Knee protector

Abstract

The utility model provides a knee protector. The cushion material is formed from a single unitary piece of material having a honeycomb structure. The honeycomb structure is non-uniform in size and / or shape to provide support and reduce pressure in selected areas. One embodiment of a protective device includes a knee guard having a housing, a cushion disposed in front of the wearer's knees, the cushion including a non-uniform stiffness.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 617,844, filed January 5, 2024, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to protective clothing or safety equipment for workers. More specifically, this disclosure relates to protective materials or padding used in protective clothing and / or safety equipment. Background Technology

[0004] For example, safety devices attached to the wearer's knees, such as knee braces, can be worn to improve wearer comfort and cushion knee injuries. Protective materials provide comfort, stability, and are designed to reduce stress and damage to the user's knees. Similar protective materials can be designed for use with a variety of other types of safety equipment, such as helmet linings for helmets / helmets, padding for impact gloves, etc. Utility Model Content

[0005] One embodiment of the present invention relates to a knee brace. The knee brace includes an upper support configured to connect to a user's leg above the knee, a lower support configured to connect to the user's leg below the knee, and a housing. The housing is coupled to and positioned between the upper and lower supports. The knee brace also includes a single integral padding layer. The padding layer includes an outer surface, an inner surface, and a plurality of units that abut against the housing. Each of the plurality of units extends between the outer and inner surfaces. Each of the plurality of units includes a channel connecting the outer and inner surfaces, a longitudinal axis extending along the channel, and a unit wall enclosing the channel. The unit wall includes a plurality of segments angled relative to the longitudinal axis.

[0006] Another embodiment of the present invention relates to a knee brace. The knee brace includes an upper support, a lower support, and a housing. The housing is coupled to and positioned between the upper and lower supports. The knee brace also includes a single integral padding layer. The padding layer includes an outer surface, an inner surface, and a plurality of units positioned along the housing. Each of the plurality of units extends between the outer and inner surfaces. Each of the plurality of units includes a channel connecting the outer and inner surfaces, a longitudinal axis extending along the channel, and a unit wall enclosing the channel. The unit wall includes inwardly angled sections and outwardly angled sections. The inwardly angled sections and the outwardly angled sections are angled relative to the longitudinal axis.

[0007] Another embodiment of the present invention relates to a knee brace. The knee brace includes an upper support, a lower support, and a shell. The shell is coupled to the upper support and the lower support and positioned between the upper support and the lower support. The knee brace also includes a single, unitary pad layer. The pad layer includes an outer surface, an inner surface, and a plurality of cells positioned along the shell. Each cell of the plurality of cells extends between the outer surface and the inner surface. Each cell of the plurality of cells includes a channel connecting the outer surface and the inner surface, a longitudinal axis extending along the channel, and a cell wall surrounding the channel. The cell wall includes a pair of inwardly angled segments and a pair of outwardly angled segments. The pair of inwardly angled segments and the pair of outwardly angled segments are angled relative to the longitudinal axis.

[0008] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art who practice the application, and which is further pointed out by the claims, or recognized by practice of the embodiments as described in the written description and / or illustrated in the accompanying drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

[0009] The accompanying drawings provide a further understanding of the present application, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain various principles and operations of the various embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0010] The present application will become more fully understood from the detailed description given herein below, and the accompanying drawings, wherein like elements are numbered alike in the several figures described, wherein:

[0011] Figure 1 is a perspective view of a knee brace according to an example embodiment.

[0012] Figure 2 is a perspective view of a knee brace according to an example embodiment. Figure 1 is an exploded view of a portion of the knee brace of

[0013] Figure 3 is a front perspective view of a pad layer of the knee brace of Figure 1

[0014] Figure 4 is a rear perspective view of the pad layer of Figure 3

[0015] Figure 5 is a side view of the pad layer of Figure 3

[0016] Figure 6 is a side view of the pad layer of Figure 3 ​​​top front perspective view of the cushion layer of

[0017] Figure 7 is a top front perspective view of the cushion layer according to an exemplary embodiment Figure 3 bottom rear plan view of the cushion layer of

