FORCE ABSORPTION AND DEFLECTION APPARATUS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]None.

FIELD OF THE DISCLOSURE

[0002]The disclosure relates to force absorption and deflection materials and apparatuses. More particularly, the disclosure relates to athletic protection guards and padding designed to absorb, disperse and deflect forces imparted onto the human body during sports and other events.

BACKGROUND OF THE DISCLOSURE

[0003]The use of protective guards or padding, particularly for contact sports and sports involving balls and pucks thrust on the ground, on ice or through the air, has become ubiquitous. Although advances have been made in materials used for padding and padding design, the essential focus of such advancements is to improve the absorption of forces, particularly forces that directly impact a body part of a sports player. Layers of cotton or other textile materials, both natural and synthetic, formed in a dense, rigidified layer, and further formed under a hard shell, such as a shin pad, provide a degree of protection by absorbing oncoming forces, often in the form of point loads, derived from projectiles and contact with other players. The force is absorbed by compressing the layers of material so as to reduce the velocity of the force and to disperse the force radially outwardly from the contact point. The amount of force absorption is often directly related to the thickness and/or number of layers of protective padding.

[0004]Another material used to provide protection from forces is polymer-based foam. Foam materials include a plurality of air-filled cavities that create a sort of asymmetrical sponge-like lattice. When a force is applied to the foam material, the foam cavities compress and collapse. After the force has been absorbed, the foam rebounds to its original shape. Like cotton-based and other textile-based padding, the foam absorbs the force by collapsing and thereby reducing the velocity of the force. The force is further dispersed radially if the object imparting the force is round or radiused such as a ball.

[0005]Although these materials are effective in absorbing forces, there are several drawbacks to the current guard designs. One significant issue is the bulkiness of such padding. In order to provide adequate protection, particularly with high-contact sports such as baseball, lacrosse, ice hockey, field hockey and softball, thick padding with hard shells have to essentially cover entire body parts. Bulky padding leads to reduced performance due to weight and range of motion limitations. Such padding is especially problematic in regions with high flexion requirements such as elbow and ankle joints. Moreover, the bulky padding also creates issues with breathability.

[0006]One example of foam-based padding is disclosed in U.S. Pat. No. 5,168,576 (hereinafter “the '576 Patent”) that discloses a body protection device that uses spaced foam modules to improve breathability and enhanced articulation. The foam modules are formed from three layers with an upper closed cell, high-density foam layer, a middle, closed-cell, medium-density foam layer and a lower, open-cell low-density foam layer. The upper layer provides enhanced impact resistance and protection to the lower layers. The lowest layer provides improved cushioning and better conformance to the body. The foam modules are embedded between upper and lower layers of resilient, breathable fabric. Hardened shell segments are strategically positioned over areas of the body protection device to provide further force protection.

[0007]To address the need for the padding to articulate with limb movement, gaps, termed intermodular membranes, are formed between the modules. By design, the intermodular membranes do not provide force protection but improve articulation of the padding. The gaps further function as recessed air chambers with channels formed through the intermodular membranes to provide exit passages for heat and moisture.

[0008]The design of the padding disclosed in the '576 Patent involves increased complexity to address articulation and breathability issues with the competing function of providing force protection. The solution provided ultimately compromises the overall protective effect of the body protection device. The modules themselves are only able to counter impact forces via compression. None of the layers provide force deflection capabilities as the foam-based modules are only capable of resisting force via compression of the static modules. In addition, by creating air gaps to address breathability issues, several sections of the device are essentially devoid of force protection. Due to the static design of the foam modules, a complex array of differentiated multi-layer foams and hard-shell segments are used to achieve force protection while addressing needs for adhering to body contours and articulation needs of various body joints. To achieve just basic articulation requirements, ultimately, areas of high flexion, such as knee and elbow joints will not have true 360° protection. What is needed is a force protection apparatus that can provide true 360° protection with enhanced breathability and superior articulation in a combination of elements that reduces the overall complexity of the force protection apparatus.

[0009]Another example of a force protection device is U.S. Patent Application No. US2018/0160746 A1 (hereinafter “the '746 Application”) that discloses force protection pads formed from a complex assembly of spaced padding modules, termed medallions, constructed in a wide variety of shapes to accommodate the contours of the underlying body areas being protected. The medallions are encapsulated in flexible inner and outer layers that provide flexibility in the gap regions between adjacent medallions. Like the force protection device disclosed in the '576 Patent, the '746 Application protection pads have several areas with limited force protection so as to permit sufficient flexibility of the overall protection pad to articulate with the underlying area being protected. Again, like the '576 Patent force protection device, the protection pads disclosed in the '746 Application can only protect limited areas and cannot provide 360° protection of an area of the body.

[0010]Due to the challenges of providing force protection with relatively rigid foam-based materials or dense, rigidified textile layers and hard-shell overlays, and the competing need for guard or pad flexibility, what is needed is a force protection apparatus that provides maximum protection with maximum flexibility. What is needed further is a force protection apparatus that can provide 360° protection to an area of a body, such as a lower leg or a forearm, exposed to impacts from all sides and all angles. What also is needed is a force protection apparatus that has high elasticity and excellent tear resistance to enable the apparatus to be placed over a body part and snugly remain in place without adversely impacting joint flexibility. It is thus an object of the disclosure to provide a force attenuation and deflection apparatus that provides 360° protection of any body part being protected. Another object of the disclosure is to provide a force protection apparatus with high elasticity and superior tear resistance that can deflect impact forces to enhance the force attenuation function of the force protection apparatus. A further object of the disclosure is to provide a force protection apparatus that addresses breathability issues without compromising force protection. A yet further object of the disclosure is to provide a force protection apparatus that provides maximum flexibility regardless what body part is being protected and what level of force protection is needed. These and other objects of the disclosure will become apparent from a reading of the following summary and detailed description of the disclosure.

SUMMARY OF THE DISCLOSURE

[0011]In one aspect of the disclosure, a force attenuation and deflection apparatus is formed from an elastomer matrix comprising alternating, integral lattice segments and nodes of varying lengths, widths and cross-sectional shapes that combine to form lattice node strings. The node strings are assembled into varying patterns and groupings to form customized force attenuation and deflection guards structured to protect a discrete human body part such as a lower leg or forearm. The nodes are structured to absorb, disperse and deflect impact forces exerted onto the human body. Because of the unique structure of the force attenuation and deflection apparatus, the multitude of spaces created between and among nodes and lattice segments provide superior breathability characteristics that do not compromise the force protective effect of the apparatus.

[0012]In another aspect of the disclosure, a force attenuation and deflection apparatus is formed from a textile matrix comprising a skeletal pattern or network of interconnected lattice segments assembled into varying patterns and groupings. The matrix is constructed so as to exhibit high elasticity, from about 400% to about 800% elongation. Elastomeric nodes of varying lengths, widths and cross-sectional shapes are positioned on the lattice segments so as to rotate freely about the lattice segments to form customized force attenuation and deflection guards structured to protect a discrete human body part such as a lower leg or forearm. The elastomeric nodes are structured to absorb, disperse and deflect impact forces exerted onto the human body.

[0013]In a further aspect of the disclosure, the elastomeric matrix nodes can be formed in a variety of dimensions and shapes to accommodate the contours and articulation requirements of specific areas of the human body. In one embodiment, the nodes are formed with cylindrical shapes of varying cross-sectional widths to apply different levels of force attenuation and deflection. Larger diameter nodes will impart greater force attenuation. For cylindrically-shaped nodes used in a textile matrix, the nodes are formed with a through-bore to permit positioning about a lattice segment. The through-bore can be formed along the longitudinal axis of the node or can be offset from the longitudinal axis. When the through-bore is positioned along the longitudinal axis, the nodes in a textile-matrix-based apparatus can rotate freely about the lattice segment onto which they are positioned. For nodes having an offset through-bore, rotation about a lattice segment is limited due to the through-bore offset. For nodes formed in an elastomeric matrix embodiment, the nodes rotate by twisting the lattice segments integrally attached to the node. The degree of node rotation is limited by the thickness, cross-sectional shape and elastomeric properties of the material used to form the lattice segments.

[0014]In still further aspect of the disclosure, a paddle node is shaped as a paddle with a rectangularly-shaped outer perimeter. The paddle node has two substantially flat face surfaces with one or both of the flat face surfaces having an elevated spine that runs substantially the length of the paddle node. If incorporated into an elastomeric matrix embodiment, paddle nodes will not have through-bores but will be formed integrally and alternatingly with lattice segments of the elastomeric matrix. For paddle nodes incorporated into a textile matrix embodiment, through-bores will be formed along the longitudinal central axis of the paddle node or offset from the longitudinal central axis. Like the cylindrically-shaped nodes, the paddle nodes having central through-bores and incorporated into textile matrix embodiments will rotate freely about the lattice segment onto which they are positioned. For paddle nodes with offset through-bores, the range of rotation will be limited by the offset. For paddle nodes formed in an elastomeric matrix embodiment, the paddle nodes rotate by twisting the lattice segments integrally attached to the node. The degree of paddle node rotation is limited by the thickness, cross-sectional shape and elastomeric properties of the material used to form the lattice segments. The shape of the paddle node also will limit rotational range when placed against an area of a human body.

[0015]In yet another aspect of the disclosure, matrix patterns, regardless whether of the elastomeric matrix or textile matrix versions, can be formed in a variety of patterns and groupings to form customized force attenuation and deflection apparatuses in the form of pads or guards that maximize protection of a discrete anatomical area of the body with minimal movement restriction imparted by the pad or guard. For areas that require a high degree of flexibility, such as an elbow or ankle, cylindrically-shaped nodes having relatively small cross-sectional diameters can be used to provide maximum flexibility without compromising the force protection effect of the apparatuses.

[0016]To further accommodate specific flexibility and force protection needs, a plurality of node string patterns can be constructed. In one embodiment, a columnar matrix pattern can be constructed with nodes aligned in columns and rows to provide blanket protection to a discrete anatomical area. In another embodiment, a staggered-row matrix pattern is formed from parallel, horizontally-oriented, staggered node strings. In this embodiment, the nodes on adjacent node strings will form columns with staggered rows of nodes to accommodate specifically-shaped contoured regions. In yet another embodiment, an interlocking-ring matrix pattern is formed from a plurality of horizontally-oriented, left-diagonally oriented and right-diagonally oriented node strings. The spatial orientation of the node strings result in the node strings intersecting to form hexagonal ring patterns. Nodes formed on or positioned on the lattice segments of the hexagonal ring patterns form interlocking rings. This pattern is particularly suitable for areas that require a high degree of flexibility such as an ankle or an elbow joint.

[0017]In a yet further embodiment, a segmented-node matrix pattern incorporates segmented nodes formed with annular grooves that separate the perimeter edges of the nodes into a middle and two lateral node elevations. This node modification provides additional flexibility to the node where node flexion is needed to adjust to discrete anatomical features. In a still further embodiment, a split-node matrix pattern incorporates two nodes on a single lattice segment that imparts additional flexibility to the node configuration.

[0018]In another aspect of the disclosure, a lower leg/foot guard is formed from either an elastomeric or a textile matrix with nodes integrally molded with, or overmolded on, the matrix. The guard is formed as a single-piece or from multiple flat panels of matrix/node combinations with the panels connected together to form the guard. Multiple combinations of matrix lattice segments and nodes of varying sizes and shapes are combined to form interconnected lattice string groupings that are customized to conform to the contoured shapes and flexion needs of specific anatomical areas.

[0019]In yet another aspect of the disclosure, a forearm guard is formed from either an elastomeric or a textile matrix with nodes integrally molded with, or overmolded on, the matrix. The guard is formed as a single-piece or from multiple flat panels of matrix/node combinations with the panels connected together to form the guard. Multiple combinations of matrix lattice segments and nodes of varying sizes and shapes are combined to form interconnected lattice string groupings that are customized to conform to the contoured shapes and flexion needs of specific anatomical areas. These and other aspects of the disclosure will become apparent from a review of the appended drawings and a reading of the following detailed description of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is lateral side view in elevation and partial phantom of a force attenuation and deflection leg/foot guard according to one embodiment of the disclosure.

[0021]FIG. 2 is a planar view of a medial flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 1.

[0022]FIG. 3 is a planar view of a lateral flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 1.

[0023]FIG. 4 is a medial side view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 1.

[0024]FIG. 5 is a posterior or back view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 1.

[0025]FIG. 6 is a top view of a fore-foot/toe area of the force attenuation and deflection leg/foot guard shown in FIG. 1.

[0026]FIG. 7 is a medial view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 1 in a loaded condition.

[0027]FIG. 8 is a medial view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 1 in an unloaded condition.

[0028]FIG. 9 is a front, top perspective view of a tension band according to the embodiment of the disclosure shown in FIG. 1.

[0029]FIG. 10 is a top, end perspective view of a cylindrically-shaped node according to one embodiment of the disclosure.

[0030]FIG. 11 a top, end perspective view of a paddle-shaped node with a through-bore according to another embodiment of the disclosure.

[0031]FIG. 12 a top, end perspective view of a solid paddle-shaped node according to further embodiment of the disclosure.

[0032]FIG. 13 is a side view in cross-section of a node string taken along the line 13-13 in FIG. 2 according to one embodiment of the disclosure.

