Patent Description:
Many garments and other articles of apparel are designed to fit closely to the human body. When designing an article of protective apparel for a close fit to the human body, however, different body shapes and sizes must be considered. Different individuals within a particular garment size will have different body shapes and sizes. For example, two individuals wearing the same shoe size may have very differently shaped heels. As another example, two individuals wearing the same shirt size may have very different chest to abdomen dimensions. These variable measurements between similarly sized individuals makes proper design of closely fitting garments difficult.

In addition to accounting for different body measurements for different individuals within a size, various contours of the human body must also be considered when designing closely fitting protective articles of apparel. These contours of the human body often include various double curvature surfaces. Spheroids, bowls, and saddle-backs are all examples of surfaces having double curvatures. If a protective garment is not properly sized for a particular wearer, the wearer may experience undesirable tightness or looseness at various locations. Such an improper fit may result in discomfort, excessive wear, or bending or creasing of the garment at the poorly fitting locations each of which can diminish the protective features of the garment.

Design Blue Limited of Portslade Brighton and Hove, United Kingdom, makes molded padding from a proprietary blend of polymer material under the brand name D3O®. One such molded piece includes a repeating array of circular and triangular pods, with molded structural members extending between and interconnecting each of the adjacent pods. <CIT> discloses expandable sheet materials comprising arrangements of slits distributed on the surface of the sheet, which allow for expansion of the sheet material upon the application of a force along or across the surface of the sheet material. <CIT> and <CIT> disclose articles of apparel with a base layer and an auxetic layer coupled to the base layer. The auxetic layer includes an auxetic structure that defines a pattern of repeating apertures. The auxetic structure is formed from an elastomeric polymer. <CIT> discloses a sneaker with an auxetic sole structure formed from adjoining, hinged members surrounding apertures. Under tension, the members rotate with respect to each other in the sole structure, thereby allowing the auxetic sole structure to expand under tension. <CIT> discloses a footwear article with an upper with openings arranged in an auxetic configuration. The openings include two sizes, such that the larger openings may expand more than the smaller openings. EP Patent Application No. <CIT> discloses a padding section according to the preamble of claim <NUM>.

In view of the foregoing, it would be desirable to provide a protective garment or other article of apparel capable of conforming to various body shapes within a given size range. It would also be desirable to provide a garment or other article of apparel that is capable of conforming to various curvatures on the human body.

In accordance with a first aspect of the invention there is provided a padding section, comprising: an upper layer, an opposing lower layer and a repeating array of cushioning regions disposed between, and continuously bonded to, the upper layer and the lower layer, each cushioning region comprising cushioning material having a same first cushion thickness; and a repeating array of apertures disposed between the cushioning regions and extending through the padding section, wherein the padding section has a first thickness and a first width and wherein upon application of a force, the padding section expands in width from the first width to a second width greater than the first width and when the application of force is removed, the width of the padding section contracts to the first width. The padding section further comprising a plurality of cushioning bridges extending between and interconnecting adjacent cushioning regions, each cushioning bridge having a bridge thickness, a bridge width and a bridge length, wherein the cushioning regions and the bridges together define a plurality of spacer regions, wherein the cushioning bridges are disposed in the spacer regions, wherein the repeating pattern of apertures is disposed in the spacer regions and wherein one aperture is disposed in each spacer region, the padding section characterised in that the cushioning region comprises sidewalls and the bridges are spaced apart from a midline of the cushioning region sidewalls, wherein when the padding section is subjected to the force, the cushioning regions pivot about the bridges and the apertures expand from a first size to a second size and when the force is removed, the apertures contract from the second size to the first size.

Optionally, the cushioning bridge thickness is less than a cushion thickness of the cushioning regions.

Optionally, the bridge length is no more than <NUM>/<NUM> of a cushion length of the cushioning region.

Optionally, the upper layer and the lower layer are at least partially bonded directly together in each spacer region.

Optionally, the padding section expands in width by <NUM>% to <NUM>% when subjected to the force.

Optionally, the padding section further comprises a perimeter flange extending around the padding section.

The foregoing and other features and advantages will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings, in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure.

The present disclosure is directed to conformable and expandable protective cushioning pads, to items comprising the pads, and to methods of making and using the foregoing and, in particular, to conformable and expandable protective cushioning pads for humans, for areas of the human body that require free range of motion. In some embodiments, the present cushioning pads may have properties that are similar to auxetic materials. The term "auxetic" as used herein generally refers to a material or structure that has a negative Poisson's ratio. Auxetic materials come in various different types and forms and can be single molecules or a particular structure of macroscopic matter. Some, but not all, auxetic structures are formed from a plurality of interconnected segments forming an array of apertures.

