Abstract:
An apparatus is disclosed, having an attachment mechanism for attaching a base material to a body part of a wearer. The apparatus further includes a padding layer overlaying the base material, and a plurality of scales. Each scale of the plurality of scales is independently attached to the padding layer, each scale either at least partially overlapping or at least partially underlying one or more adjacent scales to enable flexible adherence to a shape of the body part of the wearer.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. patent application Ser. No. 62/127,270, filed on Mar. 2, 2015, and entitled “WEARABLE PROTECTIVE SYSTEM AND METHOD FOR MAKING THE SAME,” which is incorporated by reference herein in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to protective system, and more particularly to a wearable protective system for protecting a portion of a wearer&#39;s anatomy from forces such as blunt impact, abrasions, slashings, cuttings, punctures, or the like. 
         [0003]    Various protective gear, such as knee pads, elbow pads, etc., are prevalent in modern activities, particularly in activities such as skateboarding, skating, or the like. Most of these protective gear include only a unitary pad, or a padding layer overlaid by a rigid encasement. The former, which lack an outer hard shell encasement, do not provide adequate protection or impact absorption. The latter, while offering somewhat adequate protection, are bulky, inflexible and do not provide full mobility by the wearer. Conventional protective gear either do not adequately absorb a force exerted upon it, nor adequately distribute such force away from the point of impact so as to lessen the force received by a part of a wearer&#39;s anatomy being covered by the gear. Because of these inadequate absorption and distribution qualities, most protective gear tend to be bulky in order to meet at least a minimum standard of effectiveness. Protective gear with a lower profile is typically ineffective in offering protection to a wearer. 
       SUMMARY 
       [0004]    This document presents a protective assembly that includes a scale system of a number of scales, one or more layers of impact material, a wrap for attaching to a part of a wearer&#39;s body (such as the wearer&#39;s knee or elbow, or the like). 
         [0005]    In one aspect, an apparatus includes an attachment mechanism for attaching a base material to a body part of a wearer. The apparatus further includes a padding layer overlaying the base material, and a plurality of scales. Each scale of the plurality of scales is independently attached to the padding layer, each scale either at least partially overlapping or at least partially underlying one or more adjacent scales to enable flexible adherence to a shape of the body part of the wearer. 
         [0006]    The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    These and other aspects will now be described in detail with reference to the following drawings. 
           [0008]      FIGS. 1A-1H  illustrate a scale and a scale system for absorbing and distributing impact energy. 
           [0009]      FIGS. 2A-2C  illustrate the scale system in further detail. 
           [0010]      FIGS. 3A-3B  illustrate impact material. 
           [0011]      FIGS. 4A-4B  illustrate impact material and scale interaction. 
           [0012]      FIGS. 5A-5B  illustrate a fastening system in accordance with implementations described herein. 
           [0013]      FIGS. 6A-6E  illustrate various other aspects of a fastening system in accordance with implementations described herein. 
           [0014]      FIG. 7  shows a knee pad product in accordance with implementations described herein. 
           [0015]      FIG. 8  illustrates a quick locking mechanism for the impact material. 
       
    
    
       [0016]    Like reference symbols in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0017]    This document describes a protective assembly. As shown in  FIG. 7 , a protective assembly  100  includes a scale system  102  formed of a number of scales  104 , and one or more layers of impact material (not shown). The protective assembly  100  further includes a wrap  106  or other attachment mechanism for attaching to a part of a wearer&#39;s body (such as the wearer&#39;s knee or elbow, or the like). 
         [0018]    In accordance with some implementations, the scale system  102  includes one or more scales  104 . Each of the scales  104  is a durable and abrasion-resistant plate that is shaped, formed and modeled after examples found in nature, showcasing similar shape and overlapping pattern. Accordingly, each of the scales  104  is generically or specifically formed to fit into an overlapping pattern of scales to form the scale system  102 . 
         [0019]    In such an arrangement, a scale of the scale system  102  that receives a force or other impact energy is able to distribute that force (i.e. by energy cascade) to underlying and/or adjoining scales, such that no single scale receives and absorbs the full or majority portion of the force. Impact energy refers to energy encountered by any part of the protective assembly  100  due to some variation of contact with another surface. Impact energy cascade refers to the process by which a scale  104  that overlaps other scales  104  disburses impact energy to other scales  104  it overlaps. The scale system  102  includes an assembly of overlapping scales  104  attached to the wrap  106 , and overlaying one or more layers of protective impact materials (not shown). In some implementations, each scale  104  is formed with a flare, i.e., a design element that warps the scale shape out toward other scales  104  to allow for adjacent scales to fit amongst, and slide past, other scales  104  in the scale system  102 . 
