Improved protective pads and associated garments for sporting and other uses Field of the invention

[001 ] The present invention relates to protective pads, which can be used in sport and other uses, as well as associated garments for use with such protective pads.

Background of the invention

[002] The playing of sports such as cricket and baseball involve the risk of being hit by a ball during play. There has been a need in the market of protection equipment for sports such as these, for protection systems which do not impede the sportsman, and yet provide protection while playing the game.

[003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[004] The present invention provides a protective pad comprising at least two layers, a first layer which is an open cell microcellular urethane foam adjacent to a second layer being a urethane foam which is of softer characteristics than the first layer.

[005] The at least two layers can be un-bonded or not adhered together.

[006] Alternatively the at least two layers are bonded or adhered together.

[007] The first layer can serve an impact absorbing function.

[008] The second layer can serve the function of being adapted for positioning against a part of a user's body to be protected and provides cushioning.

[009] The first layer can be comprised of urethane foam of similar characteristics to that branded as Poron- XRD.

[010] The second layer can be comprised of urethane foam of similar characteristics to that branded as Poron- 30 series-Very Soft.

[011] The first and second layers can be adhered together by means of a double sided tape. [012] The double sided tape can be comprised of a PET backing and a tackyfied acrylic adhesive.

[013] The double sided tape can have similar characteristics to that branded as

TESA4965 or TESA4964.

[014] A protective pad can have only two layers, with the first layer being of the order of 12 to 14 mm in thickness, but more preferably the first layer is 12.7mm in thickness.

[015] In a two layer pad the second layer can be of the order of 5mm to 10mm in thickness, but more preferably the second layer is 6.35mm in thickness.

[016] The protective pad can include a third layer adhered to the first layer on the side opposite to where the second layer is adhered.

[017] The third layer can be an ultra-high molecular-weight polyethylene or a high density polyethylene.

[018] The third layer can serve the function of being shape forming.

[019] For a protective pad where there are more than 2 layers, the first layer can be of the order of 3mm or 4mm to 8mm in thickness, and more preferably the first layer is 3mm to 6mm in thickness.

[020] For a protective pad where there are more than 2 layers, the second layer can be of the order of 4mm to 9.5mm in thickness, and more preferably the second layer is 6.35mm or 9.5mmin thickness.

[021 ] The third layer can be of the order of 2mm to 5mm in thickness, and more preferably the third layer is 3mm in thickness.

[022] The third layer can be adhere to the first layer by double sided tape, which can have a PET backing and a tackyfied acrylic adhesive, and or have similar characteristics to that branded as TESA4965 or TESA4964.

[023] The protective pad can include a fourth layer adhered to the third layer, on the side opposite to where the first layer is adhered.

[024] The fourth layer serves an impact absorbing function and be comprised of urethane foam of similar characteristics to that branded as Poron- XRD. [025] The fourth layer can be of the order of 2mm to 5mm in thickness and more preferably the fourth layer is 3mm in thickness.

[026] The protective pad can have three layers, with the first layer being of the order of 3 mm in thickness, the second layer is of the order of 9.5mm, with a third layer, between the first and second layers being of the order of 3mm. The third layer can be of ultra high molecular weight polyethylene or high density polyethylene.

[027] The present invention also provides a garment holding at least one protective pad as described above.

[028] The garment can includes at least one pocket to hold at least one protective pad.

[029] A single pocket can be provided for a respective protective pad.

[030] The least one pocket can includes a zipper or hook&loop means to selectively close or open the pocket.

[031 ] The garment can be manufactured from a fabric including liquid titanium

PET.

[032] The garment can also manufactured from a fabric including spandex, lycra or elastane.

[033] The garment can have liquid titanium PET present in the order of 80% to

90% of the composition of the fabric.

[034] The garment can have spandex, lycra or elastane present in the order of

10% to 20% of the composition of the fabric.

[035] The garment can also a 50+ ultraviolet protection factor or UPF rating.

[036] The garment and the pocket can assist in keeping the protective pad close to the skin of a wearer.

[037] The garment and the pocket can assist in maintaining the shape of the protective pad.