<FIG>, when taken together, illustrate an exemplary article of apparel <NUM> according to the present disclosure, which in this embodiment is a limb guard comprising a compression sleeve <NUM> and a protective pad <NUM> attached to the sleeve <NUM>. The term "article of apparel" as used herein refers to any garment, footwear or accessory configured to be worn on or carried by a human. Examples of articles of apparel include, soft protective headgear (e.g., rugby skull caps), helmets, hats, caps, shirts, pants, shorts, sleeves, knee pads, elbow pads, shoes, boots, backpacks, duffel bags, cinch sacks, and straps, as well as numerous other products configured to be worn on or carried by a person.

The protective pad <NUM> is illustrated in more detail in <FIG> and <FIG>. As shown, the pad <NUM> comprises a front side <NUM> with a front surface 14a, a back side <NUM> with a back surface 16a, an edge <NUM>, a perimeter flange <NUM> and a perimeter channel <NUM>. As shown in <FIG>, the pad <NUM> comprises a cushioning material <NUM> disposed between an outer layer <NUM> and an inner layer <NUM>. In one non-limiting example, the cushioning material can be PORON® Microcellular Polyurethane from Rogers Corporation, however, any moldable material, such as EVA, can also be used. In another non-limiting embodiment, the inner and outer layers <NUM>, <NUM> can be TPE - thermoplastic elastomer or TPU - thermoplastic polyurethane. In the present embodiment, the cushioning material <NUM> is disposed between, and encapsulated by, the outer layer <NUM> and the inner layer <NUM>. In some embodiments, the cushioning material <NUM> also may be continuously bonded to both the outer layer <NUM> and the inner layer <NUM>. The bonding can occur during the molding process and can be the result of a chemical reaction between the TPU and the Poron, when subjected to heat. Thus, it can be a thermal bond, i.e., melting/hardening of the materials. It should be noted that embodiments of the present disclosure can be implemented without one or more of the perimeter flange <NUM>, the perimeter channel <NUM>, the outer layer <NUM> and the inner layer <NUM>.

The pad <NUM> includes a repeating pattern of cushioning regions <NUM> formed in the cushioning material of the pad <NUM>. The cushioning regions <NUM> will also be referred to hereinafter as "pods <NUM>. " In the present embodiment, the pods are rectangular in shape, but it should be understood that a variety of shapes may be used e.g., square, triangular, round, oval, etc. The pods <NUM> are spaced apart from each other at regular intervals defined, on all sides, by spacer regions <NUM> having a width "W<NUM>". Each of the pods <NUM> includes an upper surface 22a and a sidewall 22b extending downwardly from the upper surface 22a to the spacer region <NUM>. The number of sidewall 22b depends on the shape of the pod <NUM>. Accordingly, a square or rectangular pod <NUM> has four sidewalls, a round pod has one and a triangular pod has three. Each pod <NUM> has a thickness "T<NUM>" defined by a thickness of the cushioning material <NUM> and, optionally, a thickness of the inner and outer layers <NUM>, <NUM>, when either or both are included in the pad <NUM>.

In an embodiment implemented without the outer layer <NUM> and the inner layer <NUM>, the pods <NUM> comprise the cushioning material <NUM>. In an embodiment implemented with the outer layer <NUM> and the inner layer <NUM>, then the pods <NUM> are encapsulated by the outer layer <NUM> and the inner layer <NUM>.

Although not illustrated as such, if desired, the sidewalls 22b may be perpendicular to the upper surface 22a or may be disposed at an angle relative to the upper surface 22a. If desired, and as shown, the upper surface 22a may be radiused at a transition region "TR" between the upper surface 22a and the sidewall 22b.

A bridge <NUM> interconnects the sidewalls 22b of adjacent pods <NUM>. The bridge <NUM> functions as a pivot point or hinge about which each pod <NUM> can rotate when subjected to a force. A length "L<NUM>" of each bridge <NUM> is defined by a distance between the sidewalls 22b, which is approximately the same as the width "W<NUM>" of the spacer regions <NUM>. Accordingly, each bridge <NUM> has a thickness of T1 and no aperture <NUM> and a spacer region <NUM> has an aperture <NUM> and essentially no thickness.

