Patent Publication Number: US-2016235132-A1

Title: Hard shell fastening device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application claim benefit of priority to U.S. Provisional Patent Application No. 62/115,516, entitled “Hard Shell Fastening Device” and filed on Feb. 12, 2015, which is specifically incorporated by reference for all that it discloses or teaches. 
    
    
     BACKGROUND 
     A variety of protective wearable articles utilize straps in conjunction with fastening mechanism(s) to secure hard or rigid protective material to a user. For example, knee pads, helmets, googles, and body armor all make use of straps that may wrap around a user&#39;s appendage such as an arm, leg, or other body part (e.g., chinstrap, torso, etc.) to supply tension and help to secure the protective wearable article. Fastening mechanisms suitable for use in such technologies include without limitation hook and loop, latches, buckles, snaps, knotting (e.g., ties), plastic clips, etc. Some of these fastening mechanisms detach too easily, provide inadequate durability, or loosen too easily and fail to provide adequate tension to the protective wearable article. 
     SUMMARY 
     Implementations described and claimed herein address the foregoing by providing a protective wearable article with a hard shell layer including a molded receptacle. The molded receptacle is sized and shaped to receive and secure a male fastening component attached to a strap or other fastening appendage usable for securing the protective wearable article to a user. 
     Implementations described and claimed herein further address the forgoing by providing a method of attaching a protective wearable article to a user. The method includes placing the protective wearable article adjacent to a portion of a user and wrapping a strap around the portion of the user, the strap including a first end fixedly attached to the protective wearable article and a second free end attached to a male fastening component. The method further comprises inserting the male fastening component into a molded receptacle formed in a hard shell layer of the protective wearable article, and sliding the rigid protrusion element along a channel of the molded receptacle to secure the rigid protrusion element within the molded receptacle. 
     Still further implementations described and claimed herein address the foregoing by providing an apparatus that includes a protective wearable article with a soft backing layer and a hard shell layer. The hard shell layer includes an irregular-shaped aperture with a first diameter larger than another diameter of the irregular-shaped aperture. The apparatus further includes a strap for securing the protective wearable article to a user and a rigid protrusion element on a first end of the strap that is sized and shaped for insertion into and securement within the irregular-shaped aperture. 
     Other implementations are also described and claimed herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a front perspective view of an example protective wearable article securable to a user via example dual-component fastening devices. 
         FIG. 2  illustrates another perspective view of an example protective wearable article attachable to a user via example dual-component fastening devices. 
         FIG. 3  illustrates another perspective view of an example protective wearable article attachable to a user via example dual-component fastening devices. 
         FIG. 4  illustrates a rear perspective view of yet another example protective wearable article suitable for implementing the disclosed technology. 
         FIG. 5  illustrates a perspective view of another example protective wearable article that includes a hard shell structure incorporating example female components of dual-component fastening devices. 
         FIG. 6  illustrates an example molded receptacle that may serve as a female portion of a dual-component fastening device that attaches a wearable protective article to a user. 
         FIG. 7  illustrates a cross-sectional view of a protective wearable article including an example dual-component fastening device. 
         FIG. 8  illustrates example operations for securing a protective wearable article to a user via a dual-component fastener device. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a front perspective view of an example protective wearable article  100  securable to a user by example dual-component fastening devices  102 ,  104 . The protective wearable article  100  is an article that protects a user from impact during an activity that poses a risk to bodily injury, such as athletic activity, transportation, work in hazardous areas, etc. In  FIG. 1 , the protective wearable article  100  is shown to be a contact-protection pad, such as a knee or elbow pad that can be attached to a human limb to provide impact protection during physical activity. However, the protective wearable article  100  may, in other implementations, be integrated into wearable technologies that protect other parts of a user including without limitation a user&#39;s torso (e.g., to secure body armor), head (e.g., as a helmet strap fastener), eyes (e.g., to secure googles); wrist, ankle, neck, back, groin, etc. (e.g., any type of medical or athletic brace). 
