Field of the Invention

A flexible panel, which comprising a layered panel having islands defined therein. Further described is a protective apparel comprising the flexible panel, and a method of manufacture for the flexible panel.

Background to the Invention

The uses for protective apparel and body armour are wide ranging, from a protective vest to protect the chest and body of a user, to protection of smaller areas of the body including elbows, knees or shins. The protective apparel may be used within certain professions, including in the military, police or security services, or may be used in other instances, such as to protect a participant during sports.

Typically, it is desired that the protective apparel is strong and resists abrasion or piercing in order to protect an area of the wearer’s body underneath the protective apparel. Nevertheless, the protective apparel should be lightweight, in order to avoid discomfort and fatiguing of the wearer. Furthermore, flexibility is often sought in protective apparel, in order to accommodate movement by the wearer. This is particularly important where the protective apparel is intended to protect certain joints, such as elbows or knees, which will not be held in a fixed orientation or position during use.

Various types of protective apparel are available within the art. However, each of these options has drawbacks for strength, weight or flexibility (or more than one of these characteristics). Accordingly, there is required an improved protective apparel, and constituent part for protective apparel.

Summary of the Invention

Against this background, there is provided a flexible panel, and a protective apparel comprising said flexible panel. The flexible panel is formed from a layered panel that is particularly lightweight and strong (enabled by a use of self-reinforced polymer layers and a foam layer therebetween). Formation of islands or plates in a surface of the layered panel cause the panel to be particularly flexible at least in certain directions. Suitable choice for the shape and configuration of the islands allows selection of the extent and direction for bending and flexing of the flexible panel.

In a first aspect there is described a flexible panel, comprising: a layered panel, the layered panel comprising: a carrier layer comprising self-reinforced polymer; a substrate layer on the carrier layer; and an overlay layer comprising self-reinforced polymer and covering at least a portion of a surface of the substrate, so that the substrate is arranged between the carrier layer and the overlay layer; wherein the flexible panel comprises a plurality of islands defined in a surface of the layered panel, the plurality of islands defined by at least one cut through the overlay layer and into the substrate of the layered panel.

The flexible panel can be used as a protective panel, being both lightweight and strong. The particular weight and strength properties are provided by the properties of the layered panel, as described in more detail below. Flexibility yet durability is provided because the carrier layer is kept as an intact and continuous layer, whereas the overlay layer is divided into islands or regions, together with at least a portion of the substrate underneath. This allows the flexible panel to be bendable in at least a first direction (in which the outer surface of the carrier layer is concave) upon application of a force, because the islands and the cuts in the overlay layer can move apart slightly providing relief at the opposing, convex surface of the panel. The bending is elastic, meaning the panel will return to being approximately flat when no bending force is applied. However, depending on the nature of the cuts in the panel as discussed below, in some cases when force is applied to the flexible panel in the opposite direction (in which the outer surface of the carrier layer would be convex) very little bending is possible, as the islands do not provide any relief to tension across the carrier layer.

The layered panel is formed as a laminated panel comprising at least a first layer (carrier layer) of self-reinforced polymer, a second layer (overlay layer) of self-reinforced polymer, and a layer of substrate (for instance, foam), the substrate being between the first and second layer of self-reinforced polymer. Self-reinforced polymer, as discussed in more detail below, is a special category of polymers that are both especially strong and pierce resistant but also lightweight. Even thin layers are very resistant to tearing or piercing compared to other materials having comparable weight or thickness. Thus the carrier layer and overlay layer provide strong and durable outer layers at the layered panel. In contrast the foam inner layer is compressible, and thereby able to absorb energy from impacts at the outer layers. The carrier layer and overlay layer of the layered panel are formed from a relatively thin material, having a fabric-like flexibility, whereas the foam is elastic but more rigid, providing shape and structure to the layered panel.

In view of all these characteristics, the layered panel, even before definition of the islands to provide extra flexibility, is a useful material for making protective panels and protective apparel. However, with the further flexibility provided by the island regions defined in the overlay layer and a substrate, the flexible panel overall offers a superior component for a protective apparel.

The islands are formed by cutting into the outward facing surface of the overlay layer of the layered panel. The cuts extend through the overlay layer and into the substrate. In some cases, the cuts may extend through the full depth of the substrate. However, the carrier layer remains continuous and intact and is not cut through. Regions forming the islands and consisting of the substrate and overlay layer could be considered as being mounted on the carrier layer. In some examples, the cut is through the overlay layer and through less than 75% the thickness or depth of the substrate, or may be through the overlay layer and through less than 50% the thickness or depth of the substrate, or may be through the overlay layer and through less than 30% the thickness or depth of the substrate. The depth of the cut through the substrate can modify the curvature of the bend of the flexible panel, wherein deeper cuts allow a greater curvature of the flexible panel in the bendable direction. If the depth of the cut through the substrate is sufficient, the flexible panel may comprise bendable regions or the pivot point of a fold between pairs of islands. For instance, the bendable regions may be arranged at an edge of each one of the plurality of islands.

The cuts may be very narrow, having imperceptible width (for instance, cut by a sharp blade). Alternatively, the cut may comprise a trench through the overlay layer and into the substrate. A trench will be understood to be formed as a crevice, for instance having both width and depth. The greater the width of the trench, the more bendable the flexible panel will be in the direction which causes the outer surface of the carrier layer to be convex, as the width of the trenches can be closed in order to accommodate a bend in the flexible panel in that direction. In some examples, the trench (at its mouth at the top surface of the overlay layer) may have a width of 2mm or less, or of 1 mm or less. As before, the trench may have a depth so that it extends through the overlay layer and through less than 75% the thickness of the substrate, or through the overlay layer and through less than 50% the thickness of the substrate. The trench may be formed by a laser cut, in which some material is ablated.

