Abstract:
Disclosed are knee pad assemblies, methods and systems comprising a knee pad base and an outer cover that forms the contacting surface of the knee pad. A removable cover may be secured to a knee pad base. Replacement cover configurations may be provided that are adapted to various surfaces, including roofing, tile, wood, carpet, concrete and asphalt. The knee pad base can be adapted for different user weights and durations for wearing the pad. The outer cover can provide a floating suspension. The knee pad base may be held in place on knee of the user by various mechanisms. The restraint mechanisms can be adjusted by the user. The knee pad assembly can also include a tension/release mechanism so that strap tension is decreased or released when kneeling but increases tension or engage when the user stands to retain the knee pad in the desired location.

Description:
CLAIM OF BENEFIT TO PRIOR APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/475,656 filed Apr. 14, 2011, and such application is hereby fully and entirely incorporated by reference herein. 
     
    
     FIELD 
       [0002]    The present invention generally relates to knee pads, systems for protecting the knee and methods for knee protection. 
       BACKGROUND 
       [0003]    Protective knee pads are used by various types of individuals, including construction workers, mechanics, sportsmen, athletes, and others who find it necessary to protect their knees as a result of their work or activities. This is particularly the case when kneeling on a hard surface. Utilization of protective knee pads placed on or around the knee for use when kneeling on hard surfaces is common practice and, in some instances, a requirement in order to effectively engage in a trade or craft. Various knee pad configurations are available and many typically comprise a rigid case or outer shell which is padded on the inside surface, is shaped to be fitted over the knee and includes attachment straps for retention on or over the knee. 
         [0004]    One drawback associated with the use of knee pads relates to the adaptability of the knee pad to a variety of surfaces. A knee pad with an outer gripping or cushioning surface may be well suited for one particular type of application or use, but poorly suited for use in another location or on another surface. As a result, a worker may need to purchase many different types of knee pads or use a knee pad that is not well suited to the particular use, which may be unsafe. 
         [0005]    Another drawback associated with the use of knee pads relates to the outer surface of the knee pad wearing out, thus necessitating costly replacement of the entire pair of knee pads. Replacing a set of knee pads every time one of the pads wears out is both costly and is not environmentally friendly. 
         [0006]    A further drawback is that the retention straps used to hold the knee pads in place may be uncomfortable for the user to wear for extended periods of time and may promote fatigue. 
         [0007]    An additional drawback to current knee pads is that heavier users may not be provided with sufficient comfort and protection. 
         [0008]    Therefore, there is a need for an improved knee pad assembly, knee pad system and method of protecting the knees of a user. 
       SUMMARY 
       [0009]    The present disclosure is directed to knee pad assemblies, methods and systems comprising a knee pad base and an outer cover that forms the contacting surface of the knee pad. In certain embodiments, a removable cover is securable to a knee pad base. A variety of cover configurations may be provided that are adapted to various surfaces, including roofing, tile, wood, carpet, concrete and asphalt. The knee pad base can be adapted for different user weights and durations for wearing the pad. The outer cover can be secured to the base using a variety of mechanisms disclosed herein or variations thereof. The knee pad base is held in place on knee of the user by various mechanisms disclosed herein and variations thereof. The restraint mechanisms can be adjusted by the user. The knee pad assembly can also include a tension/release mechanism so that strap tension is decreased or released when kneeling but would increase or engage tension when the user stands to retain the knee pad in the desired location. 
         [0010]    Additional features and advantages of the invention will be apparent from review of the written disclosure herein and consideration of the appended drawings. 
         [0011]    The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations, whether or not explicitly disclosed, or in isolation, without departing from the scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments. 
           [0013]      FIG. 2  is a perspective view of the knee pad assembly of  FIG. 1 . 
           [0014]      FIG. 3  is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments. 
           [0015]      FIG. 4  is a perspective view of the knee pad assembly of base  202  from  FIG. 3 . 
           [0016]      FIG. 5  is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments. 
           [0017]      FIG. 6  is a perspective view of the knee pad base  302  from  FIG. 5 . 
           [0018]      FIG. 7  is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments 
           [0019]      FIG. 8  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0020]      FIG. 9  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0021]      FIG. 10  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0022]      FIG. 11  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0023]      FIG. 12  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0024]      FIG. 13  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0025]      FIG. 14  is an analytic perspective view of a knee pad assembly according to example embodiments. 
           [0026]      FIG. 15  is an analytic perspective view of a knee pad assembly according to example embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    In the following descriptions, the present invention will be explained with reference to various example embodiments; nevertheless, these example embodiments are not intended to limit the present invention to any specific example, embodiment, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention. The invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims. 
         [0028]    Referring to  FIG. 1  and  FIG. 2 , a knee pad assembly  100  is shown. The assembly generally comprises a base  102  and a removable cover  104 . The base  102  fastens to the user&#39;s knee using fastening straps  106 , such as the ratcheting adjustable straps as shown in these figures with ratcheted fastener  109 . An upper and a lower strap are shown but more or fewer straps are within the scope of the invention. The base  102  presents a forward facing cover receiving portion  108 . The cover  104  is disposed over the forward facing portion  108  of base  102  as indicated in these figures and secured via attachment means, in this example via corner hooks  110  disposed at the corners of base  102 . The assembled knee pad  100  is shown in  FIG. 2 . 