     In  FIG. 1 , the protective wearable article  100  includes the hard shell layer  106  and a backing layer  122 . The hard shell layer  106  is a rigid or semi-rigid material that resists deformation by an applied contact force. For example, the hard shell layer  106  may have a hardness in the range of 90 shore A to 100 shore D. In one implementation, the hard shell layer  106  has a thickness between about 0.05 inches and 0.25 inches. The hard shell layer  106  may be made from a variety of suitable materials including without limitation plastics such as high-density polyethylene (HDPE), low-density polyethylene (LDPE), ultra-high-molecular-weight polyethylene (UHMWPE), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), acrylic, polypropylene, polycarbonate, various thermoplastic elastomers (TPEs), thermoplastic polyurethane (TPU), various non polymer materials such as aramid fiber (i.e., Kevlar), and composite materials such as fiberglass, carbon fiber, etc. 
     In contrast to the hard shell layer  106 , the backing layer  122  is a more flexible layer, such as a layer designed for comfort and contact with a user&#39;s skin or clothing. The backing layer  122  provides a supporting interface between a body part of the user and the hard shell structure  106 . In some implementations, the backing layer  122  includes materials and/or structures designed for temperature control, such as to keep a user cool and/or dry (e.g., a breathable fabric, mesh, etc.) or to trap heat and provide warmth (e.g., as an insulating material within a garments designed for outdoor use). In one implementation, the backing layer  122  includes a layer of elastically deformable void cells. For example, the backing layer  122  may be one or more layers of fabric, mesh, foam, thermoplastic urethane, thermoplastic elastomers, styrenic co-polymers, rubber, Dow Pellethane®, Lubrixol Estane®, Dupont™ Hytrel®, ATOFINA Pebax®, and Krayton polymers, etc. In some implementations, the protective wearable article  100  may not include the backing layer  122 . 
     The dual-component fastening devices  102 ,  104  each include a first female component (e.g., molded receptacles  102   a ,  104   a ) formed within the protective wearable article  100  and a second male component (e.g., rigid protrusion elements  102   b ,  104   b ) attached to a corresponding attachment appendage  108  or  118 . The attachment appendages  108 ,  118  are usable to secure the protective wearable article  100  to a user, but are not herein considered to be part of the protective wearable article  100  and do not necessarily provide impact protection to the user. In  FIG. 1 , the attachment appendages  108 ,  118  are flexible straps. In other implementations, the attachment appendages  108 ,  118  may have different characteristics depending on the nature of the wearable protective article  100  and the manner by which the wearable protective article  100  secures to a user. Some implementations may include a single attachment appendage in lieu of the two attachment appendages  108 ,  118 ; other implementations may include three or more attachment appendages. Likewise, some wearable protective articles may attach to a user with greater or fewer than the two illustrated dual-component fastening devices  102 ,  104 . 
     In View A of  FIG. 1 , each of the rigid protrusion elements  102   b ,  104   b  of the dual-component fastening devices  102 ,  104  is attached to a free end of one of the attachment appendages  108 ,  118 . The molded receptacles  102   a  and  104   a  of each of the dual-component fastening devices  102 ,  104  are formed within the hard shell layer  106  of the protective wearable article  100  and sized and shaped to receive and secure the corresponding rigid protrusion element  102   b ,  104   b . Since the dual-component fastening devices  102  and  104  are shown to be substantially identical, further details of the disclosed technology are discussed with reference to the dual-component fastening device  102 . 
     Although other shapes are contemplated, the rigid protrusion element  102   b  of  FIG. 1  has a mushroom-like shape including a stem portion  110  adjoined to a wide end portion  112 . The wide end portion  112  has a diameter that is larger than a corresponding diameter of the stem portion  110 . In one implementation, the wide end portion  112  defines a plane substantially perpendicular to a longitudinal axis of the stem portion  110 . In other implementations, the wide end portion  112  is non-planar and/or defines a plane that is non-perpendicular relative to the stem portion  110 . For example, the wide end portion  112  may be knob-like, curved, angled, etc. 
     In some implementations, the rigid protrusion element  102   b  does not include the stem portion  110 . For example, the wide end portion  112  may be a button sewn or otherwise attached to a soft or hard backing. In other implementations, the rigid protrusion element  102   b  may take on a variety of other shapes and sizes. 