In the present embodiment, the bridges <NUM> are disposed adjacent to each corner of the pods <NUM>, but it should be understood that the location of the bridges <NUM> between the pods <NUM> may be varied, and that doing so may increase or decrease the amount of rotation of the pods <NUM> upon the application of a force to the pad <NUM>. The force applied to the pad <NUM> is, for example, in an athletic application as a knee guard, be perpendicular to the plane of the pad <NUM>. For example, when wearing a knee guard, bending of the knee would exert pressure on the back of the pad, roughly perpendicular to the backside of the pad.

Referring to <FIG>, bridges <NUM> have a length "L<NUM>" defined by the spacing between the sidewalls 22b of adjacent pods <NUM> and a thickness "T<NUM>" defined by a thickness of the cushioning material <NUM> (and the inner and outer layers <NUM>, <NUM>, when included). In the present embodiment, the bridge <NUM> has a thickness T<NUM> less than the thickness T<NUM> of the pods <NUM> (i.e., T<NUM> < T<NUM>). However, it should be understood that the length, width and thickness of the bridges <NUM> can be varied as desired in order to achieve particular design objectives. As an example of varying design, a square pod with four corners, and referencing the midpoint of each side of the square, with bridges located as close as possible to the corners of the square pods will have a greater expansion threshold than those in which the bridges are located closer to the midpoint of each side of the square.

Providing-the bridges <NUM> between the pods <NUM> can be beneficial for several reasons. The bridges <NUM> limit the expansion of the apertures due to the position of the bridge relative to the sidewall, thereby minimizing tearing or expansion that might otherwise occur if expanded past an expansion threshold, as discussed below. The amount of restriction introduced by the bridges <NUM> can be varied by varying the dimensions of the bridges <NUM> and their position between the sidewalls 22b of adjacent pods <NUM>. For example, a maximum rotation may be achieved by positioning the bridges <NUM> adjacent to the corners of the pod <NUM>, whereas minimal or no rotation will occur if the bridges <NUM> are positioned at a midpoint of the pod sidewall 22b as the bridge extends and connects the sidewalls. Similarly, an amount of restriction can be varied by varying the length, width and/or thickness of the bridges <NUM>. For example, rotation about the bridge <NUM> or pivot point may be maximized by minimizing the length, width and thickness of the bridge <NUM>. Conversely, rotation about the bridge <NUM> or pivot point may be minimized by maximizing the length, width and/or thickness of the bridge <NUM>. The presence of the bridges <NUM> may also improve the flow of material during the molding of the pad <NUM>. It should be noted that the pads are cut out of molded sheets. The sheets can be molded from Poron or another material and the pattern of apertures can be die cut into the molded Poron. The sheet can be molded with or without the inner and outer layers.

In use, when a force is applied to the pad <NUM>, the vents <NUM> expand and the bridges <NUM> function as pivot points or hinges about which the pods <NUM> rotate, resulting in the expansion of the pad <NUM> in both length and width. Upon removal of the force, the vents <NUM> contract to their original size, as does the pad <NUM>.

The pods <NUM>, bridges <NUM>, spacer regions <NUM> and vents <NUM> can comprise any shape, size or configuration as is practical or desired for a particular design or application. The size, shape, thickness and material composition of the pads <NUM>, pods <NUM>, bridges <NUM> and vents <NUM> may be varied, depending on a number of factors including, but not limited to, desired amount of expansion of the pad <NUM>, the desired amount of impact resistance, the desired amount of breathability, and the like. In addition, the configuration of the pods <NUM> may be varied, and more than one type of pod shape or vent shape may be used in the pads <NUM>.

Referring now to <FIG>, in accordance with an aspect of the present disclosure, a first alternative embodiment of a pad <NUM>' is presented. A second alternative embodiment of a pad <NUM>", according to the present disclosure, is presented in <FIG>. Each of the first and second alternative pads <NUM>', <NUM>" includes the same elements as set forth above in the previous embodiments.

<FIG> shows a section <NUM> of the second alternative pad <NUM>" in which each of the pods <NUM> is molded into the shape of a square having a length "L<NUM>" of about <NUM> (<NUM> inch) on each side and a thickness T<NUM> of about <NUM> (<NUM>/<NUM> inch) inch. The width W<NUM> of the spacer regions <NUM> is about <NUM> (<NUM>/<NUM> inch). The plurality of apertures <NUM> formed in the spacer regions <NUM> have a length L<NUM> of about <NUM> (<NUM>/<NUM> inch) and can be formed in the spacer regions during the molding process, for example, or, alternatively, by die cutting apertures through the spacer regions <NUM> after the molding process. The bridges <NUM> interconnect adjacent pods <NUM> and function as pivot points or hinges about which the pods <NUM> rotate when a force is applied to the section <NUM>, resulting in the expansion of the section <NUM>. <FIG> shows section <NUM> in an unexpanded state, with an unexpanded width of "W<NUM>".