         [0020]    The impact material underlying at least a portion of the scales  104  or scale system  102  can include any material to absorb further impact, such as foam, plastic, rubber, cloth, fiber, or the like. The impact material can be formed of one or more layers of impact-absorbing or impact-resistant material. The wrap  106  includes any of a number of components and materials to keep the other components, such as scales  104  and impact material, in place. In some implementations, as will be discussed further below, the protective assembly  100  includes a fastener system (not shown). The fastener system includes one or more components associated with or connected to the wrap  106 , and used to secure the protective assembly  100  to a part of the wearer&#39;s anatomy, such as the wearer&#39;s leg, knee, elbow, head, or other parts of the wearer&#39;s body. The fastener system is ergonomically designed to be low-profile and yet retain the protective assembly  100  in place over the desired part of the wearer&#39;s anatomy. 
         [0021]      FIGS. 1A-1H  illustrate various aspects of the scales  104  of the scale system  100  of the protective assembly  100 .  FIGS. 1A-1D  show a preferred implementation of a scale  10 . In accordance with preferred implementations, each scale  10  has a back surface that includes an attachment mechanism to attach to a protective assembly, such as knee pad, elbow pad, or the like. Each scale  10  may be attached or removed from the protective assembly by a diamond shaped interface B. 1 . The diamond shaped interface provides a surface for optimal packing density of scales on the impact material, and allows each scale  10  to fit among other scales  10  in the scale system. 
         [0022]    Each scale  10  back surface employs one or more toe surfaces B. 2 . The toe surface is positioned on the back surface of the scale  10  and is formed as a rearward deflection of the scale material, with design permeating to and partially defining the shape of the front of the scale  10  due to the approximately even thickness of the scale at the toe surface A. 1 , B. 2 . The toe surface is located on the inferior portion of the scale relative to the transverse plane of the body, and covers a portion of the back surface of the scale where the scale interacts with a subsequent or adjacent scale. Rearward deflection of the scale material provides a contact point on the back surface of the scale, which contacts the front surface of subsequent or adjacent scales, enabling the disbursement of impact energy and providing clearance between individual scales for inter-scale sliding 
         [0023]    In accordance with some implementations, the scale back surface further includes flares A. 2 , B. 3 . The flares are an extension [A. 3 , B. 4 ] of the toe surface and provide a similar effect on the shape of the scale. The flares allow room for adjacent overlapping and underlapping scales. Flares are located on the back surface of the scale with design permeating to and partially defining the shape of the front surface of the Scale due to the approximately even thickness of the scale, as seen at A. 2  and B. 3 . In preferred implementations, flares are located on the medial and lateral parts of the scale  10  relative to the sagittal plane of the body. 
         [0024]    Accordingly, the scale fits ergonomically around a part of an anatomy of a wearer, such as the wearer&#39;s knee. The curvature of the scale is designed to maximize ergonomic aspect. In some aspects, the curvature of each scale cross-section parallel to the sagittal plane of the body matches leg cross-section surface profile of same location, as seen in  FIG. 1C . 1 . The curvature of each scale&#39;s cross-section parallel to the transverse plane of the body matches a wearer&#39;s leg&#39;s cross-section surface profile of the same location, as shown in  FIG. 1D . 1 . The design and shape of the scale preserves the wrap and the impact material from exposure to destructive elements, and protects underlying layers from abrasion, wear, fraying, scuffing, etc., as shown in  FIG. 1E . Further, the scale protects underlying layers and regions from cutting, slashing, laceration, etc., as shown in  FIG. 1F , and protects underlying layers and regions from puncture, piercing, penetration, perforation, etc., as shown in  FIG. 1G . Importantly, each scale disburses impact energy transferred to the impact material across a larger surface area than the initial area that the impact energy was received by the scale. 
         [0025]    Impact energy administered to one point on a scale&#39;s front surface is distributed to the impact material and to additional scales by means of each scale&#39;s perimeter, as shown in  FIG. 1H . 1 . Impact energy distribution to a larger area of the impact material lowers the pressure experienced by a wearer during impact. The scale system enables a wearer to slide across surfaces when a contact point with a surface is on the scale. Such sliding can be intentional, to execute maneuvers, brace against objects, or slow down, for example. Or the sliding can be unintentional, such as can occur when a user falls, or when sliding to avoid injury incurred by tumbling. 
         [0026]    Scale System 
         [0027]    As discussed above, the scale system enables user to slide across surfaces when a contact point with the surface is across one or more scales, such as during intentional sliding used to execute maneuvers, brace against objects, or slow down, or during unintentional sliding that often occurs when a user falls, and where sliding helps avoid tumbling. The scale system disburses impact energy on a per scale basis, and on an impact energy cascade basis, such as impact energy transferred to the impact material across a larger area than the initial area that the impact energy was administered onto the contact scales. 