[0033]FIG. 14 is a side view in cross-section of a node string taken along the line 14-14 in FIG. 2 according to another embodiment of the disclosure.

[0034]FIG. 15 is a side view in cross-section of a node string taken along the line 15-15 in FIG. 3 according to a further embodiment of the disclosure.

[0035]FIG. 16 is lateral side view in elevation and partial phantom of a force attenuation and deflection leg/foot guard formed with a textile matrix according to another embodiment of the disclosure.

[0036]FIG. 17 is a planar view of a textile matrix medial flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0037]FIG. 18 is a planar view of a textile matrix lateral flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0038]FIG. 19 is a medial side view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0039]FIG. 20 is a back view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0040]FIG. 21 is a top view of a fore-foot/toe area of the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0041]FIG. 22 is a medial side view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 16 in a loaded condition.

[0042]FIG. 23 is a medial side view in elevation of the force attenuation and deflection leg/foot guard shown in FIG. 16 in an unloaded condition.

[0043]FIG. 24 is a planar view of a skeletal textile matrix medial flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0044]FIG. 25 is a planar view of a skeletal textile matrix lateral flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0045]FIG. 26 is a planar view of a skeletal node pattern of a medial flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0046]FIG. 27 is a planar view of a skeletal node pattern of a lateral flat panel for the force attenuation and deflection leg/foot guard shown in FIG. 16.

[0047]FIG. 28 is a view of an arm guard with an arm in a supinated position according to yet another embodiment of the disclosure.

[0048]FIG. 29 is a view of an arm guard with an arm in a pronated position according to the embodiment of the disclosure shown in FIG. 28.

[0049]FIG. 30 a planar view of an arm guard flat panel for the force attenuation and deflection arm guard shown in FIG. 28.

[0050]FIG. 31 is a combination end perspective view in partial phantom and an end view of a cylindrical node with a centered through-bore according to one embodiment of the disclosure.

[0051]FIG. 32 is a combination end, perspective view and an end view of a cylindrical node with an offset through-bore according to another embodiment of the disclosure.

[0052]FIG. 33 is a planar view of an interlocking ring matrix pattern according to one embodiment of the disclosure.

[0053]FIG. 34 is a planar view of a vertically-oriented-node, staggered column matrix pattern according to another embodiment of the disclosure.

[0054]FIG. 35 is a planar view of a columnar matrix pattern according to yet another embodiment of the disclosure.

[0055]FIG. 36 is a planar view of a matrix pattern according to a further embodiment of the disclosure.

[0056]FIG. 37 is a planar view of a staggered-row matrix pattern according to a yet further embodiment of the disclosure.

[0057]FIG. 38 is an illustration of a baseball striking a conventional foam pad.

[0058]FIG. 39 is an illustration of a baseball striking a force attenuation and deflection apparatus according to one embodiment of the disclosure.

[0059]FIG. 40 is an illustration of three forms of node movement to deflect impact forces according to one embodiment of the disclosure.

[0060]FIG. 41 is an illustration of a spherical object striking a force attenuation and deflection leg guard according to one embodiment of the disclosure.

[0061]FIG. 42 is an imprint on a prescale pressure indicating film-low for a baseline 1 control test.

[0062]FIG. 43 is an imprint on a prescale pressure indicating film-low for a baseline 2 control test.

[0063]FIG. 44 is a test sample material designated Sample A1 according to one embodiment of the disclosure.

[0064]FIG. 45 is an imprint on a prescale pressure indicating film-low for Sample A1.

[0065]FIG. 46 is a test sample material designated Sample E1 according to another embodiment of the disclosure.

[0066]FIG. 47 is an imprint on a prescale pressure indicating film-low for Sample E1.

[0067]FIG. 48 is a test sample material designated Sample D2D3 according to yet another embodiment of the disclosure.

[0068]FIG. 49 is a is an imprint on a prescale pressure indicating film-low for Sample D2D3.

[0069]FIG. 50 is a test sample material designated Sample F3F4 according to a further embodiment of the disclosure.

[0070]FIG. 51 is an imprint on a prescale pressure indicating film-low for Sample F3F4.

[0071]FIG. 52 is a test sample material designated Sample B4L1 according to a yet another embodiment of the disclosure.

[0072]FIG. 53 is an imprint on a prescale pressure indicating film-low for Sample B4L1.

[0073]FIG. 54 is a test sample material designated M1 according to a still further embodiment of the disclosure.

[0074]FIG. 55 is a test sample material designated N1 according to another embodiment of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

I. General Concept

[0075]In their most general aspect, the force attenuation and deflection apparatuses disclosed herein concern the core concept of an elastomeric or skeletal textile matrix used to support force attenuation and deflection nodes. The nodes are structured to absorb, disperse and deflect impact forces exerted onto the human body through a variety of activities such as sports events. As an illustrative example, baseball players can and do experience significant impacts from baseballs while in the batter's box. Whether through direct hits from wayward or intentional pitches, or from deflections off a swung bat, the impact force of a baseball moving at a high velocity that can sometimes approach and even exceed 100 mph, provides a point-load force that can be extreme enough to damage soft tissue and even break bone tissue if left unprotected.

A. Nodes

[0076]The force attenuation and deflection nodes disclosed herein are formed in a plurality of sizes and shapes to accommodate various body contours and to maximize force protection to discrete areas of a human body. For areas that have a high degree of flexion, such as an elbow or ankle, nodes can be sized and cropped into groupings that provide the needed protection without compromising or unduly restricting movement of the underlying joint. One illustrative example of a node formed according to the disclosure is shown in FIG. 10. A cylindrical node, designated generally as 400, has an elongated cylindrically-shaped body 402 with a node through-bore 404 extending through the longitudinal central axis of the node as shown in FIG. 31. The positioning of through-bore 404 can be offset from the node longitudinal central axis 401, as shown in FIG. 32, to provide an eccentric rotation movement that can be used in areas where full rotation of the node is not warranted or desired. It should be understood that node 400 can be formed with or without through-bore 404. For the elastomeric matrix embodiments disclosed herein, node 400 will not have a through-bore as the node with be integrally formed with lattice segments as disclosed in more detail herein. For the textile matrix embodiment, nodes 400 will be formed with through-bores 404. Ends 406 of node 400 may be radiused or chamfered so as not to present defined angles that could otherwise irritate or potentially injure the tissue of the anatomical feature being protected by the node. The radiused end also may assist with the deflection of incoming impact forces.

[0077]In another illustrative, non-limiting example of an alternative node structure, as shown in FIG. 11, a paddle node, designated generally as 400′, has a general flat paddle shape with a rectangularly-shaped outer perimeter 402′ and elevated elongate spines 408 extending outwardly from approximately a centerline of both faces of node 400′. As used herein, identical reference characters having differently primed or unprimed variations and assigned to features of the disclosure are intended to identify different embodiments of the same feature. A node through-bore 404′ extends through the longitudinal axis 401′ of the node if the node is used in the textile matrix embodiment. For the elastomeric matrix embodiment, node 400′ will not have a through-bore but will be formed integrally with lattice segments as shown in FIG. 12.

[0078]Any node used in any of the matrix embodiments disclosed herein can be constructed with any dimension with respect to length, width and cross-sectional shape and remain within the scope of the disclosure. For purposes of the disclosure, the terms “small” or “smaller” when referencing nodes shall mean nodes having cross-sectional diameters or dimensions from about 1 mm to about 5 mm. Further for purposes of the disclosure, the terms “large” or “larger” when referencing nodes shall mean nodes having cross-sectional diameters or dimensions from about 6 mm to about 12 mm. It should be understood that these dimensional ranges are for illustrative purposes only. Nodes constructed with dimensions outside the noted ranges but with similar structures, materials and functions as the nodes disclosed herein are within the scope of the disclosure. As indicated above, cylindrical node 400 and paddle node 400′ are non-limiting examples of possible shapes for nodes. Other cross-sectional shapes, e.g., hexagonal, octagonal, oval, etc., may be used and remain with the scope of the disclosure. Any regular or irregular geometric shape in cross-section may be used for the nodes and remain within the scope of the disclosure. Illustrative, non-limiting examples of regular geometric shapes include square, hexagon and octagon. Illustrative examples of irregular geometric shapes include irregular polygons such as scalene triangles, isosceles triangles, parallelograms and irregular pentagons with unequal sides and unequal angles. The nodes should be lightweight and have the ability to compress, rebound and rotate, at least to some degree of rotation, to provide the desired force attenuation and deflection functions.

[0079]The materials used to construct the nodes are primarily thermoplastic polyurethanes, as disclosed in more detail herein, but any synthetic or natural substances, e.g. polyisoprene (natural rubber), polybutadiene (synthetic rubber), and ethylene-vinyl acetate, that have elastomeric properties, e.g., reversible elastic elongation from about 400% to about 800%, and suitable hardnesses from about 30 to about 70 Asker Durometer Type C, or from about 20 to about 40 Shore A, may be used. It should be understood that the ranges for suitable properties of elastomeric materials disclosed herein are illustrative and non-limiting. Materials possessing properties outside the disclosed ranges that can be used to construct nodes that perform the intended force attenuation and deflection functions remain within the scope of the disclosure. Materials having additional advantageous properties, e.g., UV resiliency, tear resistance and the like, also may be used to construct the nodes. Nodes may be formed via injection molding, compression molding, 3-D printing and like methods well known in the art. For nodes used in textile matrix embodiments, the nodes are overmolded over the lattice segments of the textile matrices to permit free rotation about the lattice segments.

B. Matrix Patterns

[0080]To address unique anatomical features, various matrix patterns may be used to customize the force attenuation and deflection apparatuses to provide adequate localized protection while minimizing movement restriction imparted by the apparatus. Referring now to FIG. 35, in one embodiment of the disclosure, a columnar matrix pattern, designated generally as 500, incorporates a plurality of lattice strings 502 having a plurality of nodes 504 integrally formed with (elastomeric matrix), or positioned (superposed) on (textile matrix), to collectively form parallel, horizontally-oriented node strings, designated generally as 506. Node strings 506 are aligned in the matrix pattern so that nodes 504 are aligned in multiple vertical columns. This matrix pattern provides comprehensive even force-protection coverage.

[0081]Referring now to FIG. 37, in another embodiment of the disclosure, a staggered-row matrix pattern, designated generally as 500′, incorporates a plurality of lattice strings 502′ having a plurality of nodes 504′ integrally formed with (elastomeric matrix), or positioned (superposed) on (textile matrix), to collectively form parallel, horizontally-oriented, staggered node strings, designated generally as 506′. In this embodiment, nodes 504′ on adjacent lattice strings align vertically in columns but form staggered rows horizontally. It should be understood for any embodiment disclosed herein that any designation of nodes as being “vertical” or “horizontal” is intended to provide orientation of the various features for illustrative purposes only. Any orientation can be altered by rotating the view of the matrix pattern.

[0082]Referring now to FIG. 33, in a yet another embodiment of the disclosure, an interlocking-ring matrix pattern, designated generally as 500″, incorporates a plurality of intersecting lattice strings including horizontal lattice strings 502″, first diagonal lattice strings 503 and second diagonal lattice strings 505 to form a series of interlocking hexagonal patterns. A plurality of node 504″ are formed integral with (for the elastomeric matrix embodiment), or positioned (superposed) about (for the textile matrix), one, or a plurality of, lattice segment(s) formed between the vertices of intersecting lattice strings. Except for nodes positioned on the upper or lower edges of interlocking ring matrix pattern 500″, each node 504″ will be part of two hexagonally-shaped rings to create the “interlocking-ring” pattern. This pattern is suitable to protect against forces that do not have small focused point-load impacts.

[0083]Referring now to FIG. 34, in a further embodiment of the disclosure, a segmented-node matrix pattern, designated generally as 500′″, includes the same lattice pattern of staggered-row matrix pattern 500′ with modified grooved nodes 504″. Segmented-node matrix pattern 500″ incorporates a plurality of lattice strings 502″ having a plurality of nodes 504″ integrally formed with (elastomeric matrix), or positioned (superposed) on (textile matrix), to collectively form parallel, horizontally-oriented, staggered node strings, designated generally as 506′″. In this embodiment, nodes 504′″ on adjacent lattice strings align vertically in columns but form staggered rows horizontally. Each node 506′″ is formed with a pair of annular grooves 507 that create a center node elevation 509 and two end node elevations 511. The node modification provides additional flexibility to the node where additional node flexion is needed to adjust to discrete anatomical features.

[0084]Referring now to FIG. 36, in a yet further embodiment of the disclosure, a split-node matrix pattern, designated generally as 500^IV, includes the same lattice pattern of staggered-row matrix pattern 500′ with modified grooved nodes 504^IV. Split-node matrix pattern 500′V incorporates a plurality of lattice strings 502^IV having a plurality of split nodes 504\\ integrally formed with (elastomeric matrix), or positioned (superposed) on (textile matrix), to collectively form parallel, horizontally-oriented, staggered node strings, designated generally as 506^IV. In this embodiment, split nodes 504^IV on adjacent lattice strings align vertically in columns but form staggered rows horizontally. Each node 506^IV is paired with another node 506^IV on each lattice segment 513 to give the appearance of a single node being split into two halves. Like segmented nodes 504″, this node modification provides additional flexibility to the nodes where additional node flexion is needed to adjust to discrete anatomical features. It should be understood that the matrix patterns disclosed herein are for illustrative purposes only. Any elastomeric or textile matrix pattern that incorporates lattice segments, lattice strings and force attenuation and deflection nodes to form networks of nodes shall remain within the scope of the disclosure.