In some examples, the trench may be v-shaped, having intersecting side surfaces, wherein the side surfaces are arranged at an angle of 120° or less with respect to each other. Use of a v-shaped trench may allow hinged or jointed portions of the flexible panel to be formed. Use of a v-shaped trench, by a suitable choice of angle between the side surfaces, can be used to adapt a curvature of the flexible panel that is possible under a force that would result in a convex outer surface for the carrier layer.

The plurality of islands may be formed as a plurality of tessellating islands. For instance the islands may be formed so that they are juxtaposed edge to edge, covering a at least a portion of a full planar surface of the flexible panel. In some cases, a perforation may be provided through the carrier layer at a point where three or more edges of an island intersect, in order to permit greater bending of the flexible panel (and more specifically the carrier layer).

Each of the plurality of islands may have a polygonal shape. For instance, the polygonal shape may be a simple, convex polygon (and so having sides that do not intersect themselves).

In some examples, the polygonal shape is a regular polygon. This means that the polygon is direct equiangular (all angles are equal in measure) and equilateral (all sides have the same length). Where the flexible panel has islands of regular polygonal shape, the flexible panel has the same propensity and ability to bend across many directions of the plane of the flexible panel.

In some other examples, the polygonal shape is an irregular polygon (for instance, elongate, such as a rectangle), and extends further in a first direction than in a second direction, the first and second direction being in the plane of the carrier layer and perpendicular to each other. Use of islands having an irregular polygon shape causes the flexible panel to have a greater ability to bend (greater curvature) in the second direction than compared to the first direction.

The plurality of islands may be formed having any shape, including but not limited to a triangle, a square, a rectangle, a trapezium, a parallelogram, a pentagon, a hexagon, a heptagon or a octagon. The one or more of the plurality of islands may have a different shape that another of the plurality of islands. However, in most cases the islands will tessellate even if different shapes are used (for instance, a tessellating arrangement of regular pentagons and triangles).

In some cases, the each of the plurality of islands is a strip or band, each strip or band extending across the plane of the layered panel in a first direction. This will allow significant bending or curvature in a direction perpendicular to the first direction, but very little bending or curvature in the first direction. This arrangement of islands can be used to create a cylinder or cone shape from the flexible panel, for instance. An edge extending in the first direction of each of the one or more island strips may be straight or curved, or comprise contours, zig zags or crenellations.

The flexible panel may have a total thickness of between 2 and 15 mm. This is relatively thin compared to panels used within comparable protective apparel in the prior art. As such, the flexible panel can be used to construct protective apparel that is more comfortable and less restrictive. The thickness of the flexible panel can be adjusted by modifying the thickness of any or all of each of the carrier layer, the substrate and the overlay layer. Typically, the carrier layer and the overlay layer is thinner than the substrate layer.

The substrate may be foam. For instance, the substrate may be an expanded polymer foam, or a microcellular polymer foam. Ideally the type of polymer foam substrate will be of the same type of polymer as the self-reinforced polymer, to allow for better adhesion of the layers during formation of the layered structure, and/or to allow easier end of life recycling.

The expanded foam is a closed cell foam but pervious, allowing some air and water to pass therethrough. Therefore, expanded foam may be useful to provide a breathable flexible panel within a protective panel. The expanded foam may be expanded polypropylene, expanded polyethylene, or expanded polystryrene. These materials are particularly versatile, being both elastic and shock proof.

Microcellular foam is a specific type of polymer foam comprising a large number of very small bubbles uniformly distributed therethrough. The small bubbles are created by dissolving a gas under high pressure within liquid or molten polymer material, and then allowing the polymer to cool whilst the gas bubbles are retained. The resulting closed cell foam is a lightweight but relatively rigid material. The microcellular foam is waterproof, and does not allow passage of moisture or air therethrough. However, if a microcellular foam is used as the substrate of the described layered panel then holes can be punched through the substrate layer before formation into the layered panel. Preferably, the microcellular foam is a microcellular polypropylene single polymer composite, a microcellular polyethylene single polymer composite, or a microcellular polyethylene/polypropylene blend.

The foam (of the substrate) may have a thickness of between 2 to 10 mm. The foam (of the substrate) may have a density of between 30 and 70 grams per litre. The thickness and/or density of the foam substrate can be chosen to provide appropriate shock absorption for incorporation of the flexible panel into a protective apparel. This will be weighed against the additional weight of an increased thickness and/or density of the foam substrate. Reducing density increases the flexibility of the substrate layer. The foam substrate acts to provide some structure to the flexible panel, especially compared to the relatively thinner layers of the carrier layer and the overlay layer. By providing structure the substrate helps the flexible panel to hold a particular shape when no bending forces are applied, even though the substrate (and flexible panel) is bendable and elastic under application of force.

In a first form of self-reinforced polymer, sheets or panels of self-reinforced polymer comprise one layer or multiple laminated layers or tapes of a self-reinforced polymer material. For instance, a self-reinforced polymer material may comprise a type of polymer produced from a simple olefin (also called an alkene with the general formula C _n H ₂ n) as a monomer. Thicker or multiple tapes or layers of the self-reinforced polymer material can be laminated to produce a stiffer or more rigid sheet of the material, although fewer or thinner tapes or layers can be used to provide a panel that is more deformable and foldable. Generally, the multiple laminated tapes or layers are consolidated by the application of heat and pressure into the sheet or layer here described as either the carrier layer or the overlay layer.