     The molded receptacle  102   a  includes at least one aperture (e.g., an inlet or cut out) for receiving and securing the rigid protrusion element  102   b . In  FIG. 1 , the aperture of the molded receptacle  102   a  is of an irregular shape with a perimeter encompassing a conjoined two-part internal area including an insertion area  114  and a locking area  116 . A diameter of the aperture at the locking area  116  is smaller than a corresponding diameter of the aperture at the insertion area  114 . In other implementations, the molded receptacle  102  assumes other of shapes and/or sizes. In at least one implementation, the molded receptacle  102   a  is heat-molded during a thermoforming process. In another implementation, the molded receptacle  102   a  is molded during an injection molding process. In still another implementation, the aperture of the molded receptacle  102   a  is cut into the hard shell structure  106  during a secondary operation after a molding process. 
     Referring to View B of  FIG. 1 , the insertion area  114  of the molded receptacle  102   a  has a diameter D 1  that exceeds a corresponding diameter of the wide end portion  112  of the rigid protrusion element  102   b . In addition, a diameter D 2  at the locking area  116  of the molded receptacle  102   a  is smaller than the corresponding diameter of the wide end portion  112  and larger than a diameter of the stem portion  110 . Consequently, the rigid protrusion element  102   b  can be threaded through the hard shell structure  106  at the insertion area  114  and moved within the aperture such that the stem portion  110  rests within the locking area  116  while the attachment appendage  108  and the wide end portion  112  are positioned on opposite sides of the hard shell structure  106 . In this position, the wide end portion  112  contacts a back surface (not shown) of the hard shell structure  106 , resisting detachment from the hard shell structure  106  when a user applies a force on the rigid protrusion element  102   b  in a direction normal to the hard shell structure  106 . 
     To place the dual-component fastening device  102  in an attached state, a user threads the rigid protrusion element  102   b  through the insertion area  114  of the molded receptacle  102   a  so that the hard shell structure  106  is positioned between first and second ends of the rigid protrusion element  102   b . Once the rigid protrusion element  102   b  is partially threaded through the insertion area  114 , the user repositions (e.g., slides) the rigid protrusion element  102   b  along a length of the molded receptacle  102   a  (in the direction of an arrow ‘A’ in  FIG. 1 ) and toward the locking area  116  until the stem portion  110  of the rigid protrusion element rests within the locking area  116 . When the stem portion  110  of the rigid protrusion element  102   b  rests within the locking area  116 , a perimeter of the wide end portion  112  may rest adjacent to a back side (not shown) of the hard shell structure  106 . 
     In  FIG. 1 , the molded receptacle  102   a  also includes a locking feature to hold the rigid protrusion element  102   b  securely in place once resting within the locking area  116 . Although other implementations may employ different locking mechanisms, this example locking feature is provided by relative dimensions of the stem portion  110  and of the molded receptacle  102   a . Again referring to View B, the aperture of the molded receptacle  102   b  has a largest diameter at D 1  in the insertion area  114 , a next largest diameter at D 2  in the locking area  116 , and a smallest diameter D 3  in a gap area between the locking area  116  and the insertion area  114 . If the stem portion  110  of the rigid protrusion element  102   b  has a diameter just slightly larger than the diameter D 3  of the gap area, the stem portion  110  may be capable of elastically deforming edge regions of the molded receptacle  102   b  out of the way under an applied force. For example, the stem portion  110  may be threaded through the insertion area  114  and pushed in a direction indicated by an arrow “A” through the gap area at D 3  to elastically deform edge regions of the molded receptacle  102   a . In this case, the elastically deformed material of the hard shell layer  106  may “snap” back into its original position as the stem portion  110  moves into the locking area  116 , effectively securing the stem portion  110  within the locking area  116  absent an applied for in a direction opposite the arrow A. 
     To facilitate the elastic deformation described above, the hard shell layer  106  may be “semi-rigid” rather than rigid. In other implementations where the hard shell layer  106  is rigid, other locking mechanisms may be employed. 