Brief description of the drawings

[038] A detailed description of a preferred embodiment will follow, by way of example only, with reference to the accompanying figures of the drawings, in which: [039] Fig.1 illustrates an enlarged schematic cross section of a two layer material for a protective pad;

[040] Fig.2 illustrates an enlarged schematic cross section of a four layer material for a protective pad;

[041 ] Fig.3 illustrates a front view of a wearer of a garment with pockets for the protective pad, indicating where Fig.4 detailed view is located;

[042] Fig.4 illustrates a front detail view of a torso and its protective pad;

[043] Fig.5 illustrates an angled view of the torso and its protective pad of Fig.4;

[044] Fig.6 illustrates a side view of the torso and protective pad of Figs 4 and 5;

[045] Fig.7 illustrates a front view of a wearer of a garment with pockets for the protective pad, indicating where Fig.8 detailed view is located;

[046] Fig.8 illustrates a front detail view of an upper thigh and its protective pad;

[047] Fig.9 illustrates an angled view of the upper thigh and its protective pad of

Fig.8;

[048] Fig.10 illustrates a side view of the upper thigh and protective pad of Figs

8 and 9;

[049] Fig.1 1 illustrates a front view of a wearer of a garment with pockets for the protective pad, indicating where Fig.12 detailed view is located;

[050] Fig.12 illustrates a front detail view of an upper and lower thigh and its protective pad;

[051 ] Fig.13 illustrates an angled view of the upper and lower thigh and its protective pad of Fig.12;

[052] Fig.14 illustrates a side view of the upper and lower thigh and protective pad of Figs 12 and 13;

[053] Fig.15 illustrates a front view of a wearer of a garment with pockets for the protective pad, indicating where Fig.16 detailed view is located;

[054] Fig.16 illustrates a front detail view of a lower arm and its protective pad;

[055] Fig.17 illustrates an angled view of the lower arm and its protective pad of

Fig.16; [056] Fig.18 illustrates a side view of the lower arm and protective pad of Figs

16 and 17;

[057] Fig.19 illustrates a cross section through a two layer pad system, where the pads are not bonded or adhered together;

[058] Fig.20 illustrates a cross section through a four layer pad system, where the pads are not bonded or adhered together;

[059] Fig.21 illustrates a detailed front view of the chest pocket on the upper garment which is on the external side or outboard side of the garment;

[060] Fig.22 illustrates a view down a lower garment, showing a thigh pocket which is on an internal side or inboard side of the garment;

[061 ] Fig.23 illustrates an enlarged schematic cross section of a four layer material for a protective pad;

[062] Fig.24 illustrates an enlarged schematic cross section of a three layer material for a protective pad;

[063] Table 1 - physical properties of Poron XRD urethane foam;

[064] Table 2- physical properties of Poron 4701 -30 very soft-unsupported urethane foam.

Detailed description of the embodiment or embodiments

[065] In general terms, and as Illustrated in Figs 1 and 2, 19 and 20, 23 and 24, there are protective pads 1 ,1 ',1 ", and 1 '", which each comprise at least two layers 10 and 14. An outboard layer when in use, or first layer 10 is an open cell microcellular urethane foam, which is adjacent to an inboard layer when in use, and is meant to be placed adjacent to the user's body, is a second layer 14 also being a urethane foam, but which is of softer characteristics than the first layer 10. The open cell microcellular urethane foam, and also be microporous in nature.

[066] The layers 10 and 14 of the protective pads 1 ", and Γ" are not bonded or adhered together, but can be located as a pad system in the appropriate arrangement in pockets of a garment or attached to the garment. Whereas the pads 1 and 1 ' and that of Figs 23 and 24 are bonded or adhered together into a single pad system of several layers which can then be positioned in a pocket or otherwise attached to a garment. [067] The first layer 10 serves an impact absorbing function, while the second layer serves the function of being positioned, directly or indirectly, against a part of a user's body to be protected. By the term "directly", it is meant that the second layer 14 can be in direct contact with the wearer's skin. Whereas by the term "indirectly' is meant that the pad material can sandwich a layer of cloth or garment between the wearer's skin and the second layer 14, such as by a garment having a pocket, as is described below.

