Abstract:
A padding system may be advantageously modular in terms of size and shape, easily removable and replaceable, and comfortable and secure while maintaining an aesthetically neat and trim look. In one embodiment, the padding system includes an inner pad coupled to an outer shell with a portion of an apparel article positioned between, The apparel may include openings to allow a direct connection between the inner pad and outer shell or fasteners may be attached to the apparel for removably engaging with one or both of the inner pad and outer shell. The inner pad may be received in a pocket, which may extend inward or outward.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to a pad system, and more specifically to a removable and modular pad system usable in a variety of environments such as military, police, recreational shooting, recreational outdoor activities, construction, and home improvement. 
     BACKGROUND OF THE INVENTION 
     Conventional knee pads are available in two types: soft shell and hard shell. Volleyball players, for example, use soft knee pads that attach with elastic straps. Hard shell knee pads generally include a soft inner pad fixed to a hard outer pad of material having a higher density (i.e., the hard shell). Like the soft shell knee pads, the most hard shell knee pads are attachable to the wearer using elastic straps. If the straps are permanently attached to the knee pad system then it is worn by sliding it over the foot and up to the knee. Otherwise, the straps may be attached using clips, buckles or a hook-and-loop fastening system (e.g., a VELCRO® fastening system). The pads may be worn under or over pants. 
     After so much movement like walking or running, the strap-style knee pads often begin to fall or at least move with respect to the knee, thus requiring effort to pull the knee pad back up or to adequately reposition it. In some environments such as a military combat situation, a soldier&#39;s split second movement to pull up his knee pad could give away his position or provoke even harsher consequences. In other, less dangerous, environments the pulling up or repositioning of strap-style knee pads can just be irritating. Protective pads that are not in the proper place may also not provide adequate protection. The pads and straps can also bind or chafe the knee or leg making the pads uncomfortable to wear. 
     One type of knee pad system provides for the knee pad to be sewn into the apparel, which essentially results in a non-removable knee pad. One drawback of such a permanent assembly is that in many activities the wearer may perspire, which in turn generates moisture that is absorbed by the knee pad. The moist knee pad may then become heavier and less comfortable. Closed-cell pads have been developed for use with pants and may be insertable into a knee pocket in the pants. However, these pads do not prevent excessive wear on the outer layer of the pants and may even accelerate the wear of the pant knees. 
     These same basic considerations apply to elbow pads, hip pads, and other protective pads. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a padding system that may advantageously provide the benefits of being modular in terms of size and shape, easily removable and replaceable, comfortable and secure all while maintaining an aesthetically, orderly, or neat and trim look. These advantages, and in particular the latter advantage, make the padding system beneficial to and desirable for military and police units. In one embodiment, the padding system is a knee pad system having an inner knee pad and an outer shell fastened to one another through openings provided in a trouser fabric located between the inner knee pad and the outer shell. The inner knee pad may be received in a pocket coupled to the trouser fabric. 
     In accordance with an aspect of the invention, a padding system includes an inner pad; a fastening assembly; and an outer shell removably attachable to one of an apparel item or the inner pad by way of the fastening device. 
     In accordance with another aspect of the invention, a padding system for an apparel item includes a pocket coupled to a surface of the apparel item; an inner pad receivable in the pocket; and an outer shell removably attachable to the inner pad by way of openings provided in either the apparel item or the pocket. 
     In accordance with yet another aspect of the invention, a pair of trousers includes a knee portion coupled to the trousers; a pocket coupled to the knee portion; an inner knee pad receivable in the pocket; and an outer shell removably attachable to the inner knee pad by way of openings provided in one of the knee portion or the pocket. 