In a second form of self-reinforced polymer, the self-reinforced polymer could be a self-reinforced polymer woven composite (for example, Dewforge ^RTM by James Dewhurst ^RTM ). In this case, the woven material typically comprises only a single layer as the carrier layer or the overlay layer (although the woven material could itself be laminated). However, the weight and density of the woven material can be varied to increase or decrease the thickness of the self-reinforced polymer net. For example, the self-reinforced polymer woven composite is a self-reinforced polypropylene woven composite or a self-reinforced polyethylene woven composite. A self-reinforced polymer woven composite is a specific type of self-reinforced polymer. Whereas typical self-reinforced polymer sheets are formed from heat and compression of layered tapes of aligned, stretched polymer fibres in the same polymer matrix, the self-reinforced polymer woven composite instead comprises a fabric or sheet formed from woven or interlocking threads or yarns of stretched polymer fibres. Before weaving, the threads or yarns may themselves be formed of multiple strands twisted or braided together. In some cases, the woven or interlocking threads or yarns can be compressed under heat and pressure to form the final self-reinforced polymer woven composite material, in which the interlocking polymer fibres are surrounded by a polymer matrix. Compared to typical self-reinforced polymer sheets formed from layered tapes, the self-reinforced polymer woven composite does not suffer from delamination, and may provide superior resistance to tearing or penetration even when used in thin layers. Moreover, the self-reinforced polymer woven composite has small gaps between the woven fibres, allowing some air flow through the self-reinforced polymer material which can be useful when used in protective apparel. Such gaps tend not to be present in self-reinforced polymer that is not provided as a woven composite. The carrier layer and/or the overlay layer may be formed from either the first or second form of self-reinforced polymer, as described above. The carrier layer and/or the overlay layer may be formed from self-reinforced polypropylene, or from self-reinforced polyethylene. Ideally, each of the carrier layer, the substrate and the overlay layer will be formed from the same type of polymer. This enables mixing and bonding of the different layers at their interfaces, upon application of heat and pressure. Moreover, this allows easier end of life recycling for the flexible panel.

The carrier layer may have a thickness of between 0.2 to 2 mm. A thinner layer may increase flexibility of the panel, but a thicker layer may increase the durability of the flexible panel and may provide slightly more rigidity and structure.

The carrier layer may comprise one to five heated and compressed laminated layers or tapes of self-reinforced polymer (for instance, when the self-reinforced polymer is of the first form, as described above). Increasing the number of laminated layers or tapes increases the thickness of the carrier layer.

The overlay layer may have a thickness of between 0.2 to 2 mm. The overlay layer may particularly function to act as a protective layer for each of the plurality of islands. Moreover, the overlay layer retains a surface tension on the substrate of each island, which improves durability of the flexible panel.

The overlay layer may comprise one to five heated and compressed laminated tapes or layers of self-reinforced polymer (for instance, when the self-reinforced polymer is of the first form, as described above). Increasing the number of laminated tapes or layers increases the thickness of the overlay layer.

The flexible panel may further comprise an opening extending through at least one island of the plurality of islands, the opening passing through the overlay layer, the substrate and the carrier layer. For instance, a hole or aperture may pass through the centre of one or more of the plurality of islands. The hole passes through the entire depth of the flexible panel (including through the carrier layer, the substrate and the overlay layer, and any additional layers). The opening, hole or aperture is provided to allow air flow through the flexible panel. This allows perspiration to pass out of any protective apparel formed from the flexible panel, and/or to allow airflow through the apparel.

Each island may further comprise a liner layer on the outer surface of the overlay layer or on the outer surface of the carrier layer. The liner layer may provide a softer layer. For instance, this is useful if the liner layer is intended to make contact with a wearer’s skin when the flexible panel is incorporated into a protective apparel. The liner layer may be formed from a felt or from another soft material. The liner layer may be made of polymer foam, including the same type of polymer as the overlay layer, the substrate and the carrier layers in order to allow improved bonding and recyclability.

In a second aspect there is a protective apparel, for protecting an area of a wearer’s body, the protective apparel comprising the flexible panel as described above. In particular, the protective apparel is configured to secure the flexible panel over the area of the wearer’s body. The protective apparel, or body armour, may be an item of clothing arranged to protect at least a part of the wearer’s body. The flexible panel forms part of the protective apparel, acting to protect the region of the wearer’s body adjacent or behind the flexible panel. The flexibility of the flexible panel avoids constricting movement for the wearer.

The protective apparel may be for protection of one or more regions of a human body, or one or more regions of an animal body. For instance, the protective apparel may be for use by sports people, for use by military persons, or for use by people in the security services. The protective apparel could be used by working animals, such as police dogs or military horses.

The protective apparel may comprise one or more straps for fastening the flexible panel to the wearer’s body. The straps may include a fastener, such as hook-and-loop fastener, or a strap and buckle, in order to connect straps and secure the protective apparel. For instance, straps may be used to secure an elbow protector or similar around a wearer’s arm and elbow.

The protective apparel may comprise a pocket, the pocket for containing the flexible panel. For instance, the protective apparel may be a protective vest formed from an outer material, in which a pocket is arranged to contain or secure a flexible panel across the chest or back portion of the wearer of the protective vest.

The protective apparel may be a body armour, an armoured vest, a chest protector, an elbow protector, a knee protector, a shin protector, an arm protector, a thigh protector, a leg protector, an abdo guard, a hat or a helmet. The protective apparel may be have an overall shape according to the art, but having at least a portion of the walls of the item of protective apparel formed from the described flexible panel. The flexible panel may from only a portion of the protective apparel, for instance the peak of a cap or helmet.

Within the protective apparel, the flexible panel may be arranged having the overlay layer, or alternatively having the carrier layer, directed towards the wearer’s body. This can be chosen according to the required movement for the wearer and the movement permitted by the configuration of the flexible panel (and islands thereon), as described herein.

In another example, a backpack or rucksack may incorporate a flexible panel as described. In particular, the flexible panel may form part of a backpad in the backpack or rucksack. The flexible panel and its permitted curvature may be configured to bend in a specific direction For instance, perpendicular to the user’s spine in use) but be relatively less bendable in another direction (for instance, parallel to the user’s spine when in use), in order to provide increased comfort and support to the wearer or user of the backpack or rucksack.

In a third aspect, there is a protective apparel, for protecting an area of the wearer’s body, comprising: a carrier layer, formed of self-reinforced polymer; and one or more armour regions mounted on the carrier layer, each armour region comprising a layer of substrate on the carrier layer, and an overlay layer of self-reinforced polymer covering at least a portion of a surface of the substrate. Here, the armour regions may be considered equivalent to the islands in the above described flexible panel in the above-described protective apparel.

