Abstract:
An article is provided that includes a core including a plurality of triangular core members. Two or more edges of each triangular core member are each attached to respective edges of other triangular core members in the plurality of triangular core members by respective hinges in a plurality of hinges. Each hinge in the plurality of hinges joins respective edges of a respective pair of substantially adjacent triangular core members in the plurality of triangular core members, is of a length to provide an offset between the pair of triangular core members, has a thickness less than thicknesses of the pair of triangular core members, and is integrally connected to the pair of triangular core members.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This Application is a continuation (and claims the benefit of priority under 35 U.S.C. §120) of U.S. application Ser. No. 14/154,090 filed on Jan. 13, 2014, and entitled “PROTECTIVE SHIN GUARD”, which application is a continuation of Ser. No. 13/545,381, filed on Jul. 10, 2012, now issued as U.S. Pat. No. 8,627,512, and entitled “IMPACT DISTRIBUTING MECHANISM”, which application is a continuation of Ser. No. 11/057,954, filed Feb. 15, 2005, now issued as U.S. Pat. No. 8,220,072 and entitled “PROTECTIVE SHIN GUARD”, each naming Mark D. Dodd as inventor. The disclosures of the prior Applications are considered part of and are incorporated by reference in its entirety in the disclosure of this Application. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to protective equipment and in particular to protective guards for extremities such as shins to be worn while engaging in sports activities. 
         [0004]    2. Description of Related Art 
         [0005]    Shin guards are widely used in amateur and professional soccer to protect players&#39; lower legs and shins from impact with other players. In soccer, since players advance the soccer ball through kicking, players are frequently kicked in the shin and lower leg by other players. Without adequate protection, the risk of injury is high. 
         [0006]    Existing shin guards provide some protection for the shins of soccer players, but the guards are typically bulky and uncomfortable. The existing shin guards are typically a single piece of rigid plastic and are secured to the shin and lower leg using straps or special sleeves. While the existing shin guards are manufactured in different sizes, obtaining a “custom” fit is almost impossible, and the shin guards often protrude outward from each side of the player&#39;s leg. The lack of custom sizing available with existing shin guards makes them less comfortable to wear, and the guards could under some circumstances impede the movement of the player. Finally, a guard that does not fit properly also fails to provide maximum impact protection to the player. 
         [0007]    A need exists, therefore, for a protective guard that provides a customized fit to a person&#39;s leg or other body part. A protective guard is further needed that is easily adjustable to extremities of different sizes and shapes so that a minimum number of sizes can be manufactured. Finally, a protective guard is needed that is easy to manufacture and is comfortable to wear during extended periods of exertion. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    The problems presented by existing protective guards are solved by the protective guard of the present invention. The protective guard includes an elastomeric sheath having a pocket disposed therein. The protective guard further includes a central core having a plurality of rigid plates. The central core is disposed within the pocket of the elastomeric sheath. The plurality of rigid plates includes a first plate that is joined by at least one hinge to a second plate. 
         [0009]    Also in accordance with the principles of the present invention, a protective guard having a conformable substrate and a plurality of core members is provided. The plurality of core members are at least partially embedded within the conformable substrate. The core members are arranged such that a first of the core members is rotationally movable about at least one axis relative to a second of the core members. 
         [0010]    Also in accordance with the principles of the present invention, a protective guard is provided that includes a conformable substrate and a plurality of core members disposed adjacent to a surface of the conformable substrate. The core members are arranged such that a first of the core members is rotationally movable about at least one axis relative to a second of the core members. 
         [0011]    Also in accordance with the principles of the present invention, a protective guard is provided that includes an elastomeric substrate and a plurality of non-elastomeric core members. The non-elastomeric core members are at least partially embedded within the elastomeric substrate. 
