Patent ID: 12193528

DETAILED DESCRIPTION OF THE INVENTION

As used throughout the present disclosure, unless specifically stated otherwise, the term “or” encompasses all possible combinations, except where infeasible. For example, the expression “A or B” shall mean A alone, B alone, or A and B together. If it is stated that a component includes “A, B, or C”, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as “at least one of” do not necessarily modify an entirety of the following list and do not necessarily modify each member of the list, such that “at least one of “A, B, and C” should be understood as including only one of A, only one of B, only one of C, or any combination of A, B, and C.

The embodiments in the following description are given as examples only and someone skilled in the art can carry out the basic idea of the invention also in some other way than what is described in the description. Though the description may refer to a certain embodiment or embodiments in several places, this does not mean that the reference would be directed towards only one described embodiment or that the described characteristic would be usable only in one described embodiment. The individual characteristics of two or more embodiments may be combined and new embodiments of the invention may thus be provided.

FIG.1depicts an embodiment of a protective structure100. The protective structure is of a plate-like construct having a first surface101and a second surface102and a first end103and a second end104. The protective structure is configured in such a way that when the protective structure is in use, for example it is installed in a garment or equipment and the user is wearing it, the second surface is towards the user. The protective structure is curved in a such way that the body part to be protected is partly surrounded by the protective structure. The curvature of the protective structure in the embodiment inFIG.1affects only one direction, but the curvature can affect many different directions. The protective structure could for example take the form of a hemisphere, a half ellipse or any combination of these. Choosing the correct curvature depends on where the protective structure is to be placed and how the impact forces are to be distributed. The material of the protective structure is rigid, which means that it retains its form during normal use. The shaping of the protective structure provides some elasticity for distributing impact forces.

The protective structure100comprises a mesh structure105and a border frame106. The mesh structure has a multitude of holes107extending from the first surface101to the second surface102. Between the holes are rib structures which function as a frame for the mesh structure. The border frame surrounds the mesh structure at least partly. In this embodiment the border frame is a flat shelf. The border frame serves to support the mesh structure and in some embodiments, it also serves as a platform for fixing the protective structure to a garment or equipment. Also, in some embodiments the border frame can be used for attaching cushioning to the second surface. Some supporting fabric layers can be fixed to the border frame, too. The holes on the mesh structure have some kind of geometrical shape. In this embodiment, holes are circular or elliptical or partly circular or elliptical. Of course, in some embodiments t hey can be rectangular or take some other form. It must be noted that shapes of the holes can vary in different parts of the mesh structure. The border frame delimits the mesh structure in such a way that some of the holes107aare whole and some holes107bare incomplete, namely, they are truncated. In some embodiments the thickness of the border frame is less than the distance between the first surface and the second surface at the edge of the mesh structure.

The edges of the holes107on the mesh structure105have rim structures109extending towards the second surface102from the mesh structure, namely, the rim structures are oriented towards the user when the protective structure100is in use. The rim structure is a wall-like construct and has a top side, an inner side and an outer side. Between the rim structures are channels which can be used, for example, for guiding air currents in the horizontal direction in relation to the protective structure, namely, inside the protective structure. The channels are formed by the sides of the rim structures and the mesh structure, and, more particularly, the outer sides of the rim structures and the lower surfaces of the rib structures (namely a surface of the rib structure that is towards the second surface). The channels are open to the second surface102. The height of the rim structure is the distance from the first surface101to the top side of the rim structure, namely, the height is measured in the hole. The inner side is towards the hole that the rim structure is surrounding. The top sides of the rim structures form at least part of the second surface, namely, the thickness of the mesh structure is the vertical distance from the first surface to the top side of the rim structure. The heights of the rim structures are greater at the middle of the mesh structure compared to the heights of the rim structures at the edge of the mesh structure. This means that the thickness of the mesh structure is greater at the middle of the mesh structure compared to the thickness of the mesh structure at the edge of the mesh structure. The first surface and the second surface have curvature radiuses. In some embodiments one of the curvature radiuses of the second surface is greater than the corresponding curvature radiuses of the first surface. The term ‘corresponding’ means here that they are on top of each other and have the same direction.