In a fourth aspect, there is a method of manufacture of the flexible panel, comprising: forming a layered panel, comprising: arranging a substrate layer on a carrier layer, the carrier layer comprising selfreinforced polymer; arranging an overlay layer to cover at least a portion of a surface of the substrate, so that the substrate is arranged between the carrier layer and the overlay layer, the overlay layer comprising self-reinforced polymer; the method of manufacture further comprising: defining a plurality of islands in a surface of the layered panel by making at least one cut through the overlay layer and into the substrate. In other words, the layered panel is formed first, and the island regions are then defined in the layered panel at the face covered by the overlay layer. It will be understood that any characteristics or attributes of features of the flexible panel described above will also apply to the corresponding features of the flexible panel manufactured according to the method described here.

Forming the layered panel may further comprise fastening together the carrier layer, the substrate layer and the overlay layer. In other words, the layered panel is a laminated panel, in which the layers are connected together. The fastening together may comprise, after arranging the carrier layer, substrate layer and overlay layer, applying heat and pressure to the layered panel. In other words, forming the layered panel further comprises, after arranging the carrier layer, substrate layer and overlay layer, applying heat and pressure to the carrier layer, substrate layer and overlay layer to form a consolidated layer. Heat and pressure causes at least a portion of the polymer material at the carrier layer, substrate and overlay layer to melt to a liquid or malleable form. Said melted polymer portions can flow and mix at the interface between layers, causing a joining or fastening of the layers together. This generates a consolidation of the layers to form a single layered panel (although each layer still retains its individual characteristics).

The one or more cut is a laser cut (in other words, a cut formed by a laser). Laser cutting is very accurate, and can be computer programmed to give specific shapes or patterns for the islands. Laser cutting removes a portion of the overlay layer and the substrate during cutting, so that the cut is formed as a trench. As an alternative, the cut could be made with a sharp blade, for instance, which allows a cut to be formed without removal of material (and thereby providing a cut that does not have any significant width).

Before defining the plurality of islands in the layered panel by making at least one cut, the method further comprises: applying a removable tape to a surface of the overlay layer; and wherein after defining the plurality of islands in the layered panel by making at least one cut, the method further comprises: removing the removable tape. The tape provides support to the flexible panel during the cutting process, and avoids damage to the overlay layer. This process also allows for a cleaner, more controllable cut.

The at least one cut may be through the overlay layer and through less than 75% the thickness of the substrate, and more preferably through the overlay layer and through less than 50% the thickness of the substrate.

The at least one cut may comprise at least one trench through the overlay layer and into the substrate. The trench (at the overlay layer) may have a width of 2mm or less, or more preferably 1 mm or less. The at least one trench may be v-shaped, having intersecting side surfaces, wherein the side surfaces are arranged having an angle of 120° or less with respect to each other. The at least one trench may be through the overlay layer and through less than 75% the thickness of the substrate, and more preferably through the overlay layer and through less than 50% the thickness of the substrate.

The plurality of islands may be formed as a plurality of tessellating islands. Each of the plurality of islands may have a polygonal shape at the surface of the carrier layer. The polygonal shape may be a regular polygon. Alternatively, the polygonal shape may be an irregular polygon, and has a maximum length in first direction that is greater than a maximum length in a second direction, the first and second direction being in the plane of the carrier layer and perpendicular to each other. In other words, the irregular polygon extends further in a first direction than in a second direction, the first and second direction being in the plane of the carrier layer and perpendicular to each other. The polygonal shape may comprise one of: a triangle, a square, a rectangle, a trapezium, a parallelogram, a pentagon, a hexagon, a heptagon or a octagon.

Each of the plurality of islands may be a strip, each strip extending across the plane of the layered panel in a first direction. An edge of the strip extending in the first direction may be straight or curved or comprise contours, zig zags or crenellations.

The protective panel may have a thickness of between 2 and 15 mm, in total.

The substrate may be foam, such as a polymer foam. For instance, the substrate may be an expanded polymer foam, or a microcellular foam.

The foam may have a thickness of between 2 to 10 mm and/or a density of between 20 and 70 grams per litre.

The carrier layer and/or the overlay layer may be formed from a self-reinforced polymer woven composite. The carrier layer and/or the overlay layer may be formed from self-reinforced polypropylene, or from self-reinforced polyethylene.

The carrier layer and/or the overlay layer may have a thickness of between 0.2 to 2 mm. The thickness of the carrier layer and/or the overlay layer may be different.

The carrier layer and/or the overlay layer may comprise one to five heated and compressed laminated layers of self-reinforced polymer. The number of laminated layers in the carrier layer and/or the overlay layer may be different.

The method may further comprise an opening extending through at least one of the plurality of islands, the opening passing through the overlay layer, the substrate and the carrier layer of the layered panel.

Forming the layered panel may further comprise arranging a liner layer on the overlay layer. The liner layer is provided at least at the island regions.

In a fifth aspect, there is a method of manufacturing a protective apparel comprising the flexible panel described above.

In a further example, a peak of a cap is formed from a layered material comprising a first layer of foam, a layer of self-reinforced polymer woven composite, and a second layer of foam, wherein the layer of self-reinforced polymer woven composite is between the first and second layer of foam.

Said peak of a cap may further comprise a second layer of self-reinforced polymer woven composite on the second layer of foam.

The first and second layer of foam may be a expanded foam or a microcellular foam.

In yet another example, there is an angled or chevron shin guard, formed using the self-reinforced polymer material. The angled or chevron shin guard could be attached to a user’s leg using straps, or by insertion into a pocket within a pair of trousers or other leg apparel. Said angled shin guard may be especially useful for a user when fly fishing, for protecting the wearer’s leg from pressure by water currents and from incoming debris in the water. The angled nature of the shin pad may direct flowing water away from the leg.

