CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application Ser. No. 63/298,858, titled "CHEST AND SHOULDER PROTECTOR" filed January 12, 2022, incorporated herein by reference in its entirety for all purposes.

FIELD OF THE INVENTION

The invention relates generally to the field of protective gear and materials, and more particularly, an apparel system comprising impact-resistant materials configured to cover at least the chest region when worn.

BACKGROUND OF THE INVENTION

Conventionally, participants in sports (e.g. soccer, martial arts, cricket, football, rugby, baseball, softball, lacrosse, field hockey, etc.) wear protective gear to cushion the force of impacts that are regularly received during those events. In recent years, the dangers of high-force impacts during such contact sports have been a matter of focus. The dangers of these impacts can be diminished or minimized by effectively cushioning participants from the forces of impacts. Accordingly, improved apparel systems comprising impact-resistant materials configured to cover the chest and shoulder regions when worn are required to adequately protect athletes from the dangers of such high-force impacts.

SUMMARY OF THE INVENTION

Aspects of the invention are directed to a chest protector.

In accordance with one aspect of the present invention, an apparel system configured to be worn on a torso of a wearer is disclosed. The apparel system comprises an apparel including an area configured to cover at least a chest region of the wearer when the apparel is worn. The apparel system also includes an impactresistant pad positionable at a location covering the chest region of the wearer when the apparel is worn and the impact-resistant pad has a contour corresponding to the chest region of the wearer. The area of the apparel comprises a pocket and the impactresistant pad is configured to be received within the pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with the accompanying drawings, with like elements having the same reference numerals. When a plurality of similar elements are present, a single reference numeral may be assigned to the plurality of similar elements with a small letter designation referring to specific elements. When referring to the elements collectively or to a non-specific one or more of the elements, the small letter designation may be dropped. According to common practice, the various features of the drawings are not drawn to scale unless otherwise indicated. To the contrary, the dimensions of the various features may be expanded or reduced for clarity. Included in the drawings are the following figures:

FIG. 1 is an image illustrating an exemplary apparel system in accordance with aspects of the present invention.

FIG. 2 is an image illustrating an exemplary impact-resistant pad and exemplary apparel in accordance with aspects of the present invention.

FIG. 3 is an image illustrating impact-resistant pad being coupled to the apparel in accordance with aspects of the present invention.

FIG 4. is a diagram illustrating a cross-sectional view of the impactresistant pad in accordance with aspects of the present invention.

FIG. 5 is an image illustrating an exemplary pouch and an exemplary attachment point of the apparel in accordance with aspects of the present invention.

FIG. 6 is an image illustrating a pair of exemplary straps in accordance with aspects of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The exemplary apparel system disclosed herein is configured to provide improved protection against the force of impacts. The apparel system is suited to be employed as a sole source of protection against the force of impacts, or in combination with other protective pads and/or layering. As used herein, the term "apparel" is intended to encompass any protective gear, clothing, or devices where impact resistance is desired and/or under which impact-resistant materials and pads may generally be employed. As used herein, the term "impact-resistant" is intended to encompass any object that partially or fully lessens, diminishes, dissipates, deflects, or absorbs the force of an impact.

The apparel system comprising exemplary impact-resistant materials described herein is particularly suitable for providing protection against high impact forces caused by projectiles in athletic activities.

While the exemplary embodiments of the invention are described herein with respect to athletic activities, it will be understood that the invention is not so limited. Suitable applications for apparatuses of the present invention include, for example, military gear, police gear, and construction gear. Other suitable applications will be readily understood by one of ordinary skill in the art from the description herein.

Referring now to the drawings, FIG. 1 illustrates an exemplary apparel system in accordance with aspects of the present invention. Apparel system is configured to be worn on a torso of a wearer and provides protection to the wearer against the force of impacts during, for example, athletic activities (e.g., lacrosse). As a general overview, apparel system includes an apparel and an impact-resistant pad configured to be coupled and/or releasably attached to the apparel. Additional details regarding apparel system are described herein.

The apparel system is configured to be worn on the wearer's torso. For one example, apparel system may be shaped or contoured in order to correspond to a portion of the anatomy of the wearer. In an exemplary embodiment, apparel system includes the apparel comprising an area configured to cover at least a chest region of the wearer when the apparel is worn. Additionally, the area may further cover at least the chest and shoulder regions of the wearer when the apparel is worn. For example, apparel may comprise fabric and may be configured as a shirt. The area of apparel may further comprise a pocket configured to receive the impact-resistant pad in a chest region of the wearer, and/or shoulder channels configured to receive portions of the impact-resistant pad in a shoulder region of the wearer (further discussed below).

