Human limb/joint protective pad and method of making

A protective pad includes a pre-tensioned resilient padded membrane resiliently suspended to a semi-rigid shell. A cavity is defined between the pre-tensioned 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.

FIELD OF THE INVENTION

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

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.

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.

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. Pat. Nos. 6,401,245 and 6,156,000 are exemplary of this common type of protective pad construction. The '245 patent discloses a knee cup10sewn to a cushioning base29directly engaging the knee of a wearer. The knee cup includes an outer shell12having a rear indentation32completely filled with a dampening insert14, 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 cup10to the cushioning base29results in the transfer of impact forces to relatively minute concentrated areas along the edge of the base29. In fact, it is not uncommon for the concentrated forces applied along relatively small stitched areas to exceed the tensile strength of the fabric base29at 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. Pat. No. 6,156,000 discloses a method for making a protective pad wherein a blank pad11is cut into a shaped pad11′ 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 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.

U.S. Pat. No. 6,151,714 discloses another type of protective pad10having a construction wherein a rigid outer shell24having a shielding element12is attached along a peripheral shell flange28to an underlying planar cushioning body16such that a cavity40is 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 surface30of the shell24, the shielding element12resists flexing as the cushioning element14flexes to permit penetration of the protected joint surface20into 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.

U.S. Pat. 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.

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

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.

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.

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.

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.

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.

In another aspect of the present invention, the resilient bonding material may extend to or substantially cover the entire exterior surface of the shell.

In yet a further aspect of the present invention, the protective pad defines an elbow pad.

Still another aspect of the present invention provides a helmet.

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

A still further aspect of the present invention provides a protective pad for protecting the genitals or breasts.

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.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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-à-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.

Referring initially toFIGS. 1 and 2, in which a first embodiment of the present invention a protective knee pad is generally indicated by reference numeral1. The protective pad includes a unitary pad body or shell2, preferably molded or otherwise formed from a rigid or semi-rigid material such as polypropylene or similar thermoplastic resins. The shell2has a convex outer surface3and a concave inner surface4adjoined by a continuous peripheral edge5. Preferably, one or more vent openings6are provided extending through the shell2. The shell2is directly fused about its periphery to a resilient padded membrane, indicated generally by reference numeral7. This is accomplished through the formation of the elastic suspension arrangement in the form of an elastic or resilient bonding material8.

Significantly, the resilient padded membrane is stretched into a tensioned state, or configuration, prior to having the shell2bonded thereto. The significance of attaching the resilient padded membrane7in such a tensioned state will become apparent from the following description. Preferably, padded membrane7is 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 material8comprises 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.

An air-filled space or cavity9is defined between the tensioned padded membrane7and the concave inner surface4of the shell2. As shown inFIG. 2, in one aspect of the invention the resilient bonding material8provided along the periphery of the shell, and generally about an outer area of engagement of the shell and the padded membrane7, extends completely over the upper convex surface3of the shell2to provide additional enhanced dampening of the force of an impact to the shell2. Openings8aare provided through the layer of bonding material8in communication with corresponding vent openings6in the shell2. Preferably, the bonding material layer openings8aare slightly larger than the corresponding openings6in underlying shell2.

Referring now toFIG. 3, in another aspect of the present invention, the protective pad11is provided having an aperture7aextending through the tensioned padded membrane7in communication with cavity9. The padded membrane aperture7ais preferably sized and shaped for frictionally engaging and at least partially conforming to the patella, or knee20a, of the leg20of a wearer. The padded membrane7engages the user's leg20, and the aperture7aenhances positional stability of the padded membrane7on the leg20. 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 inFIG. 3, the elastic or resilient bonding material8can be provided disposed about both inner and outer areas of engagement of the periphery of the shell2and the upper surface of the tensioned padded membrane7.