     In some implementations, the stem portion  110  of the rigid protrusion element  102   b  has a diameter less than the diameter D 2  of the locking area  116  such that the stem portion  110  can freely rotate when resting within the locking area  116 . In other implementaitons, it may be desirable to prevent the stem portion  110  of the rigid protrusion element  102   b  from rotating when secured in place within the locking area  116  of the molded receptacle  102   b . To address this consideration, the stem portion  110  of the rigid protrusion element  102   b  and the molded receptacle  102   a  can be formed of other (e.g., non-circular) complimentary shapes that facilitate coupling of the two elements while preventing rotation of either component relative to the other. For example, the stem portion  110  may be prohibited from rotating while positioned within the locking area  116  if the stem portion  110  and perimeter of the locking area  116  are of a same polygonal shape (e.g., rectangular, triangular, pentagonal, hexagonal, etc.). 
     In the illustrated implementation, the dual-component fastening device  102  functions to secure the attachment appendage  108  (e.g., a flexible strap) around a user&#39;s arm or leg. When the attachment appendage  108  is taught about a portion of the user (e.g., arm, leg, wrist, chin, torso, etc.) the attachment appendage  108  applies an additional force on the dual-component fastening device  102  in the direction of the arrow ‘A.’ This additional force assists in further securing the rigid protrusion element  102   b  within the locking area  116  of the hard shell structure  106 . In some implementations, the attachment appendage  108  is not a flexible strap. For example, the attachment appendage  108  may be a rigid component to which the rigid protrusion element  102   b  is attached or formed within. In  FIG. 1 , the wearable device  100  further includes an adjustment component  118  that can be optionally tightened to further secure the rigid protrusion element  102   b  within the locking area  116 . 
     In various implementations, the flexible backing portion  122  attaches to the hard shell structure  106  in different ways, such as at one or more points (not shown) along the perimeter of the hard shell structure  106 . In at least one implementation, the flexible backing portion  122  does not attach to the hard shell structure  106  within an area  120  surrounding the molded receptacle  102   b . This allows the wide end portion  112  of the molded receptacle  102   a  to rest between the hard shell structure  106  and the flexible backing portion  122  at the locking area  116  when placed in the secured position. Some implementations may not include the flexible backing portion  122 . 
       FIG. 2  illustrates another perspective view of a protective wearable article  200  (e.g., a kneepad) attachable to a user via example dual-component fastening devices  202 ,  204  and straps  208 ,  210 . Each of the dual-component fastening devices  202  and  204  includes a male component (e.g., rigid protrusion elements  202   b ,  204   b ) that can be removeably secured within a corresponding female component (e.g., molded receptacles  202   a ,  204   a , respectively). In some implementations, the protective wearable article  200  includes or incorporates the male components of the dual-component fastening devices  202 ,  204  rather than the female components. For example, the rigid protrusion elements  202   b ,  204   b  may be molded into the hard shell structure  206  or separately formed and subsequently attached, such as via an adhesive or mounting structure. However, protective wearable articles with male components formed in or attached to the hard shell structure  206  tend to be less durable and/or more expensive to produce than the design of  FIG. 2 , which integrates the female components directly into the protective wearable article  200 . 
     The hard shell structure  206  is attached to a backing layer  222  that provides an interface between a portion of the user&#39;s body and the rigid protrusion elements  202   b ,  204   b  when mated with the corresponding molded receptacle  202   a  and  204   a . Specific details of the dual-component fastening devices  202 ,  204  not described above may be the same or substantially similar to the dual-component fastening devices described with respect to  FIG. 1 . 
       FIG. 3  illustrates another perspective view of a protective wearable article  300  attachable to a user via dual-component fastening devices  302 ,  304  and straps  308 ,  310 . Each of the dual-component fastening devices  302 ,  304  is shown in a secured position with a rigid protrusion element (not shown) threaded through a corresponding molded receptacle  302   a  or  304   a . The molded receptacles  302   a ,  304   a  are formed directly within a hard shell structure  306  of the protective wearable article  300 . Although not visible in  FIG. 3 , each of the molded receptacles  302   a ,  304   a  may include an aperture with a wider diameter portion at an insertion area and a narrow diameter portion at a locking area. Easy release tabs  318  and  320  can be pulled in the direction of a vector originating within the locking area and extending in the direction of the insertion area (e.g., as indicated by the direction of arrow A in  FIG. 3 ) to aid in removing the rigid protrusion elements from the corresponding molded receptacle  302   a  or  302   b . Other details of the dual-component fastening devices  302 ,  304  not described above may be the same or substantially similar to the dual-component fastening devices described with respect to  FIGS. 1 and 2 . 