     In accordance with yet another aspect of the invention, a method for coupling a padding system to an apparel item includes the steps of (1) sliding an inner pad into a pocket coupled to the apparel item, the inner pad having a fastening device; (2) arranging the inner pad in the pocket to align the fastening device with an opening formed in either one of the pocket or the apparel item; and (3) coupling an outer shell to the inner pad using a complementary fastening device that is engageable with the fastening device of the inner pad. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings: 
         FIG. 1  is a front perspective view of a padding system according to an embodiment of the present invention; 
         FIG. 2  a cross-sectional view of the padding system of  FIG. 1  taken along line  2 - 2  of  FIG. 1  according to an embodiment of the present invention; 
         FIG. 3  is a rear plan view of an outer shell of the padding system of  FIG. 1  according to an embodiment of the present invention; 
         FIG. 4  is a front plan view of an inner pad of the padding system of  FIG. 1  according to an embodiment of the present invention; 
         FIG. 5  is a front plan view of an the outer shell of  FIG. 3  attached to the inner pad of the  FIG. 4  without any apparel material therebetween according to an embodiment of the present invention; 
         FIG. 6  is a front plan view of a knee portion of a trouser leg having openings that permit the outer to be coupled to the inner pad of the padding system according to an embodiment of the present invention; 
         FIG. 7  is a front perspective view of an apparel item with a pocket having an opening configured to receive an inner pad according to an embodiment of the present invention; 
         FIG. 8  is a cross-sectional view of a padding system with an inner pad received in an inner pocket and an outer shell coupled to the inner pad according to another embodiment of the present invention; 
         FIG. 9  is a cross-sectional view of a padding system with an inner pad received in a pocket and an outer shell coupled to an apparel item according to another embodiment of the present invention; 
         FIG. 10  is a cross-sectional view of a padding system having an inner pad received in a pocket and coupled to an apparel item and an outer shell also coupled to the apparel item according to another embodiment of the present invention; and 
         FIG. 11  is a cross-sectional view of a padding system with an inner pad not received in a pocket, but coupled to an apparel item, and an outer shell also coupled to the apparel item according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As will be described in further detail below, an embodiment of the present invention includes a padding system having an outer shell coupled to an inner pad that is received in a pocket coupled to an article of apparel, such as a trouser leg or a shirt sleeve, which may be made from a natural cloth, synthetic, laminate or other type of material. The pocket may extend inwardly or outwardly from a portion of the apparel. Thus, either the pocket or the trouser leg includes openings that permit fasteners on the outer shell to be coupled to fasteners on the inner pad. In at least one embodiment, these openings are covered by the outer shell when attached to the inner pad, which in turn provides a clean, aesthetic appearance. Alternatively, the fasteners may not extend through openings, but be secured with magnets or to the apparel directly with other fasteners, while still generally aligning the shell over the pad. The pad may fit snuggly within the pocket created in the apparel for it, while the shell is securable to the outer layer of the apparel to be positioned directly over the pad. Alternatively, the pad may simply be disposed inside the apparel with the shell on the outside, without the pad being secured within a pocket. The securement of the shell to the pad situates the pad in this embodiment. This system and its various alternate embodiments may be applied to a knee pad, an elbow pad, a hip pad, or other protective gear used in conjunction with apparel. For purposes of brevity and clarity, the description here will focus on a knee pad embodiment as set forth below. 
       FIG. 1  shows a portion of a pair of trousers  100  having a trouser leg  102  with a trouser knee portion  104  integrally formed therewith or attached thereto. A knee pad system  105  is attached to the knee portion  104 . The illustrated embodiment shows an outer shell  106  having fasteners  108 , which take the form of snaps in this embodiment. The knee portion  104  is configured with an opening  107  configured to receive an inner pad (not shown), as will be described in greater detail below. However, the fasteners  108  may take other forms such as, but not limited to, hook and loop fasteners or clips. The trousers may otherwise be referred to as or take the form of fatigues, slacks, jeans, denims, dungarees, overalls, corduroys, or chaps. Fatigues may have different names depending on the type of service or unit, for example the U.S. Army calls them army combat uniforms (ACUs). As mentioned above, the padding system may be used with apparel on other parts of the body as well, such as elbows or hips. The double-dashed lines in  FIG. 1  show stitching on the trousers  100 . 
       FIG. 2  shows the outer shell  106  fastened to an inner pad  110 , which in turn is received in a space  112  formed by a pocket  114  coupled to the knee portion  104 . The inner pocket  114  may be stitched to or otherwise attached to the knee portion  104 . The inner pocket  114  is defined by an interfacing pocket portion  113  and a region  115  of the knee portion  104  that cooperate to form the space  112 . In the illustrated embodiment, the pocket  114  is formed on or attached to an exterior surface of the trousers  100 . Therefore, the inner pad  110  contacts both the interfacing pocket portion  113  and the region  115 , which is not visible when the outer shell  106  is removed. The region  115  includes a surface  117  in contact with the wearer; whereas the interfacing pocket portion  113  is trapped between the outer shell  106  and the inner pad  110 . The pocket opening is provided near a lower section of the knee portion  104  such that the inner pad  110  is inserted into the pocket opening  107  by pushing it upwards into the pocket  114 . 
       FIGS. 3 and 4  show the outer shell  106  and inner pad  110 . Referring specifically to  FIG. 3 , the outer shell  106  includes an inner surface  116  and an approximate hourglass shape or periphery contour  118 . In the illustrated embodiment, the snap fasteners  108  are arranged adjacent the rounded corners of the contour  118 , but could be arranged in a variety of configurations. Likewise, the outer shell  106  could have different shapes and/or periphery contours other than the approximate hourglass shape. Further, the snap fasteners  108  take the form of female snap fasteners, but could also take the form of male snap fasteners. The inner surface  116  includes a convex configuration for nesting with the inner pad  110  as best shown in  FIG. 5 . The outer shell  106  is preferably made from a hard or semi-rigid plastic material, but may be made from a variety of materials, whether rigid or flexible. 