List of Figures

The disclosure may be put into practice in a number of ways and preferred embodiments will now be described by way of example only and with reference to the accompanying drawings, in which:

FIGURE 1 shows various views of a first example of a flexible panel. FIGURE 1 (a) shows a plan view of the overlay layer, FIGURE 1 (b) shows a plan view of the carrier layer, and FIGURE 1 (c) shows a cross-sectional view;

FIGURE 2 shows schematic diagrams of the bendability of the flexible panel. FIGURE 2(a) shows bending under force applied in a first direction, and FIGURE 2(b) shows bending under force applied in a second direction;

FIGURE 3 shows a photograph of an example of the flexible panel in a bent configuration;

FIGURE 4 shows various views of a second example of a flexible panel. FIGURE 4(a) shows a plan view of the overlay layer, FIGURE 4(b) shows a plan view of the carrier layer, and FIGURE 4(c) shows a cross-sectional view. FIGURES 4(d) and 4(e) show schematic diagrams of the bendability of the same flexible panel. FIGURE 4(d) shows bending under force applied in a first direction, and FIGURE 4(e) shows bending under force applied in a second direction;

FIGURE 5 shows various views of a third example of a flexible panel. FIGURE 5(a) shows a plan view of the overlay layer, FIGURE 5(b) shows a plan view of the carrier layer, and FIGURE 5(c) shows a cross-sectional view;

FIGURE 6 shows different examples of the configuration of the island regions formed in the flexible panel.

FIGURE 7 shows photographs of an elbow protector formed comprising a flexible panel as described. FIGURE 7(a) shows the elbow protector in a configuration to fit an outstretched elbow, and FIGURE 7(b) shows the elbow protector in a configuration to fit a bent elbow;

FIGURE 8 shows various views of a fourth example of a flexible panel. FIGURE 8(a) shows a plan view of the overlay layer, FIGURE 8(b) shows a plan view of an additional layer, and FIGURE 8(c) shows a cross-sectional view; FIGURE 9 shows a protective apparel formed from the described flexible panels. FIGURE 9(a) shows a shin pad formed from an example of the flexible panel as described. FIGURE 9(b) shows a portion of a flexible panel for use in a forming a protective apparel;

FIGURE 10 shows schematic diagrams of a knee protector formed from a described flexible panel. FIGURE 10(a) shows a portion of a flexible panel making up a knee protector. FIGURE 10(b) shows a perspective view of the knee protector when worn by the wearer. FIGURE 10(c) shows a cross-sectional view of the knee protector when worn by the wearer;

FIGURE 11 shows a schematic diagram of the flexible panel for a knee protector. FIGURE 11 (a) shows a cross-section of the knee protector in its flat configuration. FIGURE 11 (b) shows the knee protector in a curved or bent configuration;

FIGURE 12 shows schematic diagrams of a leg and knee protector formed from a described flexible panel. FIGURE 12(a) shows the net of the knee and leg protector formed as a single piece. FIGURE 12(b) shows a schematic view of the leg protector when worn by the wearer. FIGURE 12(c) shows a further schematic view of the leg protector when worn by the wearer;

FIGURE 13 show a schematic diagram of a further flexible panel for use in a forming a protective apparel;

FIGURE 14 shows schematic diagrams of a further flexible panel for use in a forming a protective apparel, such as a chest protector. FIGURE 14(a) shows a portion of the flexible panel in a bent or flexed configuration. FIGURE 14(b) shows a cross-sectional view of the flexible panel in which bending in different directions is supported within the same panel. FIGURE 14(c) shows the flexible panels (for instance, as shown in FIGURE 14(b)) used within body protection;

FIGURE 15 shows schematic diagrams of flexible panels overlaid and jointed at a pivot; and

FIGURE 16 shows the overlaid flexible panels used in configuration of chest protection. FIGURE 16(a) shows a first configuration for the chest protection, and FIGURE 16(b) shows a second configuration for the chest protection.

In the drawings, like parts are denoted by like reference numerals. The drawings are not to scale.

Detailed Description of Embodiments of the Invention

FIGURE 1 shows a first example of a flexible panel according to the present disclosure. FIGURE 1 (a) shows a plan view of a top surface of the flexible panel (in particular showing the overlay layer, as discussed below). FIGURE 1 (b) shows a plan view of a bottom surface of the flexible panel (in particular showing the carrier layer, as discussed below). FIGURE 1 (c) shows a cross-section through the flexible panel, at the point shown as A in FIGURES 1 (a) and 1 (b).

The flexible panel is formed from a layered panel. The layered panel comprises a carrier layer 10, which is a continuous layer without break or cut. The carrier layer 10 is formed from self-reinforced polymer, such as self-reinforced polypropylene or self-reinforced polyethylene. The layered panel further comprises a substrate 12 on the carrier layer 10. The substrate 12 is formed from a polymer foam, for instance expanded self-reinforced polypropylene or microcellular polypropylene. Finally, the layered panel comprises an overlay layer 14 covering the uppermost surface of the substrate 12. The overlay layer 14 is formed from self-reinforced polymer. Typically, the carrier layer 10, the substrate 12 and the overlay layer 14 will be formed from the same type of polymer.

The flexible panel further comprises a plurality of islands (or armour regions) 18 formed in or defined in the layered panel. In particular, the islands 18 are formed by cuts 20, creating regions or shapes in a planar surface of the layered panel. The cuts 20 are made through the overlay layer 14 and into the substrate 12. As can be seen by the cross-sectional view in FIGURE 1 (c), in this specific example the cuts 20 extend through the whole depth of the substrate 12, although not into the carrier layer 10. However, in some examples, the cuts 20 would only extend through part of the depth of the substrate 12.

The provision of the plurality of islands 18 in the layered panel allows for the flexible properties of the flexible panel. FIGURE 2(a) and 2(b) shows the bendability of the flexible panel when forces are applied in different directions.

In particular, as shown in FIGURE 2(a), application of a bending force Fi in a first direction causes the flexible panel to bend in a way such that the outer surface of the carrier layer 10 becomes concave. The bending is possible because the cuts 20 between the islands 18 open slightly, allowing for curvature of the carrier layer 10 (and the flexible panel more generally). In some cases, a pivot point of a bend may be found in the carrier layer 10 at the edge of each island 18 (although this is not shown in FIGURE 2(a).