In some embodiments the rim structures109are separate from each other. The mesh structure frame (rib structure) between the holes107can be interpreted as a beam having a U-shaped groove. The walls of the groove are rim structures of the two adjacent holes and the bottom of the groove is the rib structure between the two same adjacent holes. These grooves form the channel network in the protective structure. Preferably the protective structure is configured in such a way that there is free space inside the channels when the protective structure is in use.

The rim structures109are continuous at holes107athat do not touch the border frame106, namely, the rim structure completely surrounds the hole. The holes that are delimited by the border frame may have rim structures that end at the point where the edge of the hole meets the border frame.

When the protective structure100is manufactured by injection moulding, the usage of raw material can be minimized compared to a protective structure manufactured by die-cutting. There is always a rather big wastage when pieces of a desired size and form are die-cut from a uniform sheet with die-cut techniques. Injection moulding makes it is also possible to optimize the thickness of the mesh structure105so that sufficient stiffness and strength are achieved with a minimum of material. Injection moulding makes elaborate designs possible and thus shape whole protective structure in the desired way. The mesh structure can thus be as aesthetically pleasing as desired. Suitable materials for injection moulding are all plastic materials as well as plastic materials that are reinforced, for example carbon fibre. The material must naturally be of such a variety that it achieves sufficient hardness after curing. The protective structure can be manufactured from such a plastic grade or such a composite of a plastic and a reinforcing material that are best suited for each application. For enhancing the hardness of the protective structure, the mesh structure and the border frame can be coated with a material containing metallic particles. This prevents cracks and fracture formation. Thus, lighter and softer materials can be used. The best results are achieved when the metallic particles are metallic material having a microstructure which is fine-grained with an average grain size between 2 and 5,000 nm. The coating improves the properties of the protective structure, allowing it to be made lighter.

It must be noted that the protective structure100can be non-symmetrical. For example, the width of the protective structure can be greater near the first end103than near the second end104.

In the embodiment described in theFIG.1the holes107are positioned on the mesh structure105in such a way that they are interleaved to cover as much an area as possible and still keep the frame of the mesh structure solid, namely, the rib structures between holes should not become too narrow. In some embodiments the centre points of three adjacent holes form an equilateral triangle, the sides of which differ from each other in length by 20% at most. The length of the sides may vary because of the shapes of the holes and the geometry (curvature) of the mesh structure.

In some embodiments there is a ventilation hole108between three adjacent hole openings to the channels between the rim structures109. There can be other embodiments in which the ventilation holes are positioned differently in case the holes are placed in some other formation. For example, the centres of the holes may form an equidistant grid and the ventilation holes may be at the middle points of the squares formed by four adjacent holes. There can be ventilation holes in other places as well. For example, in the embodiment of theFIG.1there are also some ventilation holes near the border frame106. The ventilation holes are for lightening the whole protective structure100and for guiding air currents in the channels.

The mesh structure105forms a cell-like structure having a large open surface. The large open surface contributes to making the protective structure100lightweight. In some embodiments the rib structures can be dimensioned so that the width of the rib structures in the direction of the surface of the support structure is smaller than the height of the rim structure109. By varying the height of the rim structures, it is possible to regulate the stiffness and rigidity of the protective structure in the direction perpendicular to the surface of the protective structure. On the other hand, the rib structure can be kept narrow in the direction of the surface of the protective structure in order to achieve a large open area. Also, a large open area makes the air permeability of the protective structure especially high. In some embodiments the open surface area of the mesh structure is at least 60% of the total area of the mesh structure. The open area comprises both the holes107and the ventilation holes108. Of course, the open area may be even larger, but this is the smallest limit, and below that the protective structure100becomes heavy and sweaty in use.

