Patent Publication Number: US-10773149-B2

Title: Sports shin guard with cut-resistant sleeve

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     The present application derives priority from U.S. Provisional Patent Application Ser. No. 62/107,971 filed 26 Jan. 2015. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to protective sports equipment and, in particular, ice hockey shin guards with a cut-resistant sleeve that covers a user&#39;s exposed lower leg. 
     2. Description of the Background 
     Protective sports equipment is commonly used and often required many organized sports such as lacrosse, hockey and other contact sports. For example, shin guards are common precautions against painful contusions to the lower leg when the shin is kicked by another player or is struck by a puck or ball. Conventional field hockey shin guards are typically fabric-encased rubber pads and/or rigid plates, with elasticized fabric straps that wrap around the back of the leg. Conventional ice hockey shin guards typically feature a molded plastic outer layer and a softer inner padding layer with elastic straps that wrap partially around the leg to keep the shin guard in place. These conventional shin guards protect against frontal impact but offer no cut protection in the areas most prone. 
     Recent injuries in ice hockey have made this cut-type of injury a serious topic for improvement. In 2012 Erik Karlsson won the James Norris Memorial Trophy as the National Hockey League top defense player. In 2013 he was retrieving the puck in the corner when the skate of an opposing player sliced into the back of his left foot. Karlsson&#39;s Achilles tendon was nearly severed and his season ended. There have been many similar incidents, and short-track speed skating is another sport where skate cuts are common. 
     Both cut-proof and cut-resistant socks are available but skaters and players find them uncomfortable and rarely wear them. Alternative heavy knitted yarn socks do not adequately protect the ankle area and adversely affect skate fit and comfort. Sleeved shin guards are known in the sport of field hockey, but are configured differently from the present invention, including having a rigid plate essentially built into the front portion of a sleeve to cover a portion of a user&#39;s lower leg. Such shin guards often include a stirrup that extends underneath the foot. The objectives of shin guards designed for blade sports, such as ice hockey, and those designed for field hockey overlap somewhat, but the articles are otherwise of a different genus. 
     What is needed is a protective shin guard with integral cut protection about the ankle that will not shift or come loose during play and will not affect skate fit or comfort 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide a shin guard that protects the shin and knee from impacts. 
     Another object is to combine an enhanced level of integral cut protection without obstructing forward flex and mobility of a skater&#39;s leg. 
     Another object of the present invention is to provide a shin guard with integral cut protection about the ankle without affecting skate fit. 
     Yet another object of the present invention is to provide a shin guard that facilitates donning and lacing of skates with shin guard on. 
     In one aspect, a protective shin guard includes a floating knee section hingedly attached to a shin section, both sections being formed of a hard shell panel. The floating knee section is attached to the shin section by a main padding layer that underlies both hard shell panels. The main padding layer may be formed of one or more contiguous blocking panels of compressible foam (e.g., high-density microcellular polyurethane foam), or similarly by fabric layers cut-and-sewn together to encase foam pads. 
     A liner is attached beneath the main padding layer. In one embodiment the liner is removable using hook-and-loop pads or the like. The liner can also be permanently attached by sewing, soldering or other conventional means. The liner may likewise be formed of one or more contiguous blocking panels of compressible foam or by foam pads encased in hinged fabric layers. In either case, the liner may be formed with a particular hinge pattern including a radial array centered at the knee section, a lateral hinge beneath the knee cap, and a plurality of spaced vertical hinges extending down the shin. 
     The liner also includes an integral cut-resistant calf-sleeve attached along its bottom edge and extending downward. The cut-resistant calf-sleeve may be an elastic tubular sleeve formed of a weave of elastic/cut-resistant fibers, e.g., Kevlar®, Spandex, Dyneema®, fiberglass coated yarn, or the like. Alternatively, the calf-sleeve may be formed of non-cut-resistant fibers that are either treated or coated in such a way as to make the sleeve cut-resistant. One such coating material is commercialized under the tradename SuperFabric®, produced by HDM, Inc. of Oakdale, Minn. The cut-resistant calf-sleeve is long enough to surround both the calf and the ankle, and thereby provides integral cut protection about the ankle without compromising skate fit and comfort. It also provides a lower attachment feature that combines with an upper 360+ degree attachment strap to provide a better fit that will not shift or come loose during play. 
