US20130025036A1 - Articles Of Apparel Incorporating Cushioning Elements - Google Patents
Articles Of Apparel Incorporating Cushioning Elements Download PDFInfo
- Publication number
- US20130025036A1 US20130025036A1 US13/442,537 US201213442537A US2013025036A1 US 20130025036 A1 US20130025036 A1 US 20130025036A1 US 201213442537 A US201213442537 A US 201213442537A US 2013025036 A1 US2013025036 A1 US 2013025036A1
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- United States
- Prior art keywords
- material layer
- pad component
- article
- apparel
- grooves
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/10—Linings
- A42B3/12—Cushioning devices
- A42B3/125—Cushioning devices with a padded structure, e.g. foam
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/015—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches with shock-absorbing means
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/055—Protector fastening, e.g. on the human body
- A41D13/0581—Protector fastening, e.g. on the human body with permanent fastening means
- A41D13/0587—Integral with the garment
Definitions
- Athletic apparel for example, often incorporates cushioning elements that protect the wearer from contact with other athletes, equipment, or the ground. More specifically, pads used in American football and hockey incorporate cushioning elements that provide impact protection to various parts of a wearer. Helmets utilized during American football, hockey, bicycling, skiing, snowboarding, and skateboarding incorporate cushioning elements that provide head protection during falls or crashes. Similarly, gloves utilized in soccer (e.g., by goalies) and hockey incorporate cushioning elements that provide protection to the hands of a wearer. Cushioning elements may also be incorporated into bicycling shorts. Apparel that is utilized for generally non-athletic purposes may also incorporate cushioning elements, such as apparel that is worn for motorcycle riding and knee protectors for gardening or construction work.
- the cushioning elements include a pair of material layers and a pad component that is located between and secured to the material layers. At least one surface of the pad component includes a plurality of grooves. In some configurations, both surfaces include the grooves. Moreover, the grooves may be elongate and extend at least partially across the pad component. In addition, a plurality of elongate voids may extend through the pad component and from one surface to the other surface.
- FIG. 1 is a front elevational view of an individual wearing an article of apparel.
- FIG. 2 is a front elevational view of the article of apparel.
- FIGS. 3 and 4 are side elevational views of the article of apparel.
- FIG. 5 is a rear elevational view of the article of apparel.
- FIG. 6 is a perspective view of a first cushioning element.
- FIG. 7 is an exploded perspective view of the first cushioning element.
- FIG. 8 is a top plan view of the first cushioning element.
- FIGS. 9A-9C are cross-sectional views of the first cushioning element, as defined by section lines 9 A- 9 C in FIG. 8 .
- FIG. 10A is a cross-sectional view corresponding with FIG. 9A and depicting the first cushioning element in a flexed configuration.
- FIG. 10B is a cross-sectional view corresponding with FIG. 9A and depicting the first cushioning element in a stretched configuration.
- FIG. 100 is a cross-sectional view corresponding with FIG. 9C and depicting breathability of the first cushioning element.
- FIG. 11 is a perspective view of portions of a manufacturing apparatus utilized in a manufacturing process for the first cushioning element.
- FIGS. 12A-12D are schematic perspective views of the manufacturing process.
- FIGS. 13A-13D are schematic cross-sectional views of the manufacturing process, as respectively defined by section lines 13 A- 13 D in FIGS. 12A-12D .
- FIGS. 14A-14K are top plan views corresponding with FIG. 8 and depicting further configurations of the first cushioning element.
- FIGS. 15A-15J are perspective views depicting further configurations of a first pad component from the first cushioning element.
- FIGS. 16A-16R are cross-sectional views corresponding with FIG. 9A and depicting further configurations of the first cushioning element.
- FIGS. 17A-17G are elevational views of further articles of apparel incorporating the cushioning element.
- FIG. 18 is a front elevational view of another configuration of the article of apparel.
- FIG. 19 is a perspective view of a second cushioning element.
- FIG. 20 is an exploded perspective view of the second cushioning element.
- FIG. 21 is a top plan view of the second cushioning element.
- FIG. 22 is a top plan view of a second pad component from the second cushioning element.
- FIGS. 23A-23D are cross-sectional views of the second pad component, as defined by section lines 23 A- 23 D in FIG. 22 .
- FIG. 24A is a top plan view of the second pad component in a stretched configuration.
- FIG. 24B is a top plan view of the second pad component in a compressed configuration.
- FIGS. 25A-25H are top plan views corresponding with FIG. 22 and depicting further configurations of the second pad component.
- FIG. 26 is a top plan view corresponding with FIG. 22 and depicting another configuration of the second pad component.
- FIGS. 27A-27E are cross-sectional views, as defined by section lines 27 A- 27 E in FIG. 26 .
- FIG. 28 is a top plan view corresponding with FIG. 22 and depicting another configuration of the second pad component.
- FIGS. 29A-29D are cross-sectional views, as defined by section lines 29 A- 29 D in FIG. 28 .
- FIGS. 30A-30D are cross-sectional views corresponding with FIG. 29D and depicting further configurations of the second pad component.
- FIGS. 31A-31E are cross-sectional views corresponding with FIG. 23D and depicting further configurations of the second pad component.
- FIGS. 32 and 33 are top plan views corresponding with FIG. 22 and depicting further configurations of the second pad component.
- cushioning elements that may be incorporated into a variety of products, including articles of apparel, such as shorts, pants, shirts, wraps, footwear, gloves, and helmets.
- a wearer or individual 10 is depicted as wearing an article of apparel 100 with the general configuration of a pair of shorts.
- apparel 100 may be worn under other articles of apparel, apparel 100 may be worn alone, may be exposed, or may be worn over other articles of apparel.
- Apparel 100 may also be worn in combination with other pieces of equipment (e.g., athletic or protective equipment).
- apparel 100 may be loose-fitting, apparel 100 is depicted as having a relatively tight fit of a compression garment. Accordingly, the configuration of apparel 100 and the manner in which apparel 100 is worn by individual 10 may vary significantly.
- Apparel 100 is depicted individually in FIGS. 2-5 as including a pelvic region 101 and a pair of leg regions 102 that extend outward from pelvic region 101 .
- Pelvic region 101 corresponds with a pelvic area of individual 10 and covers at least a portion of the pelvic area when worn.
- An upper area of pelvic region 101 defines a waist opening 103 that extends around a waist of individual 10 when apparel 100 is worn.
- Leg regions 102 correspond with a right leg and a left leg of individual 10 and cover at least a portion of the right leg and the left leg when worn.
- Lower areas of leg regions 102 each define a thigh opening 104 that extends around a thigh of individual 10 when apparel 100 is worn.
- apparel 100 includes an exterior surface 105 that faces away from individual 10 when apparel 100 is worn, and apparel 100 includes an opposite interior surface 106 that faces toward individual 10 and may contact individual 10 when apparel 100 is worn.
- a plurality of cushioning elements 200 are incorporated into various areas of apparel 100 to impart padding, cushioning, or otherwise attenuate impact forces.
- cushioning elements 200 may protect individual 10 from contact with other athletes, equipment, or the ground.
- cushioning elements 200 are located in both of pelvic region 101 and leg regions 102 and are positioned, more specifically, to protect the hips, thighs, and tailbone of individual 10 .
- cushioning elements 200 may be incorporated into a variety of different articles of apparel, and cushioning elements 200 may be positioned in various areas of the articles of apparel to protect specific portions (e.g., muscles, bones, joints, impact areas) of individual 10 .
- the shapes, sizes, and other properties of cushioning elements 200 as well as the materials and components utilized in cushioning elements 200 , may vary significantly to provide a particular level of protection to the specific portions of individual 10 .
- cushioning element 200 is depicted in FIGS. 6-9B as having a generally elongate shape with pointed end areas, which is the shape depicted as being incorporated into apparel 100 .
- Cushioning element 200 includes a first material layer 210 , a second material layer 220 , and a pad component 230 .
- First material layer 210 and second material layer 220 cooperatively form an outer surface or covering for cushioning element 200 . That is, first material layer 210 and second material layer 220 cooperatively form a pocket or void, in which pad component 230 is located.
- first material layer 210 extends over pad component 230 and also along sides of pad component 230 to join with second material layer 220 (e.g., through stitching, adhesive bonding, or thermal bonding).
- cushioning element 200 may be incorporated into apparel 100 in a variety of ways, first material layer 210 may be positioned exterior of second material element 220 , such that cushioning element 200 protrudes outward from apparel 100 . Alternately, second material layer 220 may be positioned exterior of first material element 210 , such that cushioning element 200 protrudes inwardly.
- first material layer 210 has a shape that covers pad component 230
- second material layer 220 may have a larger size that forms additional portions of apparel 100 .
- second material layer 220 may extend into both pelvic region 101 and one of leg regions 102 . That is, second material layer 220 may form one surface of cushioning element 200 and extend to other areas apparel 100 to form a covering for individual 10 .
- first material layer 210 forms a portion of exterior surface 105
- second material layer 220 forms a portion of both exterior surface 105 and interior surface 106 .
- a portion of second material layer 220 that is secured to pad component 230 is located inward of first material layer 210 and forms a portion of interior surface 106 .
- second material layer 220 forms a portion of exterior surface 105 , as well as interior surface 106 . As such, second material layer 220 forms both a portion of a covering for pad component 230 and other portions of apparel 100 .
- first material layer 210 and second material layer 220 A variety of materials may be utilized for first material layer 210 and second material layer 220 , including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for each of material layers 210 and 220 . Although material layers 210 and 220 may be formed from the same material, each of material layers 210 and 220 may also be formed from different materials. With regard to textiles, material layers 210 and 220 may be formed from knitted, woven, non-woven, spacer, or mesh textile components that include rayon, nylon, polyester, polyacrylic, elastane, cotton, wool, or silk, for example. Moreover, the textiles may be non-stretch, may exhibit stretch in one direction, or may exhibit multi-directional stretch. Accordingly, a variety of materials are suitable for first material layer 210 and second material layer 220 .
- Pad component 230 is located between and secured to each of material layers 210 and 220 . More particularly, pad component 230 has a first surface 231 secured to first material layer 210 , an opposite second surface 232 secured to second material layer 220 , and a side surface 233 that extends between surfaces 231 and 232 .
- First surface 231 defines a plurality of first grooves 234 that extend throughout a length of pad component 230 and toward second surface 232 .
- second surface 232 defines a plurality of second grooves 235 that extend throughout the length of pad component 230 and toward first surface 231 .
- First grooves 234 are aligned with second grooves 235 .
- aligned is defined as extending in a common direction and includes (a) parallel configurations for grooves 234 and 235 and (b) non-parallel configurations for grooves 234 and 235 that are offset between zero and thirty degrees. As such, when grooves 234 and 235 are aligned, they are generally oriented extend in the same direction. Additionally, grooves 234 and 235 are offset from each other. That is, first grooves 234 are located in areas of pad component 230 that are between areas where second grooves 235 are located. Moreover, each of grooves 234 and 235 are depicted as having a triangular, V-shaped, angled, or pointed configuration.
- pads component 230 is secured to material layers 210 and 220
- one or both of surfaces 231 and 232 may also be unsecured to material layers 210 and 220 . In either configuration, surfaces 231 and 232 generally face toward material layers 210 and 220 .
- pad component 230 and grooves 234 and 235 may vary considerably, as discussed in greater detail below, some examples of suitable configurations are discussed here.
- pad component 230 may have a thickness (i.e., distance between surfaces 231 and 232 ) of ten millimeters.
- grooves 234 and 235 may have a width of five millimeters and a depth of five millimeters. As such, grooves 234 and 235 may extend through approximately fifty percent of a thickness of pad component 230 .
- grooves 234 and 235 may be spaced by twenty millimeters.
- pad component 230 A variety of materials may be utilized for pad component 230 , including various polymer foam materials that return to an original shape after being compressed.
- suitable polymer foam materials for pad component 230 include polyurethane, ethylvinylacetate, polyester, polypropylene, and polyethylene foams.
- thermoplastic and thermoset polymer foam materials may be utilized.
- pad component 230 may be formed from a polymer foam material with a varying density, or solid polymer or rubber materials may be utilized. Fluid-filled chambers may also be utilized as pad component 230 .