The protective structure100can thus on the other hand be made light, but still stiff and rigid enough. The stiffness of the protective structure can be regulated also by changing the size of the mesh structure105.

The amount of material used in the mesh structure105can be optimized in relation to the stiffness by varying the thickness of the mesh structure in a direction perpendicular to the first surface101formed by the mesh structure so that the material thickness is greater at the middle of the mesh structure compared to the thickness at the edges of the mesh structure. More material can be concentrated in those parts of the mesh structure where the benefit in relation to the stiffness is the greatest. By concentrating more material in the middle of the mesh structure the middle part of the mesh structure will become stiffer and the edges more flexible. In consequence, the middle part of the mesh structure can withstand impacts and transfer impact energy to the edges of the protective structure100more efficiently. The more flexible edge parts of the protective structure also contribute to the suitability of the protective structure in some equipment, and improving user comfort. The rim structures109can be applied for improving the aforementioned.

In some embodiments the diameters of the holes107apositioned wholly in the mesh structure are between 2 and 7 cm, namely, they constitute the holes that are not delimited by the border frame106. If the diameters are larger, namely, the holes are bigger, the projectiles may penetrate the protective structure100. These impacts may be, for example, strikes by hockey pucks.

FIG.2depicts the protective structure100presented inFIG.1as seen from the direction of the second end104. The protective structure has a longitudinal axis on the first surface from the middle point of the second end to the middle point of the first end. The protective structure is curved in such a way that if the longitudinal axis is considered as the top of the protective structure, the edges of the protective structure parallel to the longitudinal axis are lower than the longitudinal axis. The thickness of the border frame106is less than the distance between the first surface and the second surface at the edge of the mesh structure. In some embodiments there may be a step at the edge of the mesh structure105.

FIG.3depicts a second embodiment of a protective structure300having a first surface301and a second surface and the first end303and the second end304. The protective structure comprises a mesh structure305and a border frame306. The mesh structure has a multitude of holes307extending from the first surface301to the second surface. Between the holes are rib structures which function as a frame of the mesh structure. On the mesh structure between adjacent holes307are ventilation holes308.

FIG.4depicts the protective structure300presented inFIG.3as seen from the side. The outermost point of the mesh structure305sets a top level that is parallel to the longitudinal axis between the first end and the second end. The border frame306curves upwards (i.e. towards the top level of the protective structure) at the first end303and at the second end304. This kind of design ensures an ideal anatomical fit for the protective structure.

FIG.5depicts a third embodiment of a protective structure500having a first surface501and a second surface502and the first end503and the second end504. The protective structure comprises a mesh structure505and a border frame506. The mesh structure has a multitude of holes507extending from the first surface501to the second surface. Between the holes are rib structures that form the frame of the mesh structure, and one surface of the rib structures forms the outer surface of the protective structure, i.e. the first surface501. The other surface of the rib structures is towards the second surface. The protective structure is slightly curved. The middle point, namely the top point of the mesh structure is located higher than the border frame (namely the top point is vertically farthest from the border frame plane). Even the slightly outward (namely the direction away from the user of the protective structure when the protective structure is in use) curvature of the mesh structure is beneficial, because a curved structure spreads impact forces more efficiently than a flat surface.

FIG.6depicts the protective structure500presented inFIG.5as seen from below, namely from the direction of the second surface502. The holes507are surrounded by rim structures509. The rim structures are wall-like structures, and they extend towards the second surface. The rim structures have inner sides that are towards the centre of the hole, the outer sides and the top sides. The top sides of the rim structures form at least part of the second surface502. It must be noted that the second surface is partly virtual, namely there is no continuous material surface that would form the second surface.

