Patent Publication Number: US-2006005306-A1

Title: Chest protector

Description:
This application claims priority from U.S. Provisional Application 60/585,677, filed on Jul. 6, 2004, the contents of which are incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to a chest protector, and more particularly to a protective garment for protecting wearers, such as athletes, from a condition known as commotio-cortis.  
      2. Description of the Related Art  
      Athletes and other individuals who are active in the vicinity of hard, fast-moving objects, e.g., baseballs, lacrosse balls, hockey pucks, human fists, or the like, can be subject to a life-threatening injury known as commotio-cortis. Commotio-cortis, or “cardiac concussion” can occur when a person receives a powerful impact force in the cardiac region of the chest, e.g., the force created by being struck in the cardiac region by a fast-moving baseball, a lacrosse ball, a hockey puck, or even a human fist. If the impact occurs when the athlete&#39;s heart is between beats, in some cases, the heartbeat can be stopped altogether, leading to rapid loss of blood pressure, unconsciousness, coma, and in some cases death. The occurrence can be especially severe in the case of very young athletes, such as Little League baseball players.  
      Previous attempts have been made to develop protective garments for athletes to wear, e.g., garments supporting a protective quilted pad over the cardiac region, but for a variety of reasons, e.g., the garment is too cumbersome or bulky, or overly-restricts the athlete&#39;s range of motion, the protective pad is inadequate, or else the pad shifts out of place during athletic activity, these conventional protective garments are not commonly worn, and the occurrence of commotio-cortis, especially among young athletes, continues to rise.  
      It is desirable therefore, to develop a protective garment that is not bulky, does not restrict a wearer&#39;s range of motion, maintains the protective pad in place over the cardiac region, and has adequate protective padding to reduce an impact force to the cardiac region of the chest caused by a fast-moving object such as a baseball, lacrosse ball, hockey puck, fist, or the like, in order to reduce the risk of commotio-cortis.  
     SUMMARY OF THE INVENTION  
      The present invention, as set forth and broadly embodied herein, is a protective garment developed in accordance with the purposes outlined above, and which substantially obviates one or more of the problems caused by the limitations and disadvantages of the related art.  
      Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the apparatus set forth in the specification, drawings, and claims below.  
      In accordance with the purposes of the invention, as embodied and broadly described herein, a chest protector is provided, including a pad held proximate a cardiac region of a human chest, the pad including at least one layer of a visco-elastic polymer structured to absorb impact energy, convert at least a portion of the impact energy to heat, and dissipate the heat.  
      As broadly embodied herein, the pad is held in a pocket over the cardiac region, the pocket being supported in a garment.  
      Preferably the garment is a snug-fitting vest. The garment also can be a strap harness, or a shirt, structured to fit snugly and hold the pocket and the pad in place over the cardiac region of the chest, while not restricting movement of the wearer&#39;s arms and shoulders.  
      In accordance with the invention, the visco-elastic polymer of the pad is generally planar, and configured with a number of raised platforms, protrusions, or dots, spaced apart by gaps defined therebetween, the raised platforms being either rectangular, circular, or oval. It is preferable that the visco-elastic polymer is Sorbethane®, a known polymer, which receives an impact force, and converts the impact force to heat. The heat transfers to atmosphere via the open gaps between the raised portions, thereby substantially reducing the impact force applied to the chest.  
      In accordance with the invention, the pad further includes a rigid layer, e.g., plastic, attached to the non-rigid visco-elastic polymer layer. Preferably, a second non-rigid layer also is provided, which preferably is made of the same visco-elastic polymer as the first layer, but which alternatively may be made of a different visco-elastic polymer, or it may be made of foam. The second non-rigid layer may include a single sheet or multiple sheets of visco-elastic polymer or foam. When a second such non-rigid layer is provided, the rigid layer preferably is sandwiched between the non-rigid layers.  
      It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and provide further explanation of the invention, as set forth in the attached claims. 
    
    
     DESCRIPTION OF THE DRAWINGS  
      The accompanying drawings are included to provide a further understanding of the invention, constitute part of the specification, and illustrate preferred embodiments of the invention. Together with the general description above and the detailed description below, the drawings help explain the principles of the invention.  