- different pad component 230 may be formed from different materials, or may be formed from similar materials with different densities.
- the polymer foam materials forming pad component 230 attenuate impact forces to provide cushioning or protection.
- the degree of impact force attenuation may be varied throughout apparel 100 to impart a desired degree of cushioning or protection.
- the compressible polymer foam materials forming pad component 230 attenuate impact forces that compress or otherwise contact cushioning element 200 .
- the polymer foam materials of pad component 230 may compress to protect a wearer from contact with other athletes, equipment, or the ground.
- cushioning element 200 may be utilized to provide cushioning or protection to areas of individual 10 or other wearers that are covered by cushioning element 200 .
- cushioning element 200 has an advantage of simultaneously providing one or more of flex, stretch, breathability, relatively low overall mass, and launderability.
- cushioning element 200 is depicted as being flexed. In this configuration, first grooves 234 effectively expand and second grooves 235 effectively collapse to impart flexibility.
- cushioning element 200 is depicted as being stretched by a force 20 . In this configuration, the offset structure of grooves 234 and 235 permits pad component 230 to flatten or otherwise elongate due to the effects of force 20 .
- cushioning element 200 may better conform with contours of individual 10 , and cushioning element 200 may expand, collapse, flatten, and elongate to facilitate movements of individual 10 , while still conforming with the contours of individual 10 during the movements. Additionally, individual 10 may generate excess heat and perspire when wearing apparel 100 and engaging in athletic activities. Referring to FIG. 10C , the breathability of cushioning element 200 is depicted by various paths 30 , along which heat and moisture may pass to exit cushioning element 200 .
- the heat and moisture from individual 10 may, therefore, (a) pass through second material layer 220 , (b) enter one of second grooves 235 , (c) move to end areas of second groove 235 , and (d) pass through first material layer 210 , thereby exiting apparel 100 .
- the materials and structure discussed above for cushioning element 200 (a) imparts a relatively low overall mass that does not add significant weight to individual 10 during the athletic activities and (b) permits laundering without significant shrinkage or warping, even when temperatures associated with commercial laundering processes are utilized. Accordingly, cushioning element 200 may simultaneously provide impact force attenuation, flex, stretch, breathability, relatively low overall mass, and launderability.
- a manufacturing apparatus 300 is disclosed as including a press 310 and a sewing machine 320 .
- Other elements such as a mold, router, die cutter, or laser may also be utilized, but are not depicted here.
- a variety of other manufacturing apparatuses that operate in a similar manner may also be utilized. Accordingly, manufacturing apparatus 300 is only intended to provide an example of a manufacturing apparatus for the production of cushioning element 200 .
- cushioning element 200 is cut, shaped, or otherwise prepared.
- material layers 210 and 220 may be cut to a particular shape using die cutting, laser cutting, or hand cutting processes.
- first material layer 210 has a shape that covers pad component 230 and extends alongside surface 233
- second material layer 220 may have a larger size that forms additional portions of apparel 100 .
- second material layer 220 may extend into both pelvic region 101 and one of leg regions 102 . That is, second material layer 220 may form one surface of cushioning element 200 and extend to other areas apparel 100 to form a covering for individual 10 .
- Various processes may also be utilized to form pad component 230 .
- polymer resin with a blowing agent may be located in a mold having the shape of pad component 230 .
- An advantage to this process is that a single process may be used to form the polymer foam material of pad component 230 , as well as the various grooves 234 and 235 .
- a preformed layer of polymer foam may be obtained, and a router may be used to form grooves 234 and 235 .
- grooves 234 and 235 may be formed from a heated element that presses into a preformed layer of polymer foam, or a computer-controlled machine tool may be utilized.
- a three-dimensional printer may be utilized to form pad component 230 , or a polymer foam element having grooves 234 and 235 may be extruded and then cut to the shape of pad component 230 .
- first material layer 210 may be located adjacent to platen 311
- second material layer 220 may be located adjacent to platen 312
- pad component 230 may be located between layers 210 and 220 .
- platens 311 and 312 close upon and compress first material layer 210 , second material layer 220 , and pad component 230 , as depicted in FIGS. 12B and 13B .
- platen 311 compresses first material layer 210 against first surface 231 of pad component 230
- platen 312 compresses second material layer 220 against second surface 232 of pad component 230 .
- Platens 311 and 312 effectively compress pad component 230 between material layers 210 and 220 to ensure bonding.
- an adhesive may be utilized to bond pad component 230 to each of material layers 210 and 220 .
- an adhesive may be applied to either (a) areas of material layers 210 and 220 that are intended to bond with pad components 230 or (b) surfaces 231 and 232 of pad component 230 .
- the adhesive may be applied to material layers 210 and 220
- an advantage of applying the adhesive to surfaces 231 and 232 is that the adhesive is absent from areas of material layers 210 and 220 that are not intended to bond with pad component 230 .
- heat may be utilized to bond pad component 230 to each of material layers 210 and 220 .
- pad component 230 is formed from a thermoplastic polymer foam material
- heating and melting of pad component 230 at surfaces 231 and 232 may be utilized to bond pad component 230 to each of material layers 210 and 220 .
- material layers 210 and 220 may also incorporate a thermoplastic polymer material, or a thermoplastic bonding agent or thermally-activated adhesive may be utilized.
- various radiant heaters, radio frequency emitters, or other devices may be utilized.
- press 310 may be heated such that contact with platens 311 and 312 raises the temperature of pad component 230 to a level that facilitates bonding.
- an adhesive, thermoplastic polymer material, or a thermoplastic bonding agent is applied to the components of cushioning element 200 .
- an advantage of applying an adhesive to surfaces 231 and 232 is that the adhesive is absent from areas of material layers 210 and 220 that are not intended to bond with pad component 230 .
- a similar advantage applies to a thermoplastic polymer material or thermoplastic bonding agent.
- applying the adhesive, thermoplastic polymer material, or thermoplastic bonding agent to surfaces 231 and 232 prior to the formation of grooves 234 and 235 may ensure that the bonding materials are absent from grooves 234 and 235 .
- thermoplastic polymer sheets when thermoplastic polymer sheets are utilized as the bonding material, the thermoplastic polymer sheets may be bonded or secured to opposite sides of a polymer foam member (i.e., the polymer foam member that forms pad component 230 ). Then, grooves 234 and 235 may be formed using a router or other process, which effectively removes portions of the thermoplastic polymer sheets located at grooves 234 and 235 . As such, the thermoplastic polymer sheets are absent from grooves 234 and 235 and effectively limited to the areas of surfaces 231 and 232 that bond with layers 210 and 220 . Accordingly, by selecting a particular order for the manner in which components of cushioning element 200 are applied, excess materials that may form unintended bonds or detract from the aesthetic properties of cushioning element 200 may be avoided.
- first material layer 210 is unsecured to second material layer 220 .
- Additional stitching, adhesive, or thermal bonding steps may now be utilized to join material layers 210 and 220 around the periphery of pad components 230 .
- sewing machine 320 may be utilized to stitch material layers 210 and 220 together, as depicted in FIGS. 12D and 13D , thereby substantially completing the manufacture of cushioning element 200 .
- cushioning element 200 may vary, depending upon the intended use for cushioning element 200 and the product in which cushioning element 200 is incorporated. Moreover, changes to the dimensions, shapes, and materials utilized within cushioning element 200 may vary the overall properties of cushioning element 200 . That is, by changing the dimensions, shapes, and materials utilized within cushioning element 200 , the compressibility, impact force attenuation, flex, stretch, breathability, and overall mass of cushioning element 200 may be tailored to specific purposes or products. A plurality of variations for cushioning element 200 are discussed below. Any of these variations, as well as combinations of these variations, may be utilized to tailor the properties of cushioning element 200 to an intended use. Moreover, any of these variations may be manufactured through the process or variations of the process discussed above.
- cushioning component 200 may have a generally elongate shape with pointed end areas.
- the overall shape of cushioning element 200 may, however, vary to include a variety of other shapes.
- cushioning element 200 exhibits a generally rectangular shape.
- cushioning element 200 may have a round, triangular, hexagonal, or H-shaped structure, as respectively depicted in FIGS. 14B-14E .
- FIGS. 14B-14E any of these shapes may be utilized in apparel 100 , various other shapes may also be utilized.
- FIG. 14F depicts a configuration of cushioning element 200 with a shape suitable for a hip pad
- FIG. 14G depicts a configuration of cushioning element 200 with a shape suitable for a thigh pad
- FIG. 14H depicts a configuration of cushioning element 200 with a shape suitable for a tailbone pad.
- a configuration for cushioning element 200 that has a shape suitable for an elbow pad is depicted in FIG. 14I .
- first material layer 210 and second material layer 220 may also vary significantly.
- material layers 210 and 220 may be formed from various textiles, polymer sheets, leather, synthetic leather, or combinations of materials, for example.
- breathability may be enhanced when the materials are air-permeable.
- textiles are permeable to both heat and moisture.
- Polymer sheets, leather, synthetic leather, or combinations of materials may not exhibit significant permeability.
- various perforations, holes, or apertures may be formed in one or both of material layers 210 and 220 to enhance breathability.
- first material layer 210 may be entirely absent from cushioning element 200 .
- aspects relating to pad component 230 may also vary to tailor cushioning element 200 to an intended use or enhance the properties of cushioning element 200 .
- the configuration of grooves 234 and 235 may vary. Referring to FIGS. 15A and 15B , the width of grooves 234 and 235 and the spacing between grooves 234 and 235 are both increased and decreased from the configuration discussed above. Referring to FIG. 15C , grooves 234 and 235 extend across the width of pad component 230 , rather than extending across the length. In order to impart flex and stretch in multiple directions, grooves 234 and 235 may have a crossed configuration extending across both the length and width of pad component 230 , as depicted in FIG. 15D .
- pad component 230 may be segmented or otherwise formed from two or more separate elements. Referring to FIG. 15 G, for example, pad component 230 includes three spaced sections, which may enhance the flex and breathability of cushioning element 200 .
- grooves 234 and 235 may extend entirely across pad component 230 , grooves 234 and 235 may also extend only partially across pad component 230 .
- first grooves 234 extend across a majority of the length of pad component 230 , but are spaced from peripheral areas of pad component 230 .
- Second grooves 235 may have a similar configuration.
- FIG. 15I grooves 234 and 235 are located in one region of pad component 230 , but are absent from another region of pad component 230 .
- Grooves 234 and 235 may also extend only partially across pad component 230 from opposite sides of pad component 230 , as depicted in FIG. 15J . Accordingly, grooves 234 and 235 may have various configurations that extend at least partially across pad component 230 .
- FIG. 16A depicts a configuration wherein the spacing of grooves 234 and 235 varies across the width of pad component 230
- FIG. 16C depicts a configuration wherein the depth of grooves 234 and 235 varies across the width of pad component 230 .
- the depth of grooves 234 and 235 may extend through about fifty percent of the thickness of pad components 230
- the depth of grooves 234 and 235 may range from five percent to ninety-five percent of the thickness of pad component 230 in different configurations.
- first grooves 234 may be absent from pad component 230 , as depicted in FIG. 16D , but second grooves 235 may also be absent.
- grooves 234 and 235 are depicted as having a triangular, angled, or pointed configuration. Referring to FIG. 16E , grooves 234 and 235 have rounded or semi-circular shapes. Grooves 234 and 235 may also be squared, elongate and rectangular, or dovetailed (i.e., increasing in width as depth increases), as depicted in FIGS. 16F-16H . Various different shapes for grooves 234 and 235 may also be utilized in combination, as depicted in FIG. 16I .
- Pad component 230 may also have a layered configuration, as depicted in FIG. 16M .
- the layers may be different types or polymer foam or densities of polymer foam, or the layers may be different materials, such as polymer foam and rubber.
- the thicknesses of pad component 230 may be constant, pad component 230 may also have varying or tapered thicknesses, as depicted in FIG. 16N .
- a central area of pad component 230 may have greater thickness than a peripheral area of pad component 230 , as depicted in FIG. 16O .
- pad component 230 may have a rounded or contoured shape, as depicted in FIG. 16P .