[0085]In terms of desirable properties, any matrix, whether elastomeric or textile based, should exhibit the characteristics of high elasticity and superior tear resistance to permit matrix/node combinations assembled into a guard to be placed over the appropriate body part so as to snugly remain in place during activity and provide the desired force attenuation and deflection functions. Suitable materials that provide the desired characteristics include TPU-TY40BL (SSP Compounds), a thermoplastic polyurethane foam having a density of 400 kg/m³ and a 40 Asker Durometer C hardness and TPU-TY65BL (SSP Compounds), another thermoplastic urethane foam having a density of 600 kg/m³ and a 65 Asker Durometer C hardness. Injection molding, compression molding, 3-D printing and like methods of manufacture may be used to construct either the elastomeric matrix or the textile matrix as is well known in the art. Having described the basic lattice/node structure of the disclosure, illustrative, non-limiting examples of the described lattice/node structures incorporated into pads or guards are now provided.

II. Force Attenuation and Deflection Lower Leg/Foot Guard

A. Elastomeric Matrix

[0086]Referring generally now to FIGS. 1-15, in one aspect of the disclosure, a force attenuation and deflection guard or pad, designated generally as 10, is formed from a unitary or a multiple-panel elastomer matrix 12 to substantially cover the entirety of one or more body parts to impart what is essentially 360° protection from forceful impacts. Whether formed as a single unit, or formed from a series of panels secured together, each unit or panel is structured from a series of interconnected, alternating lattice line segments 14 (that collectively are referred to as lattice lines 14) and force-absorption and force-deflection nodes 16 that combine to form node strings, designated generally as 18. Pattern-lock lattice segments 20 secure adjacent lines of node strings 18 to set the lateral spacing between nodes 16 located on adjacent node strings. The combination of the lattice segments 14, the nodes 16 and the pattern-lock lattice segments 20 form elastomeric matrix 12. The overall shape of either the unitary embodiment or the assembled panel embodiment is constructed to conform generally to the shape of an anatomical feature, e.g., a lower leg and foot, as illustratively shown in the referenced figures.

[0087]The primary purpose of lattice segments 14 is to provide a support structure to secure together the plurality of nodes 16. Although nodes 16 are the primary features that perform the force attenuation and force deflection functions, due to the elastomeric properties of the materials used to construct both the lattice segments 14 and the nodes 16, disclosed in detail hereinbelow, the lattice segments also contribute to, and assist with, the functionality of nodes 16. Moreover, although the lattice structure or elastomeric matrix 12 can be formed as a series of interconnected orthogonal joints, the lattice structure can be constructed as a combination of interconnected lattice patterns that follow the particular contours of the anatomical feature over which guard 10 is applied. Each pattern can vary in overall size, contour shape and node density. The width, length and thickness of the individual lattices also can be adjusted dimensionally to optimize node rotation, spacing and therefore, density. Node density can be adjusted further by altering the dimensions of the nodes, e.g., cross-sectional diameters and thicknesses. The density and therefore impact resistance of each node can further be adjusted by using different elastomeric materials having different densities and elastomeric properties. A further optional node alteration is to alter the cross-sectional shape of the nodes as described in further detail herein.

[0088]Due to the asymmetric, unique shapes of body parts, discrete areas of guard 10 can be customized to maximize the protection of the body part area over which the discrete area of guard 10 is placed. This customization can include modifications of lattice patterns, node densities, node shapes, node sizes and materials used to make specific lattice sections and/or nodes. By way of illustration and not limitation, referring now specifically to FIG. 2, a medial ankle node pattern assembly, designated generally as 22 is structured as a circular or semi-circular pattern of a relatively dense cropping of medial ankle nodes 24. The structure and location of the medial ankle node pattern assembly is designed specifically to provide enhanced protection of the medial malleolus due to the anatomical feature's medial projection from the end of the tibia. Because this anatomical feature projects from the lower leg, it is particularly prone to injury from, for example, ball strikes. Moreover, although the structure is essentially a boney prominence, it also includes ligaments, tendons and nerves that are not embedded in a thick skeletal-muscular structure. These soft tissues lie over the bone and are thus uniquely exposed to injury from blunt force trauma events.

[0089]To ensure maximum protection, medial ankle node pattern assembly 22 is structured from a plurality of circular or semi-circular lengths of medial ankle lattice lines 26 arranged in a parallel, nested pattern that conforms to the shape of the medial malleolus. Nodes 24 are formed between segments of lattice lines 26 in an alternating pattern to form medial ankle lattice line node strings 27. To secure the distance between medial ankle lattice line strings 27, medial ankle pattern-lock lattice segments 28 are provided that connect adjacent medial ankle lattice line node strings 27 and set the resting distance between the medial ankle lattice line strings and therefore, the nodes. As used herein, the phrase, “resting distance,” refers to the distance between adjacent lattice line segments and associated laterally-adjacent nodes before guard 10 is subject to radial displacement when stretched and placed over an anatomical feature or when altered by force applied to the lattice segments. Also as used herein, the phrase, “dynamic distance,” refers to the distance between lattice segments after a force is applied to the segments.

[0090]A plurality of medial ankle nodes 24 are formed along each medial ankle lattice line 26, alternating with lattice line segments as described above, in series with the ends of each node in close proximity to, but separate from, the ends of adjacent nodes formed on the same lattice line. By separating the nodes via segments of the ankle lattice lines, the full functionality of the nodes can be realized as explained in detail herein. It should be understood, however, that the nodes may be registered against one another and remain within the scope of the disclosure. For areas in need of maximal protection, the nodes can be arranged on their lattice lines to have their ends registered together. Moreover, by varying the length of nodes 16 including medial ankle nodes 24, anatomical features having different curvatures both in terms of size and degree of curvature can be accommodated. For features, e.g., the ankle, that have relatively severe contours, medial ankle nodes 24 can be made shorter to provide more points of radial articulation. Apart from securing nodes together, segments of lattice lines 14, including medial ankle lattice lines and ankle lattice line segments 26 formed between two nodes, function as articulating joints, whereby the lattice segments can be flexed or bent due to their elastomeric properties. The more joints in a lattice line 14 (including medial ankle lattice lines and segments 26), the more the elastomeric matrix segment can be stretched and bent or wrapped about an anatomical feature.

[0091]With the distance between nested medial ankle lattice line node strings 27 set by medial ankle pattern-lock lattice segments 28, the space between the lattice lines can be filled selectively with ankle nodes 24. The cross-sectional diameters of medial ankle nodes 24 can be set such that laterally adjacent nodes can be spaced or registered against one another to adjust node density to provide varying degrees of protective coverage to an anatomical feature. Medial ankle nodes 24 formed on parallel, nested medial ankle lateral lines 26 will form a dense circular or semi-circular pattern of layered and nested node clusters to provide maximum protection to the medial ankle structure. As stated, the degree of protection can be altered by a number of variables that include the elastomeric properties of the material used to construct matrix 12, the thickness, length and spacing of the lattice segments, the elastomeric properties of the material used to construct nodes 16 (and ankle nodes 24) and the spacing, length, cross-sectional diameter and thickness of the nodes. Each one of these non-limiting examples of variables can be modified to optimize the protection of a specific anatomical feature such as a lower leg. Moreover, by locating each node in close proximity to other nodes, protection of a particular anatomical area can be maximized.

[0092]As previously described, elastomer matrix 12 can be formed as a single unit or in panel segments dedicated to the unique features of an anatomical part. By constructing elastomer matrix 12 in panels, each panel segment can be customized to address the unique features of a specific part of an anatomical feature. This can simplify construction of guard 10 by permitting discrete portions of the guard to be formed in flat segments as shown in FIGS. 2 and 3. It also provides the opportunity to construct different panels with different materials to impart different levels of force protection as explained in more detail herein. The segments can then be assembled and attached together to create a three-dimensional slip-on guard.

[0093]Referring now to FIG. 2, a medial panel, designated generally as 30, includes a variety of lattice line strings or node-string groupings differentiated to address specific force attenuation and force deflection needs of discrete areas of a lower leg and foot. A medial-side lattice string assembly, designated generally as 32, includes a plurality of parallel, curved medial-side lattice lines 34 that each have medial-side lattice line segments formed in an alternating pattern with a plurality of medial-side nodes 36 to form medial-side lattice line node strings 37. Medial-side nodes 36 are formed with varying cross-sectional diameters to provide varying degrees of force protection at different points along panel 30. The level of force protection provided by medial-side nodes 36, as well as any nodes disclosed herein, increases with the increase in cross-sectional diameter of the nodes. Medial-side pattern-lock segments 38 set and maintain the spacing of medial-side lattice line node strings 37 with respect to their resting distances both before and after the application of one or more forces.

[0094]A calf lattice string assembly, designated generally as 40, includes a plurality of parallel, curved calf lattice lines 42 that each have calf lattice line segments formed in an alternating pattern with a plurality of calf nodes 44 to form calf lattice line node strings 46. Calf nodes 44 have larger diameters than medial-side nodes 36. Moreover, the cross-sectional shapes of calf nodes 44 differ from the cross-sectional shapes of medial-side nodes 36. Whereas medial-side nodes 36 have an overall cylindrical shape, (as shown in FIG. 10), calf nodes 44 have a paddle shape (as shown in FIG. 11). These modifications of shape are used more to optimize conformity to the specific anatomical shape of the calf area rather than to increase force protection. The overall flatter shapes of the paddle-shaped calf nodes enable the nodes to cover more area per node and to mechanically conform better to the calf area, which is much less flexible and less prominent than, for example, the ankle area. As a general application, the paddle-shaped nodes are placed on anatomical areas with limited flexion. Smaller diameter nodes are placed, in general, on areas that require greater degrees of flexion, such as the ankle joint. It should be understood that the smaller nodes are not used to lower protection to a particular area of application but to maximize flexibility in the area.

[0095]The paddle shape of calf nodes 44 does not provide the same freedom of rotational movement as do the cylindrically-shaped medial-side nodes 36. Because these paddle-shaped nodes have less rolling effect, their relative sizes are increased over the size of medial-side nodes 36. This node modification is provided to increase the force protection afforded the soft tissue of the calf. Calf lattice lines 42 are arranged substantially parallel to medial-side lattice lines 34 to maintain the continuity of protection of this portion of medial panel 30. Calf pattern-lock segments 48 set and maintain the spacing of the calf lattice line node strings 46 with respect to their resting distances both before and after the application of one or more forces.

[0096]A heel lattice string assembly, designated generally as 50, includes a plurality of parallel, curved heel lattice lines 52 that each have heel lattice line segments formed in an alternating pattern with a plurality of heel nodes 54 to form heel lattice line node strings 56. Heel nodes 54 have smaller cross-sectional diameters than shin nodes 36 and calf nodes 44. This node modification is utilized primarily due to the need for greater flexibility in the heel region and due to the fact that statistically, heel strikes from objects, e.g., baseballs, is of a lower probability and a lower impact zone. The fact that the area being protected is a large, robust boney segment of the lower leg/ankle joint, i.e., the calcaneus bone, makes the application of smaller-diameter nodes more feasible. Heel pattern-lock segments 48 set and maintain the spacing of the calf lattice line node strings 56 with respect to their resting distances both before and after the application of one or more forces.

[0097]As shown in FIG. 2, the curvature of heel lattice lines 52 are opposite the curvature of ankle lattice lines 26. The two assemblies register against one another at tangential points on their curvatures. This configuration results in void sections being formed between the curved lattice line assemblies where the curved lattice lines of the respective assemblies increase in distance. The triangular voids are filled with interstitial lattice assemblies. An upper interstitial lattice assembly, designated generally as 60, includes upper interstitial lattice lines 62 that each have upper interstitial lattice line segments formed in an alternating pattern with a plurality of upper interstitial nodes 64 to form upper interstitial lattice line node strings 66. Upper interstitial node strings 66 form a wave-shaped pattern that follows the contours of the bottom ends of medial-side lattice assembly 26 and calf lattice assembly 40, and the top ends of heel lattice assembly 50 and ankle lattice assembly 22. Upper interstitial lattice assembly 60 include upper interstitial pattern-lock segments 68 to set and maintain the spacing of the upper interstitial lattice line node strings 66 with respect to their resting distances both before and after the application of one or more forces.

[0098]A lower interstitial lattice assembly, designated generally as 70, includes lower interstitial lattice lines 72 that each have calf lattice line segments formed in an alternating pattern with a plurality of lower interstitial nodes 74 to form lower interstitial lattice line node strings 76. Lower interstitial node strings 76 form a wedge or triangular shape to accommodate the curvatures of the lower ends of heel lattice assembly 50 and ankle lattice assembly 22 to ensure complete force-protection coverage of the heel and surrounding anatomical areas. Lower interstitial lattice assembly 70 include lower interstitial pattern-lock segments 78 to set and maintain the spacing of the lower interstitial lattice line node strings 76 with respect to their resting distances both before and after the application of one or more forces.