Turning now to FIGS. 2 and 3, the apparel system further includes a protective element configured to be worn by a wearer, such as the impact- resista nt pad. The impact- resista nt pad is configured to be coupled to the apparel. For example, the impact-resistant pad may be releasably attached to the apparel. In particular, the impact-resistant pad is configured to be coupled to the apparel at a location covering at least the chest region of the wearer when the apparel is worn. The impact-resistant pad may be limited to covering only the wearer's chest when the apparel is worn or it may additionally may cover the wearer's shoulders.

The geometry of the impact-resistant pad may be selected to correspond to a portion of the anatomy of the wearer, such as the chest region and/or shoulder region of the wearer. To cover the chest region and/or shoulder region of the wearer when the apparel is worn, the impact-resistant pad includes a contour that corresponds to the chest/shoulder region of the wearer when the apparel is worn. For one example, as shown in FIGS. 1 and 2, the impact-resistant pad may have a generally irregular geometry with curved or rounded corners. The impact-resistant pad may further include one or more creases, edges, or narrow channels to assist in contouring to the chest and/or shoulder regions of the wearer.

In particular, it is also desirable that impact-resistant pad has an area that is sufficiently large to cover the chest region of the wearer's chest for providing protection against force of impacts during athletic activities (e.g., lacrosse). In one exemplary embodiment, impact-resistant pad has an area that is sufficiently large for providing protection against a force of impact toward at least the chest region of the wearer. However, the impact-resistant pad may still be limited in dimensions (area) to a range that provides protection against high impact forces without being overly large to enable comfort, flexibility, and ease of movement during athletic activities.

The ability to protect against the force of impacts is of paramount importance in apparel system. Nonetheless, it is also desirable that apparel system be sufficiently thin to enable comfort, flexibility, and ease of movement during athletic activities. To this end, the impact-resistant pad may be limited in thickness to a range that provides protection against high impact forces without being overly thick.

Turning now to FIG. 4, the impact-resistant pad comprise impactresistant material facing at least the chest region of the wearer when the apparel is worn. Providing a layer of impact-resistant material covering the wearer's chest region desirably reduces or eliminates the risk of high-force impacts to a wearer taking part in an athletic activity (e.g., lacrosse).

Impact-resistant material may consist solely of first elastomer layer 110, second elastomer layer 120, high-tensile strength fibrous material layer 130, and polymer layer 140, or may comprise additional layers of impact-resistant material. Other suitable impact-resistant material layers will be known to one of ordinary skill in the art, and include for example, additional elastomer or high-tensile strength fibrous material layers.

The layers of impact-resistant material are desirably arranged in a particular order in order to optimally dissipate the force of impacts to the wearer of apparel system. In an exemplary embodiment, the first and second elastomer layers 110 and 120 are positioned on one side (e.g., an inner side) of impact-resistant material 100, and high-tensile strength fibrous material layer 130 and polymer layer 140 are positioned on the other side (e.g., an outer side) of impact-resistant material.

In a preferred embodiment, impact-resistant material 100 is arranged in the order shown in FIG. 4. In other words, first elastomer layer 110 is arranged directly adjacent second elastomer layer 120, second elastomer layer 120 is arranged directly adjacent high-tensile strength fibrous material layer 130, and high-tensile strength fibrous material layer is arranged directly adjacent polymer layer 140. In this embodiment, first elastomer layer 110 is the innermost layer of the impact-resistant pad, such that elastomer layer 110 is arranged directly adjacent the wearer when apparel system is worn by the wearer. More preferably, first elastomer layer 110 has a density sufficiently low to enable it to mold to a shape of the wearer when apparel system is worn by the wearer. Such molding may desirably increase the comfort and stability during use of apparel system.

First elastomer layer 110 has a first density. The first density is preferably low enough to provide comfort and contouring to a wearer, while high enough to provide some dissipation of the force of impacts. In an exemplary embodiment, first elastomer layer 110 has a density of at least 6 lbs. per cubic foot. In a preferred embodiment, first elastomer layer 110 has a density of at least 6 lbs. per cubic foot, and no more than 29 lbs. per cubic foot. In a more preferred embodiment, first elastomer layer 110 has a density of around approximately 9 lbs. per cubic foot.

Suitable elastomer materials for use in forming first elastomer layer 110 generally include, but are not limited to, urethane rubbers, silicone rubbers, nitrile rubbers, butyl rubbers, acrylic rubbers, natural rubbers, styrene-butadiene rubbers, and the like. Other suitable elastomers will be known to one of ordinary skill in the art from the description herein. In general, any suitable elastomer material can be used to form first elastomer layer 110 without departing from the scope of the present invention. Elastomer material may provide impact-resistance by absorbing and/or dissipating the forces of impacts along the surface of the elastomeric material.