- material layers 210 and 220 were absent from grooves 234 and 235 . That is, material layers 210 and 220 are not depicted as extending into grooves 234 and 235 . Referring to FIG. 16Q , however, material layers 210 and 220 extend into grooves 234 and 235 and are secured to surfaces within grooves 234 and 235 . In addition to enhancing flex, stretch, and breathability, this configuration may also present a unique or appealing aesthetic to apparel 100 .
- bonding agents e.g., adhesives, thermoplastic polymer sheets
- various methods may be employed to ensure that the bonding agents are limited to the areas of surfaces 231 and 232 that bond with layers 210 and 220 .
- a bonding agent 237 is located between pad component 230 and layers 210 and 220 .
- bonding agent 237 is limited to the areas of surfaces 231 and 232 that bond with layers 210 and 220 , thereby being absent from side surface 233 and the area within grooves 234 and 235 .
- cushioning element 200 may vary. Depending upon the specific type of apparel or location in the apparel, the properties may impart different degrees of impact force attenuation, flex, stretch, breathability, or other characteristics. As such, the variations discussed above may be utilized individually or in combination to impart particular characteristics to cushioning element 200 .
- Apparel 100 is depicted as having the general configuration of a pair of shorts. Another shorts configuration is depicted in FIG. 17A and includes the shapes of cushioning elements depicted in FIGS. 14F and 14G . In addition to shorts, the concepts discussed in relation to apparel 100 may be applied to other types of apparel.
- FIG. 17B depicts a pair of pants 401 that includes various cushioning elements 200 .
- a shirt 402 is depicted as including various cushioning elements 200 in locations that correspond with the sides, arms, and shoulders of a wearer.
- apparel 402 is depicted as a long-sleeved shirt, apparel 402 may have the configuration of other shirt-type garments, including short-sleeved shirts, tank tops, undershirts, jackets, and coats, for example.
- Cushioning elements 200 may also be incorporated into apparel that covers other areas of the wearer, such as hats, wraps, footwear, socks, gloves, and helmets, for example.
- a wrap 403 with one cushioning element 200 is depicted in FIG. 17D .
- Wrap 403 has a generally cylindrical configuration that may be placed upon an arm or a leg of a wearer. When, for example, the elbow is sore or injured, cushioning element 200 of wrap 403 may be located over the elbow to assist with protecting the elbow during athletic activities.
- a sockliner 404 that incorporates a cushioning element 200 is depicted in FIG. 17E . Sockliner 404 may be located within an article of footwear to cushion a lower surface of the foot.
- one or more cushioning elements 200 may be incorporated into a glove 405 , as depicted in FIG. 17F , to impart protection to a hand of the wearer.
- One or more cushioning elements 200 may also be incorporated into a helmet 406 , as depicted in FIG. 17G , to impart protection to a head of the wearer.
- cushioning elements 200 in these configurations may also simultaneously provide one or more of flex, stretch, breathability, a relatively low overall mass, and launderability.
- cushioning elements 500 are incorporated into various areas of apparel 100 .
- cushioning elements 500 are depicted as replacing the various cushioning elements 200 discussed above.
- cushioning elements 500 impart padding, cushioning, or otherwise attenuate impact forces.
- cushioning elements 500 may protect individual 10 from contact with other athletes, equipment, or the ground.
- cushioning elements 500 are located in both of pelvic region 101 and leg regions 102 and are positioned, more specifically, to protect the hips, thighs, and tailbone of individual 10 .
- cushioning elements 500 may be incorporated into a variety of different articles of apparel, such as any of pants 401 , shirt 402 , wrap 403 , sockliner 404 , glove 405 , and helmet 406 .
- Cushioning elements 500 may be positioned in various areas of the articles of apparel to protect specific portions (e.g., muscles, bones, joints, impact areas) of individual 10 . Additionally, the shapes, sizes, and other properties of cushioning elements 500 , as well as the materials and components utilized in cushioning elements 500 , may vary significantly to provide a particular level of protection to the specific portions of individual 10 .
- cushioning element 500 An example configuration for cushioning element 500 is depicted in FIGS. 19-21 as having a generally elongate shape with pointed end areas, which is the shape depicted as being incorporated into apparel 100 . As alternatives to this shape, cushioning element 500 may exhibit any of the shapes depicted in FIGS. 14A-14I , as well as any other practical shape.
- the primary components of each cushioning element 500 include a first material layer 510 , a second material layer 520 , and a pad component 530 .
- First material layer 510 and second material layer 520 cooperatively form an outer surface or covering for cushioning element 500 . That is, first material layer 510 and second material layer 520 cooperatively form a pocket or void, in which pad component 530 is located.
- first material layer 510 extends over pad component 530 and also along sides of pad component 530 to join with second material layer 520 (e.g., through stitching, adhesive bonding, or thermal bonding).
- cushioning element 500 may be incorporated into apparel 100 in a variety of ways, first material layer 510 may be positioned exterior of second material element 520 , such that cushioning element 500 protrudes outward from apparel 100 .
- second material layer 520 may be positioned exterior of first material element 510 , such that cushioning element 500 protrudes inwardly and toward individual 10 .
- first material layer 510 has a shape that covers pad component 530
- second material layer 520 may have a larger size that forms additional portions of apparel 100 .
- second material layer 520 may extend into both pelvic region 101 and one of leg regions 102 . That is, second material layer 520 may form one surface of cushioning element 500 and extend to other areas apparel 100 to form a covering for individual 10 .
- first material layer 510 forms a portion of exterior surface 105
- second material layer 520 forms a portion of both exterior surface 105 and interior surface 106 .
- a portion of second material layer 520 that is secured to pad component 530 is located inward of first material layer 510 and forms a portion of interior surface 106 .
- second material layer 520 forms a portion of exterior surface 105 , as well as interior surface 106 . As such, second material layer 520 forms both a portion of a covering for pad component 530 and other portions of apparel 100 .
- first material layer 510 and second material layer 520 may be utilized for first material layer 510 and second material layer 520 , including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for each of material layers 510 and 520 . Although material layers 510 and 520 may be formed from the same material, each of material layers 510 and 520 may also be formed from different materials. With regard to textiles, material layers 510 and 520 may be formed from knitted, woven, non-woven, spacer, or mesh textile components that include rayon, nylon, polyester, polyacrylic, elastane, cotton, wool, or silk, for example. Moreover, the textiles may be non-stretch, may exhibit stretch in one direction, or may exhibit multi-directional stretch. Accordingly, a variety of materials are suitable for first material layer 510 and second material layer 520 .
- Pad component 530 is depicted individually in FIGS. 22-23D .
- pad component 530 When incorporated into cushioning element 500 , pad component 530 is located between and secured to each of material layers 510 and 520 . More particularly, pad component 530 has a first surface 531 secured to first material layer 510 , an opposite second surface 532 secured to second material layer 520 , and a side surface 533 that extends between surfaces 531 and 532 and forms a peripheral edge. In other configurations, however, pad component 530 may be unsecured to one or both of material layers 510 and 520 .
- First surface 531 defines a plurality of elongate grooves 534 that extend throughout a length of pad component 530 and toward second surface 532 .
- grooves 534 are depicted as being stippled (i.e., speckled or dotted) to assist with distinguishing grooves 534 from other features of pad component 530 .
- grooves 534 are depicted as being aligned with each other, having a squared shape, and being formed in first surface 531 , grooves 534 may have various other configurations.
- grooves 534 may be unaligned with each other, grooves 534 may have any practical shape, and grooves 534 may be formed in first surface 531 , second surface 532 , or both of surfaces 531 and 532 .
- grooves 534 may have any of the numerous features and variations discussed above for grooves 234 and 235 , and grooves 534 may have any of the configurations for grooves 234 and 235 depicted in FIGS. 15A-15J and 16 A- 16 J, for example. Accordingly, grooves 534 may have numerous configurations.
- pad component 530 defines various elongate voids 535 that extend through pad component 530 and from first surface 531 to second surface 532 .
- voids 535 form apertures or holes in pad component 530 .
- voids 535 may have a variety of other configurations, some of which are discussed below. As depicted, voids 535 have a length that extends across a majority of a width of pad component 530 .
- End areas of voids 535 are, however, generally spaced inward from side surface 533 .
- voids 535 will effectively subdivide pad component 530 into two or more separate sections, similar to the configuration of pad component 230 depicted in FIG. 15G .
- spacing end areas of voids 535 inward from side surface 533 retains a one-piece configuration for pad component 530 .
- An advantage of the one-piece configuration is that a single element (i.e., the entirety of pad component 530 ), rather than multiple separate elements, is positioned relative to material layers 510 and 520 during the manufacturing process for cushioning element 500 .
- pad component 530 A variety of materials may be utilized for pad component 530 , including various polymer foam materials that return to an original shape after being compressed.
- suitable polymer foam materials for pad component 530 include polyurethane, ethylvinylacetate, polyester, polypropylene, and polyethylene foams.
- thermoplastic and thermoset polymer foam materials may be utilized.
- pad component 530 may be formed from a polymer foam material with a varying density, or solid (i.e., substantially non-foamed) polymer or rubber materials may be utilized. Fluid-filled chambers may also be utilized as pad component 530 .
- different pad components 530 may be formed from different materials, or may be formed from similar materials with different densities, degrees of foaming, or other properties.
- the compressible polymer foam materials forming pad component 530 attenuate impact forces that compress or otherwise contact cushioning element 500 .
- the polymer foam materials of pad component 530 may compress to protect a wearer from contact with other athletes, equipment, or the ground.
- the degree of impact force attenuation may be varied throughout apparel 100 to impart a desired degree of cushioning or protection.
- cushioning element 500 may be utilized to provide cushioning or protection to areas of individual 10 or other wearers that are covered by cushioning element 500 .
- cushioning element 500 has an advantage of simultaneously providing one or more of flex, stretch, compressibility, breathability, relatively low overall mass, and launderability.
- pad component 530 flexes, stretches, and breathes in the manner shown in FIGS. 10A-10C .
- the presence of voids 535 complements these properties.
- force 20 is shown as stretching pad component 530 .
- voids 535 expand in size more than other areas of pad component 530 to impart greater stretch.
- force 20 is shown as compressing pad component 530 .
- voids 535 decrease in size or otherwise compress more than other areas of pad component 530 to impart greater compressibility.
- This combination of stretch and compressibility may, for example, enhance the ability of cushioning element 500 to conform with movements of the body of individual 10 . That is, as individual 10 performs various actions (e.g., running, jumping, crouching, twisting) cushioning element 500 may stretch and compress, thereby not hindering movements of the body of individual 10 .
- voids 535 impart greater breathability to allow heat and moisture to exit cushioning element 500 .
- cushioning element 500 A variety of techniques may be utilized to manufacture cushioning element 500 , including the general manufacturing process discussed above for cushioning element 200 . Additionally, various processes may be utilized to form pad component 530 . In one process, polymer resin with a blowing agent may be located in a mold having the shape of pad component 530 . An advantage to this process is that a single process may be used to form the polymer foam material of pad component 530 , as well as the various grooves 534 and voids 535 . In another process, a preformed layer of polymer foam may be obtained, and a router or other cutting device may be used to form grooves 534 and voids 535 .
- a programmable, multi-function fabrication table may be utilized to form both grooves 534 and voids 535 , such as an M Series flatbed cutter manufactured by Gerber Scientific Products of Tolland, Conn., United States of America.
- grooves 534 and voids 535 may be formed from a heated element that presses into a preformed layer of polymer foam, or a computer-controlled machine tool may be utilized.
- a three-dimensional printer may be utilized to form pad component 530 .
- cushioning element 500 may vary, depending upon the intended use for cushioning element 500 and the product in which cushioning element 500 is incorporated. Moreover, changes to the dimensions, shapes, and materials utilized within cushioning element 500 may vary the overall properties of cushioning element 500 . That is, by changing the dimensions, shapes, and materials utilized within cushioning element 500 , the compressibility, impact force attenuation, flex, stretch, compressibility, breathability, and overall mass of cushioning element 500 may be tailored to specific purposes or products. A plurality of variations for cushioning element 500 are discussed below. Any of these variations, as well as combinations of these variations, may be utilized to tailor the properties of cushioning element 500 to an intended use. Moreover, any of these variations may be manufactured through the process or variations of the process discussed above.