       FIG. 1  is a perspective view of a protective pad in accordance with the invention;  
       FIG. 2  is an exploded part view of the protective pad of  FIG. 1 ;  
       FIG. 3  is a detailed top view of a protective pad in accordance with the invention.  
       FIG. 3A  is a detailed top view of a portion of the pad of  FIG. 3 .  
       FIG. 3B  is a cross-sectional view of the pad portion of  FIG. 3A .  
       FIG. 4  is a perspective view of a human torso wearing a protective garment in accordance with the invention, the garment being in the form of a vest, having a protective pad in a pocket over a cardiac region of the torso;  
       FIG. 5A  is a perspective view substantially similar to that of  FIG. 4 , except that the garment is a strap instead of a vest.  
       FIG. 5B  is a perspective view substantially similar to that of  FIG. 5A , except that the garment is a strap harness.  
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings.  
      An exemplary embodiment of the invention is a chest protector, shown broadly in  FIG. 1 , and designated by reference numeral  10 .  
      In accordance with the invention, chest protector  10  includes a protective pad  12 , configured to be disposed and held in place over a cardiac region of a human chest. Pad  12 , as depicted herein, includes at least one layer  14 , preferably having a thickness of 0.38″ to 0.50″. It is within the scope of the invention, however, for the first layer  14  to include more than one sheet of the visco-elastic polymer.  
      A visco-elastic polymer absorbs force of an impact to the polymer, and converts at least a portion of that absorbed impact force to heat. The heat then dissipates by being exchanged with atmosphere via an outer surface of the polymer.  
      Preferably the visco-elastic polymer layer  14  of pad  12  defines a generally planar surface, with a number of adjacent elevated portions, protrusions, or “dots”  16  protruding from the planar surface, preferably 0.12″ in height, the protrusions  16  defining therebetween a series of gaps or spaces  18 . The protrusions  16  are preferably generally rectangular, but may also be generally circular, or generally oval in shape.  
      In accordance with the invention, when an impact force is applied to the visco-elastic polymer of the first layer  14  of pad  12 , e.g., a fast-moving baseball or lacrosse ball strikes the pad, the impact is received across several of the raised portions  16  (the number of raised portions  16  depends on the size of the impacting object). The impact generates impact energy. The visco-elastic polymer converts at least a portion of the impact energy into heat. The heat is conducted through the pad  12 , and dissipated via heat exchange with the atmosphere, across the pad surfaces  15  at gaps  16 . Any remaining impact force, which is not converted to heat, is further dissipated by spreading across the first layer  14 .  
      Moreover, the first layer can, if desired, include more than one sheet of the visco-elastic polymer.  
      A presently preferred visco-elastic polymer to be used as the material for first layer  14  of pad  12  is Sorbethane®, which is commercially available and well known.  
      Preferably, as broadly embodied herein and depicted in  FIG. 2 , protective pad  12 , includes one or more additional layers  20  and  22 . As embodied in  FIG. 2 , layer  20  is a rigid layer, preferably having substantially the same shape and dimensions as the visco-elastic polymer layer  14 . Rigid layer  20  is made preferably of hard plastic or a suitable substitute material that is both rigid and lightweight. It is further preferred that another non-rigid layer  22  be provided, with rigid layer  20  being sandwiched between the two non-rigid layers,  14  and  22 . The second non-rigid layer  22  has substantially the same shape and dimensions as first layer  14  and rigid layer  20 .  
      It is preferable that second non-rigid layer  22  be made of a visco-elastic polymer, and preferably the same visco-elastic polymer used to construct the first layer  14 . When the second non-rigid layer  22  is a visco-elastic polymer, it is generally planar, and can be smooth, as shown in  FIG. 2 , or have raised portions and gaps, the same as the first layer of visco-elastic polymer. Moreover, the second layer can include more than one sheet of the visco-elastic polymer. As was the case with first layer  14 , the preferred visco-elastic polymer, based on testing, is Sorbethane®. A second layer of Sorbethane® converts a larger amount of the impact energy to heat, and dissipates the heat, then can be accomplished with only a single layer of Sorbethane®. The invention is not limited to use of Sorbethane® in the second non-rigid layer, however, or even to using the same visco-elastic polymer as in the first layer. It is possible to use a different visco-elastic polymer for the second non-rigid layer  22 , and it is further conceivable to use another material altogether in the second non-rigid layer  22 , for example, foam. Although foam will not perform the same force/heat conversion as a visco-elastic polymer, it nevertheless provides additional cushioning to help absorb and dissipate a portion of the impact force and, hence, further protect the cardiac region of the wearer&#39;s chest. Moreover, the second non-rigid layer can consist of more than one sheet of foam. An embodiment of the invention with multiple sheets of foam forming the inner layer, will be more bulky than an embodiment with one or more sheets of visco-elastic polymer, but as a trade-off, should be lighter in weight.  