[0099]Extending ventrally from the ankle lattice assembly is a fore-foot lattice assembly, designated generally as 80, that includes a plurality of parallel, curved fore-foot lattice lines 82 that each have fore-foot lattice line segments formed in an alternating pattern with a plurality of fore-foot nodes 84 to form fore-foot lattice line node strings 86. Fore-foot nodes 84 have larger cross-sectional diameters that medial-side nodes 36. This node modification is provided to increase the force protection afforded the somewhat delicate vascular and tendinous tissue of the upper fore-foot whereas the smaller diameter medial-side nodes 36 do not have to provide as much protection to the boney shin aspect of a lower leg. Fore-foot pattern-lock segments 88 set and maintain the spacing of the fore-foot lattice line node strings 86 with respect to their resting distances both before and after the application of one or more forces.

[0100]The fore-foot node strings 86 of fore-foot lattice assembly 80 are formed in a curved pattern to overlay the entire fore-foot and toe regions when assembled to a lateral panel, designated generally as 150 and described in more detail herein. It should be noted that the lattice lines of fore-foot lattice assembly 80 can be continuations of the ankle lattice lines 26. The lines of the respective assemblies may be demarcated by a lateral fore-foot pattern-lock segment 88. The overall pattern of fore-foot assembly 80 is in the basic shape of a “c” to wrap over the fore-foot and toe area. Due to this shape, when wrapped or folded over to conform to the shape of a foot, a void is created in the inner curvature of the “c” shaped pattern.

[0101]To address the void, a top lattice assembly, designated generally as 90, is formed in the inner curvature of fore-foot lattice assembly 80. Top lattice assembly 90 includes a plurality of parallel, curved top lattice lines 92 that each have top lattice line segments formed in an alternating pattern with a plurality of top nodes 94 to form top lattice line node strings 96. Top nodes 94 have smaller cross-sectional diameters that medial-side nodes 36. This node modification is provided to increase the flexibility of the ankle joint of which top lattice assembly 90 is positioned. Top nodes 94, despite their relatively smaller cross-sectional diameter provide sufficient force protection to the boney prominences comprising the cuneiform bones and part of the cuboid bone. One or more top pattern-lock segments 98 set and maintain the spacing of the top lattice line node strings 96 with respect to their resting distances both before and after the application of one or more forces.

[0102]Surrounding the perimeter of medial panel 30 is a medial panel attachment flange 100. Flange 100 provides an attachment means to attach medial panel 30 to other panels and/or support structures for guard 10. Flange 100 may be formed integrally with the components of medial panel 30 or may be a separate component secured to medial panel 30. One such support structure secured to medial panel 30 is guard tension band 110 shown in FIG. 9. Tension band 110 is an elastomeric structure formed in the shape of a hollowed-out shoe sole or the continuous perimeter of a shoe sole with toe, heel, inner arch and outer arch sections. Medial panel 30 is secured to tension band 110 at several points to anchor the panel, set the panel's shape at a lower end and provide a means to releasably secure guard 10 to a lower leg and footwear, such as sneakers or cleats. Extending outwardly from a distal end of attachment flange 100 are one or more toe attachment tabs 102 structured to be secured to guard tension band 110. An arch attachment tab 104 extends downwardly from attachment flange 100 in the area of ankle lattice assembly 22. A heel attachment tab 106 extends downwardly from attachment flange 100 in the area of heel lattice assembly 50. All of the tabs formed on medial panel 30 are positioned over guard tension band 110 and secured thereto with stitching, such as box stitching. Other attachment means may be used, e.g., sonic welding, overmolding, adhesive, mechanical fastener and the like and remain within the scope of the disclosure.

[0103]Referring now to FIG. 3, a lateral panel segment, designated generally as 150, like medial panel segment 30, includes a variety of lattice line string/node groupings differentiated to address specific force attenuation and force deflection needs of discrete areas of the shin and lateral portions of a lower leg and foot. A lateral shin lattice string assembly, designated generally as 152, includes a plurality of parallel, lateral shin lattice lines 154 that each have lateral shin lattice line segments formed in an alternating pattern with a plurality of lateral shin nodes 156 to form lateral shin lattice line nodes strings 157. Lateral shin nodes 156 are formed as paddle-shaped nodes, in similar fashion and size to calf nodes 156, with varying cross-sectional diameters with the larger diameter lateral shin nodes located toward the top of lateral panel segment 150, which coincides with the location of a shin when guard 10 is placed over a lower leg. The large surface areas of lateral shin nodes 156 provide larger areas of coverage per node and provide varying degrees of force protection depending upon their overall size at different points along lateral panel 150. As previously stated, the level of force protection provided by lateral shin nodes 156, as well as any nodes disclosed herein, increases with the increase in cross-sectional diameter of the nodes. Lateral shin pattern-lock segments 158 set and maintain the spacing of the lateral shin lattice line node strings 157 with respect to their resting distances both before and after the application of one or more forces.

[0104]A lateral-side lattice string assembly, designated generally as 160, includes a plurality of parallel, lateral-side lattice lines 162 that each have lateral-side lattice line segments formed in an alternating pattern with a plurality of lateral-side nodes 164 to form lateral-side lattice line node strings 166. Lateral-side nodes 164 have smaller cross-sectional diameters that lateral shin nodes 156. This node modification is provided to increase flexibility in this area of guard 10. The decrease in overall force protection provided by these smaller-diameter nodes to the soft tissue of the lateral regions of the lower leg is acceptable as this is a zone with a relatively lower probability of hits, whereas the larger diameter lateral shin nodes 156 provide more protection to the boney shin aspect of the front lower leg, which is an area with a relatively higher probability of hits. Lateral-side lattice lines 162 are arranged substantially parallel to lateral shin lattice lines 154 to maintain the continuity of protection of this portion of lateral panel 150. Lateral-side pattern-lock segments 168 set and maintain the spacing of the lateral-side lattice line node strings 166 with respect to their resting distances both before and after the application of one or more forces.

[0105]A lateral ankle lattice string assembly, designated generally as 170, includes a plurality of curved, parallel, lateral ankle lattice lines 172 that each have lateral ankle lattice line segments formed in an alternating pattern with a plurality of lateral ankle nodes 174 to form lateral ankle lattice line node strings 176. Lateral ankle nodes 174 have smaller cross-sectional diameters than the lateral-side nodes 164 due to an increased need for flexibility in the ankle area. Additional benefits of reducing the size of the nodes (for this lattice string assembly or any lattice string assembly disclosed herein) are a reduction in materials used and the associated cost as well as a reduction in overall weight of guard 10. Lateral ankle lattice string assembly 170 is positioned below lateral shin lattice assembly 152 and lateral-side lattice assembly 160 and spans the entire width of lateral panel 150 except for a lateral panel attachment flange 210 described in more detail herein below. Lateral ankle pattern-lock segments 178 set and maintain the spacing of the lateral ankle lattice line node strings 176 with respect to their resting distances both before and after the application of one or more forces.

[0106]An outer lateral ankle lattice string assembly, designated generally as 180, includes a plurality of parallel, curved outer lateral ankle lattice lines 182 that each have outer lateral ankle lattice line segments formed in an alternating pattern with a plurality of outer lateral ankle nodes 184 to form outer lateral ankle lattice line node strings 186. Outer lateral ankle nodes 184 have essentially the same cross-sectional diameters as lateral ankle nodes 174. Outer lateral ankle pattern-lock segments 188 set and maintain the spacing of the outer lateral ankle lattice line node strings 186 with respect to their resting distances both before and after the application of one or more forces.

[0107]As shown in FIG. 3, the curvature of outer lateral ankle lattice lines 182 are opposite the curvature of lateral ankle lattice lines 172. The two assemblies register against one another at tangential points on their curvatures. This configuration results in void sections being formed between the curved lattice line assemblies where the curved lattice lines of the respective assemblies increase in distance. The triangular voids are filled with interstitial lattice assemblies. An upper lateral interstitial lattice assembly, designated generally as 190, includes upper lateral interstitial lattice lines 192 that each have upper lateral interstitial lattice line segments formed in an alternating pattern with a plurality of upper lateral interstitial nodes 194 to form upper lateral interstitial lattice line node strings 196. Upper lateral interstitial node strings 196 form a V-shaped pattern that follows the contours of the bottom ends of lateral shin lattice assembly 152 and lateral-side lattice assembly 160, and the top ends of lateral ankle lattice assembly 170 and outer lateral ankle lattice assembly 180. Upper lateral interstitial lattice assembly 190 include upper lateral interstitial pattern-lock segments 198 to set and maintain the spacing of the upper interstitial lattice line node strings 196 with respect to their resting distances both before and after the application of one or more forces.

[0108]A lower lateral interstitial lattice assembly, designated generally as 200, includes lower lateral interstitial lattice lines 202 that each have lower lateral interstitial lattice line segments formed in an alternating pattern with a plurality of lower lateral interstitial nodes 204 to form lower lateral interstitial lattice line node strings 206. Lower lateral interstitial node strings 206 form a wedge or triangular V-shape to accommodate the curvatures of the lower ends of lateral ankle lattice assembly 170 and outer lateral ankle lattice assembly 180 to ensure complete force-protection coverage of the heel and surrounding anatomical areas. Lower lateral interstitial nodes 204 have essentially the same cross-sectional diameters as lateral ankle nodes 174. Lower lateral interstitial lattice assembly 200 includes lower lateral interstitial pattern-lock segments 208 to set and maintain the spacing of the lower interstitial lattice line node strings 206 with respect to their resting distances both before and after the application of one or more forces.

[0109]Surrounding the perimeter of lateral panel segment 150 is a lateral panel attachment flange 210. Flange 210 provides an attachment means to attach lateral panel segment 150 to medial panel segment 30 and/or to support structures for guard 10. Flange 210 can be formed integral with, or attached to the other components of lateral panel segment 150. Guard tension band 110 is one such support structure that can be attached to lateral panel segment 150. As previously indicated, tension band 110 is an elastomeric structure formed in the shape of a shoe sole. Lateral panel 150 may be secured to tension band 110 directly at its base or indirectly by relying on the attachment points of medial panel segment 30 for attachment to guard tension band 110. To secure lateral panel segment 150 to medial panel segment 30, flange 210 is positioned adjacent to, and in registration with, flange 100 of medial panel segment 30. Alternatively, flange 210 may be at least partially overlapped with flange 100. A zig-zag stitching pattern may be used to secure the two panel segments together. Alternative attachment means include sonic welding, overmolding, adhesive, mechanical fastener and the like.

[0110]Guard tension band 110 is essentially an injection molded band formed from a thermoplastic polyurethane. The polyurethane material selected for this illustrative embodiment has a Shore A hardness of about 60 and an elongation factor greater than 600%. This ensures the band has sufficient elastomeric and resiliency properties to effectively stretch over a piece of footwear and rebound with sufficient force to retain guard 10 on the footwear during all intended activities. Illustrative examples of acceptable polyurethanes include Elastollan® (BASF), Avalon (Huntsman) and polyurethanes manufactured by Hexpol. It should be understood that this list is intended purely for illustrative purposes and other materials such as polybutadiene-based materials may be used to form guard tension band 110 and remain within the scope of the disclosure.

[0111]As indicated previously, separating guard 10 into panel segments provides the ability to use different materials to make the different panel segments. As shown in FIG. 4, a multi-panel guard 10 has panels made from different materials to impart different force protection levels and to improve the overall functionality of the guard including the ease with which to don and remove the guard. In an illustrative embodiment, medial panel 30 is formed from TPU-TY40BL (SSP Compounds), a thermoplastic polyurethane foam having a density of 400 kg/m³ and a 40 Asker Durometer C hardness. Lateral panel 150 is formed from TPU-TY65BL (SSP Compounds), another thermoplastic urethane foam having a density of 600 kg/m³ and a 65 Asker Durometer C hardness. A non-woven polyester seam 220 is secured between medial panel 30 and lateral panel 150 with a zig-zag stitching pattern 101 to provide additional strength at this major flexion joint. To further rigidify guard 10, one or more steel wire stays 222 may be overmolded into key points in the guard to provide structure to the guard and to improve the positioning of the guard on a body part. As shown in FIG. 4, wire stay 222 is secured laterally within a pattern-locking segment 88 of lateral panel 150.

[0112]Having described the structure of guard 10, attention is turned to the function of the novel guard construction. Each node, due to its cross-dimensional size and material composition, has elastomeric properties that enable the node to compress and laterally disperse forces applied to the node. Due to the novel connection means, i.e., the elastomeric string segments that join nodes together, each node can rotate about its axis via twisting rotation of the elastomeric string segments. With the mechanical ability to rotate, the nodes can deflect forces imparted on the nodes from an angle other than a force directed along a vector orthogonal to a tangent of the cylindrically-shaped node. The freedom of rotational movement of the nodes provides an additional degree of force attenuation and force deflection not available in static foam-based or padding-based guards. Moreover, due to the material composition of the elastomeric string segments, the string segments also can contribute to force attenuation when a force is directed onto the string segments. The elastomeric nature of the construction further allows the guard to be stretched dynamically, as shown in FIG. 8, to enable the guard to be placed over a body part and rebound to remain secured to the body part during activity. The same elastic function occurs when a force is applied to the guard. Individual lattice node strings can stretch dynamically away from one another to absorb and deflect the force and then rebound to their resting distances (or dynamically stretched distances when placed over a body part without any applied impact force) after the force has been fully dissipated. These advantageous functional features are borne out from the testing results disclosed in detail herein.