- first material layer 510 and second material layer 520 may also vary significantly.
- material layers 510 and 520 may be formed from various textiles, polymer sheets, leather, synthetic leather, or combinations of materials, for example.
- breathability may be enhanced when the materials are air-permeable.
- textiles are permeable to both heat and moisture.
- Polymer sheets, leather, synthetic leather, or combinations of materials may not exhibit significant permeability.
- various perforations, holes, or apertures may be formed in one or both of material layers 510 and 520 to enhance breathability.
- first material layer 510 may be entirely absent from cushioning element 500 , similar to FIG. 14K .
- aspects relating to pad component 530 may also vary to tailor cushioning element 500 to an intended use or enhance the properties of cushioning element 500 .
- grooves 534 may have any of the variations for grooves 235 and 235 discussed above.
- FIG. 25A various aspects of voids 535 are modified to illustrate variations. More particularly, an individual void 535 may have (a) a lesser length, (b) an arrangement that is aligned with other voids 535 , (c) a lesser width, (d) a greater width, (e) a tapered or non-rectangular shape, or (f) a non-linear shape.
- voids 535 may extend across a majority of a width of pad component 530 to maximize the stretch and compressibility properties shown in FIGS. 24A and 24B . By altering the length, however, the degree of stretch and compressibility may be varied in cushioning element 500 or specific areas of cushioning element 500 .
- the width of voids 535 may also vary from one millimeter to twenty millimeters or more. One consideration with width relates to the ability of objects to protrude through voids 535 . By forming voids 535 to have a lesser relative width, the probability of an object protruding through or into voids 535 is decreased.
- shape voids 535 may be rectangular, triangular, non-regular or any shape that imparts a desired degree of flex, stretch, compressibility, and breathability. Moreover, the shapes of voids 535 may be varied for aesthetic reasons.
- grooves 534 and voids 535 may also vary significantly. Referring to FIG. 25B , grooves 534 extend across the width of pad component 530 , whereas voids 535 extend through a majority of the length of pad component 530 . Although grooves 534 and voids 535 may be arranged to be perpendicular to each other, grooves 534 and voids 535 may also be offset at other angles, as depicted in FIG. 25C . Similarly, grooves 534 and voids 535 may also be parallel to or aligned with each other, as depicted in FIG. 25D . Although voids 535 may be arranged to be parallel to each other, voids 535 may also be non-parallel. As an example, FIG.
- FIG. 25E depicts voids 535 as radiating outward from a common area.
- FIG. 25F depicts various voids 535 as intersecting each other to form two X-shaped structures. Accordingly, numerous aspects relating to the shape, orientation, and arrangement of grooves 534 and voids 535 may vary considerably.
- FIG. 25G Another configuration of pad component 530 is depicted in FIG. 25G , in which voids 535 form shapes representing the number one and a star. Voids 535 may, therefore, form relatively complex shapes that provide information or fashion indicia. As examples, voids 535 may (a) display an athlete's assigned number, (b) form a team name, (c) represent a trademark or other identifying information for a manufacturer of apparel 100 , or (d) show an abstract depiction for aesthetic purposes. As the complexity of the information or indicia increases, however, one consideration relates to segregating separate sections of pad component 530 with voids 535 . Referring again to FIG.
- two separate voids 535 outline the number one, which forms a pair of connecting portions 537 at upper and lower areas of the number one to ensure that a central area of the number one remains connected to a remainder of pad component 530 .
- the void 535 outlining the star does not form structures similar to connecting portions 537 .
- a central area of the star is separate from a remainder of pad component 530 .
- additional steps may be necessary to ensure that the central area of the star remains properly positioned relative to the remainder of pad component 530 .
- both grooves 534 and voids 535 are present in pad component 530 . In some configurations, however, grooves 534 may be absent from pad component 530 . Referring to FIG. 25H , for example, voids 535 extend through various areas of pad component 530 and provide stretch, compressibility, and breathability throughout cushioning element 500 without grooves 534 .
- Grooves 534 and voids 535 cross or otherwise intersect each other in many of the prior examples of pad component 530 discussed above. Referring to FIG. 26 , however, areas of grooves 534 and voids 535 are aligned with each other. Another manner of considering this structure is that grooves 534 and voids 535 are superimposed or otherwise overlay each other. In any event, FIG.
- FIG. 26 depicts configurations where (a) grooves 534 extend from the end areas of various voids 535 , (b) grooves 534 and voids 535 alternate across pad component 530 , (c) voids 535 extend inward from side surface 533 and to end areas of grooves 534 , and (d) grooves 534 alternate between being formed in first surface 531 and second surface 532 . Any of these various configurations may be utilized to modify the properties or aesthetics of pad component 530 , as well as decreasing the probability of an object protruding through or into voids 535 . Moreover, forming grooves 534 within areas of voids 535 may enhance the structural integrity of pad component 530 .
- FIGS. 28 and 29 A- 29 D Another configuration is depicted in FIGS. 28 and 29 A- 29 D, wherein pad component 530 includes a beveled edge 536 that extends around pad component 530 and forms an angled transition between surfaces 531 and 533 .
- grooves 534 and voids 535 may be absent from the area of beveled edge 536
- grooves 534 are depicted as extending through beveled edge 536
- voids 535 are depicted as extending to beveled edge 536 .
- voids 535 may extend into the area of beveled edge 536 or end areas of grooves 534 and voids 535 may be spaced from beveled edge 536 .
- An advantage of forming pad component 530 to include beveled edge 536 relates to the transition between first surface 531 and side surface 533 . More particularly, beveled edge 536 forms a smoother or less abrupt transition between cushioning elements 500 and areas of apparel 100 where cushioning elements 500 are absent. As noted above, apparel 100 may be worn under other articles of apparel or may be worn in combination with other pieces of equipment (e.g., athletic or protective equipment). In either of these scenarios, beveled edge 536 may ensure that the apparel or equipment covering cushioning elements 500 smoothly transitions to areas where cushioning elements 500 are absent. In further configurations, as respectively depicted in FIGS.
- beveled edge 536 may (a) extend to second surface 532 , rather than side surface 533 , (b) exhibit an outwardly-protruding and rounded configuration, (c) exhibit an inwardly-protruding and rounded configuration, or (d) form an indentation in a side of pad component 530 .
- the specific configuration for beveled edge 536 may depend upon whether apparel 100 is intended to be worn over or under other articles of apparel or equipment.
- a configuration similar to FIG. 30D may allow equipment to interface and effectively join with cushioning element 500 . That is, a portion of the equipment may extend into the indented area formed by beveled edge 536 .
- voids 535 are depicted as having various example configurations that are tapered, cross-shaped, protruding or curving outwardly and inwardly, slanted, and T-shaped. Voids 535 may be any of these shapes, as well as other shapes, to impart desired properties to cushioning element 500 , such as flex, stretch, compressibility, and breathability, for example. Through selecting a shape for one or more of voids 535 , therefore, particular properties may be imparted to cushioning element 500 .
- tapered and T-shaped voids 535 may permit cushioning element 500 to flex more in one direction than in an opposite direction.
- various non-uniform shapes for voids 535 e.g., tapered, cross-shaped, protruding or curving, slanted, and T-shaped
- voids 535 may be utilized to limit the ability of objects to protrude through voids 535 , thereby contacting the individual wearing apparel 100 , while imparting the desired properties to cushioning element 500 .
- different grooves 534 and voids 535 may have different widths or shapes to further vary the properties of cushioning element 500 .
- the layers may be different types of polymer foam or densities of polymer foam, or the layers may be different materials, such as polymer foam and rubber.
- the layers may also have different colors to impart aesthetic qualities to cushioning element 500 .
- voids 535 may extend through one layer and into the other layer to expose the color of the underlying layer.
- voids 535 are depicted as being tapered so that the color of the underlying layer may be seen, thereby enhancing the aesthetic attributes of cushioning element 500 .
- a similar concept may apply to grooves 534 , which may extend through one layer and into the other layer to expose the color of the underlying layer.
- pad component 530 may be constant, pad component 530 may also have varying or tapered thicknesses, as depicted in FIG. 31C , to further modify the properties or aesthetics of cushioning element 500 .
- a central area of pad component 530 may have greater thickness than a peripheral area of pad component 530 , as depicted in FIG. 31D .
- pad component 530 may have a rounded or contoured shape, as depicted in FIG. 31E , to better conform with contours of individual 10 .
- FIGS. 32 and 33 Further configurations of pad component 530 are depicted in FIGS. 32 and 33 . These configurations of pad component 530 may be utilized, for example, in a thigh area or a hip area of apparel 100 . As with configurations of pad component 530 discussed above, these configurations include grooves 534 and voids 535 that cross each other and extend in various directions, as well as having beveled edge 536 . Moreover, these configurations of pad component 530 incorporate combinations and orientations of grooves 534 and voids 535 in specific areas in order to impart varying degrees of flex, stretch, compressibility, and breathability, for example. Accordingly, many of the features and variations discussed above may be incorporated into one pad component 530 to provide different combinations of properties to different areas of cushioning element 500 .
- cushioning element 500 may vary. Depending upon the specific type of apparel or location in the apparel, the properties may impart different degrees of impact force attenuation, flex, stretch, compressibility, breathability, or other properties. As such, the variations discussed above may be utilized individually or in combination to impart particular characteristics or combinations of properties to cushioning element 500 .
Abstract
Cushioning elements for apparel may include a pair of material layers and a pad component that is located between and secured to the material layers. At least one surface of the pad component includes a plurality of elongate grooves. In addition, a plurality of elongate voids extend through the pad component.
Description
- This U.S. patent application is a continuation-in-part application and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 13/189,716, which was filed in the U.S. Patent and Trademark Office on 25 Jul. 2011 and entitled Articles Of Apparel Incorporating Cushioning Elements, such prior U.S. patent application being entirely incorporated herein by reference.
- Materials or elements that impart padding, cushioning, or otherwise attenuate impact forces are commonly incorporated into a variety of products. Athletic apparel, for example, often incorporates cushioning elements that protect the wearer from contact with other athletes, equipment, or the ground. More specifically, pads used in American football and hockey incorporate cushioning elements that provide impact protection to various parts of a wearer. Helmets utilized during American football, hockey, bicycling, skiing, snowboarding, and skateboarding incorporate cushioning elements that provide head protection during falls or crashes. Similarly, gloves utilized in soccer (e.g., by goalies) and hockey incorporate cushioning elements that provide protection to the hands of a wearer. Cushioning elements may also be incorporated into bicycling shorts. Apparel that is utilized for generally non-athletic purposes may also incorporate cushioning elements, such as apparel that is worn for motorcycle riding and knee protectors for gardening or construction work.
- Various cushioning elements that may be utilized in apparel and a variety of other products are disclosed below. In general, the cushioning elements include a pair of material layers and a pad component that is located between and secured to the material layers. At least one surface of the pad component includes a plurality of grooves. In some configurations, both surfaces include the grooves. Moreover, the grooves may be elongate and extend at least partially across the pad component. In addition, a plurality of elongate voids may extend through the pad component and from one surface to the other surface.
- The advantages and features of novelty characterizing aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying figures that describe and illustrate various configurations and concepts related to the invention.
- The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying figures.