         [0012]    Other objects, features, and advantages of the present invention will become apparent with reference to the drawings and detailed description that follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  illustrates a front view of a protective guard according to the present invention, the protective guard having a conformable substrate and a central core disposed therein; 
           [0014]      FIG. 2  depicts a perspective view of the protective guard of  FIG. 1  secured to a leg of a person; 
           [0015]      FIG. 3  illustrates a partial front view of the central core of  FIG. 1 , the central core including a plurality of core members; 
           [0016]      FIG. 4  depicts a partial front view of a plurality of round core members according to the principles of the present invention; 
           [0017]      FIG. 5  illustrates a partial front view of a plurality of oval core members according to the principles of the present invention; 
           [0018]      FIG. 6  depicts a partial front view of a plurality of rectangular core members according to the principles of the present invention; 
           [0019]      FIG. 7  illustrates a cross-sectional bottom view of the core members of  FIG. 3  taken at VII-VII; 
           [0020]      FIG. 8  depicts a cross-sectional bottom view similar to  FIG. 7  of a plurality of core members according to the principles of the present invention; 
           [0021]      FIG. 9  illustrates a cross-sectional bottom view of the core members of  FIG. 6  taken at IX-IX; 
           [0022]      FIG. 10  depicts a cross-sectional bottom view of the conformable substrate and central core of  FIG. 1  taken at X-X; 
           [0023]      FIG. 11  illustrates a cross-sectional bottom view similar to  FIG. 10  of a conformable substrate and central core according to the principles of the present invention; and 
           [0024]      FIG. 12  depicts a cross-sectional bottom view similar to  FIG. 10  of a conformable substrate and central core according to the principles of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, chemical, and material changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the invention, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims. 
         [0026]    As used herein, the term “elastomer” refers to a polymeric or rubber (natural or synthetic) material that has elongation rates greater than 100%. 
         [0027]    The term “conformable” refers to the ability of a material to be shaped to the contours of a surface without permanently deforming or setting the material. The conformable material could be placed adjacent to a first surface to provide a contour fit to the first surface, and then could subsequently be placed adjacent a second surface and similarly provide a contour fit to the second surface. 
         [0028]    Referring to  FIG. 1 , a protective guard  11  according to the principles of the present invention includes a conformable substrate  13  and a central core  15 . The central core  15  is connected to or embedded within the conformable substrate  13  to provide impact protection to a body part of a person. The conformable substrate  13  preferably includes a pocket  19  (see  FIG. 10 ) within the conformable substrate that houses the central core  15 . When the central core  15  is contained within pocket  19 , the conformable substrate  13  functions as a sheath, and an entry slot  21  may be optionally provided to allow access to pocket  19 , thereby allowing the central core  15  to be selectively removed or inserted into the conformable substrate  13 . However, it is preferable that the pocket  19  is not accessible by an entry slot, thereby creating a sealed space for the conformable substrate  13 . The pocket  19  closely matches the shape of the central core  15  and is preferably formed by molding the conformable substrate  13  around the central core  15 . 
         [0029]    The conformable substrate  13  is preferably constructed from an elastomeric material such that the conformable substrate  13  can be easily wrapped around and shaped to the contours of a person&#39;s lower leg or shin  61  (see  FIG. 2 ). The preferred material for the conformable substrate is Monprene MP-1880, a thermoplastic elastomer manufactured by Teknor Apex, Thermoplastic Elastomer Division of Pawtucket, R.I. Other suitable materials could include without limitation other thermoplastic elastomers, natural rubber, polyisoprene, styrene butadiene rubber, chloroprene rubber, polybutadiene, nitrile rubber, butyl rubber, ethylene propylene rubber, ethylene propylene diene rubber, chlorosulfonated polyethylene, polysulfide rubber, silicone rubber, polyurethane, and closed or open-cell neoprene or foam. 
         [0030]    Referring to  FIG. 3 , the central core  15  includes a plurality of core members  31 . Each core member is preferably joined by at least one hinge  33  to another of the core members  31  such that the core members  31  are capable of rotational movement relative to one another. The rotational movement between two core members typically occurs along an axis that is positioned between the core members. When hinges  33  are used to connect the core members  31 , the axis of rotation corresponds to the rotational axis of the hinge. Representative axes of rotation for the central core  15  of  FIG. 3  are illustrated as axis  35   a , axis  35   b , and axis  35   c . The ability of the core members  31  to rotationally move relative to one another allows the central core  15  to be conformable to a shin of a person even though the material that forms the core members  31  would not necessarily be conformable if used in a single piece. 
         [0031]    Referring more specifically to  FIGS. 3-6 , the core members could be any shape or size. While the preferred shape is the triangular shape of core members  31  ( FIG. 3 ), a central core  15   a  is partially shown in  FIG. 4  having round core members  31   a  connected by hinges  33   a .  FIG. 5  partially illustrates a central core  15   b  having a plurality of oval core members  31   b  connected by hinges  33   b .  FIG. 6  partially illustrates a central core  15   c  having rectangular core members  31   c  connected by hinges  33   c . Other shapes could include without limitation hexagonal, octagonal, or free-form shapes. 