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-à-vis prior art protective pad constructions. Particularly, the tensioned padded membrane7is suspended about the periphery of the shell2by the elastic suspension arrangement or the elastic or resilient bonding material8in 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 membrane7stores kinetic energy that tends to return it to the initial unstressed condition. Accordingly, as best illustrated inFIG. 3, upon application of a force against the exterior shell surface3, the resilient padded membrane7overlying the joint surface20atemporarily stretches or flexes into the cavity9such that the impact energy or force against the shell is transferred to, and substantially absorbed by, both the elasticity of the bonding material8and the resiliency of the padded membrane7. Subsequently, the padded membrane7returns 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.

Additional impact energy dampening is achieved as a result of air trapped within the cavity9. In other words, because the rate of egress of air from the cavity9during an impact is restricted to the pathways defined by the shell apertures6, the trapped air acts as an additional cushioning mechanism. The elasticity of the bonding material8combined with its relatively large engagement or contact area between the shell2and padded membrane7by means of the resilient bonding material8substantially 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 shell2from the padded membrane7, leading to appreciably improved pad durability over the prior art.

Referring briefly toFIG. 3A, in a further aspect of the present invention, a protective pad21is provided with a shell22having an outwardly-extending perimeter flange25contacting the tensioned padded membrane7. The elastic bonding material8preferably covers the extended engagement area of the flange25at the exterior of the shell22, as well as at the inner surface4of the shell22adjacent to the flange25. An aperture7amay be provided extending through the padded membrane7, as heretofore described with respect to the protective pad11ofFIG. 3.

Referring briefly toFIG. 4, in another aspect of the present invention, a protective pad31is provided having the elastic or resilient bonding material8virtually surrounding the area of junction between the shell22and the membrane7. In this manner, the resilient connecting arrangement8extends from a lower surface of the stretched padded membrane7, around a peripheral edge of the padded membrane, to the outer area of engagement between the shell2and the padded membrane7. The elastic suspension arrangement or bonding material8is further formed at the inner area of engagement between the shell2and the padded membrane7. An aperture7ais typically provided in the padded membrane7.

Referring briefly toFIG. 5, in yet another aspect of the present invention, a protective pad41is provided having a thin layer of the bonding material8coating the lower exterior surface of the stretched padded membrane7and extending to the exterior area of engagement between the edge5of the shell2and the padded membrane7. The thin layer of bonding material8on the padded membrane7contacts the skin of the user's leg20(seeFIG. 3) during use and further contributes to the elasticity of the padded membrane7, absorbing impact energy during use.

Referring briefly toFIG. 6, in still another aspect of the present invention, a protective pad51is provided having the bonding material8encapsulating the entire convex outer surface3of the shell2. The bonding material8further extends along the exterior and interior areas of engagement of the shell2with the stretched padded membrane7, and may further extend around a peripheral edge of the padded membrane7to 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 opening8ais preferably provided through the bonding material8in communication with, and corresponding to, the air opening6of the shell2.

Referring briefly toFIG. 7, in yet another aspect of the present invention, a protective pad61is provided having a shell62including an outwardly extending peripheral flange65. The bonding material8is preferably provided disposed between the underside of the flange65and the corresponding area of the stretched padded membrane7. In this manner the elastic suspension arrangement8is sandwiched between the flange65and the membrane7.

Referring now toFIG. 7A, in still a further aspect of the present invention, a protective pad is formed having a shell62with the outwardly extending peripheral flange65which is formed with a channel63facing the stretched membrane7and extending through the length of the flange. During the fabrication the liquefied bonding material8is distributed at a high temperature and pressure from a supply mechanism to a molding tip67and is initially injected into the channel63. Upon passing through the length of the flange65, a barrier or bonding material formation is developed at the interior of the shell in the vicinity of the padded membrane7. Upon further application of the liquefied bonding material, the flange65and the entire shell62are spaced from the membrane7, so that a layer of resilient bonding material8is formed therebetween. Upon further application, the bonding material8extends around a peripheral edge of the flange65to the exterior surface of the shell62.