      In accordance with the invention, a garment  30  is provided, wearable by an athlete to be protected, for supporting a pocket  32  over the athlete&#39;s cardiac region. The protective pad  12  is configured to be inserted into and held in place inside the pocket  32 . Pocket  32  can either be opened and closed, or it can be sealed shut. An openable and closeable pocket  32  is the preferred embodiment, since it allows pad  12  to be removed periodically to be washed, repaired or replaced.  
      As embodied in  FIGS. 4, 5A , and  5 B, the garment  30  can have one of several possible configurations, depending on the preference of the wearer.  
      Preferably, garment  30  is configured in the shape of a vest  34 , as shown in  FIG. 4 . Referring to  FIG. 4 , vest  34  is a tight, sleeveless garment, fitting snugly against the wearer&#39;s torso, so as to not create excessive bulk beneath the wearer&#39;s outer garments, and also so as to not restrict arm or shoulder movement. The vest  34  preferably is made of a fabric capable of stretching to conform to the shape of the wearer&#39;s torso, and also capable of wicking perspiration or other moisture away from the wearer&#39;s skin. Preferred fabrics include Lycra®, or a blend of Lycra® and nylon.  
      Alternatively, garment  30  can be configured in the form of a single strap  36 , as shown in  FIG. 5A  or a strap harness  38 , as shown in  FIG. 5B . A strap or strap harness may be preferable to some athletes, because of even more reduced bulk and less restriction of movement. When a strap harness  38  or single strap  36  are used as garment  30 , nylon is the preferred fabric. It is further preferred that pocket  32  be made of a breathable fabric to allow airflow therethrough. A suitable fabric is Breath-O-Prene®, which is known and commercially available.  
      It is further preferred that, whether the garment is a vest  34 , strap  36 , or a strap harness  38 , any connectors needed to hold portions of the garment together should be low profile hooks and nylon loops, which provide good peel and shear strength in order to hold fast, while presenting a low profile to avoid snagging on the wearer&#39;s outer garments.  
      A protective garment configured as broadly described above, i.e., a snug-fitting vest with a pocket over the cardiac region of the chest, holding a protective pad comprising two generally planar layers of the same visco-elastic polymer (i.e., Sorbethane®), with at least the outer layer having a plurality of raised protrusions with spaces defined therebetween, and a rigid plastic layer sandwiched between the two Sorbethane® layers reduces an impact force by approximately 45%. Example 1 below depicts the results of a comparative test, comparing the force reduction realized by a protective garment in accordance with the present invention, in comparison with no protection whatsoever, and with a conventional protective garment. Examples 2 and 3 below depict the results of tests on different embodiments of the present invention, realizing force reduction of approximately 41%-58%.  
     EXAMPLE NO. 1  
      A baseball was thrown by a standard pitching machine at various speeds, against a vertical surface. A sensor was fixed to the vertical surface, connected to a computer processor programmed with speed and force analysis software, to measure the impact force. A series of tests was conducted, pitching the ball against the vertical surface (1) while it was unprotected; (2) while it was protected by a pad of the invention, consisting of an outer layer of a single sheet of 0.5″ thick Sorbethane®, a middle layer of rigid plastic, and an inner layer of a single sheet of 0.5″ thick Sorbethane®, designated, for testing purposes, the B-series of the invention, and (3) while it was protected by a prior art pad, consisting of quilted padding sewn into a vest. In each test, the speed of the ball and the resultant impact force was measured. For purposes of comparison, each measured impact force was normalized to a ball speed of 60 mph. Table 1 below lists the ball test, the type of protection, the actual ball speed, the normalized ball speed, the impact force felt by the sensor on the surface at the actual ball speed and the impact force at the normalized speed. The percentage of force reduction was calculated by comparing the impact force felt in the protected cases, compared to the impact force felt in the unprotected cases.  