B. Textile Matrix

[0113]Referring generally now to FIGS. 16-27, in another aspect of the disclosure, a force attenuation and deflection guard or pad, designated generally as 10′, is formed from a unitary or a multiple-panel textile matrix 12′ to substantially cover the entirety of one or more body parts to impart what is essentially 360° protection from forceful impacts. Textile, as used herein, is defined broadly to mean fabric or cloth formed from woven raw materials including natural and synthetic fibers. More particularly, textile materials used to form the textile matrix may be a material or a combination of materials that consist of a monofilament, or multiple filaments spun to create a thread/yarn. The thread/yarn is ultimately knitted, woven, molded or otherwise shaped into a network or matrix. The underlying materials used may be natural or synthetic, or a combination of the two. Polyamide 6 (Nylon) is an illustrative example of one material that can be used to form the textile matrix. It should be understood that different materials may be used to alter the strength, stretch and durability of the textile matrix and remain within the scope of the disclosure.

[0114]In contrast to the elastomer matrix embodiment, the textile matrix embodiment uses a skeletal textile matrix with structurally separate nodes superposed about individual matrix lattice segments. In this embodiment, the terms, “lattice lines” and “lattice segments” are used interchangeably. Whether the textile matrix is formed as a single unit or formed from a series of panels secured together, each unit or panel is structured from a series of interconnected textile lattice lines or segments 14′ that form a skeletal network with textile force-absorption and force-deflection elastomeric textile nodes 16′ strategically positioned on individual textile lattice lines or segments 14′. Although the nodes for this embodiment are termed “textile nodes,” the nodes are formed from elastomeric materials to impart the desirable force attenuation characteristics of the elastomeric materials. Depending upon the force protection needs of a specific area of guard 10, a single textile lattice line or segment 14′ may have one or more textile nodes 16′ secured about the textile lattice segment. Other textile lattice lines or segments that intersect or cross over the subject textile lattice line or segment 14′ may function as stops to prevent the axial translation of textile nodes 16′ along the textile lattice segment. The combination of a textile lattice line or segment with textile nodes 16′ secured to the textile lattice segment form textile lattice line node strings, designated generally as 18′. Textile pattern-lock lattice segments 20′ secure adjacent lines of textile lattice line node strings 18′ to set the lateral spacing between textile nodes 16′ located on adjacent textile lattice line node strings. The combination of textile lattice segments 14′, textile nodes 16′ and textile pattern-lock lattice segments 20′ form textile matrix 12′. The overall shape of either the unitary embodiment or the assembled panel embodiment is constructed to conform generally to the shape of an anatomical feature, e.g., a lower leg and foot, as illustratively shown in FIGS. 16, 19 and 20.

[0115]The primary purpose of textile lattice lines or segments 14′ is to provide a support structure to secure together the plurality of textile nodes 16′. A secondary function is to enhance the force attenuation and force deflection functions of textile nodes 16′. The stretch characteristics of the material used to construct the textile lattice segments will enable textile nodes positioned on the textile lattice segments to be spread, which provides both force attenuation and force deflection effects. Moreover, any elastomeric properties of the materials used to construct textile lattice lines or segments 14′ will enable the textile lattice lines to contribute to, and assist with, the force-absorption functionality of textile nodes 16′.

[0116]With respect to the overall structure of textile matrix 12′, the lattice structure can be formed as a series of interconnected orthogonal joints, such as shown in FIGS. 34-37, or the lattice structure can be constructed as a combination of interconnected lattice patterns that follow the particular contours of the anatomical feature over which guard 10′ is applied such as shown in skeletal form (without nodes) in FIGS. 24 and 25. The node patterns associated with these skeletal textile matrix forms are shown in FIGS. 26 and 27. In similar fashion to elastomeric matrix 12, each pattern can vary in overall size, contour shape and node density. The width, length and thickness of the individual lattices also can be adjusted dimensionally to optimize node spacing and therefore, density. Node density can be adjusted further by altering the dimensions of the nodes, e.g., cross-sectional diameter and thicknesses. The density and therefore impact resistance of each node can further be adjusted by using different elastomeric materials having different densities. A further optional node alteration is to alter the cross-sectional shape of the nodes as described in further detail herein.

[0117]Like guard 10, due to the asymmetric, unique shapes of body parts, discrete areas of guard 10′ can be customized to maximize the protection of the body part area over which the discrete area of guard 10′ is placed. This customization can include modifications of lattice patterns, node densities, node shapes, node sizes and materials used to make specific lattice sections and/or nodes. Such lattice customizations are shown illustratively in FIG. 17. Referring now specifically to FIG. 17, a textile medial ankle node pattern assembly, designated generally as 22′ is structured as a circular or semi-circular pattern of a relatively dense cropping of textile medial ankle nodes 24′. The structure and location of the textile medial ankle node pattern assembly is designed specifically to provide enhanced protection of the medial malleolus due to the anatomical feature's medial projection from the end of the tibia. Because this anatomical feature projects from the lower leg, it is particularly prone to injury from, for example, ball strikes. Moreover, although the structure is essentially a boney prominence, it also includes ligaments, tendons and nerves that are not embedded in a thick skeletal-muscular structure. These soft tissues lie over the bone and are thus uniquely exposed to injury from blunt force trauma events.

[0118]To ensure maximum protection, textile medial ankle node pattern assembly 22′ is structured from a plurality of circular or semi-circular lengths of textile medial ankle lattice lines 26′ arranged in a parallel, nested pattern that conforms to the shape of the medial malleolus. To secure the distance between textile medial ankle lattice lines 26′, textile medial ankle pattern-lock lattice segments 28′ are provided that connect adjacent textile medial ankle lattice lines 26′ and set the resting distance between the textile medial ankle lattice lines and therefore, the textile nodes.

[0119]A plurality of textile medial ankle nodes 24′ are positioned along each textile medial ankle lattice line 26′ in series with the ends of each node in close proximity to, but separate from, the ends of adjacent textile nodes positioned on the same textile lattice line. Alternatively, textile nodes may register against one another, axially, when positioned on the same textile lattice segment and/or laterally when positioned on adjacent textile lattice segments and maintain their full functionality. For areas in need of maximal protection, the textile nodes can be arranged on their textile lattice lines to have their ends registered together. Moreover, like nodes 16, by varying the length of textile nodes 16′ (shown in FIG. 16) including textile medial ankle nodes 24′, anatomical features having different curvatures both in terms of size and degree of curvature can be accommodated. For features, e.g., the ankle, that have relatively severe contours, textile medial ankle nodes 24′ can be made shorter and/or smaller in cross-sectional diameter to provide more points of, and more freedom for, radial articulation. Apart from securing nodes in discrete patterns, textile lattice lines or segments 14′, including textile medial ankle lattice lines 26′, function as articulating joints, whereby the lattice lines can be flexed or bent due to their elastomeric properties. The longer textile lattice line 14′ (including textile medial ankle lattice lines 26′), the more the textile matrix segment can be stretched and bent about an anatomical feature.

[0120]With the distance between nested textile medial ankle lattice lines 26′ set by textile medial ankle pattern-lock lattice segments 28′, the space between adjacent textile lattice lines can be filled selectively with textile medial ankle nodes 24′. The combination of textile medial ankle lattice lines 26′ and textile medial ankle nodes 24′ form textile medial ankle lattice line node strings 27′. The cross-sectional diameters of textile medial ankle nodes 24′ can be set such that laterally adjacent nodes can be spaced or registered against one another to provide less or more dense protective coverage of an anatomical feature, respectively. Textile medial ankle nodes 24′ secured about parallel, nested textile medial ankle lateral lines 26′ will form a dense circular or semi-circular pattern of layered and nested node clusters to provide maximum protection to the medial ankle structure. The degree of protection can be altered by a number of variables that include the elastomeric properties of the material used to construct textile matrix 12′ (shown in FIG. 16), the thickness, length and spacing of the lattice segments, the elastomeric properties of the material used to construct textile nodes 16′ (and textile medial ankle nodes 24′), and the spacing, length, cross-sectional diameter and thickness of the nodes. Each one of these non-limiting examples of variables can be modified to optimize the protection of a specific anatomical feature such as a lower leg. Moreover, by locating each node in close proximity to other nodes, protection of a particular anatomical area can be maximized.

[0121]As previously described, textile matrix 12′ can be formed as a single unit or in panel segments with each panel segment dedicated to the unique features of an anatomical part. By constructing textile matrix 12′ in panels, each panel segment can be customized to address the unique features of a specific part of an anatomical feature. This can simplify construction of guard 10′ by permitting discrete portions of the guard to be formed in flat segments as shown in FIGS. 17 and 18. It also provides the opportunity to construct different panels with different materials to impart different levels of force protection as explained in more detail herein. The segments can then be assembled and attached together to create a three-dimensional slip-on type guard.

[0122]Referring now to FIG. 17, a medial textile panel, designated generally as 30′, includes a variety of textile lattice line strings or textile node-string groupings differentiated to address specific force attenuation and force deflection needs of discrete areas of a lower leg and foot. A textile medial-side lattice string assembly, designated generally as 32′, includes a plurality of parallel, curved textile medial-side lattice lines 34′ with a plurality of textile medial-side nodes 36′ positioned thereon. The combination of textile medial-side lattice lines 34′ and textile medial-side lattice nodes 36′ form textile medial-side lattice line node strings 37′. Textile medial-side nodes 36′ are formed with varying cross-sectional diameters to provide varying degrees of force protection at different points along textile panel 30′. The level of force protection provided by textile medial-side nodes 36′ increases with the increase in cross-sectional diameter of the nodes. Conversely, a reduction in cross-sectional diameter will reduce the protective effect, especially with respect to force attenuation. Cross-sectional diameter has less of an effect with respect to force deflection as any size cylindrically-shaped node will rotate depending upon the angle at which a force is applied to the node. Textile medial-side pattern-lock segments 38′ set and maintain the spacing of textile medial-side lattice line node strings 37′ with respect to their resting distances both before and after the application of one or more forces.

[0123]A textile calf lattice string assembly, designated generally as 40′, includes a plurality of parallel, curved textile calf lattice lines 42′ with a plurality of textile calf nodes 44′ positioned thereon. The combination of textile calf lattice lines 42′ and textile calf nodes 44′ form textile calf lattice line node strings 46′. Textile calf nodes 44′ have larger diameters than textile medial-side nodes 36′. Moreover, the cross-sectional shapes of textile calf nodes 44′ differ from the cross-sectional shapes of textile medial-side nodes 36′. Whereas textile medial-side nodes 36′ have an overall cylindrical shape, (as shown in FIG. 10), textile calf nodes 44′ have a paddle shape (as shown in FIG. 11). Like calf nodes 44, these modifications of shape are used more to optimize conformity to the specific anatomical shape of the calf area rather than to increase force protection. The overall flatter shapes of the paddle-shaped textile calf nodes enable the nodes to cover more area per node and to mechanically conform better to the calf area, which is much less flexible and less prominent than, for example, the ankle area. As stated previously, as a general application, the paddle-shaped nodes are placed on anatomical areas with limited flexion. Smaller diameter nodes are placed, in general, on areas that require greater degrees of flexion, such as the ankle joint. It should be understood that the smaller nodes are not used to lower protection to a particular area of application but to enhance the flexibility of a specific area of a guard.

[0124]The paddle shape of textile calf nodes 44′ does not provide the same freedom of rotational movement as do the cylindrically-shaped textile medial-side nodes 36′. Because these paddle-shaped nodes have less rolling effect, their relative sizes are increased over the size of textile medial-side nodes 36′. This node modification is provided to increase the force protection afforded the soft tissue of the calf. Textile calf lattice lines 42′ are arranged substantially parallel to textile medial-side lattice lines 34′ to maintain the continuity of protection of this portion of medial textile panel 30′. Textile calf pattern-lock segments 48′ set and maintain the spacing of the textile calf lattice line node strings 46′ with respect to their resting distances both before and after the application of one or more forces.

[0125]A textile heel lattice string assembly, designated generally as 50′, includes a plurality of parallel, curved textile heel lattice lines 52′ with a plurality of textile heel nodes 54′ positioned thereon. The combination of curved textile heel lattice lines 52′ and textile heel nodes 54′ form textile heel lattice line node strings 56′. Textile heel nodes 54′ have smaller cross-sectional diameters than textile medial-side nodes 36′ and textile calf nodes 44′. This node modification is utilized primarily due to the need for greater flexibility in the heel region and due to the fact that statistically, heel strikes from objects, e.g., baseballs, is of a lower probability and a lower impact zone. The fact that the area being protected is a large, robust boney segment of the lower leg/ankle joint, i.e., the calcaneus bone, makes use of smaller-diameter nodes more feasible. Although smaller diameter nodes are used for this string assembly, it should be understood that any cross-sectional diameter and any cross-sectional shape can be used to construct these nodes and any of the nodes disclosed herein and remain within the scope of the disclosure. Textile heel pattern-lock segments 58′ set and maintain the spacing of the textile heel lattice line node strings 56′ with respect to their resting distances both before and after the application of one or more forces.