-
FIG. 1 is a front elevational view of an individual wearing an article of apparel. -
FIG. 2 is a front elevational view of the article of apparel. -
FIGS. 3 and 4 are side elevational views of the article of apparel. -
FIG. 5 is a rear elevational view of the article of apparel. -
FIG. 6 is a perspective view of a first cushioning element. -
FIG. 7 is an exploded perspective view of the first cushioning element. -
FIG. 8 is a top plan view of the first cushioning element. -
FIGS. 9A-9C are cross-sectional views of the first cushioning element, as defined bysection lines 9A-9C inFIG. 8 . -
FIG. 10A is a cross-sectional view corresponding withFIG. 9A and depicting the first cushioning element in a flexed configuration. -
FIG. 10B is a cross-sectional view corresponding withFIG. 9A and depicting the first cushioning element in a stretched configuration. -
FIG. 100 is a cross-sectional view corresponding withFIG. 9C and depicting breathability of the first cushioning element. -
FIG. 11 is a perspective view of portions of a manufacturing apparatus utilized in a manufacturing process for the first cushioning element. -
FIGS. 12A-12D are schematic perspective views of the manufacturing process. -
FIGS. 13A-13D are schematic cross-sectional views of the manufacturing process, as respectively defined bysection lines 13A-13D inFIGS. 12A-12D . -
FIGS. 14A-14K are top plan views corresponding withFIG. 8 and depicting further configurations of the first cushioning element. -
FIGS. 15A-15J are perspective views depicting further configurations of a first pad component from the first cushioning element. -
FIGS. 16A-16R are cross-sectional views corresponding withFIG. 9A and depicting further configurations of the first cushioning element. -
FIGS. 17A-17G are elevational views of further articles of apparel incorporating the cushioning element. -
FIG. 18 is a front elevational view of another configuration of the article of apparel. -
FIG. 19 is a perspective view of a second cushioning element. -
FIG. 20 is an exploded perspective view of the second cushioning element. -
FIG. 21 is a top plan view of the second cushioning element. -
FIG. 22 is a top plan view of a second pad component from the second cushioning element. -
FIGS. 23A-23D are cross-sectional views of the second pad component, as defined bysection lines 23A-23D inFIG. 22 . -
FIG. 24A is a top plan view of the second pad component in a stretched configuration. -
FIG. 24B is a top plan view of the second pad component in a compressed configuration. -
FIGS. 25A-25H are top plan views corresponding withFIG. 22 and depicting further configurations of the second pad component. -
FIG. 26 is a top plan view corresponding withFIG. 22 and depicting another configuration of the second pad component. -
FIGS. 27A-27E are cross-sectional views, as defined bysection lines 27A-27E inFIG. 26 . -
FIG. 28 is a top plan view corresponding withFIG. 22 and depicting another configuration of the second pad component. -
FIGS. 29A-29D are cross-sectional views, as defined bysection lines 29A-29D inFIG. 28 . -
FIGS. 30A-30D are cross-sectional views corresponding withFIG. 29D and depicting further configurations of the second pad component. -
FIGS. 31A-31E are cross-sectional views corresponding withFIG. 23D and depicting further configurations of the second pad component. -
FIGS. 32 and 33 are top plan views corresponding withFIG. 22 and depicting further configurations of the second pad component. - The following discussion and accompanying figures disclose various configurations of cushioning elements that may be incorporated into a variety of products, including articles of apparel, such as shorts, pants, shirts, wraps, footwear, gloves, and helmets.
- Apparel Configuration
- With reference to
FIG. 1 , a wearer or individual 10 is depicted as wearing an article ofapparel 100 with the general configuration of a pair of shorts. Althoughapparel 100 may be worn under other articles of apparel,apparel 100 may be worn alone, may be exposed, or may be worn over other articles of apparel.Apparel 100 may also be worn in combination with other pieces of equipment (e.g., athletic or protective equipment). Althoughapparel 100 may be loose-fitting,apparel 100 is depicted as having a relatively tight fit of a compression garment. Accordingly, the configuration ofapparel 100 and the manner in whichapparel 100 is worn by individual 10 may vary significantly. -
Apparel 100 is depicted individually inFIGS. 2-5 as including apelvic region 101 and a pair ofleg regions 102 that extend outward frompelvic region 101.Pelvic region 101 corresponds with a pelvic area ofindividual 10 and covers at least a portion of the pelvic area when worn. An upper area ofpelvic region 101 defines awaist opening 103 that extends around a waist of individual 10 whenapparel 100 is worn.Leg regions 102 correspond with a right leg and a left leg ofindividual 10 and cover at least a portion of the right leg and the left leg when worn. Lower areas ofleg regions 102 each define athigh opening 104 that extends around a thigh of individual 10 whenapparel 100 is worn. Additionally,apparel 100 includes anexterior surface 105 that faces away from individual 10 whenapparel 100 is worn, andapparel 100 includes an oppositeinterior surface 106 that faces towardindividual 10 and may contact individual 10 whenapparel 100 is worn. - A plurality of
cushioning elements 200 are incorporated into various areas ofapparel 100 to impart padding, cushioning, or otherwise attenuate impact forces. Whenapparel 100 is worn during athletic activities, for example, cushioningelements 200 may protect individual 10 from contact with other athletes, equipment, or the ground. With regard toapparel 100, cushioningelements 200 are located in both ofpelvic region 101 andleg regions 102 and are positioned, more specifically, to protect the hips, thighs, and tailbone ofindividual 10. As described in greater detail below, cushioningelements 200 may be incorporated into a variety of different articles of apparel, andcushioning elements 200 may be positioned in various areas of the articles of apparel to protect specific portions (e.g., muscles, bones, joints, impact areas) ofindividual 10. Additionally, the shapes, sizes, and other properties of cushioningelements 200, as well as the materials and components utilized incushioning elements 200, may vary significantly to provide a particular level of protection to the specific portions ofindividual 10. - Cushioning Element Configuration
- An example configuration for cushioning
element 200 is depicted inFIGS. 6-9B as having a generally elongate shape with pointed end areas, which is the shape depicted as being incorporated intoapparel 100. Cushioningelement 200 includes afirst material layer 210, asecond material layer 220, and apad component 230.First material layer 210 andsecond material layer 220 cooperatively form an outer surface or covering for cushioningelement 200. That is,first material layer 210 andsecond material layer 220 cooperatively form a pocket or void, in whichpad component 230 is located. Whereassecond material layer 220 is depicted as having a generally planar configuration,first material layer 210 extends overpad component 230 and also along sides ofpad component 230 to join with second material layer 220 (e.g., through stitching, adhesive bonding, or thermal bonding). Although cushioningelement 200 may be incorporated intoapparel 100 in a variety of ways,first material layer 210 may be positioned exterior ofsecond material element 220, such thatcushioning element 200 protrudes outward fromapparel 100. Alternately,second material layer 220 may be positioned exterior offirst material element 210, such thatcushioning element 200 protrudes inwardly. - Whereas
first material layer 210 has a shape that coverspad component 230,second material layer 220 may have a larger size that forms additional portions ofapparel 100. For example,second material layer 220 may extend into bothpelvic region 101 and one ofleg regions 102. That is,second material layer 220 may form one surface ofcushioning element 200 and extend toother areas apparel 100 to form a covering forindividual 10. In this configuration,first material layer 210 forms a portion ofexterior surface 105, whereassecond material layer 220 forms a portion of bothexterior surface 105 andinterior surface 106. More particularly, a portion ofsecond material layer 220 that is secured to padcomponent 230 is located inward offirst material layer 210 and forms a portion ofinterior surface 106. Another portion ofsecond material layer 220 that is spaced frompad component 230 forms a portion ofexterior surface 105, as well asinterior surface 106. As such,second material layer 220 forms both a portion of a covering forpad component 230 and other portions ofapparel 100. - A variety of materials may be utilized for
first material layer 210 andsecond material layer 220, including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for each ofmaterial layers material layers material layers first material layer 210 andsecond material layer 220. -
Pad component 230 is located between and secured to each ofmaterial layers pad component 230 has afirst surface 231 secured tofirst material layer 210, an oppositesecond surface 232 secured tosecond material layer 220, and aside surface 233 that extends betweensurfaces First surface 231 defines a plurality offirst grooves 234 that extend throughout a length ofpad component 230 and towardsecond surface 232. Similarly,second surface 232 defines a plurality ofsecond grooves 235 that extend throughout the length ofpad component 230 and towardfirst surface 231.First grooves 234 are aligned withsecond grooves 235. As utilized herein, “aligned” is defined as extending in a common direction and includes (a) parallel configurations forgrooves grooves grooves grooves first grooves 234 are located in areas ofpad component 230 that are between areas wheresecond grooves 235 are located. Moreover, each ofgrooves pad component 230 is secured tomaterial layers surfaces material layers material layers - Although features of
pad component 230 andgrooves pad component 230 may have a thickness (i.e., distance betweensurfaces 231 and 232) of ten millimeters. Given this thickness,grooves grooves pad component 230. Moreover,grooves element 200, as discussed below. These dimensions and percentages, however, are intended to merely be examples, and the dimensions and percentages may vary considerably from the specific numbers identified above. - A variety of materials may be utilized for
pad component 230, including various polymer foam materials that return to an original shape after being compressed. Examples of suitable polymer foam materials forpad component 230 include polyurethane, ethylvinylacetate, polyester, polypropylene, and polyethylene foams. Moreover, both thermoplastic and thermoset polymer foam materials may be utilized. In some configurations ofcushioning element 200,pad component 230 may be formed from a polymer foam material with a varying density, or solid polymer or rubber materials may be utilized. Fluid-filled chambers may also be utilized aspad component 230. Also,different pad component 230 may be formed from different materials, or may be formed from similar materials with different densities. As discussed in greater detail below, the polymer foam materials formingpad component 230 attenuate impact forces to provide cushioning or protection. By selecting thicknesses, materials, and densities for each of thevarious pad component 230, the degree of impact force attenuation may be varied throughoutapparel 100 to impart a desired degree of cushioning or protection. - The compressible polymer foam materials forming
pad component 230 attenuate impact forces that compress or otherwise contactcushioning element 200. When incorporated intoapparel 100 or another article of apparel, for example, the polymer foam materials ofpad component 230 may compress to protect a wearer from contact with other athletes, equipment, or the ground. Accordingly, cushioningelement 200 may be utilized to provide cushioning or protection to areas of individual 10 or other wearers that are covered by cushioningelement 200. - In addition to attenuating impact forces, cushioning
element 200 has an advantage of simultaneously providing one or more of flex, stretch, breathability, relatively low overall mass, and launderability. Referring toFIG. 10A , cushioningelement 200 is depicted as being flexed. In this configuration,first grooves 234 effectively expand andsecond grooves 235 effectively collapse to impart flexibility. Referring toFIG. 10B , cushioningelement 200 is depicted as being stretched by aforce 20. In this configuration, the offset structure ofgrooves permits pad component 230 to flatten or otherwise elongate due to the effects offorce 20. An advantage to flex and stretch is that cushioningelement 200 may better conform with contours ofindividual 10, andcushioning element 200 may expand, collapse, flatten, and elongate to facilitate movements ofindividual 10, while still conforming with the contours of individual 10 during the movements. Additionally, individual 10 may generate excess heat and perspire when wearingapparel 100 and engaging in athletic activities. Referring toFIG. 10C , the breathability ofcushioning element 200 is depicted byvarious paths 30, along which heat and moisture may pass to exitcushioning element 200. The heat and moisture from individual 10 may, therefore, (a) pass throughsecond material layer 220, (b) enter one ofsecond grooves 235, (c) move to end areas ofsecond groove 235, and (d) pass throughfirst material layer 210, thereby exitingapparel 100. Furthermore, the materials and structure discussed above for cushioning element 200 (a) imparts a relatively low overall mass that does not add significant weight to individual 10 during the athletic activities and (b) permits laundering without significant shrinkage or warping, even when temperatures associated with commercial laundering processes are utilized. Accordingly, cushioningelement 200 may simultaneously provide impact force attenuation, flex, stretch, breathability, relatively low overall mass, and launderability. - Manufacturing Process
- A variety of techniques may be utilized to manufacture
cushioning element 200. With reference toFIG. 11 , a manufacturing apparatus 300 is disclosed as including apress 310 and asewing machine 320. Other elements, such as a mold, router, die cutter, or laser may also be utilized, but are not depicted here. A variety of other manufacturing apparatuses that operate in a similar manner may also be utilized. Accordingly, manufacturing apparatus 300 is only intended to provide an example of a manufacturing apparatus for the production ofcushioning element 200. - Initially, the various components of