       FIG. 4  illustrates a rear perspective view of a protective wearable article  400  attachable to a user via straps  408 ,  410  and dual-component fastening devices (not shown). In one implementation, the protective wearable article  400  is a same article as the protective wearable article  300 , illustrated in  FIG. 3 . Each of the straps  408  and  416  includes a rigid protrusion element (not shown) on a first end that can be removably secured within a corresponding molded receptacle (not shown) formed on a front side of a hard shell structure (not shown). A second end of the straps  408  and  416  is non-removeably attached to the protective wearable article  400 , such as via stitching to a backing layer  422 , adhesive to the hard shell structure, or any other suitable method of attachment. When the straps  408  and  416  are secured in place around a user&#39;s body part (e.g., arm, leg, etc.), tightening either of the straps, such as via adjustment components  418  and  424 , serves to further secure the attached the rigid protrusion element within the corresponding molded receptacle. 
       FIG. 5  illustrates another perspective view of a protective wearable article  500  that includes a hard shell structure  506  incorporating example female components (e.g., molded receptacles  502   a ,  502   b ) of two dual-component fastening devices. In one implementation, the protective wearable article  500  includes straps (not shown) with free ends attached to male components for mating with the molded receptacles  502   a ,  504   a . Guiding structures  524 ,  526  protrude outward from the hard shell structure  500  providing ridges that help guide the corresponding male components into the molded receptacles  502   a ,  502   b.    
     In various implementations, the guiding structures  524 ,  526  may be shaped differently; however, in  FIG. 5 , each of the guiding structures  524 ,  526  forms a protruded rim partially encircling a portion of a locking area  514  of the molded receptacle  502   a . This rim effectively reduces a diameter of the locking area  514  on an outward-facing surface of the hard shell structure  506  as compared to a diameter of the locking area  514  on an opposite surface of the hard shell structure  506 . First and second ends of each of the guiding structures  524 ,  526  are separated from one another by a distance greater than a diameter of an insertion area  516  of the molded receptacles  502   a ,  502   b . These ends approach one another in proximity with distance in a direction of a vector originating at the insertion area  516  and extending to the locking area  514 . 
       FIG. 6  illustrates an example molded receptacle  600  that may serve as a female portion of a dual-component fastening device that operates to attach a wearable protective article to a user. The molded receptacle  600  is integrated within a hard shell structure  606  (e.g., a rigid or semi-rigid structure) including an aperture  602 . The aperture  602  further includes an insertion area  614  and a locking area  616 . 
     In one implementation, the molded receptacle  600  is sized and shape to mate with a male fastening element, such as the rigid insertion elements shown in  FIGS. 1-2 . The molded receptacle  600  includes a guiding structure (e.g., a lipped guiding portion  620 ) that protrudes outward from a generally planar surface of the hard shell structure  606  and extends over the aperture  602 , providing a track for receiving and guiding a corresponding male fastening element into the aperture  602 . A diameter of the aperture  602  exposed at the insertion area  614  is wider than a diameter exposed at the locking area  616 . This geometry may help to secure the male fastening element within the molded receptacle  600 . 
     In operation, a male fastening element may be inserted into the molded receptacle  600  laterally through the portion of the aperture  602  exposed at the insertion area  614 . The male fastening element can be guided in the same direction as the lateral insertion until a portion of the male fastening element rests within the locking area  616 . At this position, a geometric mismatch between the size of the aperture  602  at the locking area  616  and a comparatively large diameter of an end portion of the male fastening component serves to prevent the fastening component from detaching from the molded receptacle  602 , such as when the male fastening component is pulled in a direction normal to the hard shell structure  606 . When integrated into a protective wearable article, a strap may supply outward tension on the male fastening component (e.g., in the direction of a vector originating at the insertion area  614  and extending to the locking area  616 ). This strap tension may also help to secure the male fastening component within the molded receptacle  602 . 