     The present invention is described in greater detail in the detailed description of the invention, and the appended drawings. Additional features and advantages of the invention will be set forth in the description that follows, will be apparent from the description, or may be learned by practicing the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which: 
         FIG. 1  is a front perspective exploded view of the shin guard  2  shown with removable liner  6  removed from main outer assembly  4 . 
         FIG. 2  is a rear perspective exploded view of the shin guard  2  with liner  6  removed from main outer assembly  4 . 
         FIG. 3 (A-B) is a composite side-view illustration of the shin guard  2  illustrating the hinge function of the main outer assembly relative to the removable liner, shown in the playing position at  FIG. 3(A)  and in the raised position as at  FIG. 3(B)  for fining over the hockey skate when dressing. 
         FIG. 4 (A-C) is a sequential assembly view of the steps (A-C) involved in donning the shin guard  2 .  FIG. 4(A)  is a perspective view of the liner removed from the main outer assembly and being donned separately, though the liner may be permanently attached to the main assembly piece and need not be donned separately.  FIG. 4(B)  is a side perspective view of the liner partially in place.  FIG. 4(C)  is a perspective view of the liner fully in place. 
         FIG. 5 (E-H) is a composite view illustrating the coverage of the shin guard  2  with cut-guard sleeve  8  compared to a conventional shin guard in  FIG. 5 (A-D).  FIG. 5(A)  is right-side view illustrating a conventional shin guard.  FIG. 5(B)  is left-side view illustrating the conventional shin guard.  FIG. 5(C)  is rear view of the conventional shin guard.  FIG. 5(D)  is rear perspective view of the conventional shin guard  2  illustrating its lack of cut protection.  FIG. 5(E)  is right-side view illustrating the shin guard  2  according to the present invention with cut-guard sleeve  8 .  FIG. 5(F)  is left-side view illustrating the shin guard  2  with cut-guard sleeve  8 .  FIG. 5(G)  is rear view of the shin guard  2  with cut-guard sleeve  8 .  FIG. 5(H)  is a rear perspective view of the shin guard  2  with cut-guard sleeve  8  illustrating its enhanced cut protection. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     The embodiments of the present invention described herein all regard a protective shin guard that employs a particular impact-resistant hard-shell outer assembly and shock-absorptive inner liner. The main outer assembly employs a first flex-padding configuration comprising a floating hard-shell knee section attached to a hard-shell shin section by a main padding layer, and flanking side panels hingedly attached to the hard-shell shin section by the main padding layer. The inner liner may be removably attachable inside the main outer assembly by hook-and-loop. Alternatively, the liner can be permanently attached by sewing, soldering or other conventional means. The liner employs a second flex-padding configuration and includes a cut-resistant calf-sleeve attached at its lower extremity to provide cut protection to the lower calf and ankle. 
     The shin guard is attached to the leg by the cut-resistant calf-sleeve in combination with a behind-the-knee strap. The knee strap is a 360+ degree compression strap, preferably elastic, that wraps fully around the leg and works in conjunction with flanking side leg panels to pull them in from all sides for a secure compression fit. 
     Referring to  FIGS. 1-2 , a first embodiment of a protective shin guard  2  of the type worn for ice-hockey is shown according to the invention. The protective shin guard  2  generally comprises the main outer assembly  4  (at right) and liner  6  (at left, shown detached from main outer assembly  4 ). The main outer assembly  4  includes a floating knee section  42  and a shin section  44  connected to one another by main padding, layer  48  that covers a substantial portion of the interior of both sections  42 ,  44 . One skilled in the art will understand that the connection between the floating knee section  42  and shin section  44  may alternately be by pins, flexible hinges, or may be in any other suitable manner. Both floating knee section  42  and shin section  44  may be integrally-molded from impact resistant plastic such as nylon or polycarbonate. Alternately, one or both floating knee section  42  and shin section  44  of the main outer assembly  4  may comprise a plurality of articulated panel(s), in either case the shin section  44  is trough-shaped adapted to conform to the leg of the wearer, with a generally arcuate cross-section profile. The knee section  44  is generally concave and conforms to the knee. 
     The illustrated embodiment of shin section  44  can include a central Y-shaped shin bone panel  402  seated within a conforming U-shaped bottom panel  404 , and two flanking side leg panels  106 ,  108 . The hard shell outer panel(s) of the shin section  16  may also include one or more pass-through vents  111  into the padding layer  20  for air circulation. 