cushioning element 200 are cut, shaped, or otherwise prepared. For example, material layers 210 and 220 may be cut to a particular shape using die cutting, laser cutting, or hand cutting processes. Whereasfirst material layer 210 has a shape that coverspad component 230 and extends alongsidesurface 233,second material layer 220 may have a larger size that forms additional portions ofapparel 100. For example,second material layer 220 may extend into bothpelvic region 101 and one ofleg regions 102. That is,second material layer 220 may form one surface ofcushioning element 200 and extend toother areas apparel 100 to form a covering forindividual 10. Various processes may also be utilized to formpad component 230. For example, polymer resin with a blowing agent may be located in a mold having the shape ofpad component 230. An advantage to this process is that a single process may be used to form the polymer foam material ofpad component 230, as well as thevarious grooves grooves grooves pad component 230, or a polymer foamelement having grooves pad component 230. - Once the various components of
cushioning element 200 are cut, shaped, or otherwise prepared, the components may be placed between twoplatens press 310, as depicted inFIGS. 12A and 13A . More particularly,first material layer 210 may be located adjacent to platen 311,second material layer 220 may be located adjacent to platen 312, andpad component 230 may be located betweenlayers platens first material layer 210,second material layer 220, andpad component 230, as depicted inFIGS. 12B and 13B . More particularly,platen 311 compressesfirst material layer 210 againstfirst surface 231 ofpad component 230, andplaten 312 compressessecond material layer 220 againstsecond surface 232 ofpad component 230. -
Platens pad component 230 betweenmaterial layers bond pad component 230 to each ofmaterial layers material layers pad components 230 or (b) surfaces 231 and 232 ofpad component 230. Although the adhesive may be applied tomaterial layers surfaces material layers pad component 230. As another example, heat may be utilized tobond pad component 230 to each ofmaterial layers pad component 230 is formed from a thermoplastic polymer foam material, heating and melting ofpad component 230 atsurfaces bond pad component 230 to each ofmaterial layers press 310 may be heated such that contact withplatens pad component 230 to a level that facilitates bonding. - One consideration at this stage of the manufacturing process relates to the method by which an adhesive, thermoplastic polymer material, or a thermoplastic bonding agent is applied to the components of
cushioning element 200. As noted above, an advantage of applying an adhesive tosurfaces material layers pad component 230. A similar advantage applies to a thermoplastic polymer material or thermoplastic bonding agent. Moreover, applying the adhesive, thermoplastic polymer material, or thermoplastic bonding agent tosurfaces grooves grooves grooves grooves grooves surfaces layers cushioning element 200 are applied, excess materials that may form unintended bonds or detract from the aesthetic properties of cushioningelement 200 may be avoided. - Following compression and bonding,
platens cushioning element 200, as depicted inFIGS. 12C and 13C . At this stage of the manufacturing process,first material layer 210 is unsecured tosecond material layer 220. Additional stitching, adhesive, or thermal bonding steps may now be utilized to joinmaterial layers pad components 230. As an example,sewing machine 320 may be utilized to stitchmaterial layers FIGS. 12D and 13D , thereby substantially completing the manufacture ofcushioning element 200. - Further Cushioning Element Configurations
- Aspects of
cushioning element 200 may vary, depending upon the intended use for cushioningelement 200 and the product in whichcushioning element 200 is incorporated. Moreover, changes to the dimensions, shapes, and materials utilized withincushioning element 200 may vary the overall properties of cushioningelement 200. That is, by changing the dimensions, shapes, and materials utilized withincushioning element 200, the compressibility, impact force attenuation, flex, stretch, breathability, and overall mass ofcushioning element 200 may be tailored to specific purposes or products. A plurality of variations for cushioningelement 200 are discussed below. Any of these variations, as well as combinations of these variations, may be utilized to tailor the properties of cushioningelement 200 to an intended use. Moreover, any of these variations may be manufactured through the process or variations of the process discussed above. - As discussed above,
cushioning component 200 may have a generally elongate shape with pointed end areas. The overall shape ofcushioning element 200 may, however, vary to include a variety of other shapes. Referring toFIG. 14A , cushioningelement 200 exhibits a generally rectangular shape. In further configurations, cushioningelement 200 may have a round, triangular, hexagonal, or H-shaped structure, as respectively depicted inFIGS. 14B-14E . Although any of these shapes may be utilized inapparel 100, various other shapes may also be utilized. As examples,FIG. 14F depicts a configuration ofcushioning element 200 with a shape suitable for a hip pad,FIG. 14G depicts a configuration ofcushioning element 200 with a shape suitable for a thigh pad, andFIG. 14H depicts a configuration ofcushioning element 200 with a shape suitable for a tailbone pad. A configuration for cushioningelement 200 that has a shape suitable for an elbow pad (e.g., for a shirt, jacket, or arm sleeve) is depicted inFIG. 14I . - Various aspects relating to
first material layer 210 andsecond material layer 220 may also vary significantly. As discussed above, material layers 210 and 220 may be formed from various textiles, polymer sheets, leather, synthetic leather, or combinations of materials, for example. Moreover, breathability may be enhanced when the materials are air-permeable. In general, textiles are permeable to both heat and moisture. Polymer sheets, leather, synthetic leather, or combinations of materials, however, may not exhibit significant permeability. As depicted inFIG. 14J , various perforations, holes, or apertures may be formed in one or both ofmaterial layers FIG. 14K ,first material layer 210 may be entirely absent from cushioningelement 200. - Aspects relating to pad
component 230 may also vary to tailorcushioning element 200 to an intended use or enhance the properties of cushioningelement 200. As an example, the configuration ofgrooves FIGS. 15A and 15B , the width ofgrooves grooves FIG. 15C ,grooves pad component 230, rather than extending across the length. In order to impart flex and stretch in multiple directions,grooves pad component 230, as depicted inFIG. 15D . Althoughgrooves FIGS. 15E and 15F . In another configuration,pad component 230 may be segmented or otherwise formed from two or more separate elements. Referring to FIG. 15G, for example,pad component 230 includes three spaced sections, which may enhance the flex and breathability ofcushioning element 200. - Although
grooves pad component 230,grooves pad component 230. Referring toFIG. 15H , for example,first grooves 234 extend across a majority of the length ofpad component 230, but are spaced from peripheral areas ofpad component 230.Second grooves 235 may have a similar configuration. InFIG. 15I ,grooves pad component 230, but are absent from another region ofpad component 230.Grooves pad component 230 from opposite sides ofpad component 230, as depicted inFIG. 15J . Accordingly,grooves pad component 230. - Various aspects relating to the relative size and locations of
grooves FIG. 16A , for example,grooves pad component 230, rather than being offset.FIG. 16B depicts a configuration wherein the spacing ofgrooves pad component 230, andFIG. 16C depicts a configuration wherein the depth ofgrooves pad component 230. Although the depth ofgrooves pad components 230, the depth ofgrooves pad component 230 in different configurations. In some configurations,first grooves 234 may be absent frompad component 230, as depicted inFIG. 16D , butsecond grooves 235 may also be absent. - In many of the configurations discussed above,
grooves FIG. 16E ,grooves Grooves FIGS. 16F-16H . Various different shapes forgrooves FIG. 16I . - Various additional features may be incorporated into
pad component 230. Referring toFIG. 16J ,various apertures 236 extend throughpad component 230, which may enhance the breathability ofcushioning element 200. In some configurations, a greater thickness may be desired, as inFIG. 16K , or a lesser thickness may be desired, as inFIG. 16L .Pad component 230 may also have a layered configuration, as depicted inFIG. 16M . As an example, the layers may be different types or polymer foam or densities of polymer foam, or the layers may be different materials, such as polymer foam and rubber. Although the thicknesses ofpad component 230 may be constant,pad component 230 may also have varying or tapered thicknesses, as depicted inFIG. 16N . In some configurations ofcushioning element 200, a central area ofpad component 230 may have greater thickness than a peripheral area ofpad component 230, as depicted inFIG. 16O . Additionally,pad component 230 may have a rounded or contoured shape, as depicted inFIG. 16P . - In each of the configurations discussed above, material layers 210 and 220 were absent from
grooves grooves FIG. 16Q , however, material layers 210 and 220 extend intogrooves grooves apparel 100. - In the manufacturing process discussion above, it was noted that various bonding agents (e.g., adhesives, thermoplastic polymer sheets) may be utilized to
bond layers component 230. Moreover, various methods may be employed to ensure that the bonding agents are limited to the areas ofsurfaces layers FIG. 16R , abonding agent 237 is located betweenpad component 230 andlayers bonding agent 237 is limited to the areas ofsurfaces layers side surface 233 and the area withingrooves - Based upon the above discussion, various properties of cushioning
element 200 may vary. Depending upon the specific type of apparel or location in the apparel, the properties may impart different degrees of impact force attenuation, flex, stretch, breathability, or other characteristics. As such, the variations discussed above may be utilized individually or in combination to impart particular characteristics tocushioning element 200. - Further Apparel Configurations
-
Apparel 100 is depicted as having the general configuration of a pair of shorts. Another shorts configuration is depicted inFIG. 17A and includes the shapes of cushioning elements depicted inFIGS. 14F and 14G . In addition to shorts, the concepts discussed in relation toapparel 100 may be applied to other types of apparel.FIG. 17B , for example, depicts a pair ofpants 401 that includesvarious cushioning elements 200. Referring toFIG. 17C , ashirt 402 is depicted as includingvarious cushioning elements 200 in locations that correspond with the sides, arms, and shoulders of a wearer. Althoughapparel 402 is depicted as a long-sleeved shirt,apparel 402 may have the configuration of other shirt-type garments, including short-sleeved shirts, tank tops, undershirts, jackets, and coats, for example. - Cushioning
elements 200 may also be incorporated into apparel that covers other areas of the wearer, such as hats, wraps, footwear, socks, gloves, and helmets, for example. As an example, awrap 403 with onecushioning element 200 is depicted inFIG. 17D .Wrap 403 has a generally cylindrical configuration that may be placed upon an arm or a leg of a wearer. When, for example, the elbow is sore or injured, cushioningelement 200 ofwrap 403 may be located over the elbow to assist with protecting the elbow during athletic activities. As another example, asockliner 404 that incorporates acushioning element 200 is depicted inFIG. 17E .Sockliner 404 may be located within an article of footwear to cushion a lower surface of the foot. Additionally, one ormore cushioning elements 200 may be incorporated into aglove 405, as depicted inFIG. 17F , to impart protection to a hand of the wearer. One ormore cushioning elements 200 may also be incorporated into ahelmet 406, as depicted inFIG. 17G , to impart protection to a head of the wearer. In addition to attenuating impact forces, cushioningelements 200 in these configurations may also simultaneously provide one or more of flex, stretch, breathability, a relatively low overall mass, and launderability. - Second Cushioning Element Configuration
- With reference to
FIG. 18 , a plurality ofcushioning elements 500 are incorporated into various areas ofapparel 100. In effect, cushioningelements 500 are depicted as replacing thevarious cushioning elements 200 discussed above. As withcushioning elements 200, cushioningelements 500 impart padding, cushioning, or otherwise attenuate impact forces. Whenapparel 100 is worn during athletic activities, for example, cushioningelements 500 may protect individual 10 from contact with other athletes, equipment, or the ground. With regard toapparel 100, cushioningelements 500 are located in both ofpelvic region 101 andleg regions 102 and are positioned, more specifically, to protect the hips, thighs, and tailbone ofindividual 10. Although shown withapparel 100, cushioningelements 500 may be incorporated into a variety of different articles of apparel, such as any ofpants 401,shirt 402, wrap 403,sockliner 404,glove 405, andhelmet 406. Cushioningelements 500 may be positioned in various areas of the articles of apparel to protect specific portions (e.g., muscles, bones, joints, impact areas) ofindividual 10. Additionally, the shapes, sizes, and other properties of cushioningelements 500, as well as the materials and components utilized incushioning elements 500, may vary significantly to provide a particular level of protection to the specific portions ofindividual 10. - An example configuration for cushioning
element 500 is depicted inFIGS. 19-21 as having a generally elongate shape with pointed end areas, which is the shape depicted as being incorporated intoapparel 100. As alternatives to this shape, cushioningelement 500 may exhibit any of the shapes depicted inFIGS. 14A-14I , as well as any other practical shape. The primary components of eachcushioning element 500 include afirst material layer 510, asecond material layer 520, and apad component 530.First material layer 510 andsecond material layer 520 cooperatively form an outer surface or covering for cushioningelement 500. That is,first material layer 510 andsecond material layer 520 cooperatively form a pocket or void, in whichpad component 530 is located. Whereassecond material layer 520 is depicted as having a generally planar configuration,first material layer 510 extends overpad component 530 and also along sides ofpad component 530 to join with second material layer 520 (e.g., through stitching, adhesive bonding, or thermal bonding). Although cushioningelement 500 may be incorporated intoapparel 100 in a variety of ways,first material layer 510 may be positioned exterior ofsecond material element 520, such thatcushioning element 500 protrudes outward fromapparel 100. Alternately,second material layer 520 may be positioned exterior offirst material element 510, such thatcushioning element 500 protrudes inwardly and towardindividual 10. - Whereas