In the alternative, as shown in FIGURE 2(b), application of a bending force F ₂ in a second, opposite direction causes only minimal bending of the flexible panel. In particular, any gap at the cuts 20 between islands 18 are closed causing side faces of the substrate 12 to buttress together. The continuous carrier layer 10 and the substrate foam layer 12 provides a restraining force so as to prevent substantial bending of the flexible panel in this direction. In this way, when said flexible panel is incorporated into protective apparel, the flexible panel can be used to protect a joint of the wearer from over extension, as it can be configured so as to bend in an intended direction of a joint but not bend significantly in the opposite direction.

As such, the flexible panel as described with respect to FIGURE 1 (a) to FIGURE 2(b) provides a panel that is strong and resilient to impacts, whilst still allowing significant flexibility in a first direction only. FIGURE 3 shows a photograph of the flexible panel as described with reference to FIGURES 1 (a) to 2(b) whilst a bending force is applied. In particular, the flexible panel shown in FIGURE 3 is in the configuration of the panel in FIGURE 2(a).

In will be understood that self-reinforced polymers (or polyolefins), from which the carrier layer and the overlay layer are formed, are a particular family of thermocomposite materials in which both the reinforcing fibre and the polymer matrix are formed from the same polymer family. The fibres are manufactured as a highly orientated form of the same polymer matrix. Self-reinforced polymeric composite materials possess many advantages including thermoformability, high stiffness, high tensile strength, and outstanding impact resistance at low density. Self-reinforced materials are particularly impact resistant for a given weight or density of material. This may allow thinner sheets of material to be used, thereby reducing the overall weight of the flexible panel compared to manufacture from other materials. Furthermore the material can be melted and recycled, thus fulfilling requirements for use of more sustainable materials. Moreover, the self-reinforced material is waterproof.

It will be understood that, although the term ‘polymer’ and ‘self-reinforced polymer’ are used within this description, this could refer to any thermoplastic composite material or self-reinforced thermoplastic composite material. It could also refer to any polymer or selfreinforced polymer or self-reinforced polymer composite or self-reinforced polyolefin. Particular examples of materials that could be used include self-reinforced polypropylene, or self-reinforced polyethylene.

The self-reinforced polymer discussed here is formed of stretched, molecularly oriented strands or fibres of the polymer material, for example of polypropylene or other crystalline or semi-crystalline thermoplastic material. After a layer, sheet or panel of selfreinforced polymer has been thermo-compressed, the highly oriented strands or fibres of the polymer are embedded in a matrix of the same polymer (wherein the matrix is not highly oriented). For example, self-reinforced polypropylene comprises fibres of polypropylene embedded in a polypropylene matrix.

Different methods can be used for processing of self-reinforced polymer composites. In a first method, hot compaction is used, in which aligned, stretched fibres or strands of the polymer are layered. The strands or fibres are compressed together and heated to a precise temperature. This heating results in melting of only the outer layer or ‘skin’ of each strand or fibre, which has a lower melting point than the core of the strand or fibre. Heating causes around 10% of the strand or fibre to melt (at its outermost surface), and the applied pressure causes the molten polymer to flow around and between the fibres to form a continuous matrix. Once cooled, the polymer material of the matrix solidifies, and contains the strands or fibres. This method results in tapes of self-reinforced polymer material.

A second method that can be used is co-extrusion. In this process, fibres or strands of the polymer in a highly-oriented form can be formed by extrusion. In addition, another grade of the same polymer can be extruded or coated on the surface of each fibre or strand. The polymer used for coating each strand is a lower melting point grade of the polymer than the higher melting point grade of the same polymer used for the fibres. As such, this results in coated stands of the same polymer material, which can be aligned and then compacted whilst heated to form tapes of self-reinforced polymer material.

Said tapes of self-reinforced polymer material can be built up in layers. The laminated structure can then be heated and compressed, in order to form sheets or layers of selfreinforced polymer material. Use of different numbers of layers of thermo-compressed tapes can provide self-reinforced polymer material sheets having different thickness. In turn, the thickness of the self-reinforced polymer sheet determines the rigidity, or the flexibility of the sheet.

In an alternative, the fibres of self-reinforced polymer as described above can be formed into strands. The strands can be woven to form a fabric. The fabric may be heated and compressed after weaving, such that the outer coating of each strand or fibre (comprising the lower-melting point type of the same polymer) melts, but the core of each fibre remains solid. Compression during heating again causes the melted polymer of the outer coating to flow, and form a matrix in which the strands of the polymer are contained. This is a particular form of self-reinforced polymer, named self-reinforced polymer woven composite. An example of self-reinforced polypropylene woven composite is Dewforge ^RTM by James Dewhurst ^RTM . The self-reinforced polymer woven composite can be beneficial as it does not suffer from delamination. Different thicknesses or densities of self-reinforced polymer woven composite can be provided by varying the density of the stitches in the woven fabric, or by creating strands before weaving that are thicker by twisting together multiple strands. However, the self-reinforced polymer woven composite may be limited in the maximum thickness of a sheet formed in this way, compared to the layered self-reinforced polymer which may be formed with almost any thickness. A single layer of self-reinforced polypropylene woven composite may be around 0.35 mm, for instance.

In view of these methods of forming the self-reinforced polymer material, a panel, sheet or layer of self-reinforced polymer will comprise strands of the polymer either woven or bonded, wherein each strand is surrounded by polymer of the same type but having a slightly lower melting point. Each of the carrier layer and overlay layer described herein comprises at least one layer of self-reinforced polymer strands, being woven or bonded via a matrix.

Referring to FIGURE 4, there is shown a further example of a flexible panel according to the present disclosure. FIGURE 4(a) shows a plan view of a top surface of the flexible panel (in particular showing the overlay layer, as discussed below). FIGURE 4(b) shows a plan view of a bottom surface of the flexible panel (in particular showing the carrier layer, as discussed below). FIGURE 4(c) shows a cross-section through the flexible panel, at the point shown as A in FIGURES 4(a) and 4(b).