In an exemplary embodiment, first elastomer layer comprises a layer of closed cell, low density soft elastomeric foam. In a preferred embodiment, first elastomer layer comprises a layer of AIRILON® padding material, provided by Unequal Technologies Company, of Glen Mills, Pennsylvania, USA.

Second elastomer layer 120 has a second density which is higher than the first density of first elastomer layer 110. The second density is preferably high enough to substantially maintain its structure during impacts, and avoid "bottoming out" (i.e., reaching full compression) during impacts regularly received during athletic activities. Second elastomer layer 120 may provide exception impact-resistance via a "hysteretic damping" mechanism that dissipates impact force by converting impact energy into heat. In an exemplary embodiment, second elastomer layer 120 has a density of at least 30 lbs. per cubic foot. In a preferred embodiment, second elastomer layer 120 has a density of at least 30 lbs. per cubic foot, and no more than 50 lbs. per cubic foot. In a more preferred embodiment, second elastomer layer 120 has a density of around approximately 32 lbs. per cubic foot.

Suitable elastomer materials for use in forming second elastomer layer 120 generally include any of the types of materials recited above with respect to first elastomer layer 110. In an exemplary embodiment, second elastomer layer comprises a layer of closed cell, high density elastomeric foam. In a preferred embodiment, first elastomer layer comprises a layer of ACCELLERON® padding material, provided by Unequal Technologies Company, of Glen Mills, Pennsylvania, USA.

Layer 130 comprises high-tensile strength fibrous material. The high- tensile strength fibers are configured to dissipate the energy of an impact along the length of the fibers, thus spreading out the force along the entire surface of impactresistant material 100.

Suitable high-tensile strength fibrous materials include, but are not limited to, aramid fibers, para-aramid or synthetic fibers, fiberglass, or other high- tensile strength fibers. Other suitable high-tensile strength fiber materials will be known to one of ordinary skill in the art from the description herein.

In an exemplary embodiment, layer 130 comprises a layer of elastomeric coated aramid fibers. In a preferred embodiment, layer 130 comprises a layer of TRIDUR® padding material, provided by Unequal Technologies Company, of Glen Mills, Pennsylvania, USA. Alternatively, the fibers used could be KEVLAR® material, provided by E.I. du Pont de Nemours and Company, of Wilmington, Delaware, USA.

The high-tensile strength fibers of layer 130 may be coated with one or more substances. In an exemplary embodiment, the high-tensile strength fibers 130 are coated with a polymer material. The polymer material may be the same as or different from the polymer material of polymer layer 140. In a preferred embodiment, the polymer material coating high-tensile strength fibrous material layer 130 may be part of polymer layer 140. In an alternative embodiment, the polymer material coating high-tensile strength fibrous material layer 130 is separate from polymer layer 140.

Polymer layer 140 comprises a polymer material. Polymer layer 140 may consist of a single layer of polymer material, or may comprise a plurality of layers of polymer material formed one on top of the other. The polymer material of polymer layer 140 blocks and redirects the energy from impacts laterally along the surface of polymer layer 140.

Suitable polymer materials for use in forming polymer layer 140 generally include natural or synthetic polymers, such as polypropylene, polyethylene, polystyrene, polyvinyl chloride, nylon, etc. Other suitable polymers will be known to one of ordinary skill in the art from the description herein. In an exemplary embodiment, polymer layer 140 comprises multiple layers of polypropylene. In a preferred embodiment, polymer layer 140 comprises a layer of IMPACSHIELD® padding material, provided by Unequal Technologies Company, of Glen Mills, Pennsylvania, USA.

As stated above, the ability to dissipate the force of impacts is of paramount importance in apparel system comprising the impact-resistant pad. Nonetheless, it is also desirable that impact-resistant pad be sufficiently thin to enable comfort, flexibility, and ease of movement during athletic activities. To this end, the layers of impact-resistant material may be limited in thickness to a range that provides adequate impact-resistance without being overly thick. In an exemplary embodiment, first elastomer layer 110 and second elastomer layer 120 each have a total thickness from 6.0 mm to 12.0 mm. In a more preferred embodiment, first elastomer layer 110 and second elastomer layer 120 each have a total thickness from 8.0 mm to 10 mm. In an exemplary embodiment, high- tensile strength fibrous material layer 130 has a total thickness from 1 to 2 mm. In an exemplary embodiment, polymer layer 140 has a total thickness (including all layers thereof) from 0.2 mm to 1.0 mm. In a more preferred embodiment, polymer layer 140 has total thickness from 0.3 mm to 0.7 mm. In view of the embodiments above, it is desirable that impact-resistant material 100 have a total thickness of no more than 25.0 mm. The total system (110, 120, 130 and 140 combined) preferably ranges from a minimum of 12.5mm to a maximum thickness of 25mm based on the desired level of protection. The remaining components of impact- resista nt pad may or may not substantially increase the thickness of impact-resistant pad beyond the thickness of impact-resistant material.