first material layer 510 has a shape that coverspad component 530,second material layer 520 may have a larger size that forms additional portions ofapparel 100. For example,second material layer 520 may extend into bothpelvic region 101 and one ofleg regions 102. That is,second material layer 520 may form one surface ofcushioning element 500 and extend toother areas apparel 100 to form a covering forindividual 10. In this configuration,first material layer 510 forms a portion ofexterior surface 105, whereassecond material layer 520 forms a portion of bothexterior surface 105 andinterior surface 106. More particularly, a portion ofsecond material layer 520 that is secured to padcomponent 530 is located inward offirst material layer 510 and forms a portion ofinterior surface 106. Another portion ofsecond material layer 520 that is spaced frompad component 530 forms a portion ofexterior surface 105, as well asinterior surface 106. As such,second material layer 520 forms both a portion of a covering forpad component 530 and other portions ofapparel 100. - A variety of materials may be utilized for
first material layer 510 andsecond material layer 520, including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for each ofmaterial layers material layers material layers first material layer 510 andsecond material layer 520. -
Pad component 530 is depicted individually inFIGS. 22-23D . When incorporated intocushioning element 500,pad component 530 is located between and secured to each ofmaterial layers pad component 530 has afirst surface 531 secured tofirst material layer 510, an oppositesecond surface 532 secured tosecond material layer 520, and aside surface 533 that extends betweensurfaces pad component 530 may be unsecured to one or both ofmaterial layers -
First surface 531 defines a plurality ofelongate grooves 534 that extend throughout a length ofpad component 530 and towardsecond surface 532. For purposes of reference in the various figures,grooves 534 are depicted as being stippled (i.e., speckled or dotted) to assist with distinguishinggrooves 534 from other features ofpad component 530. Althoughgrooves 534 are depicted as being aligned with each other, having a squared shape, and being formed infirst surface 531,grooves 534 may have various other configurations. For example,grooves 534 may be unaligned with each other,grooves 534 may have any practical shape, andgrooves 534 may be formed infirst surface 531,second surface 532, or both ofsurfaces grooves 534 may have any of the numerous features and variations discussed above forgrooves grooves 534 may have any of the configurations forgrooves FIGS. 15A-15J and 16A-16J, for example. Accordingly,grooves 534 may have numerous configurations. - In addition to
grooves 534,pad component 530 defines variouselongate voids 535 that extend throughpad component 530 and fromfirst surface 531 tosecond surface 532. In effect, voids 535 form apertures or holes inpad component 530. Althoughvoids 535 are depicted as being aligned (i.e., extending in a common direction and being either parallel or offset between zero and thirty degrees) with each other and perpendicular togrooves 534,voids 535 may have a variety of other configurations, some of which are discussed below. As depicted,voids 535 have a length that extends across a majority of a width ofpad component 530. End areas ofvoids 535 are, however, generally spaced inward fromside surface 533. In configurations wherevoids 535 extend entirely acrosspad component 530,voids 535 will effectively subdividepad component 530 into two or more separate sections, similar to the configuration ofpad component 230 depicted inFIG. 15G . As such, spacing end areas ofvoids 535 inward fromside surface 533 retains a one-piece configuration forpad component 530. An advantage of the one-piece configuration is that a single element (i.e., the entirety of pad component 530), rather than multiple separate elements, is positioned relative tomaterial layers element 500. - A variety of materials may be utilized for
pad component 530, including various polymer foam materials that return to an original shape after being compressed. Examples of suitable polymer foam materials forpad component 530 include polyurethane, ethylvinylacetate, polyester, polypropylene, and polyethylene foams. Moreover, both thermoplastic and thermoset polymer foam materials may be utilized. In some configurations ofcushioning element 500,pad component 530 may be formed from a polymer foam material with a varying density, or solid (i.e., substantially non-foamed) polymer or rubber materials may be utilized. Fluid-filled chambers may also be utilized aspad component 530. Also,different pad components 530 may be formed from different materials, or may be formed from similar materials with different densities, degrees of foaming, or other properties. - The compressible polymer foam materials forming
pad component 530 attenuate impact forces that compress or otherwise contactcushioning element 500. When incorporated intoapparel 100 or another article of apparel, for example, the polymer foam materials ofpad component 530 may compress to protect a wearer from contact with other athletes, equipment, or the ground. By selecting specific thicknesses, materials, and densities for each of thevarious pad component 530, the degree of impact force attenuation may be varied throughoutapparel 100 to impart a desired degree of cushioning or protection. Accordingly, cushioningelement 500 may be utilized to provide cushioning or protection to areas of individual 10 or other wearers that are covered by cushioningelement 500. - In addition to attenuating impact forces, cushioning
element 500 has an advantage of simultaneously providing one or more of flex, stretch, compressibility, breathability, relatively low overall mass, and launderability. Given the presence ofgrooves 534,pad component 530 flexes, stretches, and breathes in the manner shown inFIGS. 10A-10C . The presence ofvoids 535 complements these properties. Referring toFIG. 24A , for example,force 20 is shown as stretchingpad component 530. In this configuration, voids 535 expand in size more than other areas ofpad component 530 to impart greater stretch. Referring toFIG. 24B ,force 20 is shown as compressingpad component 530. In this configuration, voids 535 decrease in size or otherwise compress more than other areas ofpad component 530 to impart greater compressibility. This combination of stretch and compressibility may, for example, enhance the ability of cushioningelement 500 to conform with movements of the body ofindividual 10. That is, asindividual 10 performs various actions (e.g., running, jumping, crouching, twisting) cushioningelement 500 may stretch and compress, thereby not hindering movements of the body ofindividual 10. Additionally, voids 535 impart greater breathability to allow heat and moisture to exitcushioning element 500. - A variety of techniques may be utilized to manufacture
cushioning element 500, including the general manufacturing process discussed above for cushioningelement 200. Additionally, various processes may be utilized to formpad component 530. In one process, polymer resin with a blowing agent may be located in a mold having the shape ofpad component 530. An advantage to this process is that a single process may be used to form the polymer foam material ofpad component 530, as well as thevarious grooves 534 and voids 535. In another process, a preformed layer of polymer foam may be obtained, and a router or other cutting device may be used to formgrooves 534 and voids 535. For example, a programmable, multi-function fabrication table may be utilized to form bothgrooves 534 andvoids 535, such as an M Series flatbed cutter manufactured by Gerber Scientific Products of Tolland, Conn., United States of America. In other processes,grooves 534 andvoids 535 may be formed from a heated element that presses into a preformed layer of polymer foam, or a computer-controlled machine tool may be utilized. As yet further examples, a three-dimensional printer may be utilized to formpad component 530. - Further Cushioning Element Configurations
- Aspects of
cushioning element 500 may vary, depending upon the intended use for cushioningelement 500 and the product in whichcushioning element 500 is incorporated. Moreover, changes to the dimensions, shapes, and materials utilized withincushioning element 500 may vary the overall properties of cushioningelement 500. That is, by changing the dimensions, shapes, and materials utilized withincushioning element 500, the compressibility, impact force attenuation, flex, stretch, compressibility, breathability, and overall mass ofcushioning element 500 may be tailored to specific purposes or products. A plurality of variations for cushioningelement 500 are discussed below. Any of these variations, as well as combinations of these variations, may be utilized to tailor the properties of cushioningelement 500 to an intended use. Moreover, any of these variations may be manufactured through the process or variations of the process discussed above. - Various aspects relating to
first material layer 510 andsecond material layer 520 may also vary significantly. As discussed above, material layers 510 and 520 may be formed from various textiles, polymer sheets, leather, synthetic leather, or combinations of materials, for example. Moreover, breathability may be enhanced when the materials are air-permeable. In general, textiles are permeable to both heat and moisture. Polymer sheets, leather, synthetic leather, or combinations of materials, however, may not exhibit significant permeability. As with the configuration ofcushioning element 200 depicted inFIG. 14J , various perforations, holes, or apertures may be formed in one or both ofmaterial layers first material layer 510 may be entirely absent from cushioningelement 500, similar toFIG. 14K . - Aspects relating to pad
component 530 may also vary to tailorcushioning element 500 to an intended use or enhance the properties of cushioningelement 500. As an example,grooves 534 may have any of the variations forgrooves FIG. 25A , various aspects ofvoids 535 are modified to illustrate variations. More particularly, anindividual void 535 may have (a) a lesser length, (b) an arrangement that is aligned withother voids 535, (c) a lesser width, (d) a greater width, (e) a tapered or non-rectangular shape, or (f) a non-linear shape. Regarding length, voids 535 may extend across a majority of a width ofpad component 530 to maximize the stretch and compressibility properties shown inFIGS. 24A and 24B . By altering the length, however, the degree of stretch and compressibility may be varied incushioning element 500 or specific areas ofcushioning element 500. The width ofvoids 535 may also vary from one millimeter to twenty millimeters or more. One consideration with width relates to the ability of objects to protrude throughvoids 535. By formingvoids 535 to have a lesser relative width, the probability of an object protruding through or intovoids 535 is decreased. Regarding shape, voids 535 may be rectangular, triangular, non-regular or any shape that imparts a desired degree of flex, stretch, compressibility, and breathability. Moreover, the shapes ofvoids 535 may be varied for aesthetic reasons. - The arrangement of
grooves 534 andvoids 535 may also vary significantly. Referring toFIG. 25B ,grooves 534 extend across the width ofpad component 530, whereasvoids 535 extend through a majority of the length ofpad component 530. Althoughgrooves 534 andvoids 535 may be arranged to be perpendicular to each other,grooves 534 andvoids 535 may also be offset at other angles, as depicted inFIG. 25C . Similarly,grooves 534 andvoids 535 may also be parallel to or aligned with each other, as depicted inFIG. 25D . Althoughvoids 535 may be arranged to be parallel to each other,voids 535 may also be non-parallel. As an example,FIG. 25E depictsvoids 535 as radiating outward from a common area. In addition,FIG. 25F depictsvarious voids 535 as intersecting each other to form two X-shaped structures. Accordingly, numerous aspects relating to the shape, orientation, and arrangement ofgrooves 534 andvoids 535 may vary considerably. - Another configuration of
pad component 530 is depicted inFIG. 25G , in which voids 535 form shapes representing the number one and a star.Voids 535 may, therefore, form relatively complex shapes that provide information or fashion indicia. As examples,voids 535 may (a) display an athlete's assigned number, (b) form a team name, (c) represent a trademark or other identifying information for a manufacturer ofapparel 100, or (d) show an abstract depiction for aesthetic purposes. As the complexity of the information or indicia increases, however, one consideration relates to segregating separate sections ofpad component 530 withvoids 535. Referring again toFIG. 25G , twoseparate voids 535 outline the number one, which forms a pair of connectingportions 537 at upper and lower areas of the number one to ensure that a central area of the number one remains connected to a remainder ofpad component 530. The void 535 outlining the star, however, does not form structures similar to connectingportions 537. As a result, a central area of the star is separate from a remainder ofpad component 530. During manufacturing, additional steps may be necessary to ensure that the central area of the star remains properly positioned relative to the remainder ofpad component 530. - In each of the various configurations discussed above, both
grooves 534 andvoids 535 are present inpad component 530. In some configurations, however,grooves 534 may be absent frompad component 530. Referring toFIG. 25H , for example, voids 535 extend through various areas ofpad component 530 and provide stretch, compressibility, and breathability throughoutcushioning element 500 withoutgrooves 534. -
Grooves 534 andvoids 535 cross or otherwise intersect each other in many of the prior examples ofpad component 530 discussed above. Referring toFIG. 26 , however, areas ofgrooves 534 andvoids 535 are aligned with each other. Another manner of considering this structure is thatgrooves 534 andvoids 535 are superimposed or otherwise overlay each other. In any event,FIG. 26 depicts configurations where (a)grooves 534 extend from the end areas ofvarious voids 535, (b)grooves 534 andvoids 535 alternate acrosspad component 530, (c) voids 535 extend inward fromside surface 533 and to end areas ofgrooves 534, and (d)grooves 534 alternate between being formed infirst surface 531 andsecond surface 532. Any of these various configurations may be utilized to modify the properties or aesthetics ofpad component 530, as well as decreasing the probability of an object protruding through or intovoids 535. Moreover, forminggrooves 534 within areas ofvoids 535 may enhance the structural integrity ofpad component 530. - Another configuration is depicted in FIGS. 28 and 29A-29D, wherein