This example has the same layered panel comprising the carrier layer 10, substrate 12 and overlay layer 14 as described above with reference to FIGURE 1 . As before, islands 18 are formed in the layered panel through the overlay layer 14 and into the substrate 12. In contrast to the example shown in FIGURE 1 , the cut defining the islands 18 forms a v-shaped trench 24. In the example of FIGURE 4, the side walls of the v-shaped trench 24 intersect at the carrier layer 10, and have an angle of a therebetween. In this case, the angle a is around 80°, but it could be up to 120°. Provision of a v-shaped trench 24 allows for greater flexibility of the flexible panel to give a flexible panel is substantially bendable in two directions. This is illustrated further in FIGURES 4(d) and (e).

FIGURE 4(d) shows the flexible panel of FIGURE 4(a) to 4(c) when force Fi is applied in a first direction, causing the outer surface of the carrier layer 10 to become concave. The flexible panel is bendable, with gaps opening between islands 18 defined in the layered panel. FIGURE 4(d) shows the flexible panel of FIGURE 4(a) to 4(c) when force F ₂ is applied in a second direction, opposite the first direction, causing the outer surface of the carrier layer 10 to become convex. The flexible panel is then bendable in the opposite direction, with the v-shaped trenches 24 closing. Appropriate choice of the angle of the v-shaped trench 24 allows selection of the extent of curvature of the flexible panel. For instance, a larger angle, a, at the v-shaped trench 24 allows a greater curvature to be achieved upon provision of the bending force in the second direction. Finally, in the flexible panel of FIGURE 4(a), 4(b) and 4(c), a perforation 22 is provided at the point of intersection of edges of different islands 18. This perforation can allow for greater flexibility in the carrier layer 10 of the flexible panel.

Referring to FIGURE 5, there is shown a still further example of a flexible panel according to the present disclosure. FIGURE 5(a) shows a plan view of a top surface of the flexible panel (in particular showing the overlay layer 14, as discussed below). FIGURE 5(b) shows a plan view of a bottom surface of the flexible panel (in particular showing the carrier layer 10, as discussed below). FIGURE 5(c) shows a cross-section through the flexible panel, at the point shown as A in FIGURES 5(a) and 5(b).

The flexible layer of FIGURE 5(a) to 5(c) is similar to that shown in FIGURE 1 , and discussed above. However, in the flexible layer of FIGURE 5, the cut defining the plurality of islands is formed as a trench 24, having a width W. Here, the width is less than 2mm. Moreover, the trench 24 has a depth that is only a partial thickness of the substrate layer 12. In the example of FIGURE 5, the depth of the trench 24 is around 30% of the thickness of the substrate 12. Reducing the depth of the trench 24 restricts the curvature of the flexible panel in a direction that would provide a concave outer surface of the carrier layer 10.

A further difference between the flexible layer of FIGURE 5 and the flexible layer of FIGURE 1 is the provision of openings or holes 26 through the flexible panel of FIGURE 5. In particular, an opening, hole or aperture 26 is formed through each island 18 of the flexible panel. This can be useful for air flow, for instance, especially when the flexible panel is used within a protective apparel. In this example, an opening or hole 26 is formed through the centre of each one of the islands 18, however the opening could be off-centre, and could be through only some or one of the islands.

It will be understood that the islands 18 can have various shapes. In particular, the islands 18 can be formed as tessellating polygons. The islands 18 may all have the same shape, or may be a combination of different shapes. Different shapes of the islands, and the area of the islands, will affect the curvature or bend of a flexible panel. For instance, a larger number of smaller area islands in a flexible panel will offer greater curvature for the flexible panel than a smaller number of islands of larger area.

Islands having a regular polygon shape allow bending of the flexible panel more equally in each direction of the plane than islands of an irregular polygon shape. For example, when the same bending force is applied the curvature in a first direction of the panel of the flexible panel having regular polygon islands will be approximately the same as the curvature in a second direction, perpendicular to the first direction. In contrast, islands having an irregular polygon shape allow bending of the flexible panel to have a greater or lesser curvature in a first direction in the plane, than in a second direction in the plane. For example, the islands can be formed as rectangles, having a greater length in a first direction than the length in a second direction, that is perpendicular to the first direction. Then, the curvature in the first direction of the panel of the flexible panel is less than the curvature in a second direction when approximately the same bending force is applied.

FIGURE 6 shows a number of different configurations for the islands within the flexible panel. Each pattern or configuration allows for different properties of curvature or bending of the flexible panel. For instance, FIGURE 6(a) shows the islands as strips, which allows more significant curvature of bending in a first direction , but little bending in a second /direction. FIGURE 6(b) allows for bending in both an xand /direction. FIGURE 6(c) allows for bending in both an x and / directions but, due to the smaller area of each island than compared to the flexible panel of FIGURE 6(b), may allow for a greater curvature of bending in both directions then compared to the flexible panel of FIGURE 6(b).

FIGURE 7 shows a photograph of an elbow protector formed from a flexible panel according to the present disclosure. In particular, the elbow protector is formed from a flexible panel similar to that described with reference to FIGURE 1 . It can be seen that the elbow protector is highly flexible in one direction, but would prevent overextension of the elbow in the opposite direction. The use of the described layered panel within the flexible panel provides excellent protection. In particular, the self-reinforced polymer material is resilient and strong, and the substrate provides structure but elasticity, allowing absorption of impact energy.

Referring FIGURE 8, there is shown a still further example of a flexible panel according to the present disclosure. FIGURE 8(a) shows a plan view of a top surface of the flexible panel (in particular showing the overlay layer, as discussed below). FIGURE 8(b) shows a plan view of a bottom surface of the flexible panel (in particular showing an additional layer, as discussed below). FIGURE 8(c) shows a cross-section through the flexible panel, at the point shown as A in FIGURES 8(a) and 8(b).