[068] The first layer 10 is comprised of urethane foam of similar characteristics to that branded as Poron- XRD, and is of a density of 240 kgs per metre cubed. For details of the characteristics of this material reference is made to Table 1 on sheet 8/9 of the drawings- see also http://www.xrd.tech/documents/2826/XRD-Standard-Physical- Properties.aspx.

[069] The second layer 14 is comprised of urethane foam of similar characteristics to that branded as Poron- 4701 -30 series-very soft and unsupported, and is of a density of 240 kgs per metre cubed. For details of the characteristics of this material reference is made to Table 2 on sheet 9/9 of the drawings -see also https://www.rogerscorp.com/documents/4372/ems/poron/industri al/PORON-4701 -30- Very-Soft-Global-Standards-Data-Sheet.pdf.

[070] For correct interpretation of Figs 1 and 2 (and Figs 23 and 24), the upper and lower lines 13 simply indicate the upper and lower, or inner and outer surfaces of the respective layers. The lines 13 do not indicate an additional layer of double sided tape even though the lines 12 and 13 are of similar thickness and line-weight. Whereas in Figs19 and 20, much thinner or no lines are present in the upper and lower levels of the pad system.

[071 ] In the pads 1 and 1 ' of Figs 1 and 2, the first layer 10 and second layer 14 are adhered together by means of a double sided tape layer 12, such as a self-adhesive double sided tape. The double sided tape is preferably one which has a PET backing and a tackyfied acrylic adhesive. For this purpose, it has been found that one branded TESA4965 or TESA4964, which is 205 micrometres in thickness, and is a double sided transparent filmic tape, suits the purpose well, as it readily copes with environments where there is heavy stress and or high temperatures and or critical substrates. Thus a double sided adhesive tape with similar characteristics to that branded as TESA4965 or TESA4964, is preferred. [072] As illustrated in Fig.1 , the protective pad 1 has only two layers, with the first layer 10 as described above, being of the order of 12 to 14 mm in thickness, but more preferably the first layer 10 is 12.7mm in thickness. Whereas the second layer 14 is of the order of 5mm to 10mm in thickness, but in the embodiment illustrated the second layer 14 is 6.35mm in thickness.

[073] As illustrated in Fig.2, the protective pad 1 ' has a third layer 16 adhered to the first layer 10 on the side opposite to where the second layer 14 is adhered. The third layer is a layer of UHMWPE or ultra-high molecular-weight polyethylene (or alternatively it can be a High Density Polyethylene(HDPE)), and is positioned at this location, for a multiple of purposes, including the function of being shape forming. The third layer is preferably able to be "cold moulded", that is have forces and deformations applied to it so that it adopts a particular shape, such a curved shape so as to more appropriately match the shape of the body part against which the pad V might be used. Such cold forming can be accomplished by passing the completed pad 1 ' (whether with three or four layers) through a roller bending machine, such as a three roller machine.

[074] Ultra High Molecular Weight Polyethylene (UHMW, UHMWPE) or HDPE is chosen for the third layer 16 because they are a thermoplastic characterised by long molecular chains and high resistance to cut, wear and chemical corrosion. UHMWPE and HDPE have extremely long molecular chains, with a high or ultra-high molecular weight, give it the ability to withstand high impact and extreme load. It strength and durability are especially important

[075] Another function of this third layer 16 include a force dissipation layer whereby contact with the pad 1 ' by a ball, will have the force dissipated over a wider area. This works synergistically with the underlying impact absorbing first layer 10.

[076] As illustrated in Fig.2 the first layer 10 is of the order of 4mm to 8mm in thickness, and in respect of the embodiment illustrated, the first layer is 6mm in thickness. Whereas the second layer 14 is of the order of 4mm to 8mm in thickness, and in respect of the embodiment illustrated, the second layer is 6.35mm in thickness. The third layer 16 is of the order of 2mm to 5mm in thickness, and in respect of the embodiment illustrated, the third layer is 3mm in thickness.