[0126]As shown in FIG. 17, the curvature of textile heel lattice lines 52′ are opposite the curvature of textile ankle lattice lines 26′. The two assemblies register against one another at tangential points on their curvatures. This configuration results in void sections being formed between the curved lattice line assemblies where the curved lattice lines of the respective assemblies increase in distance. To provide protection for these areas, the triangular voids are filled with interstitial lattice assemblies. A textile upper interstitial lattice assembly, designated generally as 60′, includes textile upper interstitial lattice lines 62′ with a plurality of textile upper interstitial nodes 64′ positioned thereon. The combination of textile upper interstitial lattice lines 62′ and textile upper interstitial nodes 64′ form textile upper interstitial lattice line node strings 66′. Textile upper interstitial lattice line node strings 66′ form a wave-shaped pattern that follows the contours of the bottom ends of textile medial-side lattice assembly 26′ and textile calf lattice assembly 40′, and the top ends of textile heel lattice assembly 50′ and textile ankle lattice assembly 22′. Textile upper interstitial lattice assembly 60′ include textile upper interstitial pattern-lock segments 68′ to set and maintain the spacing of the textile upper interstitial lattice line node strings 66′ with respect to their resting distances both before and after the application of one or more forces.

[0127]A textile lower interstitial lattice assembly, designated generally as 70′, includes textile lower interstitial lattice lines 72′ with a plurality of textile lower interstitial nodes 74′ positioned thereon. The combination of textile lower interstitial lattice lines 72′ and textile lower interstitial nodes 74′ form textile lower interstitial lattice line node strings 76′. Textile lower interstitial lattice line node strings 76′ form a wedge or triangular shape to accommodate the curvatures of the lower ends of textile heel lattice assembly 50′ and textile ankle lattice assembly 22′ to ensure complete force-protection coverage of the heel and surrounding anatomical areas. Textile lower interstitial lattice assembly 70′ include textile lower interstitial pattern-lock segments 78′ to set and maintain the spacing of the textile lower interstitial lattice line node strings 76′ with respect to their resting distances both before and after the application of one or more forces.

[0128]Extending ventrally from the textile ankle lattice assembly is a textile fore-foot lattice assembly, designated generally as 80′, that includes a plurality of parallel, curved textile fore-foot lattice lines 82′ formed with a plurality of textile fore-foot nodes 84′. The combination of textile fore-foot lattice lines 82′ and textile fore-foot nodes 84′ form textile fore-foot lattice line node strings 86′. Textile fore-foot nodes 84′ have larger cross-sectional diameters that textile medial-side nodes 36′. This node modification is provided to increase the force protection afforded the somewhat delicate vascular and tendinous tissue of the upper fore-foot whereas the smaller diameter textile medial-side nodes 36′ do not have to provide as much protection to the boney shin aspect of a lower leg. Textile fore-foot pattern-lock segments 88′ set and maintain the spacing of the textile fore-foot lattice line node strings 86′ with respect to their resting distances both before and after the application of one or more forces.

[0129]The textile fore-foot node strings 86′ of textile fore-foot lattice assembly 80′ are formed in a curved pattern to overlay the entire fore-foot and toe regions when assembled to a lateral textile panel, designated generally as 150′ and described in more detail herein. It should be noted that the textile lattice lines of textile fore-foot lattice assembly 80′ can be continuations of textile ankle lattice lines 26′. The lattice lines of the respective assemblies may be demarcated by a textile lateral fore-foot pattern-lock segment 88′. The overall pattern of textile fore-foot assembly 80′ is in the basic shape of a “c” to wrap over the fore-foot and toe area. Due to this shape, when wrapped or folded over to conform to the shape of a foot, a void is created in the inner curvature of the “c” shaped pattern.

[0130]To address the void, a textile top lattice assembly, designated generally as 90′, is formed in the inner curvature of textile fore-foot lattice assembly 80′. Textile top lattice assembly 90′ includes a plurality of parallel, curved textile top lattice lines 92′ formed with a plurality of textile top nodes 94′ positioned thereon. The combination of textile top lattice lines 92′ and textile top nodes 94′ form textile top lattice line node strings 96′. Textile top nodes 94′ have smaller cross-sectional diameters than textile medial-side nodes 36′. This node modification is provided to increase the flexibility of the ankle joint of which textile top lattice assembly 90′ is positioned. Textile top nodes 94′, despite their relatively smaller cross-sectional diameter provide sufficient force protection to the boney prominences comprising the cuneiform bones and part of the cuboid bone. One or more textile top pattern-lock segments 98′ set and maintain the spacing of textile top lattice line node strings 96′ with respect to their resting distances both before and after the application of one or more forces.

[0131]Surrounding the perimeter of medial textile panel 30′ is a medial panel attachment flange 100′. Flange 100′ provides an attachment means to attach medial textile panel 30′ to other panels and/or support structures for guard 10′. One such support structure is guard tension band 110 shown in FIG. 9. As described with respect to the elastomer matrix embodiment, tension band 110 is an elastomeric structure formed in the shape of a hollowed-out shoe sole or the continuous perimeter of a shoe sole. Medial textile panel 30′ is secured to tension band 110 at several points to anchor the panel and to provide a means to releasably secure guard 10′ to a lower leg and footwear, such as sneakers or cleats. Extending outwardly from a distal end of attachment flange 100′ are one or more toe attachment tabs 102′ structured to be secured to guard tension band 110, disclosed in more detail below. An arch attachment tab 104′ extends downwardly from attachment flange 100′ in the area of ankle lattice assembly 22′. A heel attachment tab 106′ extends downwardly from attachment flange 100′ in the area of heel lattice assembly 50′. All of the tabs formed on medial textile panel 30′ are positioned over guard tension band 110 and secured thereto with stitching, such as box stitching. Other attachment means may be used, e.g., sonic welding, overmolding, adhesive, mechanical fastener and the like and remain within the scope of the disclosure.

[0132]Referring now to FIG. 18, a lateral textile panel segment, designated generally as 150′, like medial textile panel segment 30′, includes a variety of lattice line string/node groupings differentiated to address specific force attenuation and force deflection needs of discrete areas of the shin and lateral portions of a lower leg and foot. A textile lateral shin lattice string assembly, designated generally as 152′, includes a plurality of parallel, textile lateral shin lattice lines 154′ with a plurality of textile lateral shin nodes 156′ positioned thereon. The combination of textile lateral shin lattice lines 154′ and textile lateral shin nodes 156′ form textile lateral shin lattice line node strings 157′. Textile lateral shin nodes 156′ are formed as paddle-shaped nodes, in similar fashion and size to textile calf nodes 156′, with varying cross-sectional diameters with the larger diameter textile lateral shin nodes located toward the top of lateral textile panel segment 150′, which coincides with the location of a shin when guard 10′ is placed over a lower leg. The large surface areas of textile lateral shin nodes 156′ provide larger areas of coverage per node and provide varying degrees of force protection depending upon their overall size at different points along lateral textile panel 150′. As previously stated, the level of force protection provided by textile lateral shin nodes 156′, as well as any nodes disclosed herein, increases with the increase in cross-sectional diameter of the nodes. Textile lateral shin pattern-lock segments 158′ set and maintain the spacing of textile lateral shin lattice line node strings 157′ with respect to their resting distances both before and after the application of one or more forces.

[0133]A textile lateral-side lattice string assembly, designated generally as 160′, includes a plurality of parallel, textile lateral-side lattice lines 162′ with a plurality of textile lateral-side nodes 164′ positioned thereon. The combination of textile lateral-side lattice lines 162′ and textile lateral-side nodes 164′ form textile lateral-side lattice line node strings 166′. Textile lateral-side nodes 164′ have smaller cross-sectional diameters than textile lateral shin nodes 156′. This node modification is provided to increase flexibility in this area of guard 10′. The decrease in overall force protection provided by these smaller-diameter nodes to the soft tissue of the lateral regions of the lower leg is acceptable as this is a zone with a relatively lower probability of hits, whereas the larger diameter textile lateral shin nodes 156′ provide more protection to the boney shin aspect of the front lower leg, which is an area with a relatively higher probability of hits. Textile lateral-side lattice lines 162′ are arranged substantially parallel to textile lateral shin lattice lines 154′ to maintain the continuity of protection of this portion of lateral textile panel 150′. Textile lateral-side pattern-lock segments 168′ set and maintain the spacing of textile lateral-side lattice line node strings 157′ with respect to their resting distances both before and after the application of one or more forces.

[0134]A textile lateral ankle lattice string assembly, designated generally as 170′, includes a plurality of curved, parallel, textile lateral ankle lattice lines 172′ with a plurality of textile lateral ankle nodes 174′ positioned thereon. The combination of the textile lateral ankle lattice lines 172′ and the textile lateral ankle nodes 174′ form textile lateral ankle lattice line node strings 176′. Textile lateral ankle nodes 174′ have smaller cross-sectional diameters than textile lateral-side nodes 164′ due to an increased need for flexibility in the ankle area. Additional benefits of reducing the size of the nodes are a reduction in materials used and the associated cost as well as a reduction in overall weight of guard 10′. Textile lateral ankle lattice string assembly 170′ is positioned below textile lateral shin lattice assembly 152′ and textile lateral-side lattice assembly 160′ and spans the entire width of lateral textile panel 150′ except for a lateral panel attachment flange 210′ described in more detail herein below. Textile lateral ankle pattern-lock segments 178′ set and maintain the spacing of textile high ankle lateral lattice line node strings 176′ with respect to their resting distances both before and after the application of one or more forces.

[0135]A textile outer lateral ankle lattice string assembly, designated generally as 180′, includes a plurality of parallel, curved textile outer lateral ankle lattice lines 182′ with a plurality of textile outer lateral ankle nodes 184′ positioned thereon. The combination of the textile outer lateral ankle lattice lines 182′ and textile outer lateral ankle nodes 184′ form textile outer lateral ankle lattice line node strings 186′. Textile outer lateral ankle nodes 184′ have essentially the same cross-sectional diameters as textile lateral ankle nodes 174′. Textile outer lateral ankle pattern-lock segments 188′ set and maintain the spacing of the textile outer lateral ankle lattice line node strings 186′ with respect to their resting distances both before and after the application of one or more forces.

[0136]As shown in FIG. 18, the curvature of textile outer lateral ankle lattice lines 182′ are opposite the curvature of textile lateral ankle lattice lines 186′. The two assemblies register against one another at tangential points on their curvatures. This configuration results in void sections being formed between the curved lattice line assemblies where the curved lattice lines of the respective assemblies increase in distance. The triangular voids are filled with interstitial lattice assemblies. A textile upper lateral interstitial lattice assembly, designated generally as 190′, includes textile upper lateral interstitial lattice lines 192′ with a plurality of textile upper lateral interstitial nodes 194′ positioned or superposed thereon. The combination of textile upper lateral interstitial lattice lines 192′ and textile upper lateral interstitial nodes 194′ form textile upper lateral interstitial lattice line node strings 196′. Textile upper lateral interstitial node strings 196′ form a V-shaped pattern that follows the contours of the bottom ends of textile lateral shin lattice assembly 152′ and textile lateral-side lattice assembly 160′, and the top ends of textile lateral ankle lattice assembly 170′ and textile outer lateral ankle lattice assembly 180′. Textile upper lateral interstitial lattice assembly 190′ includes textile upper lateral interstitial pattern-lock segments 198′ to set and maintain the spacing of textile upper interstitial lattice line node strings 196′ with respect to their resting distances both before and after the application of one or more forces.

[0137]A textile lower lateral interstitial lattice assembly, designated generally as 200′, includes textile lower lateral interstitial lattice lines 202′ with a plurality of textile lower lateral interstitial nodes 204′ positioned thereon. The combination of textile lower lateral interstitial lattice lines 202′ and textile lower lateral interstitial nodes 204′ form textile lower lateral interstitial lattice line node strings 206′. Textile lower lateral interstitial node strings 206′ form a wedge or triangular V-shape to accommodate the curvatures of the lower ends of textile lateral ankle lattice assembly 170′ and textile outer lateral ankle lattice assembly 180′ to ensure complete force-protection coverage of the heel and surrounding anatomical areas. Textile lower lateral interstitial nodes 204′ have essentially the same cross-sectional diameters as textile lateral ankle nodes 174′. Textile lower lateral interstitial lattice assembly 200′ includes textile lower lateral interstitial pattern-lock segments 208′ to set and maintain the spacing of textile lower interstitial lattice line node strings 206′ with respect to their resting distances both before and after the application of one or more forces.

[0138]Surrounding the perimeter of lateral textile panel segment 150′ is a lateral textile panel attachment flange 210′. Flange 210′ provides an attachment means to attach lateral textile panel segment 150′ to medial textile panel segment 30′ and/or to support structures for guard 10′. Guard tension band 110 is one such support structure that may be secured to lateral textile panel segment 150′. Lateral textile panel 150′ may be secured to tension band 110 directly at its base or indirectly via the attachment points of medial textile panel segment 30′ for attachment to guard tension band 110. To secure lateral textile panel segment 150′ to medial textile panel segment 30′, flange 210′ is positioned adjacent to, and in registration with, flange 100′ of medial textile panel segment 30′. Alternatively, flange 210′ may be at least partially overlapped with flange 100′. A zig-zag stitching pattern 101′ may be used to secure the two panel segments together. Alternative attachment means include sonic welding, overmolding, adhesive, mechanical fastener and the like.