FIGURE 8 is similar to the flexible panel of FIGURE 5, except that it includes a further layer (denoted an additional layer 28). The additional layer 28 is arranged over the outermost face of the carrier layer 10 (so that the carrier layer 10 is arranged between the substrate 12 and the additional layer 28). The additional layer 28 provides an extra protection from impacts or piercing through the flexible panel. Scores or relief cuts 30 may be provided in the additional layer to align with the edges of the islands 18 formed through the overlay layer 14 in order to maintain flexibility of the flexible panel. The opening 26 through the layered panel also extends through the additional layer 28 in the flexible panel of FIGURE 8.

FIGURE 9(a) shows a photograph of a shin guard or shin protector formed from a flexible panel similar to that discussed above in respect of FIGURE 5. In particular, it can be seen that holes or openings are provided through each island defined in the layered panel forming the flexible panel. This allows for air flow through the shin guard. A photograph of a generic flexible panel similar to that discussed above in respect of FIGURE 5 can be seen in FIGURE 9(b).

In a particular example (not shown) an angled or chevron shin guard could be provided, formed using the self-reinforced polymer material. Specifically, the shin guard may have a chevron cross-sectional shape. The angled or chevron shin guard could be attached to a user’s leg using straps, or by insertion into a pocket in a pair of trousers or other leg apparel. Said angled shin guard may be especially useful within fly fishing, for protecting the wearer’s leg from pressure by water currents and from incoming debris in the water. The angled nature of the shin pad can be used to direct the flow of water away from the leg.

FIGURE 10(a), 10(b) and 10(c) depict a knee protector formed from a flexible panel as described. The cuts defining the islands in the layered panel of the flexible panel provide a pivot point 100 for bends (a bend point) in the knee protector. The knee protector as shown includes a v-shaped trench 24 as described with reference to FIGURE 4. This can be used to cause the knee protector to bend around the knee, as shown in FIGURE 10(c).

The knee protector may also have an extra soft liner layer 1 10 over the overlay layer, as shown in the cross-sectional views of the knee protector in FIGURE 1 1 (a) and 11 (b). This may be especially useful when the liner layer 1 10 makes contact with the wearer’s skin. In will be understood that in this example, the overlay layer 14 faces the wearer’s body, and the carrier layer 10 faces away from the wearer’s body. The liner layer may be formed of a low density foam. The low density foam may be of the same type of polymer as the carrier layer, the substrate, and/or the overlay layer. Alternatively the liner layer may be a soft material, such as a felt, cotton or other soft layer.

FIGURE 12(a), 12(b) and 12(c) depict a knee and leg protector formed from a flexible panel, as described. As with the knee protector, the cuts defining the islands in the layered panel of the flexible panel provide a pivot point for bends (a bend point) in the leg protector. As shown in FIGURE 12(a), the knee and leg protector is formed from a single flexible panel, to provide a net. The leg protector is arranged to protect the knee cap and at least the top of the tibia bone. FIGURE 13 shows a flexible panel, in which the islands are provided as strips or stripes.

FIGURE 14(a) shows a flexible panel, in which the islands are provided as strips. This allows the panel to have a greater curvature in a direction perpendicular to the longitudinal direction of each strip. This allows, for instance, the flexible panel to be particularly useful for use as a protective panel within the protective apparel, for instance to cover the chest of the wearer, and/or to cover the abdomen or upper leg of the wearer.

FIGURE 14(b) shows a flexible panel as described, in which islands are formed therein by the cutting of trenches through the overlay layer, and/or through the carrier layer. Cutting of trenches from different sides or through alternative faces of the panel and extending in different directions, or cut outs at trenches 24 of different angles, allow a mixture of directions of bending (and also support by prevention of bending) in different areas of the flexible panel. For instance, a first region 145 would permit bending in a first direction, whereas a second region 140 would permit bending in a second direction. In this way, a flexible panel can be designed that allows for multiple directions of bending and support, which could be used for full body protection to take account of twists and movement desired for a wearer’s body (such as illustrated in FIGURE 14(c). Alternatively, such a panel could be used as a backplate held against the wearer’s spine in a backpack, to take account of the different directions of flex that are desirably supported or prevented for a wearer’s spine.

FIGURE 15 shows examples of the flexible panel that are overlaid or overlapped. For instance this could be used to cover an opening in the protective apparel. In a further example, FIGURE 16(a) and 16(b) show a chest armour or protective apparel, comprising interlinked and/or overlapped shells formed from the described flexible panels. The interlinked shells may interleave around the wearer’s chest in order to provide coverage and protection (as shown in FIGURE 16(a) and 16(b), in different configurations for the chest protection). The interlinked shells can move independently of each other, to provide a comfortable body armour without significant constraint for the wearer. The interlinked shells may be joined at one or more pivot point 160.

In general, where a flexible panel is used within a protective apparel, overlapping of sections of the flexible panel may be used to cover openings in the protective apparel. Said overlapping sections are able to move independently from each other. In internal lining may be placed underneath the overlapping section of the flexible panel.

It will be understood that features disclosed herein may be combined in any way and are not limited to the specific implementation described above. Each feature disclosed in this specification, unless stated otherwise, may be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

As used herein, including in the claims, unless the context indicates otherwise, singular forms of the terms herein are to be construed as including the plural form and vice versa. For instance, unless the context indicates otherwise, a singular reference herein including in the claims, such as "a" or "an" means "one or more”. Throughout the description and claims of this disclosure, the words "comprise", "including", "having" and "contain" and variations of the words, for example "comprising" and "comprises" or similar, mean "including but not limited to", and are not intended to (and do not) exclude other components.

The use of any and all examples, or exemplary language ("for instance", "such as", "for example" and like language) provided herein, is intended merely to better illustrate the invention and does not indicate a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention.

Any steps described in this specification may be performed in any order or simultaneously unless stated or the context requires otherwise. All of the aspects and/or features disclosed in this specification may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.