Referring now primarily toFIGS. 8A-9F, the protective pad1heretofore described with respect toFIGS. 1 and 2is preferably fabricated in the following manner. As shown inFIGS. 8A and 9A, a sheet of the resilient padded membrane7, which may be formed having substantially rectangular configuration, is initially attached to the respective padded membrane receiving members or clamps72provided at a base71of an open injection mold70. The clamps72are typically attached to the outer periphery or the longitudinal and transverse edges of the padded membrane7. Significantly, in the next operational step, as shown inFIGS. 8B and 9B, to accumulate the required kinetic energy the padded membrane7is stretched in multiple directions into a tensioned state or configuration by retracting the fabric clamps72outwardly. In this operational step the required kinetic energy is generated and stored within the stretched padded membrane. Alternatively, the resilient padded membrane7can be precut and then loaded into the injection mold70either manually or automatically. Subsequently, the shell2is placed, with its concave surface facing downward, onto the stretched padded membrane7. After that, as shown inFIGS. 8C and 9C, a bonding mold73is positioned over the shell2. The bonding mold73has a concave configuration complementary to the desired configuration of the bonding material8to be deposited on the shell2, as well as concave surfaces or grooves73aextending along the perimeter thereof. A gap75is defined between the bonding mold73and the shell2. Multiple bonding material inlet tubes74extend through respective openings (not shown) in the bonding mold73, and communicate with the gap75. The bonding material inlet tubes74are connected to a suitable pump and supply mechanism (not shown) for dispensing the resilient bonding material8in a melted, liquid state. Accordingly, the liquefied bonding material8is distributed at high heat and pressure from the pump and supply mechanism, through the inlet tubes74, and injected into the gap75, wherein the bonding material8fills the gap75and the spaces defined by the concave surfaces73aextending along the perimeter of the shell2retaining its elasticity. As shown inFIGS. 8D and 9D, after the bonding material8solidifies, the elastic suspension arrangement is formed, and the bonding mold73is lifted from the shell2. Next, as shown inFIGS. 8E and 9E, a suitable excising device76is used to cut the excess padded membrane material7bfrom the padded membrane7. In some instances, the excess fabric padded membrane material7bmay extend a substantial distance outwardly from the boundaries of the shell2. In that case, the excess padded membrane material7bmay be cut to define straps (not shown) to be used in attachment of the protective pad1to 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 pad1is removed from the mold70, as shown inFIGS. 8F and 9F.

In this manner, an engaging surface is defined by a pre-tensioned padded membrane7elastically suspended in a transverse plane from an essentially rigid, or sometimes resilient, outer periphery of the shell2, with the padded membrane adjoined to the shell by means of the elastic bonding material8acting as an elastic suspension arrangement. It will be apparent to those skilled in the art that the fabrication method for the protective pad1heretofore described represents only one possible fabrication method and the protective pad1may be fabricated according to other techniques.

Referring next toFIGS. 10A-11F, the protective pad11heretofore described with respect toFIG. 3is preferably fabricated in the following manner. As shown inFIGS. 10A and 11A, a sheet of the padded membrane7, which can be formed having substantially rectangular configuration, is initially attached or clamped to respective receiving members or clamps82provided at a base81of an injection mold80. The base81includes a base opening81aextending centrally therethrough. The clamps82are typically attached to both the longitudinal and transverse edges of the padded membrane7. Next, as shown inFIGS. 10B and 11B, to accumulate and store the required kinetic energy the padded membrane7is stretched in multiple directions, by retracting the fabric clamps82outwardly, into a tensioned state or configuration. As shown inFIGS. 10C and 11C, the shell2is then placed on the tensioned padded membrane7, after which a bonding mold83is positioned over the shell2. The bonding mold83has a concave configuration which is complementary to the configuration for the bonding material8to be deposited on the shell2. The mold83also contains concave surfaces or grooves83aalong the perimeter thereof. Multiple exterior bonding material inlet tubes84extend through respective openings (not shown) in the bonding mold83. Furthermore, a pair of interior bonding material inlet tubes85extend through the central base opening81aof the base81. The exterior bonding material inlet tubes84and the interior bonding material inlet tubes85are connected to a suitable pump and supply mechanism (not shown) for dispending the liquefied bonding material8. Accordingly, the liquefied bonding material8is distributed from the pump and supply mechanism, through the exterior bonding material inlet tubes84, into the spaces defined by the concave surfaces83a. This occurs in such a manner that the bonding material8conforms to the configuration of the concave surfaces83aextending along the outer perimeter of the shell2at the junction thereof with the padded membrane7. The interior bonding material in the tubes85are utilized to deliver the liquefied bonding material, so as to form the required bond between the inner perimeter of the shell2and the stretched fabric of the padded membrane7. As shown inFIGS. 10D and 11D, after the bonding material8at least partially cures, so as to form the elastic suspension arrangement, the bonding mold83is lifted from the shell2. Next, as shown inFIGS. 10E and 11E, a suitable excising device76is used to cut the excess padded membrane material7bfrom the padded membrane7. Finally, the fabricated protective pad11is removed from the injection mold80, as shown inFIGS. 10F and 11F. It is understood that the fabrication method for the protective pad11heretofore described represents only one possible fabrication method. Thus, the protective pad11may be fabricated according to other techniques according to the knowledge of those skilled in the art.

