protective foam segments  222  that are attached by a WEB-type hot melt adhesive and thermal processing to the anterior and posterior panels  220  or  230  in sizes, shapes and positions that provide protection, while promoting flexible motion of the wearer. The WEB-type hot melt adhesive permits air ventilation and is capable of withstanding typical temperatures encountered during laundering. Preferably, the adhesive is stable at a temperature as high as 100 degrees Celsius. In the preferred embodiment, the WEB-type adhesive is the adhesive sold under the trademark MELTACE WEB 100E by Donsung NSC Co., Ltd.  
         [0015]     Fabric panels  226  are preferably affixed by the WEB-type, air-ventilating adhesive and thermal processing to the protective foam segments  222  on the surfaces of protective foam segments  222  that are not in immediate contact with fabric panels  220  or  230 . The size and shape of each fabric panel  226  is preferably substantially larger than the associated protective foam segment  222  to which it is attached, so as to enable attaching each fabric panel  226  to the fabric panel  220  or  230  at areas beyond the associated protective foam segment  222 . Preferably, each fabric panel  226  is stitched to the fabric panel  220  or  230  around the entire perimeter of the associated protective foam segment.  
         [0016]     Preferably, fabric panels  220 ,  230  and  226  are made of a synthetic fabric constructed to promote moisture-wicking and to be capable of stretching in multiple directions. “Moisture-wicking” is defined herein as the ability to absorb perspiration and other fluids, while “stretching in multiple directions” is defined as the ability to stretch under typical force applied to a garment and still return to the original relaxed condition when the force is removed. In the preferred embodiment, the fabric would comprise Polyester microfibers combined with Spandex sold under various trademarks and produced by Y.R.C. Textile Co., Ltd.  
         [0017]     Preferably, protective foam segments  222  are made of perforated closed cell foam.  
         [0000]     Exoskeletal Assembly  
         [0018]     With respect to  FIGS. 1A, 1B  and  4 , the exoskeletal assembly  40  preferably includes a pair of main arches  130  and  140 , a pair of epaulette assemblies  70  and  80 , a pair of shoulder cap assemblies  50  and  60 , a pair of sub arches  38  and  48 , a plurality of arch member connectors  122 , a flexible cord  126 , a fastener  128 , a plurality of straps  100 , and a plurality of buckles  110  to accept the straps  100  for the purposes of attaching the exoskeletal system  40  to the wearer.  
         [0019]     Each arch member  130  and  140  is generally U-shaped in configuration and preferably of one-piece molded plastic construction. The arch member  130  is preferably constructed to include a chest portion  32  and a back portion  34  and a connecting portion  36 . Similarly, the arch member  140  is shown as having a chest portion  42 , a back portion  44 , and a connecting portion  46 .  
         [0020]     Each epaulette assembly  70  and  80  is preferably comprised of a one-piece molded hard plastic element that is generally convex in shape. Each such assembly has a fabric covered foam interior liner and a flexible connector  78  and  80  for attaching the epaulette assembly to the respective arch member  130  and  140 .  
         [0021]     Each shoulder cap assembly  50  and  60  is preferably comprised of a one-piece molded hard plastic element that is generally convex in shape. Each such assembly has a fabric covered foam interior liner and a flexible connector  76  and  86  for attaching the epaulette assembly to the respective arch member  130  and  140 .  
         [0022]     The sub arches  38  and  48  are preferably of one-piece molded plastic construction generally curved in shape. The sub arch is preferably connected to the same-side arch member  130  and  140  so as to be positioned under the connecting member  36  and  46  and between the arch member chest and back portions  32  and  34  or  42  and  44 . The sub arch is preferably attached to the arch member by mechanical means, such as rivets or screws and nuts at points near the tops of the arch member front portion  32  and arch member back portion  34 . The chest portion and the back portion are configured to have raised areas of varying shapes and sizes within their perimeters to provide added structural strength.  
         [0023]     Each chest portion  32  and  42  and each back portion  34  and  44  preferably is perforated at various positions within its perimeter to promote airflow away from the wearer&#39;s body.  
         [0024]     Each epaulette assembly  70  and  80  and each shoulder cap assembly  50  and  60  is preferably attached to the connecting portion  36  and  46  of the corresponding main arch at a point approximately above the wearer&#39;s shoulder by using mechanical connectors such as rivets or screws and nuts. The preferred assembly is accomplished by aligning the apertures in the connecting portion  36  or  46 , the shoulder cap assembly flexible connector  76  or  80 , and the epaulette assembly flexible connector  78  or  88  with the shoulder cap assembly flexible connector positioned between the connecting portion  36  and the epaulette assembly flexible connector.  
         [0025]     Arch members  130  and  140  are preferably connected by placing the two arch members in adjacent relationship at a desired distance apart, with the back portion  34  substantially parallel to the back portion  44 . A plurality of the connectors  122  are used to span between and connect the back portions  34  and  44  by means of a mechanical fastener such as a rivet or a screw and nut.  
         [0026]     Arch members  130  and  140  are preferably connected at the front by placing the arch members  130  and  140  adjacent to one another, with the chest portion  32  substantially parallel to the chest portion  44 . Flexible cord  126  is threaded through apertures in chest portions  32  and  42  and fastener  128  is used to maintain the wearer&#39;s desired tension in flexible cord. The preferred fastener  128  is constructed of molded hard plastic and enables the wearer to quickly and frequently lock or unlock its hold on flexible cord  126 .  
         [0000]     Sub Pad Assembly  
         [0027]     With respect to  FIGS. 1A, 3A  and  3 B, the sub pad assembly  20  will be described, but the description applies equally to the other sub pad assembly  30 . The advantage of the sub pad assemblies is that conventional shoulder pad systems can be retrofit for optimal use with the protective garment  10 . The sub pad assembly  20  preferably includes an elongated one-piece shoulder portion  21 . A pair of supplemental pads  144  and  146  are preferably releasably attachable with the shoulder portion.  
         [0028]     The shoulder portion  21  is preferably made of a one-piece perforated and thermal formed flexible padding material, such as EVA closed cell foam, sandwiched between sheets of a fabric material that is air permeable and moisture wicking. In the preferred embodiment, the sheets of fabric material are affixed to the one-piece perforated and thermal-formed foam using a WEB-type thermal adhesive that allows air ventilation as previously described.  
         [0029]     The shoulder section  21  is preferably thermal formed into a plurality of subsegments to promote flexibility of said shoulder section  21 .  
         [0030]     Referring to  FIG. 3B , the shoulder section  21  has a plurality of fabric panels  147  that are preferably constructed of the loop portion of a hook-and-loop fastening system.  
         [0031]     Referring to  FIG. 3A , the surfaces of supplemental pads  144  and  146  that come in immediate contact with fabric panel  147  on shoulder section  21  are constructed of the hook portion of a hook-and-loop fastening system.  
         [0032]     Referring to  FIGS. 3B, 4  and  5 , the sub pad assembly  20  is attached to the exoskeletal assembly. The attachment is preferably accomplished by aligning apertures  43  and  47  in the sub pad assembly with apertures  41  and  45 , respectively, on arch member  140  and then inserting a mechanical fastener, such as a rivet or a screw and nut, through the aligned said apertures.  
         [0033]     Referring to  FIGS. 3A and 5 , straps  122  and  132  having matingly engageable hook-and-loop material on respective surfaces thereof are provided on the sub pad assemblies  20  and  30  for wrapping around the sub arches  38  and  48 .