pad component 530 includes abeveled edge 536 that extends aroundpad component 530 and forms an angled transition betweensurfaces grooves 534 andvoids 535 may be absent from the area ofbeveled edge 536,grooves 534 are depicted as extending throughbeveled edge 536 andvoids 535 are depicted as extending tobeveled edge 536. In other configurations, however, voids 535 may extend into the area ofbeveled edge 536 or end areas ofgrooves 534 andvoids 535 may be spaced frombeveled edge 536. An advantage of formingpad component 530 to includebeveled edge 536 relates to the transition betweenfirst surface 531 andside surface 533. More particularly, bevelededge 536 forms a smoother or less abrupt transition betweencushioning elements 500 and areas ofapparel 100 wherecushioning elements 500 are absent. As noted above,apparel 100 may be worn under other articles of apparel or may be worn in combination with other pieces of equipment (e.g., athletic or protective equipment). In either of these scenarios, bevelededge 536 may ensure that the apparel or equipment coveringcushioning elements 500 smoothly transitions to areas wherecushioning elements 500 are absent. In further configurations, as respectively depicted inFIGS. 30A-30D , bevelededge 536 may (a) extend tosecond surface 532, rather thanside surface 533, (b) exhibit an outwardly-protruding and rounded configuration, (c) exhibit an inwardly-protruding and rounded configuration, or (d) form an indentation in a side ofpad component 530. The specific configuration forbeveled edge 536 may depend upon whetherapparel 100 is intended to be worn over or under other articles of apparel or equipment. Moreover, a configuration similar toFIG. 30D may allow equipment to interface and effectively join withcushioning element 500. That is, a portion of the equipment may extend into the indented area formed bybeveled edge 536. - A variety of other aspects relating to pad
component 530 may also vary to modify the properties or aesthetics ofcushioning element 500. Referring toFIG. 31A , voids 535 are depicted as having various example configurations that are tapered, cross-shaped, protruding or curving outwardly and inwardly, slanted, and T-shaped.Voids 535 may be any of these shapes, as well as other shapes, to impart desired properties to cushioningelement 500, such as flex, stretch, compressibility, and breathability, for example. Through selecting a shape for one or more ofvoids 535, therefore, particular properties may be imparted to cushioningelement 500. For example, tapered and T-shapedvoids 535 may permit cushioningelement 500 to flex more in one direction than in an opposite direction. Moreover, various non-uniform shapes for voids 535 (e.g., tapered, cross-shaped, protruding or curving, slanted, and T-shaped) may be utilized to limit the ability of objects to protrude throughvoids 535, thereby contacting theindividual wearing apparel 100, while imparting the desired properties to cushioningelement 500. Similarly,different grooves 534 andvoids 535 may have different widths or shapes to further vary the properties of cushioningelement 500. Although many of the concepts presented above are discussed in relation tovoids 535, any of these concepts may also be applied togrooves 534. - Another aspect relating to pad
component 530 that may modify the properties or aesthetics ofcushioning element 500 relates to forming a layered structure, as depicted inFIG. 31B . As an example, the layers may be different types of polymer foam or densities of polymer foam, or the layers may be different materials, such as polymer foam and rubber. The layers may also have different colors to impart aesthetic qualities tocushioning element 500. For example, voids 535 may extend through one layer and into the other layer to expose the color of the underlying layer. Moreover, voids 535 are depicted as being tapered so that the color of the underlying layer may be seen, thereby enhancing the aesthetic attributes ofcushioning element 500. A similar concept may apply togrooves 534, which may extend through one layer and into the other layer to expose the color of the underlying layer. - Although the thickness of
pad component 530 may be constant,pad component 530 may also have varying or tapered thicknesses, as depicted inFIG. 31C , to further modify the properties or aesthetics ofcushioning element 500. In some configurations ofcushioning element 500, a central area ofpad component 530 may have greater thickness than a peripheral area ofpad component 530, as depicted inFIG. 31D . Additionally,pad component 530 may have a rounded or contoured shape, as depicted inFIG. 31E , to better conform with contours ofindividual 10. - Further configurations of
pad component 530 are depicted inFIGS. 32 and 33 . These configurations ofpad component 530 may be utilized, for example, in a thigh area or a hip area ofapparel 100. As with configurations ofpad component 530 discussed above, these configurations includegrooves 534 andvoids 535 that cross each other and extend in various directions, as well as having bevelededge 536. Moreover, these configurations ofpad component 530 incorporate combinations and orientations ofgrooves 534 andvoids 535 in specific areas in order to impart varying degrees of flex, stretch, compressibility, and breathability, for example. Accordingly, many of the features and variations discussed above may be incorporated into onepad component 530 to provide different combinations of properties to different areas ofcushioning element 500. - Based upon the above discussion, various properties of cushioning
element 500 may vary. Depending upon the specific type of apparel or location in the apparel, the properties may impart different degrees of impact force attenuation, flex, stretch, compressibility, breathability, or other properties. As such, the variations discussed above may be utilized individually or in combination to impart particular characteristics or combinations of properties to cushioningelement 500. - The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.
Claims (39)
1. An article of apparel incorporating at least one cushioning element for attenuating impact forces, the cushioning element comprising:
a first material layer and a second material layer; and
a pad component located between the first material layer and the second material layer, the pad component including a first surface and an opposite second surface, the first surface facing the first material layer, and the second surface facing the second material layer, and the pad component including (a) a plurality of elongate grooves that extend from the first surface toward the second surface and (b) a plurality of elongate voids that extend through the pad component and from the first surface to the second surface.
2. The article of apparel recited in claim 1 , wherein the grooves are aligned with each other and the voids are aligned with each other.
3. The article of apparel recited in claim 2 , wherein the grooves and the voids intersect.
4. The article of apparel recited in claim 1 , wherein end areas of the grooves are located at a peripheral edge of the pad component, and end areas of the voids are spaced inward from the peripheral edge.
5. The article of apparel recited in claim 1 , wherein end areas of the voids are spaced inward from a peripheral edge of the pad component, and a plurality of additional grooves extend from the end areas of the voids to the peripheral edge.
6. The article of apparel recited in claim 1 , wherein at least two of the grooves have different widths.
7. The article of apparel recited in claim 1 , wherein at least two of the voids have different widths.
8. The article of apparel recited in claim 1 , wherein at least one of the voids has a non-uniform width.
9. The article of apparel recited in claim 1 , wherein the pad component includes a polymer foam material.
10. The article of apparel recited in claim 1 , wherein the pad component includes a first layer and a second layer with different properties, the first layer forming the first surface and the second layer forming the second surface, the grooves extending from the first surface and into the second layer.
11. The article of apparel recited in claim 10 , wherein each of the first layer and the second layer are polymer foam materials.
12. The article of apparel recited in claim 10 , wherein each of the first layer and the second layer are polymer foam materials with different colors.
13. The article of apparel recited in claim 1 , wherein the first material layer and the second material layer are textile materials.
14. The article of apparel recited in claim 13 , wherein the first material layer is a mesh textile.
15. The article of apparel recited in claim 1 , wherein the first material layer is secured to the first surface and the second material layer is secured to the second surface.
16. The article of apparel recited in claim 1 , wherein the first material layer forms at least a portion of an exterior surface of the article of apparel.
17. The article of apparel recited in claim 16 , wherein the second material layer forms at least a portion of an interior surface of the article of apparel.
18. The article of apparel recited in claim 1 , wherein the first material layer is joined to the second material layer around at least a portion of a periphery of the pad component.
19. An article of apparel incorporating at least one cushioning element for attenuating impact forces, the cushioning element comprising:
a first material layer and a second material layer; and
a pad component located between the first material layer and the second material layer, the pad component including a first surface and an opposite second surface, the first surface facing the first material layer, and the second surface facing the second material layer, and the pad component including:
(a) a plurality of elongate grooves that extend into the pad component from the first surface, end areas of the grooves being located at a peripheral edge of the pad component,
(b) a plurality of elongate voids that extend through the pad component, end areas of the voids being spaced inward from the peripheral edge, and
(c) a plurality of additional grooves that extend from the end areas of the voids to the peripheral edge.
20. The article of apparel recited in claim 19 , wherein the grooves are aligned with each other, the voids are aligned with each other, and the grooves and the voids intersect.
21. The article of apparel recited in claim 19 , wherein the pad component includes a first layer and a second layer with different properties, the first layer forming the first surface and the second layer forming the second surface, and the grooves extending through the first layer and into the second layer.
22. The article of apparel recited in claim 19 , wherein the first material layer and the second material layer are textile materials, the first material layer being secured to the first surface and forming at least a portion of an exterior surface of the article of apparel, and the second material layer being secured to the second surface and forming at least a portion of an interior surface of the article of apparel.
23. The article of apparel recited in claim 22 , wherein the first material layer is joined to the second material layer around at least a portion of a periphery of the pad component.
24. The article of apparel recited in claim 19 , wherein the pad component includes a bevel between the first surface and the peripheral edge.
25. An article of apparel incorporating at least one cushioning element for attenuating impact forces, the cushioning element comprising a pad component with a first surface and an opposite second surface, the first surface facing toward an exterior surface of the apparel, and the second surface facing toward an interior surface of the apparel, and the pad component including:
a plurality of elongate grooves formed in the first surface, end areas of the grooves being located at a peripheral edge of the pad component;
a plurality of elongate voids that extend from the first surface to the second surface, end areas of the voids being spaced inward from the peripheral edge; and
a plurality of additional grooves that extend from the end areas of the voids to the peripheral edge.
26. The article of apparel recited in claim 25 , wherein the pad component further includes a first material layer and a second material layer, the first material layer being secured to the first surface and the second material layer being secured to the second surface.
27. The article of apparel recited in claim 26 , wherein the first material layer and the second material layer are textile materials, the first material layer forming at least a portion of the exterior surface, and the second material layer forming at least a portion of the interior surface.
28. The article of apparel recited in claim 26 , wherein the grooves are aligned with each other, the voids are aligned with each other, and the grooves and the voids intersect.
29. The article of apparel recited in claim 25 , wherein at least two of the grooves have different widths.
30. The article of apparel recited in claim 25 , wherein at least two of the voids have different widths.
31. The article of apparel recited in claim 25 , wherein at least one of the voids has a non-uniform width.
32. The article of apparel recited in claim 25 , wherein the pad component includes a first foam layer and a second foam layer with different properties, the first foam layer forming the first surface and the second foam layer forming the second surface, the grooves extending through the first foam layer and into the second foam layer.
33. The article of apparel recited in claim 25 , wherein the pad component includes a bevel between the first surface and the peripheral edge.
34. The article of apparel recited in claim 33 , wherein the grooves extend to the bevel.
35. An article of apparel incorporating at least one cushioning element for attenuating impact forces, the cushioning element comprising:
a first material layer and a second material layer; and
a pad component located between and secured to the first material layer and the second material layer, the pad component including a first surface and an opposite second surface, the first surface facing the first material layer, and the second surface facing the second material layer, and the pad component including a plurality of elongate voids that extend through the pad component and from the first surface to the second surface.
36. The article of apparel recited in claim 35 , wherein end areas of the voids are spaced inward from a peripheral edge of the pad component.
37. The article of apparel recited in claim 35 , wherein end areas of the voids are spaced inward from a peripheral edge of the pad component, and a plurality of grooves extend from the end areas of the voids to the peripheral edge.
38. The article of apparel recited in claim 35 , wherein the first material layer is a mesh textile.
39. The article of apparel recited in claim 35 , wherein the pad component includes a plurality of grooves, at least one of the grooves intersecting at least one of the voids.
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