     As seen in  FIG. 2 , the floating knee section  42  is attached to the shin section  44  by the main padding layer  48  which underlies the hard shell panels. The main padding layer  48  is a thin layer of padding and may be a single fabric layer, but is more preferably formed of one or more contiguous blocking panels of compressible foam (e.g., high-density microcellular polyurethane foam) hinged together, or by opposing fabric layers cut-and-sewn together to encase foam pads. 
     Also seen in  FIG. 2 , is an optionally removable and adjustable knee cushion  49  formed of one or more contiguous blocking panels of compressible foam hinged together, or by opposing fabric layers cut-and-sewn together to encase foam pads. Knee cushion  49  is a small transitional pad attached at the top of the knee section  44  that softens the edge of the knee section  44  against the lower thigh and protects the lower thigh area. If attached by strap, knee cushion  49  can be adjusted to cover more or less of a user&#39;s thigh. If removable, knee cushion  49  is preferably attached by hook-and-loop so as to be easily removable and washable. 
     In the illustrated embodiment, as seen in  FIG. 3 , the main padding layer  48  is extended on each side to form opposing side leg panels  106 ,  108 , the latter being hinged to the main padding layer beneath shin bone panel  402  by selected molded or sewn bridge areas of reduced material thickness. These bridge areas effectively form living binges  107 ,  109  ( FIG. 3 ) which add flexibility, allowing the side panels  106 ,  108  to pivot with respect to the U-shaped bottom panel  404 . In addition, side leg panels  106 ,  108  may include overlying pads  116 ,  118  of high density foam for increased side-impact protection. 
     Referring back to  FIGS. 1-2 , liner  6  includes an upper knee pad  62  joined to a lower shin pad  64  at a hinge  66 . Liner  6  is removably or permanently attached beneath the main padding layer  44  for skin contact. If removable, liner  6  is preferably attached by hook-and-loop so as to be easily removable and washable. The knee pad  62  is optionally attached to the main padding layer  48  using multiple pieces of hook-and-loop. In the illustrated embodiment, three hook-or-loop pads  144  are spaced along the main padding layer  44  and three mating pads  146  spaced along liner  6  to index the position of liner  6 . It is important that the hook-and-loop pads  144 ,  146  not extend below the knee cap area in order to allow liner  6  to hinge properly as described below. 
     Liner  6  is preferably formed of one or more contiguous blocking panels of compressible foam (e.g., high-density microcellular polyurethane foam) hinged together, or by opposing fabric layers cut-and-sewn together to encase foam pads. The knee pad  62  is roughly circular to occupy the interior of concave knee section  44 , and may be defined by a spider-web array of hinges  67 . Lower shin pad  64  is roughly crest-shaped and may be defined by an array of spaced vertical hinges  68 . Importantly, hinge  66  occurs beneath the knee cap. 
     Liner  6  includes a cut-resistant calf-sleeve  80  attached to the lower shin pad  64 . Cut-resistant calf-sleeve  80  is formed of a cut-resistant yet stretchable material comprising a woven fabric blend of two separate fibers, the first being an ultra-high-molecular-weight polyethylene high-performance material such as DuPont™ Kevlar® aramid or Dyneema® fiber and the second being an elasticized fiber such as Spandex®. The two fiber strands are knitted together in an overall resulting fabric blend at weight percentages as desired to provide a particular level of cut resistance. Preferably the resulting fabric blend may be 60-90 weight percent (%) of the high-performance fiber and 10-40% of the elastic fiber which provides an acceptable range of cut resistance. There are three standardized methods for testing cut resistance: ASTM F1790 (U.S.), ISO 13997 (International) and EN  388  (Europe), and for present purposes at least an ANSI/ISEA 105-2011 performance level 1 fabric should be used and “cut resistant” is herein defined as a fabric that exhibits a cut resistance level equal to or in excess of ANSI/ISEA 105-2011 (2011) performance level 1. Sleeve  80  may be treated or coated to achieve the desired level of cut resistance. The resulting fabric is sewn in the form of a tubular sleeve and as seen in  FIG. 2  the upper front edge of the sleeve  80  is sewn or otherwise attached to the bottom edge of the lower shin pad  64  of liner  6 . The cut-resistant calf-sleeve  80  is long enough to surround both the calf and the ankle, and thereby provides integral cut protection about the ankle without compromising skate comfort or fit. It also provides a lower attachment feature that combines with an upper 360+ degree attachment strap to provide a better overall fit of the shin guard that will not shift or come loose during play. 