[0139]As indicated previously, separating guard 10′ into panel segments provides the ability to use different materials to make the different panel segments. As shown in FIG. 19, a textile multi-panel guard 10′ has panels made from different materials to impart different force protection levels and to improve the overall functionality of the guard including the ease with which to don and remove the guard. In an illustrative embodiment, medial textile panel 30′ is formed from TPU-TY40BL (SSP Compounds), a thermoplastic polyurethane foam having a density of 400 kg/m³ and a 40 Asker Durometer C hardness. Lateral textile panel 150 is formed from TPU-TY65BL (SSP Compounds), another thermoplastic urethane foam having a density of 600 kg/m³ and a 65 Asker Durometer C hardness. A non-woven polyester seam 220′ (shown in FIG. 16) is secured between medial textile panel 30′ and lateral textile panel 150′ to provide additional strength at this major flexion joint. To further rigidify guard 10, one or more optional steel wire stays (not shown) may be overmolded into key points in the guard to provide structure to the guard and to improve the positioning of the guard on a body part. It should be understood that the wire stays are an optional additional structural element that may not need to be utilized in certain embodiments of the force attenuation and force deflection guards disclosed herein. Conversely, it should be understood that the wire stays may be incorporated into any of the force attenuation and force deflection guards disclosed herein.

[0140]Having described the structure of guard 10′, attention is turned to the function of the novel guard construction. Each node of guard 10′, due to its cross-dimensional size and material composition, has elastomeric properties that enable the node to compress and laterally or radially disperse forces applied to the node. Unlike the nodes of guard 10, each node of guard 10′ is separately formed (overmolded) from the underlying textile lattice structure. Each node of guard 10′ is formed with a through-bore that permits the node to be positioned on, or superposed about, a lattice line or segment. The through-bore has a cross-sectional diameter larger than the cross-sectional diameter of the lattice segment that permits the node to rotate freely 360° about the lattice segment. The ability to rotate is the primary factor that enables the novel nodes to deflect rather than to simply absorb forces applied to the nodes. Rather than merely compress when a force is applied, like prior art guards as shown in FIG. 38, depending upon the angle at which a force is applied to a node or group of nodes, the node(s) rotate(s) to deflect the force, as shown in FIGS. 39-41, which essentially reduces or eliminates one or more of the force vectors of the applied force. This thereby reduces the overall impact of the force on the tissue underlying the guard. With the mechanical ability to rotate, the nodes can deflect forces imparted on the nodes from an angle other than a force directed along a vector orthogonal to a tangent of the cylindrically-shaped node. The freedom of rotational movement of the nodes provides an additional degree of force attenuation and force deflection not available in static foam-based or padding-based guards. Moreover, due to the material composition of the elastomeric string segments, the string segments also can contribute to force attenuation when a force is directed onto the string segments.

III. Force Attenuation and Deflection Forearm Guard

[0141]Referring now to FIGS. 28-30, in another aspect of the disclosure, a force attenuation and deflection forearm guard or pad, designated generally 300, is formed from a unitary or a multiple-panel textile matrix 312 to substantially cover the entirety of a forearm to impart what is essentially 360° protection from forceful impacts. Similar to guard 10′, whether the textile matrix 312 is formed as a single unit or formed from a series of panels secured together, each unit or panel is structured from a series of interconnected lattice segments 314 with force-absorption and force-deflection nodes 316 strategically positioned on, or superposed about, individual lattice segments 314 such that the nodes can rotate freely about the lattice segments. Depending upon the force protection needs of a specific area of guard 300, a single lattice segment 314 may have one or more nodes 316 secured about the lattice segment. Other lattice segments that cross over the subject lattice segment 314 may function as stops to prevent the axial translation of nodes 316 along the lattice segment over which they are positioned. The combination of a lattice segment with one or more nodes 316 secured about the lattice segment form lattice line node strings, designated generally as 318. Pattern-lock lattice segments 320 secure adjacent lines of node strings 318 to set the lateral spacing between nodes 316 located on adjacent lattice line node strings. The combination of the lattice segments 314, the nodes 316 and the pattern-lock lattice segments 320 form textile matrix 312. The overall shape of either the unitary embodiment or the assembled panel embodiment is constructed to conform generally to the shape of an anatomical feature, e.g., a forearm/elbow joint, as illustratively shown in FIGS. 28-30.

[0142]In similar fashion to lattice segments 14, the primary purpose of lattice segments 314 is to provide a support structure to secure together the plurality of nodes 316. A secondary function is to enhance the force attenuation and force deflection functions of nodes 316. The stretch characteristics of the material used to construct the lattice segments will enable nodes positioned on the lattice segments to be spread, which provides both force attenuation and force deflection effects. Moreover, any elastomeric properties of the materials used to construct lattice segments 314 will enable the lattice lines to contribute to, and assist with, the force attenuation and deflection functionality of nodes 316.

[0143]With respect to the overall structure of textile matrix 312, the lattice structure can be formed as a series of interconnected orthogonal joints, such as shown in FIG. 35, or the lattice structure can be constructed as a combination of interconnected lattice patterns that follow the particular contours of the anatomical feature(s) over which guard 300 is applied. In similar fashion to textile matrix 12′, each pattern can vary in overall size, contour shape and node density. The width, length, thickness and cross-sectional shape of the individual lattices also can be adjusted dimensionally to optimize node spacing and therefore, density. Node density can be adjusted further by altering the dimensions of the nodes, e.g., cross-sectional diameters and thicknesses. The density and therefore impact resistance of each node can further be adjusted by using different elastomeric materials having different densities. A further optional node alteration is to alter the cross-sectional shape of the nodes (including, but not limited to, cylindrically-shaped nodes and paddle-shaped nodes) as described in further detail herein.

[0144]Like guard 10′, due to the asymmetric, unique shapes of body parts, discrete areas of guard 300 can be customized to maximize the protection of the body part area over which the discrete area of guard 300 is placed. This customization can include modifications of lattice patterns, node densities, node shapes, node sizes and materials used to make specific lattice sections and/or nodes. Such lattice customizations are shown illustratively in FIG. 30. Referring now specifically to FIG. 30, an elbow node pattern assembly, designated generally as 320 is structured as an irregular circular pattern of a relatively light cropping of elbow nodes 324. The structure and location of the elbow node pattern assembly is designed specifically to provide enhanced flexibility to the elbow joint. Because this anatomical articulating feature requires maximum freedom from movement impedance, pattern assembly is formed from a series of interconnected triangular node grouping that offer maximum flexibility relative to the other pattern assemblies disclosed herein. Although the elbow is essentially a boney prominence, ligaments and tendons lie over the bone and are thus uniquely exposed to injury from blunt force trauma events. The need to strike a balance between protection against external forces and flexibility is achieved with the triangular node groupings.

[0145]To create the interlocking triangular pattern, a plurality of substantially parallel, horizontal elbow lattice lines 326 extend across elbow node pattern assembly 320. A first set of substantially parallel, diagonal elbow lattice lines 327 extend from a top left to a bottom right of elbow node pattern assembly 320 when FIG. 30 is viewed with the drawing above the figure designation. A second set of substantially parallel, diagonal elbow lattice lines 329 extend from a top right to a bottom left of elbow node pattern assembly 320. The intersections of the horizontal elbow lattice lines, the first diagonal elbow lattice lines and the second diagonal elbow lattice lines form triangles. Positioned on the lattice segments that form the sides of the triangles are elbow nodes 324 that combine to form interlocked triangle patterns in elbow node pattern assembly 320. The vertices lock the lattice lines into triangle shapes and set the resting distance between the elbow nodes. Because of this unique locked structure, there is no need for pattern-lock lattice lines for elbow node pattern assembly 320. It should be understood that any shaped node disclosed herein or within the scope of the disclosure may be used for elbow nodes 324. It should be understood further that more than one elbow node 324 may be positioned on a single elbow lattice line, axially spaced or registered against one another and remain within the scope of the disclosure.

[0146]The degree of protection provided by elbow node pattern assembly 320 can be altered by a number of variables that include the elastomeric properties of the material used to construct textile matrix 312, the thickness, length and spacing of the lattice segments, the elastomeric properties of the material used to construct nodes 324, and the spacing, length, cross-sectional diameter and thickness of the nodes. Each one of these non-limiting examples of variables can be modified to optimize the protection of a specific anatomical feature such as an elbow. Moreover, if more protection is needed, the spacing of the substantially parallel horizontal, first diagonal and second diagonal elbow lattice lines can be adjusted to increase (closer together lines) or decrease (farther apart lines) the level of protection provided by elbow node pattern assembly 320.

[0147]As previously described, textile matrix 312 can be formed as a single unit or in panel segments with each panel segment dedicated to the unique features of an anatomical part. By constructing textile matrix 312 in panels, each panel segment can be customized to address the unique features of a specific part of an anatomical feature. This can simplify construction of forearm guard 300 by permitting discrete portions of the guard to be formed in flat segments as shown in FIG. 30. For the forearm/elbow guard, only one panel segment is used to form the entire guard. It should be understood that forearm guard 300 can be constructed in multiple panels such as shown for the lower leg/foot guard 10′ disclosed above. If there is a need to construct forearm guard 300 from different materials to impart different levels of force protection, a multi-panel approach can be utilized. As only one panel is used for forearm guard 300 disclosed herein, the panel is rolled so that lateral ends or edges of the panel are registered against one another or overlapped to create a three-dimensional slip-on type guard as explained in more detail below.

[0148]Referring now to FIG. 30, a forearm textile panel, designated generally as 302, includes a variety of lattice line strings or node-string groupings differentiated to address specific force attenuation and force deflection needs of discrete areas of a forearm and elbow. A lower inner radial lattice string assembly, designated generally as 330, includes a plurality of staggered outwardly diagonally-oriented (relative to elbow lattice string assembly 320) lower inner radial lattice lines 332 with a plurality of staggered lower inner radial nodes 334 positioned thereon. The diagonal orientation of lower radial lattice string assembly 330 is set to follow the contours of the lower radial or thumb side of a forearm. The cross-sectional diameters of lower inner radial nodes 334 are larger than the cross-sectional diameters of elbow nodes 326 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0149]An upper radial lattice string assembly, designated generally as 336, includes a plurality of staggered horizontally oriented upper radial lattice lines 338 with a plurality of staggered, horizontally-oriented radial nodes 340 positioned thereon. The horizontal orientation of upper radial lattice string assembly 330 is set to follow the contours of the upper arm on the radial or thumb side of the arm. The cross-sectional diameters of upper radial nodes 340 are substantially the same as lower radial nodes 324 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0150]A lower outer radial lattice string assembly, designated generally as 342, includes a plurality of staggered inwardly diagonally-oriented (relative to elbow lattice string assembly 320) lower outer radial lattice lines 344 with a plurality of inwardly diagonally oriented and staggered lower outer radial nodes 346 positioned thereon. The diagonal orientation of lower outer radial lattice string assembly 342 is set to follow the contours of the lower radial or thumb side of a forearm when pronated. The cross-sectional diameters of outer lower radial nodes 346 are larger than the cross-sectional diameters of elbow nodes 326 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0151]An upper elbow lattice string assembly, designated generally as 350, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) upper elbow lattice lines 352 with a plurality of staggered, inwardly diagonally-oriented upper elbow nodes 354 positioned thereon. The diagonal orientation of upper elbow lattice string assembly 350 is set to follow the contours of the triceps region of the upper arm. The cross-sectional diameters of upper elbow nodes 354 are substantially the same as lower radial nodes 324 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0152]An inner ulnar lattice assembly, designated generally as 356, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) inner ulnar lattice lines 358 with a plurality of staggered, inwardly diagonally-oriented inner ulnar nodes 360 positioned thereon. The diagonal orientation of inner ulnar lattice string assembly 356 is set to follow the contours of the ulnar region of the forearm. The cross-sectional diameters of inner ulnar nodes 360 are substantially the same as lower radial nodes 324 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0153]An outer ulnar lattice assembly, designated generally as 362, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) outer ulnar lattice lines 364 with a plurality of staggered, inwardly diagonally-oriented outer ulnar nodes 366 positioned thereon. The diagonal orientation of outer ulnar lattice string assembly 364 is set to follow the contours of the lower ulnar region of the forearm. The cross-sectional diameters of a majority of the inner ulnar nodes 366 are substantially the same as lower radial nodes 324 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow. Several inner ulnar nodes 366a have smaller diameters than the majority of inner ulnar nodes 336 to fill small gaps between lattice string assemblies.

[0154]An outer upper elbow lattice assembly, designated generally as 370, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) outer upper elbow lattice lines 372 with a plurality of staggered, inwardly diagonally-oriented outer upper elbow nodes 374 positioned thereon. The diagonal orientation of outer upper elbow lattice string assembly 370 is set to follow the contours of the inner lower humerus region of the upper arm. The cross-sectional diameters of the outer upper elbow nodes 375 are substantially the same as lower radial nodes 324 to provide more protection to an area particularly prone to ball strikes and one that has less flexibility requirements than the elbow.

[0155]An outer upper humerus lattice assembly, designated generally as 376, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) outer upper humerus lattice lines 378 with a plurality of staggered, inwardly diagonally-oriented outer upper humerus nodes 380 positioned thereon. The diagonal orientation of outer upper humerus lattice string assembly 376 is set to follow the contours of the biceps region of the upper arm. The cross-sectional diameters of the outer upper humerus nodes 380 are substantially smaller than lower radial nodes 324 to address the flexibility requirements of the biceps to supinate the hand.