[077] The third layer 16 is adhered to the first layer 10 by a double sided tape layer 12, which is of the type as described above with respect to the first mentioned layer 12. [078] In Fig.2, the protective pad V has a fourth layer 18 adhered to the third layer 16, on the side opposite to where the first layer 10 is adhered. The fourth layer 18 also serves, like first layer 10, an impact absorbing function and be comprised of the same urethane foam as is the first layer 1 0. The fourth layer 18 is of the order of 2mm to 5mm in thickness, and in respect of the embodiment illustrated, the fourth layer is 3mm in thickness.

[079] The third layer 16 being of a generally "hard" layer compared to the fourth layer, is best not left as the outboard layer, because in games such as cricket, contact with third layer 16 by a ball, may be mistaken as a "snick" or a bat contact noise. To prevent this the fourth layer 18 also serves the function of "deadening" the sound that would otherwise occur should a ball contact the third layer.

[080] The pads 1 " and 1 "' of Figs 19 and 20, are pad systems similar to that of

Figs 1 and 2, and are comprised of the same layers and materials in the same layer order or arrangement, except that the pads 1 " and 1 "' do not have their respective layers adhered or bonded together. Instead they are positioned adjacent to each other in the system as illustrated in Figs 19 and 20, and as they are inserted in this fashion into a pocket, they will function in much the same way as the respective pads 1 and 1 '.A fifth and sixth embodiment of a pad or pad system, which will be constructed in the same manner and as illustrated in Fig 1 or 19, that is one being where the layers are adhered or bonded, and the other where there is no bonding or joining. The fifth and sixth embodiments are each comprised of two layers, the first layer 10 being a 12.7mm impact absorbing layer comprised of Poron-XRD material (being of Poron product code PORXRDMA-15500-65) like that described above, but in this embodiment, the second layer 14 is a 9.53mm cushioning layer comprised of Poron 30 Series material (Poron Product code 4701 -30-15375). It is expected that this combination of layers will give up to approximately 95% of performance of the four layer pad 1 ' or 1 '" in absorbing high velocity impacts. Such a pad is expected to withstand high velocity impact but is 20%lighter than the four layer pad or pad system V or V" . This pad is also expected to be more flexible, providing greater comfort and would be best used in short "intense" competitions like 20/20 cricket, notwithstanding that it is expected that it will stand up to longer and less "intense competitions, such as test cricket.

[081 ] As illustrated in Figs 3 to 18, garments, in the form of an upper garment 20 and a lower garment 30, and a sleeve garment 40 each of which hold, at various locations, at least one protective pad as described above. It will be understood that these can be combined into a single garment if desire for example upper and lower combined, or upper and lower and sleeves, or upper and sleeves.)

[082] The garments 20, 30 and 40, will generally be an undergarment for sports players, but could also be outer garments, for example, for sports players or if used with or by the elderly.

[083] The upper garment 20 has a pocket 21 to receive a chest pad, the garment 30 has pockets 31 , 32 to respectively receive an upper thigh pad and a thigh pad, while the sleeve 40 has a pocket 41 to hold a lower arm pad. Thus each pocket holds at least one protective pad 1 , 1 ' or pad system 1 " or V". If desired a pocket can hold more than one pad, but with the increased effectiveness of the pads 1 or 1 ', it is expected that single pocket only need be provided for a respective protective pad 1 or r.

[084] The pocket 21 for example, has a zipper means 21 .1 or hook & loop means such as that sold under the Velcro brand, to selectively close or open the pocket 21 to insert the pad 1 or 1 ' or pad system 1 " or 1 "', or to take out the protective pad 1 or V or pad system 1 " or 1 "'.

[085] The garment or garments 20, 30 and 40 can be manufactured from a material or fabric sold under the brand name SUPER-TEX Q:7L0201 S (see: http://www.stretchtex.com.au/products-swimwear.html). This material is normally used for swimwear, and is generally described as a polyester elastane fabric which is good for sublimation printing. The characteristics of this material is that it is manufactured from a fabric which includes 84% liquid titanium PET which has a wicking finish, and 16% spandex material, also known as lycra or elastane. It also provide a UPF of 50+.