<FIG> shows the section <NUM> in an expanded state with a width of "W<NUM>", i.e., expanded in the direction of arrows "A". As can be seen in <FIG>, when the section <NUM> is expanded in the direction of arrows A, for example, by stretching, section <NUM> becomes wider than when in the unexpanded state (i.e., W<NUM> > W<NUM>). In use, the bridges <NUM> function as pivot points or hinges about which the pods <NUM> rotate, and the rotation of the pods <NUM> about the bridges <NUM> facilitates the expansion of the section <NUM> from a width of W<NUM> to W<NUM>.

It will be recognized that whether a structure has a negative Poisson's ratio, may depend upon the degree to which the structure is expanded. Structures may have a negative Poisson's ratio up to a certain expansion threshold, but when expanded past the expansion threshold may have a positive Poisson's ratio. For example, when the section <NUM> in <FIG> is expanded in the direction of arrows A past a threshold (e.g., past the state shown in <FIG>), the section <NUM> may be expanded to an extent that the section <NUM> becomes slightly thinner (in a direction perpendicular to the arrows A) before the structure of the section <NUM> is torn apart or otherwise damaged. Accordingly, the term "auxetic" as used herein refers to structures or materials that have a negative Poisson's ratio within certain expansion thresholds. Furthermore, while the term "auxetic" is used herein to refer to a structure that has a negative Poisson's ratio, it will be recognized that structures may be "near auxetic. " A "near auxetic" structure is a structure having a Poisson's ratio of about zero, or less than <NUM>.

In one aspect of the present disclosure, referring now to <FIG>, a relationship between the bridge length (b), the node length (n), the groove width (g) and the aperture length (p) can be defined as follows: <MAT> and <MAT> For example, for a square pod with a side length of about <NUM> (<NUM> inches) and a spacer region width of about <NUM> (<NUM> inches) the maximum bridge length is about <NUM> (<NUM> inch), and the maximum aperture length is about <NUM> (<NUM> inch).

The section <NUM> described herein may be incorporated into various articles of apparel, including for example, skull caps commonly worn in rugby or under a football helmet. The skull cap is used to provide additional protection for the wearer's head as well as allowing a tight fitting football helmet to slip easily over the head. The negative Poisson's ratio of the structure described herein allows the skull cap and foam to fit a large number of different head sizes. Additional protection for the head is provided by the auxetic section to protect the head from impacts commonly experienced during training or competition. Also, section <NUM> may be provided over the entire skull cap, or only over a portion of the skull cap.

The present pads may be manufactured using techniques disclosed in <CIT> and <CIT> and U. Publication <CIT>.

It should be noted that the terms "first," "second," and the like herein do not denote any order or importance, but rather are used to distinguish one element from another, and the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Similarly, it is noted that the terms "bottom" and "top" are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. In addition, the modifier "about" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this disclosure belongs.

Claim 1:
A padding section (<NUM>), comprising:
an upper layer, an opposing lower layer and a repeating array of cushioning regions disposed between, and continuously bonded to, the upper layer and the lower layer, each cushioning region comprising cushioning material (<NUM>) having a same first cushion thickness; and
a repeating array of apertures (<NUM>) disposed between the cushioning regions and extending through the padding section (<NUM>),
wherein the padding section (<NUM>) has a first thickness and a first width and wherein upon application of a force, the padding section (<NUM>) expands in width from the first width to a second width greater than the first width and when the application of force is removed, the width of the padding section (<NUM>) contracts to the first width,
further comprising a plurality of cushioning bridges (<NUM>) extending between and interconnecting adjacent cushioning regions, each cushioning bridge (<NUM>) having a bridge thickness, a bridge width and a bridge length,
wherein the cushioning regions and the bridges (<NUM>) together define a plurality of spacer regions (<NUM>),
wherein the cushioning bridges (<NUM>) are disposed in the spacer regions (<NUM>),
wherein the repeating pattern of apertures (<NUM>) is disposed in the spacer regions (<NUM>) and wherein one aperture is disposed in each spacer region,
characterised in that the cushioning region comprises sidewalls (22b) and the bridges (<NUM>) are spaced apart from a midline of the cushioning region sidewalls (22b),
wherein when the padding section (<NUM>) is subjected to the force, the cushioning regions pivot about the bridges (<NUM>) and the apertures (<NUM>) expand from a first size to a second size and when the force is removed, the apertures (<NUM>) contract from the second size to the first size.