         [0029]    The knee pad base can be configured in short or long versions as appropriate for the particular application and a user&#39;s desired level of coverage. The cover is correspondingly sized. 
         [0030]    The cover may be formed from any suitable material, including rubber and plastic, and formed in any suitable shape. In addition, the cover may fully or partially comprise multirole materials such as leather, cloth, plastic, fiber glass, foam, rubber, carbon fiber, composites, metal or any other material that is designed for the end user&#39;s specific job requirements. 
         [0031]    A wide variety of cover attachments means are within the scope of the invention. Such means include, but are not limited to hooks, snaps, clips, hook and loop components (e.g. VELCRO fasteners) on respective portions of the base and cover, and combinations of two or more different attachment means. 
         [0032]    The user&#39;s ability to change covers on the knee pad bases allows for a single pair of knee pads to be adapted to a wide variety of surface types. The ability to change covers also provides the user with the option to replace individual worn covers, wash soiled covers, and/or use job specific covers as needed, avoiding the need to purchase a replacement or additional set of knee pads. 
         [0033]    Referring to  FIGS. 3 and 4 , another example embodiment of a knee pad assembly  200  is shown. The base  202  is provided with one or more front facing suspension components  212 , such as rubber or foam pads. In this example embodiment, base  202  is slideably engaged with pad  204  by straps  214  that are integrated into the corners of pad  204 . Straps  214  secure the knee pad assembly  200  to a user by wrapping straps  214  securely around the back of the users knee. It should also be noted that straps  214  could also be integrated with base  202  and slide through corresponding openings (not shown) in pad  204  to also achieve the floating suspension effect. Cords may also be used instead of straps. 
         [0034]    While secured, the back surface of pad  204  engages the suspension member  212  of base  202 , and slides on guide rails  216 , allowing pad  204  to float on suspension member  212  and remain aligned via guide rails  216 , without being fixably connected to base  202 . This allows pad  204  to move in toward the knee and out away from the knee, depending on the pressure exerted on the front surface of pad  204  while in use. This provides cushioned suspension for the knee while the improved knee pad assembly is in use. The spring force of the compression component  212  may be adapted to a desired range of cushioning or compression based upon a user&#39;s weight, and/or the conditions of use of the knee pad, and/or the length of time of intended use. Preferably a material with an ILD (Indention Load Deflection) of between 45 and 100 may be used. Urethane and other foams may also be used with densities of weights between 1 and 10 pounds per square foot of material. The outer cover  204  may comprise a semi-rigid or a hard plastic shell (or similar material) that will compress one or more of the suspension components  212  and distribute the force over the cover  204 . The cover  204  cooperates with a plurality of integrated straps  214 , guide rails  216  and guide plate  218  to facilitate slideable engagement, and uniform alignment, of the cover to the base. 
         [0035]    This example embodiment also illustrates a tension/release mechanism or feature. When kneeling, compression placed on the cap  204  would compress suspension components  212  and release strap tension on straps  214  and when standing, compression would be released and strap tension would be allowed to return. The purpose is to release strap tension on the back of the worker&#39;s leg, nerves and blood vessels while the worker is kneeling, yet maintain security of the knee pad when the worker is standing or walking. The cap  204 , straps  214 , suspension components  212 , guide rails  216  and guide plate  218  cooperate to achieve this feature, as well as providing a uniform alignment of the cap  204  with the base  202 , and providing extended comfort to the user. 
         [0036]    Referring to  FIGS. 5 and 6 , another embodiment of a knee pad assembly  300  is shown. The base  302  comprises a knee cup  304  and a suspension member  306  disposed on the outer front surface of the base. An outer cover or shell  308  is disposed over knee cup  304  and suspension member  306  by straps  310 . This arrangement allows force applied to the cover to compress the collapsible or suspension member towards the base to provide cushioning. The edges of the cover  308  slide toward the user&#39;s knee along the outer perimeter surface of the base. When the pressure on the cover is released, the suspension member  306  expands to its original shape. In one variant, the suspension member  306  is partially collapsible in order to provide adequate support and air space while collapsible enough to provide desired cushioning. In addition open areas  312  in suspension member  306  allow additional cushioning and support for the knee. Similar to the embodiments described and depicted in  FIGS. 3 and 4 , the contact and cooperation between cover or shell  308  and suspension member  306  provides a floating type suspension for the knee while the knee pad  300  is strapped to a user by straps  310 . 