[086] The garment or garments 20, 30 and 40 can include liquid titanium PET present in the order of 80% to 90% of the composition of the fabric, with the remaining 10% to 20%) of the composition of the fabric being spandex or similar.

[087] Having a 50+ ultraviolet protection factor or UPF rating provides the garment 20 or 30 with protection from UV radiation while playing their sport.

[088] The garments 20, 30 or 40 and their respective pockets 21 , 31 , 32 and 41 assist in keeping the protective pad 1 or 1 ' 1 or 1 ' or pad system 1 " or 1 "', close to the skin of a wearer. The elastic nature of the material of the garment , due to the presence of spandex, assists in this functionality

[089] The garment 20, 30 or 40 and their respective pockets 21 , 31 , 32 and 40 can also assist in maintaining the shape of the protective pad V or the third layer in pad system 1 "', which has had its shape cold moulded or formed.

[090] In Figs 3 to 6 and 21 , the garment 20 has an external or outboard "chest" pocket 21 to carry a chest pad 1 or 1 ', or pad system 1 " or 1 "' . The shape of the pocket 21 and pad 1 or 1 ' or pad system 1 " or 1 "' is appropriately shaped for the contact sports, and illustrated in Figs 3 to 6 and 21 is a pad for "chest" protection in cricket but also suitable for use in other contact sports like baseball or cricket . This pocket 21 is located on the outside of the garment 29, and preferably is selectively sealed by means of a zip 21 .1 or Velcro or similar, so that the wearer can remove the pad 1 or 1 ' when going in the field. For pockets where there is a lesser risk of bodily interference or the body's movement, such as the lower arm pocket 41 on sleeve 40, this pocket can be an open pocket on the outside of the garment. As illustrated in Fig.22 the lower garment 30, has a thigh pocket 31 , which is located internally or the inboard side of the garment 30.

[091 ] In Figs 7 to 10 and 22 on the garment 30 is an upper thigh pocket 31 and protective pad 1 or 1 ' or pad system 1 " or 1 "', whereas in Figs 1 1 to 14 there is illustrated an upper and lower thigh pocket 32 with protective pad 1 or 1 ' or pad system 1 " or 1 '".

[092] In Figs 15 to 18 is the garment 40 has lower arm pocket 41 and provides the location to hold protective pad 1 or 1 ' or pad system 1 " or 1 "' to protect the wearer's elbow and lower arm region.

[093] The respective pockets 21 , 31 , 32, and 41 are shaped according to the pad 1 or Γ or pad system 1 " or 1 "' that it has to accommodate. This keeps the protective pads, close to the skin of the wearer. If desired, pockets can be located at any desired region of the upper garment 20 or lower garment 30 or sleeve 40. Thus for example for a garment for use by a baseball catcher or umpire, the upper garment20 with sleeves 40 attached to be single garment would be an undergarment, and a pocket for a frontal chest abdomen, shoulders and arms protective pad system would be provided. Alternatively these can be sewn into the garment. [094] In respect of the second layer 14, but also the first layer 10 and fourth layer 18, because they are made from foam which is an open cell microcellular urethane foam, which is also microporous, this allows these foams to be readily combined with antimicrobial protection agents and substances, such as that sold under the brand MICROBAN, which inhibit the growth of bacteria, mould and mildew that would otherwise cause stains, odours and deterioration of the protective pads 1 , Γ or pad system 1 " or 1 "'. Such substances can be infused in the foam at manufacture of the foam.

[095] The whether a four layer protective pad 1 ' or 1 "' or a two layer protective pad 1 or 1 " is utilised, will depend upon the nature and environment of the application or sport. For example, in senior male cricket or baseball, due to the speed at which the ball will travel, protective pads 1 ' or 1 "' will be utilised, whereas for junior male or female competitions, protective pad 1 or 1 " might be worn instead. The pad 1 or 1 " will provide protection against impact of lower speeds, while pad 1 'or V" can be used for expected higher speed impact. In the case of use with elderly persons, if an environment has lots of sharp contact points, then pad 1 ' or 1 " might be used to prevent damage or tearing of skin in addition to protection against impacts, whereas pad 1 or 1 " might be used for protection from impact alone.