         [0032]    Referring to  FIG. 7 , the core members  31  of protective guard  11  are preferably substantially flat, rigid plates constructed from a non-elastomeric material. In a preferred embodiment, the core members  31  are made from a hard plastic material such as acrylonitrile butadiene styrene (ABS), styrene, polyethylene, polypropylene, acrylic, polyvinyl chloride (PVC), fluoroplastics, nylon, acetal, polycarbonate, polyimide, polyamide-imide, polyphenylene sulfide, polyarylates, polyethylene terephthalate, polybutylene terephthalate, polyether ether ketone, polysulfone, polyether sulfone, polyetherimide, or polyphenylene oxide. However, it should be understood that any rigid material may be used, including composites, metal, or wood. Although a non-elastomeric material is preferred, the core members  31  could even be formed from an elastomeric material if rotational movement between the core members  31  would allow the elastomeric material to better conform to the shin of a person. Preferably, the material used to form the core members  31 , and thus the central core  15 , is a material that is compatible with the material chosen for the conformable substrate  13 . Since it is preferred to mold the conformable substrate  13  over the central core  15 , it is highly desirous to use a central core material to which the conformable substrate  13  will adhere. A coating or adhesive may be applied to the central core  15  prior to the molding process to achieve additional adhesion between the central core  15  and the conformable substrate  13 . 
         [0033]    Referring to  FIG. 9 , the central core  15 c of  FIG. 6  is illustrated in cross section and includes core members  31   c  connected by hinges  33   c . While it is preferred that the core members of the present invention be substantially flat so that an impact force directed to the protective guard does not damage the conformable substrate, the core members  31   c  illustrated in  FIG. 9  include ridges  41 . The ridges  41  may be capable of absorbing additional energy by flattening in the presence of an impact force. Other alternatives to a substantially flat core member may be provided by a core member that is slightly concave or convex in cross section. The core members could alternatively be fluid-filled capsules such as those containing air or gel, or the core members could also be a plastic or metal mesh that is hinged together similar to chain mail armor. 
         [0034]    Referring again to  FIG. 7  and also to  FIG. 8 , the hinges that connect the core members could be provided in several different forms.  FIG. 7  illustrates the preferred hinge  33 , which is a “living hinge.” The living hinge is preferably integrally attached between the core members  31  and is made from the same material as each of the core members  31 . The living hinge may be created by machining or etching the core members  31  from a single sheet of material having a relatively constant thickness. The sheet of material is thinned in any region that will become a hinge. This thinning process to create the hinges  33  also creates the general shape of the core members  31 . Living hinges are a strong way of maintaining a rotational connection between core members  31 . The living hinges  33  allow repeated rotations between core members  31  while maintaining the relative positions of the core members  31  during the process of assembling the central core  15  and the conformable substrate  13 . 
         [0035]    Referring to  FIG. 8 , another option for providing hinges is illustrated in reference to a central core  15   d  having core members  31   d  and hinges  33   d . Hinges  33   d  are formed by arranging precut core members  31   d  onto a membrane or other material  51  that includes an adhesive to secure the core members  31   d  to the membrane  51 . The membrane  51  could be an adhesive tape or other film, or alternatively the membrane could be another piece of plastic or elastomer to which the core members  31   d  are bonded. Membrane  51  could be applied to both sides of the core members  31   d  or only on one side as shown in  FIG. 8 . 
         [0036]    Although not illustrated, mechanical, multi-part hinges could also be used to connect adjacent core members. 
         [0037]    Referring again to  FIG. 3 , certain of the core members are located in an outer perimeter region  37 , while other of the core members are located in an inner region  39 . The core members  31  located in the inner region  39  are preferably connected by hinges  33  along each edge of the core member  31  to each adjacent core member  31 . For core members  31  located in the outer perimeter region  37 , hinges  33  are only attached to one or two edges of each core member  31 . However, regardless of whether a particular core member  31  is disposed within the outer perimeter region  37  or the inner region  39 , it is not required that every edge of a core member  31  be connected by a hinge to another core member  31 . In fact, hinges are not mandatory. Hinges simply provide a good way to maintain relative positioning of the core members  31  during assembly of the central core  15  and the conformable substrate  13 . If the relative positioning of the core members  31  could be maintained without hinges, the fixation of the core members  31  within or to the conformable substrate  13  would allow the desired capability of rotational movement between adjacent core members  31 . Alternatives for positioning the core members  31  are discussed below in reference to the assembly of the central core  15  and the conformable substrate  13 . 