                                       TABLE 1                                      Normal-                           Ball   ized   Actual   Normal-   Reduc-       Test   Type of   Speed   Ball Speed   Force   ized   tion       No.   Protection   (mph)   (mph)   (lbs)   Force (lbs)   (%)                                                 A-1   None   54.90   60   1370   1497.3   0.2       A-2   None   57.05   60   1430   1504.0   −0.2       Average                   1500.7   0.0       B-1   invention   59.87   60   814   815.8   45.6       B-2   invention   58.42   60   813   835   44.4       Average                   824   45.0       C-1   prior art   61.38   60   1450   1417.4   5.5       C-2   prior art   58.19   60   1330   1371.3   8.6       Average                   1394.4   7.1                  
 
      As can be seen from the above data, a 60 mph baseball, striking an unprotected vertical surface, e.g., an athlete&#39;s chest, applies an average impact force of approximately 1500 lbs. An athlete wearing a prior art protective garment, with quilted padding sewn into the fabric of a vest, obtained only a 7% reduction of force, and still received an average force of 1394 lbs. An athlete wearing the protective garment according to the present invention of the B-series, as broadly described above, should receive a 45% reduction of the impact force, and receive an impact force reduced to 824 lbs.  
     EXAMPLE NO. 2  
      In another test, the same testing apparatus described above was used to test a second embodiment of the present invention, having an outer layer of two (2) 0.5″ thick sheets of Sorbethane®, a middle rigid plastic layer, and an inner layer of a single ⅜″ thick sheet of foam, designated, for testing purposes, the D-series of the invention. Table 2 lists the actual ball speed, the normalized ball speed (at 60 mph), the actual impact force, the normalized impact force, and the percent of force reduction.  
                                       TABLE 2                                      Normal-                           Ball   ized   Actual   Normal-   Reduc-       Test   Type of   Speed   Ball Speed   Force   ized   tion       No.   Protection   (mph)   (mph)   (lbs)   Force (lbs)   (%)               D1-4   Invention   55.95   60   832   892.3   39.3       D2-5   Invention   61.90   60   892   864.7   41.2       D3-6   Invention   60.86   60   866   853.7   41.9       Average                   870.2   40.8                  
 
     EXAMPLE NO. 3  
      In a third test, the same testing apparatus was used to test a third embodiment of the present invention, having an outer layer of a single sheet of 0.5% thick Sorbethane®, a middle rigid plastic layer, and an inner layer of two (2) ⅜″ sheets of foam, designated, for testing purposes, the E-series of the invention. Table 3 lists the same types of data listed above.  
                                       TABLE 3                                      Normal-                           Ball   ized   Actual   Normal-   Reduc-       Test   Type of   Speed   Ball Speed   Force   ized   tion       No.   Protection   (mph)   (mph)   (lbs)   Force (lbs)   (%)               E1-7   Invention   59.81   60   610   611.9   58.4       E2-8   Invention   60.14   60   622   620.6   57.8       E3-9   Invention   57.68   60   602   626.2   57.4       Average                   870.2   57.9                  
 
      As can be seen, an athlete wearing the protective garment according to the present invention of the D-series, as broadly described above, should receive an approximate 41% reduction of the impact force, and an athlete wearing a protective garment according to the E-series, as broadly described above, should receive an approximate 58% reduction of the impact of force. The E-series of the invention, having two sheets of foam, may be more bulky than, for example, the B-series, but as a trade-off, should weigh less than the B-series.  
      The present invention reduces of eliminates many of the problems associated with conventional protective garments, by providing a snug garment that is not bulky and does not restrict the wearer&#39;s range of motion, with a protective pad, held in place in a pocket over the cardiac region of the chest, which does not shift out of place during athletic activity, and which is capable of receiving an impact, converting impact energy into heat, and dissipating the heat, thereby obtaining a force reduction of about 45%-58%, and thereby reducing the risk of commotio-cortis.  
      It will be apparent to those skilled in the art that modifications and variations may be made to the structure of the present invention without departing from the spirit or scope of the invention. It is intended, therefore, that the present invention cover such modifications and variations, provided they fall within the scope of the attached claims and their legal equivalents.  
      Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being established by the following claims and their equivalents.