     The shin guard  2  is attached to the leg by the cut-resistant calf-sleeve  80  in combination with a 360+ degree compression strap  100 , best seen in  FIG. 3 . The 360+ degree compression strap  100  is preferably elastic, wraps fully around the leg and works in conjunction with the flanking side leg panels  106 ,  108  to pull them in from all sides for a secure compression fit. The 360+ compression strap  100  is an approximately one-to-two foot long section of webbing fixedly attached on one side of the shin guard  2 . The 360+ compression strap  100  extends at about a 45 degree angle upward and outward from the upper corner of the side panel  106 . A distal attachment pad  102  is mounted on the end of 360+ compression strap  100 , with inwardly-facing hook material and preferably an outwardly tacky rubberized surface to serve as a pull-tab. The entire outwardly-facing back surface of 360+ compression strap  100  (except for attachment pad  102 ) bears opposing loop material. In use, the player pulls the 360+ compression strap  100  back and wraps it around the top of the calf, moving from outside, back and around inside to the front of the shin guard  2 , and around front of the leg until the 360+ compression strap  100  has made a 360 degree rotation around the shin guard  2 . At this point, and given a comfortable tension, the distal attachment pad  102  is then secured to the medial attachment pad to secure the shin guard  2  in place, importantly, the 360+ compression strap  100  cannot be fastened until the player first wraps it more than 360 degrees around the leg. Only past this point may the inwardly-facing hook material of distal attachment pad  102  be secured to the outwardly facing loop material on the back surface of 360+ compression strap  100  to secure the strap  100  for proper hold. Optional elevated channels may be formed in the exterior surface of shin section  44  to guide and constrain the path of the 360+ compression strap  100 , and to prevent sliding of the 360+ compression strap  100  during play. The hinged leg panels  106 ,  108  allow the 360+ degree strap  100  to compress inward from the sides, front and back allowing for a 360 compression hold around the leg for a more secure retention. 
       FIG. 3  also illustrates the hinge function of the main outer assembly  4  relative to liner  6 . The cut-proof sleeve  80  maintains the mire shin guard  2  on the leg, but cut-proof sleeve  80  is not directly attached to the main outer assembly  4 . Only the upper knee pad  62  is joined to a lower shin pad  64  at hinge  66 , and so once the 360+ degree compression strap  100  is loosened (as at A) the shin guard  2  can be pivoted outward (as at B) relative to the removable liner  6 . Thus, the shin guard  2  is shown in the playing position at A and in the raised position as at B, and this pivoting feature allows the wearer to simply raise it rather than taking it off when donning or lacing skates. This aspect of the disclosure would be welcomed relief for ice hockey players that would prefer to have shin guards in place before donning or doffing skates. 
       FIG. 4  is a sequential assembly view of the steps (A-C) involved in putting on the shin guard  2 . Note: Liner  6  need not be separated from the main outer assembly before donning. As seen in  FIG. 4(A) , the player may don liner  6  first, sliding their foot down through the cut-resistant sleeve  80 . The cut-resistant sleeve  80  is slid fully over the foot as at (B), until the upper knee pad  62  is seated atop the knee, hinge  66  is directly beneath the knee, and the lower shin pad  64  runs down the shin as seen at (C). Once liner  6  is on as at C, the main outer assembly  4  can be placed over it and 360+ degree compression strap  100  tightened as desired. The hinging function of the main outer assembly  4  relative to liner  6  allows the player to pull up and lift the shin guard  2  over the player&#39;s skate in order to secure the shin guard into position. 
       FIG. 5  is a composite view illustrating the coverage of the shin guard  2  with cut-guard sleeve  80  compared to a conventional shin guard. As seen at A-D conventional shin guards leave the heel mostly unprotected and prone to injury from other skates. However, as seen at E-H, the cut resistant sleeve  80  completely surrounds the heel, tucking beneath the shin guard  2  and skate collar. The woven fabric nature of sleeve  80  offers superior protection without compromising skate comfort and fit. The sleeve  80  also provides some ‘compression’ around the sides and back of the ankle for improved support. 
     It should now be apparent that the above-described protective shin guard  2  allows a user freedom of movement, especially in a hockey scenario, yet maximum protection and secure fit. 
     The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims, and by their equivalents.