         [0038]    Referring to  FIG. 10 , the protective guard  11  preferably includes core members  31  that are completely embedded within the conformable substrate  13 . As mentioned previously, a pocket  19  could be provided with an entry slot that allows for insertion of the central core  15  after the conformable substrate  13  is formed. However, it is preferred that the central core  15  be molded within the conformable substrate  13 , which would automatically form a pocket  19  around the central core  15 . It is preferred that hinges  33  are present between the core members  31  to maintain the relative position of the core members  31  during the molding process. It is possible, however, that the core members  31  be individually placed during the molding process to eliminate the need for the hinges  33 . After the molding process, the relative positions (e.g. spacing) of the core members  31  would be fixed within the conformable substrate  13 , yet the core members  31  would still be capable of rotational movement relative to one another. 
         [0039]    Referring to  FIG. 11 , a protective guard  111  having a conformable substrate  113  and a central core  115  is illustrated. The central core  15  includes a plurality of core members  131  connected by hinges  133 . The central core  115  is partially embedded within a pocket  119  of the conformable substrate  113 , thereby exposing the core members  131  near a surface of the conformable substrate  113 . The central core  115  may be secured to the conformable substrate  113  by the embedding process, or a bonding agent or other adhesive may be used to further secure the central core  115 . As discussed previously in reference to  FIG. 10 , the hinges  133  between core members  131  could be eliminated if the core members  131  were individually placed during the assembly process. Individual core members  131  could be placed during the molding of the conformable substrate  113 , or the core members could be bonded within the pocket  119  of the conformable substrate  113  after the molding process is complete. After securing the core members  131  to the conformable substrate  113 , the relative positions (e.g. spacing) of the core members  131  would be fixed, yet the core members  131  would still be capable of rotational movement relative to one another. 
         [0040]    Referring to  FIG. 12 , a protective guard  211  having a conformable substrate  213  and a central core  215  is illustrated. The central core  215  includes a plurality of core members  231  connected by hinges  233 . The central core  215  is bonded to a surface of the conformable substrate  213 . The central core  215  is preferably secured to the conformable substrate  213  by a bonding agent or adhesive. As discussed previously with reference to  FIGS. 10 and 11 , the hinges  233  between core members  231  could be eliminated if the core members  231  were individually placed during the bonding process. After securing the core members  231  to the conformable substrate  213 , the relative positions (e.g. spacing) of the core members would be fixed, yet the core members would still be capable of rotational movement relative to one another. 
         [0041]    In use, the protective guard  11 ,  111 ,  211  of the present invention provides impact protection for an extremity or other body part of a person. As shown in  FIG. 2 , the protective guard  11  is conformable to the shin and lower leg  61  of a person. The conformable substrate  13  and the central core  15  combine to provide superior impact protection. While the conformable substrate  13  by itself is conformable to a leg or other body part, the more rigid characteristics of the material used in the central core  15  would normally not be easily conformable to the person&#39;s leg. However, by separating the central core  15  into a plurality of core members  31  and by allowing the core members  31  to be rotationally movable relative to one another, the central core  15  as a whole is also conformable to the leg of the person. An attachment aperture  65  is provided on each side of the conformable substrate  13  to allow protective guard  11  to be attached to the person&#39;s leg with a strap  67  routed through the attachment aperture  65 . An ankle guard  71  may also be provided to wrap around the ankle of the person. The ankle guard  71  could include a central core, but preferably is formed solely from the conformable substrate used with protective guard  11 ,  111 ,  211 . Similarly, the protective guard itself could be formed solely from the conformable substrate and used without the central core. If only the conformable substrate is used, the material may be thicker in areas of predicted impact or may be formed from two or more elastomers having different durometers (i.e. a multi-durometer conformable substrate). 
         [0042]    It should be noted that the protective guard  11 ,  111 ,  211  of the present invention could be used to protect body parts other than the lower leg of a person including without limitation forearms, elbows, and knees. The protective guard  11 ,  111 ,  211  could also be used to protect body parts of non-human animals as well. 
         [0043]    It should be apparent from the foregoing that an invention having significant advantages has been provided. While the invention is shown in only a few of its forms, it is not just limited but is susceptible to various changes and modifications without departing from the spirit thereof.