Impact-resistant pad is not limited to the above-described components, but may include alternative or additional components, as would be understood by one of ordinary skill in the art from the description herein.

In one embodiment, impact-resistant pad further includes a fabric material 50 surrounding the impact-resistant material. Fabric material 50 collectively surrounds first elastomer layer 110, second elastomer layer 120, high-tensile strength fibrous material layer 130, and polymer layer 140. Fabric material 50 may be provided to increase the comfort and/or aesthetic appearance of the impact-resistant pad. Additionally, fabric material 50 may be provided in order to facilitate coupling the impact-resistant pad to the wearer. For example, fabric material 50 may accommodate impact- resista nt material while providing a connection point (discussed further below) for securing the impact-resistant pad to the wearer.

While impact-resistant pad is described herein as comprising two elastomer layers, it will be understood from the description herein that the invention is not so limited. To the contrary, impact-resistant pad may include three or more elastomer layers of varying densities. Where three or more elastomer layers are included, it may be desirable that the elastomer layers each have a different density, to provide a different profile of impact dissipation. It may further be desirable to arrange the three or more elastomer layers in order of their densities, e.g., from lowest density to highest density (in a direction moving away from the wearer). This may assist in achieving the goals of impact dissipation and comfort encompassed by aspects of the present invention. Additionally, while impact-resistant pad is described herein as comprising polymer layer 140, it will be understood from the description herein that in some embodiments, polymer layer 140 may be omitted. In particular, where high-tensile strength fibrous material layer 130 comprises a layer of coated fibers, polymer layer 140 may be unnecessary, and may be omitted.

Referring now to FIGS. 5 and 6, the impact-resistant pad may be releasably attached to the apparel via attachment means. In one exemplary embodiment, fabric material 50 of the impact- resista nt pad may provide at least one attachment or connection point for securing the impact-resistant pad to the wearer. The attachment or connection point may be located adjacent to the shoulders of the wearer when the apparel is worn, e.g. on top of the shoulder region, directly in front of the shoulder region, or directly behind the shoulder region (as shown in FIG. 5), thereby minimizing or limiting the movement of the impact-resistant pad relative to the wearer when the apparel system is worn during an athletic activity, for example. Still further, the attachment or connection point may include at least one channel (FIG. 5) located at a region covering the shoulder region of the wearer, such that the impactresistant pad may be secured to the wearer by allowing a portion of the impactresistant pad to encircle the wearer's neck. As best shown in FIGS. 2 and 3, the apparel may include a pair of channels extending from and in communication with the pocket in the chest region of the wearer, and extending over each shoulder of the wearer, to form a single, combined region in which the impact-resistant pad can be received and held.

The attachment or connection point (e.g. channel or pocket) provided by the apparel corresponds to a matching attachment or connection point of the impactresistant pad. In an exemplary embodiment, the attachment or connection point of the impact-resistant includes at least one strap configured to partially or completely extend over the shoulders of the wearer when the apparel is worn. The at least one strap may be further configured to encircle the wearer's neck (as best shown in FIGS. 2 and 3) for securing the impact-resistant pad to the wearer. In operation, a pair of straps comprise hook-and-loop-type fastener (e.g., Velcro®) that are configured to secure the impactresistant pad to the wearer, such that movement of impact-resistant pad relative to the apparel and ultimately, the wearer is reduced or eliminated. One of ordinary skill in the art would further understand from the description herein that other attachment means, such as adhesives, may be used. When affixed or coupled to the apparel, the impactresistant pad is configured to cover the chest region of the wearer and/or the wearer's abdomen (as best shown in FIGS. 1 and 2), with impact-resistant material (best shown in Fig. 4) when the apparel is worn. In addition to or alternatively, the impact- resista nt pad may include respective attachment points configured to attach or connect to one another in addition to or in place of connecting to the apparel. The attachment points on the impactresistant pad may attach adjacent to or directly behind the wearer's neck, e.g. by encircling the wearer's neck. Suitable structures for forming attachment points will be known, and include hook and loop fasteners, snaps, bucks, etc.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.