[0018] Figure 8 is a bottom rear plan view of the cushion layer according to an exemplary embodiment Figure 3 cross-sectional view of the cushion layer of

[0019] Figure 9 is a perspective view of a cell of the cushion layer according to an exemplary embodiment

[0020] Figure 10 is a perspective view of a cell according to an exemplary embodiment Figure 9 side view of the cell of

[0021] Figure 11 is a graph showing load versus deflection on the cushion layer according to an exemplary embodiment

[0022] Figure 12 is a graph showing load versus deflection on the cushion layer compared to a prior art knee brace according to an exemplary embodiment

[0023] Figure 13 is a graph showing stiffness versus load of the cushion layer compared to a prior art knee brace according to an exemplary embodiment

[0024] Figure 14 is a pressure map of the cushion layer according to an exemplary embodiment

[0025] Figure 15 is a perspective view of a cell of the cushion layer according to another exemplary embodiment

[0026] Figure 16 is a perspective view of a cell of the cushion layer according to another exemplary embodiment

[0027] Figure 17 is a perspective view of a cell of the cushion layer according to another exemplary embodiment

[0028] Figure 18 is a smoothed pressure map of the knee pressure according to an exemplary embodiment

[0029] Figure 19 is a cell map based on the pressure map of Figure 18 after undergoing a packing algorithm

[0030] Figure 20 is a plan view of packed cells formed based on the pressure map of Figure 18 according to an exemplary embodiment

[0031] Figure 21 is a three-dimensional pad layer formed based on Figure 17 a packing unit according to exemplary embodiments.

[0032] Figure 22 is an exploded view of a safety hat according to exemplary embodiments.

[0033] Figure 23 is a perspective view of a pad layer of a safety hat according to exemplary embodiments. Figure 22

[0034] Figure 24 is an impact protection glove according to exemplary embodiments.

[0035] Figure 25 is a pad layer of an impact protection glove according to exemplary embodiments. Figure 24 DETAILED DESCRIPTION

[0036] One or more embodiments of protective apparel or safety equipment having a pad layer are described herein with general reference to the drawings. Various types of safety equipment and protective apparel (e.g., knee guards, helmets, gloves, etc.) include pads to provide protection and / or support. For example, as discussed herein, various embodiments of knee guards including pad layers having non-uniform stiffness and / or honeycomb structures are described.

[0037] In various embodiments, the pad layer can be formed from a single, unitary piece of polymeric material having a plurality of cells. Generally, the compression / stiffness properties can be adjusted by controlling the geometry of the cells and the size of the cells. In particular embodiments, the cells of the pad layer have different sizes, dimensions, and / or shapes in different regions of the pad layer. Applicant has found that these differences in structure provide selected compression or stiffness properties in critical regions of the safety equipment. Further, Applicant has found that varying the honeycomb structure can result in a pad layer that exhibits a relatively linear load deflection response within particular regions of the pad layer. In this manner, the pad material can be designed to minimize high pressure zones (e.g., around the knee for a knee guard) and distribute pressure more evenly across the pad material. In particular embodiments, the cell walls of the pad layer are formed from a material having a Z-shaped cell profile, where larger area cells are located in a central region corresponding to the knee of a wearer. Further, as will be described in greater detail below, methods of manufacturing pad layers for protective layers are discussed herein.

[0038] Referring to Figures 1-2 ​​, aspects of a piece of protective equipment, shown as a knee guard 110, for protecting and / or supporting a user's knee are shown. The knee guard 110 includes a shell 180. In various embodiments, the shell 180 is coupled to an upper support 120 and a lower support 130 via a grommet 112. The upper support 120 is configured to be coupled to a user's leg above the knee, such as via a strap 122 wrapped around the user's leg above the knee. The lower support 130 is configured to be coupled to a user's leg below the knee, such as via a strap 132 wrapped around the user's leg below the knee. The shell 180 is coupled to the upper support 120 and the lower support 130 and extends between the upper support 120 and the lower support 130. The shell 180 is formed of a first material, such as a flexible and durable polymeric material. The shell 180 is made of a material that has a higher stiffness than the padding layer 140.