     Briefly referring to  FIG. 4 , the inner pad  110  includes complementary fasteners  120 , which in the illustrated embodiment take the form of male snap fasteners, but could also take the form of female snap fasteners. The inner pad  110  also includes an outer surface  122  and an approximate hourglass shape  124 , but less pronounced than that of the outer shell  106 . The outer surface  122  is concave and configured to nest with the inner surface  116  of the outer shell  106 . The inner pad  110  is made from open or closed cell foam, but closed cell foam is preferable for preventing unwanted moisture absorption. The inner  110  may be made from other flexible materials that are easily bendable, yet spring back to their shape  124  when inserted into the pocket  114  ( FIG. 2 ). 
       FIG. 6  shows the knee portion  104  with openings  126  for the outer shell  108 , which in turn is shown in dashed lines as merely projected onto the knee portion  104  for illustrative reference purposes. In the illustrated embodiment, the openings  126  are sized to closely receive the mating fasteners  108  ( FIG. 3) and 120  ( FIG. 4 ), respectively. Preferably, when the outer shell  106  is coupled to the inner pad  110 , the openings  126  are covered by the outer shell  106 . 
       FIG. 7  shows the inner pad  110  being inserted into the pocket  114  through the pocket opening  107 . Preferably, the inner pad  110  is rolled, folded, or partially folded to fit within the pocket  114  because a maximum width of the inner pad  110  exceeds a width of the pocket opening  107 . Once in the pocket  114 , the inner pad  110  springs back to its unrolled or unfolded shape and may be maneuvered by hand to align with the openings  126 . 
       FIG. 8  shows a trouser leg  200  having a knee portion  204  and a padding system  205 . Similar or identical features will retain the same reference numerals as the previous embodiment and merely be incremented by one hundred, but will not be described again in detail. An outer shell  206  is fastened to an inner pad  210  with fasteners  208 . A pocket  214  extends inward from the knee portion  204  instead of outward as illustrated in  FIG. 2 . The pocket  214  includes a pocket opening  207  near a bottom region of the knee portion  204 . The pocket opening  207  may be closed with hook and loop fasteners, snaps, or buttons to better secure the pad and prevent debris or dirt from entering the pocket  214 . The opening  207  may take the form of a flap that covers the ingress region of the pocket  214 . Moreover, other fastening, closing, and covering systems may be employed. 
       FIG. 9  shows a trouser leg  300  with a knee portion  304  and a padding system  305 . Again, similar or identical features will retain the same reference numerals as the previous embodiment and merely be incremented by one hundred, but will not be described again in detail. In the illustrated embodiment, an outer shell  306  is coupled directly to the knee portion  304  with a fastener system  330 . Thus, the outer shell  306  may have fasteners  332  that take the form of male snaps whereas the knee portion  304  may have crimped on fasteners  334  that take the form of female snaps. However, other types of fastener systems  330 , such as hook and loop fastener systems, may be employed. The inner pad  310  is received into a pocket  314  in a folded manner and then expands within the pocket  314  to prevent it from falling out. It is appreciated that a pocket opening  307  may be located on the side or top of the pocket  314 . 
       FIG. 10  shows a slightly different embodiment of a trouser leg  400  with a knee portion  404  and a padding system  405 . Again, similar or identical features will retain the same reference numerals as the previous embodiment and merely be incremented by one hundred, but will not be described again in detail. In the illustrated embodiment, an outer shell  406  is coupled directly to the knee portion  404  with a first fastener system  430 . In addition, an inner pad  410  is coupled to the knee portion  404  with a second fastener system  436 , which may also be attached to the pocket  414 . Alternatively, the pocket  414  may extend outward from the knee portion  404  and both the outer shell  406  and inner pad  410  may be fastened to the pocket  314 . 
       FIG. 11  shows yet another embodiment of a trouser leg  500  with a knee portion  504 . In the illustrated embodiment, an outer shell  506  is attached directly to the knee portion  504  and an inner pad  510  is attached directly to the knee portion  504 , but not located in any type of a pocket. The outer shell  506  and inner pad  510  may be attached with first and second fastener systems  530 ,  534 , respectively or may be attached directly to each other through openings (not shown) in the knee portion  504 . 
     While the preferred embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention, such as which way the pockets extend, how the shell and pad are coupled to the apparel and coupled together, whether a pocket is provided and what type of fastener systems may be utilized. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined by reference to the claims that follow.