Between the rim structures509are channels510. The channels forms passages that are delimited by the rim structures (the outer sides of the rim structures), the surfaces of the rib structures which are towards the second surface and the second surface502(i.e., the plane between the top sides of the adjacent rim structures). At the edges of the mesh structure505, the border frame506delimits the channel network. In some embodiments there may be some openings or grooves in the border frame that connect outer areas to the channels when the protective structure500is in use. There are ventilation holes508on the rib structures connecting the channel to the first surface501. In this example the ventilation holes are situated between three adjacent holes507the centre points of which form a triangle. The ventilation holes serve to enhance air circulation. Also, they further decrease the total weight of the protective structure500. Furthermore, careful positioning and shaping the ventilation holes allows for guiding and spreading the stress and impact forces of a strike on the protective structure. Also, the ventilation holes improve elasticity of the protective structure and prevent shearing forces on the rib structures.

FIG.7depicts a fourth embodiment of a protective structure700as seen from below, namely from the direction of the second surface702. The protective structure comprises a mesh structure705and a border frame706. In the mesh structure are a multitude of holes707. There are rim structures709which circle the holes in the mesh structure and channels710between the rim structures. The rim structure comprises an inner side713, an outer side714, and a top side712. In this embodiment there is a collar structure711on the inner wall of the rim structure. The collar structure has a first collar surface and a second collar surface that are approximately parallel to the first surface and to the second surface near the collar structure. In addition, the collar structure has a side surface that is parallel to the inner side of the rim structure. The side surface defines the height of the collar structure. The height of the collar structure is less than the height of the rim structure, namely the distance between the first surface and the top side of the rim structure (the second surface). In some cases, the collar structures may serve to increase the stiffness of the outer surface of the mesh structure (namely the first surface). Also, if some form of cushioning is used under the protective structure, namely between the second surface and the user, the collar structures can serve to prevent the cushioning from bulging out of the hole. In some embodiments the collar structure is positioned in such a way that the first collar surface forms a part of the first surface, namely the outer side of the mesh structure705. This means that the diameter of the hole707on the first surface is less than the diameter of the hole on the second surface. In that case the collar structures do not form any steps on the first surface. Naturally, there are embodiments where the collar structures are positioned differently.

FIG.8depicts the protective structure700presented inFIG.7as seen from the side as a cross section. The rim structure709circles the hole707extending downwards, namely towards the second surface702. The collar structure711circles the hole and extends towards the middle point of the hole. Between the rim structures are channels710which form a channel network. The first collar surfaces are parallel and in the same level as the first surface701near the first collar surface. This means that the first surface is continuous, namely there are no sharp angles, and the curvature of the first surface is smooth. It must be noted that the first surface is partly virtual at the holes. In some embodiments the collar structure (the second collar surface) is in the same level as the second surface.

FIG.9depicts a fifth embodiment of a protective structure900. The protective structure has a first surface901and a second surface902. The protective structure comprises a mesh structure905and a border frame906. The protective structure further comprises a cushioning layer912and a supporting fabric layer. The border frame is configured in such a way that the cushioning and the supporting fabric layer can be fixed to the border frame. The fixing can be, for example, done by knitting, stapling, gluing or similar means. In some embodiments the supporting fabric layer is used to stretch the protective structure. In that case the mesh structure is tensioned and the protective structure, in addition to spreading the impact, also recoils from the impacts.

The mesh structure905effectively transfers the energy of an impact to the mesh structure from the firm crossing points of the mesh structure parts into every direction of the protective structure. The mesh structure can also be designed so that some projectile hitting the mesh structure transfers impact energy through the mesh structure into a cushioning layer912underneath the mesh structure. The cushioning could be for example a plastic foam structure or some such. The mesh structure and especially the rim structures will thus penetrate a certain distance into the cushioning whereas the energy of the impact is absorbed into the cushioning.

Some advantageous embodiments of the device according to the invention have been described above. The invention is however not limited to the embodiments described above, but the inventive idea can be applied in numerous ways within the scope of the claims.