Referring next toFIGS. 10G-11I, the protective pad31heretofore described with respect toFIG. 4is preferably fabricated in the following manner. As shown inFIGS. 10G and 11G, the protective pad11previously fabricated typically according to the steps ofFIGS. 10D-11Fis placed in an inverted configuration of an injection mold90. The mold90is usually formed having a base91that holds a concave bonding mold93including a concave surface or groove93aextending around the perimeter thereof. As shown inFIGS. 10Hand11H, a lid92, having a concave surface or groove92a(FIG. 11I), is then placed over the pad11. Multiple bonding material inlet tubes94extend through respective openings (not shown) in the lid92, and communicate with the concave surface92a. The bonding material inlet tubes94are connected to a suitable pump and supply mechanism (not shown) for the liquefied bonding material8. Accordingly, the liquefied bonding material8is distributed from the pump and supply mechanism, through the inlet tubes94and into the space defined by the concave surface92a, wherein the bonding material8conforms to the configuration of the concave surface92aof the lid92and the concave surfaces93aextending along the perimeter of the bonding mold93. Thus, the elastic suspension arrangement is formed virtually surrounding the entire area of engagement between the shell and the padded membrane. Finally, as shown inFIGS. 10I and 11I, after the bonding material8is at least partially cured, and the elastic suspension arrangement formed, the fabricated protective pad31is removed from the bonding mold93of the injection mold90. It is understood that the fabrication method for the protective pad31heretofore described represents only one possible fabrication method, and the protective pad31may be fabricated according to other techniques according to the knowledge of those skilled in the art.

Referring now toFIGS. 12-14, illustrating an elbow protective pad101fabricated according to the principles of the invention. The elbow pad101includes an elongated, semi-rigid, generally elliptical pad body or shell102. The outer periphery of the shell102may generally define the shape of the numeral “8” when viewed from the front, as shown inFIG. 12, and includes concave side edges102a. As further shown inFIG. 13, the shell102has a convex outer surface103, a concave inner surface104and a continuous edge105. Preferably, one or more vent openings106are provided extending through the shell102. During the manufactured process a resilient padded membrane107, fabricated from a resilient material such as neoprene, prior to being connected to the shell102is stretched in multiple directions, so as to be placed into a pre-tensioned state or configuration. After that it is bonded to the edge105at the outer area of engagement of the shell102. In this manner the elastic suspension arrangement is formed using an elastic or resilient bonding material108such as previously described with respect to prior embodiments of the invention. The elastic or resilient bonding material108preferably may extend to or cover a substantial portion or the entire outer surface103of the shell102, as shown inFIG. 13. However, it should be noted that the bond between the shell102and the padded membrane107can be also formed in a manner previously described with respect to the embodiments ofFIGS. 3,3a,4,5,6and7. An air-containing cavity109is defined between the shell102and the tensioned padded membrane107. When viewed in longitudinal cross-section, as shown inFIG. 13, the tensioned padded membrane107typically protrudes into the cavity109in the center region of the protective pad101at a protrusion107a. In use, the protective pad101is strapped to the user's arm (not shown) using straps (not shown), for example, with the user's elbow contacting the padded membrane107. During the force of an impact, the shell102, tensioned padded membrane107, the elastic suspension arrangement utilizing resilient boding material and air-filled cavity109absorb the impact energy in the same manner as previously described with respect to the knee pad embodiment ofFIGS. 1-7.