         [0037]    Referring to  FIG. 7 , depicted is yet another exemplary embodiment where knee pad assembly  400  is comprised of base  402 , which is a partial shell that is disposed behind the user&#39;s leg, such as on the calf and behind the knee, and cap  404 . For example, straps or a neoprene back of leg wrap  402  may be substituted for the base and straps described in the preceding examples. The cover  404  is then placed over the knee cap and restrained in place via tension members  418 , such as cords, on either side of the base spanning between the base and the cover. This arrangement promotes good pressure management on the user&#39;s knee and leg. The cover  404  is shown with a honeycomb pattern  420  in a soft rubber material in order to enhance traction and provide cushioning for the user. A further feature illustrated in this example is the ratchet system  422  disposed on top of cover structure  404  and functionally connected to the tension members  418 . Via the ratchet system  422 , the wearer has the ability to tighten or loosen strap pressure (snugness) of the knee pad. A dial  424  or other user actuator is provided to allow the user to actuate the ratchet system. 
         [0038]    Referring to  FIGS. 8 through 15 , depicted are various means to removeably attach a pad to a base.  FIG. 8  provides a base  502  with one or more sleeves or pockets  504  to receive the tongues  508  of cover  506 . The front receiving surface  510  of the base  502  and back surface  511  of cover  506 , may further be provided with a respective portion of a hook and loop fastener  512  to further secure the cover to the base. The cover  506  shown in this example is a generally rectangular and slightly curved semi-rigid board comprising a polyethylene material. However, the board can vary in size, shape and material as appropriate for the particular usage. 
         [0039]    Referring to  FIG. 9 , an exemplar knee pad assembly is shown with another cover fastening means. An elastic hem  522  is provided around the perimeter  524  of the cover receiving surface  526  of the base  520 . The perimeter  528  of the cover  530  includes corresponding protruding tabs or projections  532  that are sized and shaped for being received in the elastic hem  522 . Hook and loop  527  may also be used as shown in  FIG. 8 , and can further be used with all embodiment disclosed herein. 
         [0040]    Referring to  FIG. 10 , a further embodiment of a knee pad assembly is shown. The base and cover is shown in  FIG. 9 . In addition, an overlay cover  534  is now provided. The overlay cover  534  is disposed over the cover  530  and then secured to the base with a plurality of reinforced strap loops  536 . The straps  538  used to secure the base to the knee region of the user are placed through the reinforced loops  536  of the overlay cover  534  to secure the cover and overlay in place. 
         [0041]    Referring to  FIG. 11 , another embodiment of a knee pad assembly is shown. The cover or overlay  540  includes a plurality of elastic bands or cords  542 . The cords  542  can extend through the cover  540  for better securement. A tab  544  is provided at an approximate mid-point of each band  542 . The cover  540  is secured to the base  546  by inserting the tabs  544  into respective slots or pockets  548  in the base  546 . Channels  550  in the outer perimeter surface  552  of the base  546  may be provided to further retain the bands in place. Hook and loop fasteners  554  may further be provided on respective portions of the cover and base to further secure the cover to the base. 
         [0042]      FIG. 12  illustrates a cord-lock means  562  for securing the cover  564  to the base  566 . Raised corners  568  on the cover are inserted behind portions of the locking cord  570 . The locking cord or cords  570  are then tightened by pulling on cords  563  and retainer  562  is then used to maintain the tension in the retaining cord(s). 
         [0043]      FIGS. 13 through 15  illustrate other exemplar attachment embodiment means for a knee pad assembly. The cover or overlay  578  includes a plurality of elastic bands or cords  572  shown at the corners of the cover  578 . The cords can extend through the cover in a crossing pattern or “X” shape  574  for better securement, as shown in  FIG. 14 . A tab  576  is provided at an approximate mid-point of each band  572 . The cover  578  is secured to the base  580  by inserting the tabs  576  into respective slots or pockets  582  in the base at the corners thereof. The corner pockets may be raised to facilitate insertion and removal of the tabs.  FIG. 15  further illustrates that cover  578  may be used to secure pads used in previous embodiments to a base such as base  580 . Note that the underlayment of pad  584  of  FIG. 15  includes a plurality of slots  586  for receiving the knee pad retaining straps  581 . 
         [0044]    The compressibility factor (including material property and physical dimensions and shape) of the collapsible or suspension members disclosed herein can be varied to accommodate different user weight ranges and to accommodate a user&#39;s desired cushioning factor. The cover can be secured using a variety of means as discussed in this disclosure. Alternatively, the cover may include straps that secure the assembly directly to the user&#39;s knees, such as elastic cord or adjustable straps that extend behind the knee of the user. 
         [0045]    The collapsible or suspension members may comprise a wide variety of materials, including, springs, pen cell foam, closed cell foam, air bag, molded EVA, soft 3D fabric (spacer mesh), a resilient honeycomb structure, rubber, or any combination of these or other materials. 
         [0046]    The cushioning factor can also be selected according to body weight or according to average time spent kneeling/hour. For example, body weight ranges of 80 to 150 lb, 150 to 225 lb, and over 225 lb; kneeling 10 min./hour, 30 min./hour and 50 min./hour. However more or fewer ranges may be specified. 
         [0047]    Features of the various embodiments discussed herein can be mixed and matched in any manner of additional embodiments that are all within the scope of the invention regardless of whether or not explicitly discussed herein. 
         [0048]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention. 
         [0049]    For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.