[096] While the above describes the use of pockets 21 , 31 ,32, 41 for a user to insert and remove a pad 1 or 1 ' or pad system 1 " or 1 "', there is envisaged embodiments wherein the garments 20, 30 and or 40 have their protective pads 1 or 1 ' or pad system 1 " or 1 "', sown or glued to the inner or outer surfaces of the garment, or permanently stitched into pockets, whether the garment is an under garment or outer garment.

[097] While the above describes thicknesses of the layers of the protective pads

1 and V or pad system 1 " or 1 "', these dimensions have been identified as giving the best balance between the level of protection to be provided, the agility of the user and the additional weight to be carried.

[098] For the second layers 14 of pads or pad systems 1 , 1 ', 1 ", 1 "' which are

6.35mm in thickness, the Poron product code utilised is POR4710-30-1520-04.

[099] For the first layers 10 of pads or pad systems 1 , 1 " which are12.7mm in thickness, the Poron product code utilised is PORXRDMA-15500-65. [0100] For the first layers 10 of pads or pad systems 1 ', 1 "' which are 6mm in thickness, the Poron product code utilised is PORXRDMA-15236, whereas the third layers 18 are 3mm in thickness and the Poron product code utilised is PORXRDMA- 15118-65.

[0101] In the embodiments described above, and illustrated in Figs 1 to 22, the pads detailed have a thickness of the order of 18mm to 19mmm. Whereas there are illustrated in Figs 23 and 24, alternative pad construction embodiments which have a nominal thickness of approximately 15.5mm. This decrease is thickness makes the pads produced more acceptable to sports people, and yet provide a level of protection to give confidence to the user.

[0102] In Fig. 23 pad construction has the layer closest to the user's body being a

6.35mm layer of Poron series 30, like that described above, with the next layer being a 3mm thickness of Poron XRD(also as described above) with the layer 12.1 .0 being an adhesive layer of TESA4965 or TESA4964 double sided tape, or of similar liquid or applied adhesive. The next layer up is another 3mm layer but of UHMWPE or HDPE, bonded by layer 12.1.1 being an adhesive layer of TESA4965 or TESA4964 double sided tape, or of similar liquid or applied adhesive. The layer furthest from the user's body is another 3mm layer of Poron XRD adhered by an adhesive layer 12.1.2 being an adhesive layer of TESA4965 or TESA4964 double sided tape, or of similar liquid or applied adhesive. The overall thickness of this pad construction of Fig. 23 is of the order of 15.35mm.

[0103] In Fig. 24 the pad construction has only 3 layers, with the layer closest to the user's body being a 9.5mm layer of Poron series 30, like that described above in other embodiments, with the next layer being a 3mm thickness of UHMWPE or HDPE, bonded by layer 12.1 .1 being an adhesive layer of TESA4965 or TESA4964 double sided tape, or of similar liquid or applied adhesive. The third or outer layer, being that furthest from the user's body, is another 3mm layer of Poron XRD like that described above in other embodiments, which is adhered by an adhesive layer 12.1.1 being an adhesive layer of TESA4965 or TESA4964 double sided tape, or of similar liquid or applied adhesive. The overall thickness of this pad construction of Fig. 24 is of the order of 15.5mm.

[0104] In Figs 23 and 24, for correct interpretation of these Figs, the upper and lower lines 13 simply indicate the upper and lower, or inner and outer surfaces of the respective layers. The lines 13 are not indicative of an additional layer of double sided tape even though the lines 12 and 1 3 are of similar thickness and line-weight.

[0105] Several sports and applications have been described above, and the list is not and cannot be exhaustive. However to name other sports and applications the following non-exhaustive list is provided: contact sports, mixed martial arts, martial arts generally, cricket, baseball, soft ball, football including round ball games like soccer, American football, Gaelic football, Australian Rules football, rugby league football, rugby football, cycling, hockey, ice hockey, climbing, lacrosse, basketball.

[0106] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[0107] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0108] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.