Referring now toFIGS. 12,15and16, in another aspect of the present invention, a protective elbow elastic pad, indicated generally by reference numeral111, includes bonding material108forming the suspension arrangement provided along both the outer and inner areas of engagement of the shell102with the tensioned padded membrane107. One or more apertures107bare preferably provided extending through the tensioned padded membrane107.

Referring now toFIGS. 12,17and18, in yet another elbow pad embodiment of the protective pads, indicated by reference numeral121, the bonding material108forming the elastic suspension arrangement is provided along both the inner and outer areas of engagement of the shell102with the padded membrane107, and also extending to or covering the exterior surface of the padded membrane107with a layer of the bonding material108. Accordingly, the layer of the elastic bonding material108of the suspension arrangement, in addition to the resilient padded membrane107, the shell102and the air contained in the cavity109, absorbs impact energy upon striking of an object or person against the shell102.

Referring now toFIGS. 19-22, in another embodiment of the present invention, a protective helmet131is provided having a generally semi-spherical, semi-rigid shell132. The shell132includes a convex outer surface133and a concave inner surface134adjoined by a continuous edge135, as shown inFIG. 21. One or more vent openings136preferably extend through the shell132. An elastic bonding material138is provided along the areas of engagement of the shell132with a pre-tensioned resilient padded membrane137forming an elastic or resilient suspension arrangement. As illustrated inFIG. 21, the resilient padded membrane is stretched into a tensioned state prior to having the shell132bonded thereto. During the tensioning process, the padded membrane137stores kinetic energy that tends to return it to the initial unstressed condition. The bonding material108may extend or cover the convex outer surface133of the shell132, as best shown inFIG. 21. A cavity139is defined between the tensioned padded membrane137and the shell132. Preferably, one or more vent openings138aare provided extending through the resilient bonding material138in communication with the corresponding vent openings136extending through the shell132. As illustrated inFIG. 22, upon being positioned on the head of a user the tensioned padded membrane137forms a concave middle portion137a. Thus, upon application of a force against the exterior of the helmet131, the resilient padded membrane137overlying the head of a user temporarily stretches or flexes into the inner cavity139. In this manner, the impact energy of force against the shell132is transferred to and absorbed by the elasticity of the suspension arrangement including the bonding material138and the resiliency of the padded membrane137. The protective helmet131is preferably fastened to the user's head using conventional straps (not shown).

Referring now toFIGS. 23-25, in yet another embodiment of the present invention, a shoulder pad141is provided having a semi-rigid pad body or shell142including a convex outer surface143and a concave inner surface144adjoined by a continuous edge145, as shown inFIG. 25. The shell142further includes a chest cover portion150which, in use, extends over a portion of the chest (not shown) of a wearer, and back cover portion151which extends over a portion of the back (not shown) of the wearer. A neck notch152defined between the chest cover portion150and the back cover portion151is configured for receiving the neck (not shown) of the wearer. The elastic suspension arrangement including the resilient bonding material148suspends a pre-tensioned resilient padded membrane147within the shell142, and preferably covers the exterior areas of engagement of the padded membrane147with the shell142, as well as the convex outer surface143of the shell142. The pre-tensioned padded membrane147preferably includes a concave portion147athat extends into the curvature defined by the concave shell142. The elastic bonding material148may further extend partially along the outer surface of the tensioned padded membrane147, as further shown inFIG. 25. A cavity149is defined between the pre-tensioned padded membrane147and the concave inner surface144of the shell142. The protective pad141is 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 pad141shown inFIGS. 23-25, but would comprise a mirror image of the protective pad141.