         [0028]    The scale system also disburses impact energy administered to one point on scale front surface will be distributed, in a cascading manner, to the impact material and to additional scales by means of the scale&#39;s perimeter, as shown in  FIG. 2A . 1 , and impact energy administered from contact scales to subsequent or adjacent underlying scales will be further disbursed, in a cascading manner, to additional subsequent scales that the previous scale overlaps, as seen in  FIG. 2A . 2 . 
         [0029]    The scale system further provides impact energy distribution to a larger area in the impact material, by means of disbursement by each individual scale and by means of disbursement across multiple scales, which lowers pressure experienced during impact. The scale system preserves the wrap  106  and impact material from exposure to destructive elements. As such, the scale system protects underlying layers from abrasion, wear, fraying, scuffing, etc., as shown in  FIG. 2B . 1 , protects underlying layers from cutting, slashing, laceration, etc., as shown in  FIG. 2B . 2 , and protects underlying layers from puncture, piercing, penetration, perforation, etc., as shown in  FIG. 2B . 3 . The scale system itself fits ergonomically around a wearer&#39;s knee or other body part, such as a wearer&#39;s elbow, wrist, hip, etc. Accordingly, the multiple, the individual, rigid scales enable the scale system to assume curved shapes as seen in  FIG. 2C . 1 , and permit movement of one scale across another, enabling scale system to assume, and transition between, multiple curved shapes, as seen in  FIG. 2C . 2 . 
         [0030]    Impact Material 
         [0031]    The impact material can be placed at one or more coverage zones to protect major frontal components of a wearer&#39;s body, such as a knee. 
         [0032]    For example, a shape of the impact material can cover the approximate shape of the patellar ligament. The impact material covers over the surface of the skin up to approximately one inch above the superior portion of the patella, as shown in  FIG. 3A . 1 , to define a superior coverage zone limit, and covers over the surface of the skin down to the approximate location of the termination of the patellar ligament into the tibial tuberosity, as shown in  FIG. 3A . 2 , to define an inferior coverage zone limit. 
         [0033]    The impact material covers over the surface of the skin medially to fully cover the bulge on surface of the knee caused by the medial tibial and femoral condyles and associated tissues, as shown in  FIG. 3A . 3 , to define a medial coverage zone limit, and covers over the surface of the skin laterally to fully cover the bulge on the surface of the knee caused by the lateral tibial and femoral condyles and associated tissues, as shown in  FIG. 3A . 4 , to define a lateral coverage zone limit. 
         [0034]    In some implementations, the impact material shape has corners rounded between the superior, as shown in  FIG. 3A . 1 , inferior [ FIG. 3A . 2 ], medial [ FIG. 3A . 3 ], and lateral [ FIG. 3A . 4 ] limits, and the coverage zone is shaped as an asymmetrical diamond shape projected onto the surface of the knee. The impact material employs features to enable assumption of three-dimensional shape from a two-dimensional manufactured state, and is left/right specific for optimized ergonomics. 
         [0035]    In some implementations, a “lightning split” or jagged separation or partial offset, enables the impact material to assume conic shape of surface of knee local to the patella from a flat manufactured state, as illustrated in  FIG. 3B . 1 . Offset cut sections improves material coverage over the length of the split, as shown in  FIG. 3B . 2 . The superior medial split enables impact material to assume curved shape of surface of knee medial to the patella from flat manufactured state, as shown in  FIG. 3B . 3 , and a superior lateral split enables the impact material to assume a curved shape of the surface of a wearer&#39;s knee lateral to the patella from the flat manufactured state, as seen at  FIG. 3B . 4 . 
         [0036]    The impact material employs features to enable flexibility, reduce material use, and increase ventilation. For instance, in some implementations, a central portion of impact material employs a pattern of swells to enable multi-directional flexibility, reduce material use, and allow ventilation to frontal portion of knee, as shown in  FIG. 3B . 5  and  FIG. 4A . 1 . Medial, lateral, and superior portions of the impact material employ curved grooves to enable flexion of the impact material perpendicular to the direction of the groove, to reduce material use, and to allow ventilation to medial and lateral portions of knee, as seen in  FIG. 3B . 6 . 