[0156]A medial elbow lattice assembly, designated generally as 382, includes a plurality of staggered, horizontally-oriented (relative to elbow string assembly 320) medial elbow lattice lines 384 with a plurality of staggered, horizontally-oriented medial elbow nodes 386 positioned thereon. The horizontal orientation of medial elbow lattice string assembly 376 is set to follow the contours of the medial elbow region. The cross-sectional diameters of the medial elbow nodes 386 are substantially smaller than lower radial nodes 324 to address the flexibility requirements of the medial elbow area.

[0157]An inner upper humerus lattice assembly, designated generally as 388, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) inner upper humerus lattice lines 390 with a plurality of staggered, inwardly diagonally-oriented inner upper humerus nodes 392 positioned thereon. The diagonal orientation of inner upper humerus lattice string assembly 388 is set to follow the contours of the biceps region of the upper arm. The cross-sectional diameters of the inner upper humerus nodes 392 are substantially smaller than lower radial nodes 324 to address the flexibility requirements of the biceps to supinate the hand.

[0158]A lateral elbow lattice assembly, designated generally as 394, includes a plurality of staggered, horizontally-oriented (relative to elbow string assembly 320) lateral elbow lattice lines 395 with a plurality of staggered, horizontally-oriented lateral elbow nodes 396 positioned thereon. The horizontal orientation of lateral elbow lattice string assembly 394 is set to follow the contours of the lateral elbow region. The cross-sectional diameters of the lateral elbow nodes 396 are substantially smaller than lower radial nodes 324 to address the flexibility requirements of the lateral elbow area.

[0159]A lateral lower radial lattice assembly, designated generally as 397, includes a plurality of staggered, inwardly diagonally-oriented (relative to elbow string assembly 320) lateral lower radial lattice lines 398 with a plurality of staggered, inwardly diagonally-oriented lateral lower radial nodes 399 positioned thereon. The diagonal orientation of lateral lower radial lattice string assembly 397 is set to follow the contours of the lower radial region of the forearm. The cross-sectional diameters of the lateral lower radial nodes 399 are substantially smaller than lower radial nodes 324 to address the flexibility requirements of the lower radial region of the forearm.

[0160]Surrounding the perimeter of forearm panel 302 is a forearm panel attachment flange 310. Flange 310 provides an attachment means to attach the lateral sides of forearm panel 302 to form forearm guard 300. To secure the forearm panel into guard 300, forearm panel 302 is rolled until the lateral edges of the panel, i.e., flange 310 either register against one another or are overlapped. A zig-zag stitch 301 (shown in FIG. 28) is then used to secure the lateral edges together to form forearm guard 300. Other attachment means may be used, e.g., sonic welding, overmolding, adhesive, mechanical fastener and the like known in the art, and remain within the scope of the disclosure.

[0161]It should be understood that the description of forearm guard 300 is meant to be illustrative and nonlimiting. Forearm guard 300 may be formed with an elastomeric matrix construction identical to that disclosed for lower leg/foot guard 10. Such a construction will include the same lattice line and node alignments and orientations, lattice string groupings and lattice assemblies as described for textile matrix forearm guard 300 with the primary difference being the lattice lines and nodes being formed integrally rather than as separate structures in the textile embodiment. Those descriptions of the elements of forearm guard 300 are incorporated here by reference with the substitution of an elastomeric matrix material for the textile matrix material (and implicitly, integral rather than separate lattice lines and nodes) of forearm guard 300.

[0162]Having described the structure of guard 300, attention is turned to the function of the novel guard construction. Like the nodes for guard 10′, each node of guard 300, due to its cross-dimensional size and material composition, has elastomeric properties that enable the node to compress and laterally or radially disperse forces applied to the node. Unlike the nodes of guard 10, each node of guard 300 is separately formed (overmolded) from the underlying textile lattice structure. Each node of guard 300 is formed with a through-bore that permits the node to be positioned on, or superposed about, a lattice line or segment. The through-bore has a cross-sectional diameter larger than the cross-sectional diameter of the lattice segment that permits the node to rotate freely 360° about the lattice segment unless some mechanical restriction is present, e.g., the rotation restriction provided by paddle-shaped nodes as described herein. The ability to rotate is the primary factor that enables the novel nodes to deflect rather than to simply absorb forces applied to the nodes. Rather than merely compress when a force is applied, like prior art guards as shown in FIG. 38, depending upon the angle at which a force is applied to a node or group of nodes, the node(s) rotate(s) to deflect the force, as shown in FIGS. 39-41, which essentially reduces or eliminates one or more of the force vectors of the applied force. This thereby reduces the overall impact of the force on the tissue underlying the guard. With the mechanical ability to rotate, the nodes can deflect forces imparted on the nodes from an angle other than a force directed along a vector orthogonal to a tangent of the cylindrically-shaped node. The freedom of rotational movement of the nodes provides an additional degree of force attenuation and force deflection not available in static foam-based or padding-based guards. Moreover, due to the material composition of the elastomeric string segments, the string segments also can contribute to force attenuation when a force is directed onto the string segments.

[0163]Any of the elastomeric matrixes and textile matrixes and node combinations disclosed herein may be used to form guards for any part of the human body including the torso, limbs and head. As used herein, torso shall mean any body area between and including the neck and hip areas. Moreover, the force attenuation and deflection apparatuses disclosed herein may be combined with layers of fabric or other materials such as thermoplastic polyurethane sheet layers, Lycra®, Nylon and the like and remain within the scope of the disclosure. It further should be understood that the force attenuation and deflection apparatuses disclosed herein may have other applications beyond sports protective gear. As an illustrative, non-limiting example, similarly-constructed guards may be used in the construction industry to provide cushioning and force protection.

IV. Testing

[0164]To demonstrate the efficacy of the force attenuation and deflection apparatuses disclosed herein, multiple samples of the textile matrix embodiment were prepared in accordance with the disclosure. The samples were tested by firing spherical projectiles in the form of conventional baseballs against the samples in a controlled setting to create direct and angular impacts. For direct impacts, the testing protocol involved a pneumatic cannon set to fire conventional baseballs at a velocity of approximately 85 mph. A silicon rubber pad with a durometer of Shore 40A hardness was positioned over a steel backing plate to simulate human skin. Each test sample was secured to a front face of the silicon rubber pad. To measure the distribution of pressure from impact events, a pressure indicating film (Fujifilm Prescale® Type Low) was positioned between the silicon rubber pad and the test samples. The pressure indicating film has a pressure-indicating range of 350 to 1400 psi+/−10% and produces a level of color intensity that correlates to the pressure applied to the film and underlying test materials.

[0165]Two controls were utilized to establish baseline or benchmark values for each pressure generated by an impact force. The controls involved firing a conventional baseball at the silicon rubber pad/pressure-indicating film combination without any test samples applied thereon.

An imprint on a prescale pressure indicating film-low for the baseline 1 control test is shown in FIG. 42.

An imprint on a prescale pressure indicating film—low for the baseline 2 control test is shown in FIG. 43.
The control tests show the pressure distribution and the area size that experienced a specific magnitude of impact force or pressure. The results were compared to several test samples formed via 3-D printing as described in more detail.

[0166]A first sample, designated A1, was constructed from a Nylon 6 network (textile matrix) with nodes overmolded onto the matrix. The nodes were formed from thermoplastic urethane foam. The sample weight was 26.7 g. The baseball COR was 0.514. The impact force was measured to be 4,211 lbs. The sample used relatively large nodes (9 mm) spaced closely together in staggered node rows as shown in FIG. 44.

An imprint on a prescale pressure indicating film-low for Sample A1 is shown in FIG. 45.
As compared to the control test, the A1 sample exhibited superior force dispersion as exhibited by the relatively larger surface areas that absorbed the impact forces measured in psi values.

[0167]Another sample, designated E1, was constructed from a Nylon 6 network (textile matrix) with nodes having smaller diameters than the diameters of the nodes used for sample A1 overmolded onto the matrix. The nodes were formed from thermoplastic urethane foam. The sample weight was 11.6 g. The baseball COR was 0.498. The impact force was measured to be 4,506 lbs. The sample used relatively smaller nodes spaced apart relative to the configuration of sample A1 with nodes positioned in staggered rows as shown in FIG. 46.

An imprint on a prescale pressure indicating film-low for Sample E1 is shown in FIG. 47.
Again, as compared to the control test, the E1 sample exhibited superior force dispersion as exhibited by the relatively larger surface areas that absorbed the impact forces measured in psi values.

[0168]To test the effect of using a double layer of the force attenuation and deflection apparatuses disclosed herein, a sample, designated D2D3, was constructed from two layers of a Nylon 6 network (textile matrix) with 9 mm nodes overmolded onto the matrix of each layer. The nodes were formed from thermoplastic urethane foam. The sample weight was 28.7 g. The baseball COR was 0.505. The impact force was measured to be 4,157 lbs. The sample was formed with relatively large nodes as shown in FIG. 48 with the nodes spaced and formed in staggered rows. The layers were arranged to position nodes in an alternating overlay pattern.

An imprint on a prescale pressure indicating film-low for Sample D2D3 is shown in FIG. 49.
Again, as compared to the control test, the D2D3 sample exhibited superior force dispersion as exhibited by the relatively larger surface areas that absorbed the impact forces measured in psi values.

[0169]Another sample, designated F3F4, was constructed from a Nylon 6 network (textile matrix) with smaller nodes than the nodes used in sample D2D3 overmolded onto the matrix. The nodes were formed from thermoplastic urethane foam. The sample weight was 23.6 g. The baseball COR was 0.502. The impact force was measured to be 4,400 lbs. The sample was formed with relatively smaller nodes (as compared to the nodes in sample D2D3) as shown in FIG. 50 with the nodes spaced and formed in staggered rows. The layers were arranged to position nodes in an alternating overlay pattern.

An imprint on a prescale pressure indicating film-low for Sample F3F4 is shown in FIG. 51.
Once again, compared to the control tests, the force attenuation and deflection material provided superior force dispersion results.

[0170]A yet further sample, designated B4L1, was constructed from a Nylon 6 network (textile matrix) with 9 mm nodes overmolded onto the matrix. The nodes were formed from thermoplastic urethane foam. The sample weight was 30.4 g. The baseball COR was 0.493. The impact force was measured to be 3,909 lbs. The sample used relatively large nodes spaced apart in staggered node rows as shown in FIG. 52. A Delrin layer along with another compression layer were placed between the test sample and test apparatus.

An imprint on a prescale pressure indicating film—low for Sample B4L1 is shown in FIG. 53.
The additional layers appear to have lessened the force dispersion effects of the sample material.

[0171]To further demonstrate the efficacy of the force attenuation and deflection apparatuses disclosed herein, multiple samples of the textile matrix embodiment were prepared in accordance with the disclosure. The samples were tested by firing spherical projectiles in the form of conventional baseballs against the samples in a controlled setting to create angled impacts. The testing protocol involved a pneumatic cannon set to fire conventional baseballs at a velocity of approximately 85 mph. A silicon rubber pad with a durometer of Shore 40A hardness was positioned over a steel backing plate to simulate human skin. The steel backing plate was set at a 45° angle relative to the ball-flight direction. Each test sample was secured to a front face of the silicon rubber pad. To measure the distribution of pressure from impact events, a pressure indicating film (Fujifilm Prescale® Type Low) was positioned between the silicon rubber pad and the test samples. The pressure indicating film has a pressure-indicating range of 350 to 1400 psi+/−10% and produces a level of color intensity that correlates to the pressure applied to the film and underlying test materials.

[0172]A control was utilized to establish a baseline or benchmark value for each angle of deviation (deflection) achieved when a baseball was fired at the angled test apparatus. The control values were as follows:

The angle of deviation obtained from the control test were compared against the angles of deviation of sample materials.

[0173]A test sample, designated M1, was constructed from a Nylon 6 network (textile matrix) with nodes overmolded onto the matrix. The nodes were formed from thermoplastic urethane foam. The sample weight was 26.7 g. The inbound velocity was 86.6 mph. The sample used relatively large nodes (9 mm) spaced closely together in staggered node rows as shown in FIG. 54.

As shown in the results, the sample caused the baseball to deflect or rebound at a greater angle than the control test, which shows the impact of the nodes rotating and thereby deflecting the force.

[0174]To further test the effects of the disclosed force attenuation and deflection materials, another test sample, designated N1, was formed similar to M1 with a textile material layer placed over the sample as shown in FIG. 55.

The test results of sample N1 show a significant deflection event that further supports the efficacy of the disclosed force attenuation and deflection apparatuses and materials.

[0175]While the present disclosure has been described in connection with several embodiments thereof, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the true spirit and scope of the disclosure. Although two different guards have been described herein as illustrative, non-limiting examples, it should be understood that the force attenuation and deflection materials and combination assemblies disclosed herein can be incorporated into any pads or guards and be combined with any additional layers of textiles, fabrics or other compressive materials and remain within the scope of the disclosure. Such combinations may be used to construct force attenuation and deflection apparatuses to protect any part of a human body including any and all areas of the limbs, torso and head. Accordingly, it is intended by the appended claims to cover all such changes and modifications as come within the true spirit and scope of the disclosure. What we claim as new and desire to secure by United States Letters Patent is