       FIG. 7  illustrates a cross-sectional view of a protective wearable article  700  including an example dual-component fastening device  702  in a secured position. The protective wearable article  700  includes a hard shell layer  706  and a soft backing layer  722 . The dual-component fastening devices is formed by a molded receptacle (not shown) formed within the hard shell layer  706  and a rigid protrusion element  702   a  sized and shaped to mate with the molded receptacle  702   b . When secured within the molded receptacle  702   b , a wide end portion  712  of the rigid protrusion element rests between the hard shell layer  706  and the soft backing layer  722 , as shown, while a stem portion  710  of the rigid protrusion element rests within an aperture of the molded receptacle. 
       FIG. 8  illustrates example operations for securing a protective wearable article to a user via a dual-component fastener device. A placement operation  805  places a protective wearable article adjacent to a portion of a user&#39;s body. In one implementation, the protective wearable article includes a hard shell layer and a backing layer. The placement operation  805  places the backing layer in contact with the user&#39;s clothing or skin at a desired location. For example, the desired location may be a location wherein the hard shell layer aligns with the user&#39;s kneecap, elbow, wrist, skill, or other protectable structure. 
     A wrapping operation  810  wraps a strap around the portion of the user&#39;s body near the location selected via the placement operation  805 . The strap includes a first end attached to the protective wearable article (e.g., via stitching, adhesive, or other fixed or selectively detachable attachment mechanism). For example, a first end of the strap may be attached to a perimeter portion of the wearable protective article. A second free end of the strap includes or is further attached to a male fastening component, such as a rigid protrusion element. The strap and the rigid protrusion element may be attached to one another by any reliable attachment mechanism or means. The wrapping operation  810  may, for example, wrap the strap around a user&#39;s arm, leg, torso, wrist, ankle, chin, head, etc. 
     An insertion operation  815  inserts the male fastening component into a molded receptacle formed in the hard shell layer of the protective wearable article. In one implementation, the molded receptacle is formed at a perimeter region of the wearable protective article that opposes another perimeter region where the first end of the strap attaches to the wearable protective article. The molded receptacle includes an aperture, and the insertion operation  815  inserts the male fastening component into the aperture at an insertion area having a diameter larger than a diameter of at least one other region of the aperture. 
     A sliding operation  820  slides the male fastening component along a channel of the molded receptacle to secure the male fastening component in the locking area. In one implementation, the channel connects the insertion area of the aperture to a locking area of the aperture, and the locking area has a smaller diameter than the insertion area. Further, the locking area may be closer to a perimeter of the protective wearable article than the insertion area. Thus, the sliding operation  820  may entail sliding the male fastening component within the channel toward the perimeter of the protective wearable article (e.g., as described with respect to  FIGS. 1 and 6 , above). In some implementations, the molded receptacle may include guiding structures (e.g., protrusions, ridges, flanges, lips, etc.) that help to guide the male fastening component within the channel. When resting within the locking area of the molded receptacle, a wide base portion of the male fastening component may rest between the hard shell structure and the backing layer while a narrower stem portion rests within the diameter at the locking area. 
     A tension in the strap wrapped against the user transfers a force that acts to further secure the male fastening component within the locking area of the molded receptacle. When positioned within the locking area, a user may not be able to remove the rigid protrusion element from the molded receptacle by applying a force on the attachment appendage in a direction that is normal to the hard shell structure. However, the male fastening component may be released from the molded receptacle via a force that pushes the male fastening component in a direction of the insertion area. In one implementation, easy release tabs, handles, or other ‘easy grab’ components are included to supply a point of leverage for detaching the male fastening component from the corresponding female receptacle. 
     The logical operations making up the embodiments of the invention described herein are referred to variously as operations, steps, objects, or modules. Furthermore, it should be understood that logical operations may be performed in any order, adding or omitting operations as desired, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language. The above specification, examples, and data provide a complete description of the structure and use of exemplary embodiments of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different embodiments may be combined in yet another embodiment without departing from the recited claims.