         [0037]    A superior portion of impact material may feature name of company and/or product incised into material to identify brand and minimally affects flexibility, material reduction, and ventilation, as shown in  FIG. 3B . 7 , and utilizes features to correctly position the impact material onto the wearer&#39;s knee. For instance, a horseshoe knee saddle assists in the correct positioning of the impact material with respect to wearer&#39;s patella, as shown in  FIG. 3B . 8 . Medial [ FIG. 3B . 9 ], lateral [ FIG. 3B . 10 ], and superior [ FIG. 3B . 11 ] folds enable proper seating of the impact material and to control lateral translation of the impact material and vertical translation of the impact material. 
         [0038]    In some preferred implementations, the impact material utilizes features to assist in the proper positioning of the scales. The impact material and scale interaction may be facilitated by a ridge and groove system, as shown in  FIG. 4A . 2 , by mated locking shapes, as shown in  FIG. 4A . 3 , and/or by a hook and loop system, as shown in  FIG. 4A . 4 . 
         [0039]    Fastener System 
         [0040]    The fastener system incorporates a running strap and a receiving strap, which are both are attached to the fabric matrix at each strap&#39;s proximal end. The running strap is formed and adapted to run through the receiving strap, as shown in  FIG. 5A . 1  and  FIG. 5B . 1 . In some implementations, the running strap is narrower than the receiving strap. The running strap includes an attachment mechanism on a portion of an inside surface of a distal end and an outside surface of a proximal end, as shown in  FIG. 5A . 2  and  FIG. 5B . 2 . 
         [0041]    In other words, the receiving strap is formed and configured to receive the running strap, and employs a slot to receive the running strap, as shown in  FIG. 5A . 3  and  FIG. 5B . 3 . A length of the slot in the receiving strap is oriented perpendicular to the length of the running strap and the receiving strap. The slot is located toward the proximal end of the receiving strap, which has an attachment mechanism on a portion of an inside surface of distal end and an outside surface of the proximal end, as shown in  FIG. 5A . 4 ,  FIG. 5B . 4 . 
         [0042]    The fastener system is secured by first running the running strap through the slot in the receiving strap and synching the knee pad by pulling on the straps, as shown in  FIG. 5B . 5 . Equal tension applied to straps running in opposing directions eliminates the effect of shifting/rotating of the knee pad around the leg that other fastening systems have on other knee pads. The fastener system locks the running strap and the receiving strap in place through contact of the attachment surfaces located on both the inner and outer surfaces of the running strap and the receiving strap, as shown in  FIG. 5B . 6 , and ensures a secure lock on the wearer&#39;s leg. 
         [0043]    In some implementations, a position of the fastener system is located across the superior tendons of the gastrocnemius muscle secures position of knee pad and enhances ergonomics, as shown in  FIG. 6A . 1  and  FIG. 6B . 1 . The transverse cross sectional area of the wearer&#39;s leg located in coincidence with superior tendons of gastrocnemius muscle [ FIG. 6C . 1 ] is less than transverse cross sectional area of leg located in coincidence with gastrocnemius muscle or tibiofemoral joint, as shown in  FIG. 6C . 2 . 
         [0044]    The fastener system seats best at the point of smallest circumference on the wearer&#39;s leg, so that the knee pad remains secured in place due to required increase in strap circumference in order to move onto larger part of leg, as shown in  FIG. 6D . 1 . A transverse cross sectional area of leg located in coincidence with superior tendons of gastrocnemius muscle changes minimally during flexion and extension of the wearer&#39;s leg. Muscle tissue changes shape during flexion and extension, and results in a change in the transverse cross sectional area of the leg on plane intercepting muscle tissue, as can be seen in  FIG. 6E . 1 . The wearer&#39;s tendon resists cross sectional area changes and therefore does not contribute significantly to a change in transverse cross sectional area of the leg, as shown in  FIG. 6E . 2 . A reduction in apparent shear between the fabric of the fastener system and the wearer&#39;s skin results in decreased awareness of the knee pad&#39;s attachment to the wearer&#39;s leg. 
         [0045]    Knee Brace System 
         [0046]    A fabric matrix employs a sleeve features located over the medial and lateral portions of the knee. The sleeve features are designed to accept support ribs, to stabilize the knee pad and support the knee joint. Medial and lateral support ribs prevent superior portion of knee pad from bunching downward. An inferior leg strap serves as an anchor due to placement over the superior tendons of the wearer&#39;s calf muscles. Upper boundary fabric of the sleeve features rest on the support ribs and stabilize the superior portion of the knee pad in full extension mode. The support ribs emulate a motion control brace model. Medial and lateral support ribs support the medial and lateral ligaments of the knee joint, and the support ribs emulate an unload/offload brace model. Meanwhile, medial and lateral support ribs share torque load on the wearer&#39;s knee joint in bent-knee condition. 
         [0047]    Although a few embodiments have been described in detail above, other modifications are possible. Other embodiments may be within the scope of the following claims.