[0039] The knee guard 110 includes a padding layer 140 coupled to an inner surface 181 of the shell 180. In various embodiments, the padding layer is coupled to the shell 180 by fasteners, protrusions, etc. The padding layer 140 is coupled to the shell 180 between the inner surface 181 of the shell 180 and a user's knee. In various embodiments, the padding layer 140 extends from one sidewall 184 to an opposing sidewall 184, such that the padding layer 140 is adjacent to and / or coupled to a front wall 182 between the sidewalls 184. The sidewalls 184 extend from opposite sides of the front wall 182 of the shell 180. In other words, a first sidewall 184 extends rearwardly away from a first side of the front wall 182, and a second sidewall 184 extends rearwardly from a second side of the front wall 182 opposite the first side of the front wall 182. In various specific embodiments, the sidewalls 184 extend beyond or past a front edge or a rear edge of the padding layer 140, such that each of the sidewalls 184 provides a support force against a side (medial and lateral sides) of the knee when the user is kneeling. In various embodiments, the support force is applied inwardly against the sides of the knee when the user is kneeling.

[0040] In various embodiments, the padding layer 140 is formed of a single, unitary piece of polymeric material. In specific embodiments, the padding layer 140 is formed of a thermoplastic elastomer. In various embodiments, the padding layer 140 has a honeycomb structure. In such embodiments, the padding layer 140 has different sized cells at different locations to provide different compression / stiffness characteristics at selected locations or portions of the padding based on the expected loading of the padding in those locations or areas of the knee guard 110. As will be discussed in greater detail below, in various embodiments, the padding layer 140 is designed such that the padding layer 140 exhibits a relatively linear load deflection response within a location or area. Applicant believes that this design minimizes high pressure zones (e.g., around the knee) and distributes pressure more evenly across the padding layer 140.

[0041] Referring to Figures 3-8 various views of the cushion layer 140 are shown. The cushion layer 140 includes a plurality of cells 142. The cushion layer 140 includes an outer surface 144 positioned within and / or coupled to the shell 180 and an inner surface 146 facing a user’s knee. Each of the cells 142 extends between the outer surface 144 and the inner surface 146. The cells 142 include channels 148 extending between and connecting the outer surface 144 and the inner surface 146 of the cushion layer. Each channel 148 is surrounded or enclosed by a cell wall 150.

[0042] In various embodiments, the cushion layer 140 is made of a material that allows for a reduced thickness of the cushion layer 140 as compared to other cushioning structures (e.g., foam cushioning, etc.) used in knee guards. In various embodiments, the cushion layer 140 has a thickness of less than 40 mm. In specific embodiments, the cushion layer has a thickness of less than 35 mm, specifically less than 30 mm, and more specifically less than 25 mm. In specific embodiments, the cushion layer 140 has a thickness of 19 mm.

[0043] In various embodiments, the cells 142 of the cushion layer 140 have a non-uniform size. In other words, the size of the cells 142 is different in various locations within the cushion layer 140. As will be discussed in greater detail below, the size of the cells 142 is determined by a packing algorithm. In various embodiments, the size of the cells 142 in a central section 152 of the cushion layer 140 is greater than the size of the cells 142 in side sections 154. The central section 152 of the cushion layer 140 is positioned against and / or adjacent to the front wall 182 of the shell 180 when the knee guard 110 is assembled. The side sections 154 of the cushion layer 140 are positioned against and / or adjacent to the side walls 184 of the shell 180 when the knee guard 110 is assembled.

[0044] Referring to Figures 9-10 detailed views of the cell 142 shape and / or size according to exemplary embodiments are shown. Each cell 142 includes a cell wall 150 having a plurality of wall sections 156. In specific embodiments, the plurality of wall sections 156 are angled relative to a longitudinal axis 157 of the cell 142 and / or the channel 148. In specific embodiments, the size of the cell 142 is defined by the size of the channel 148. In specific embodiments, the size of the cell 142 is defined by the cell wall 150.

[0045] In various implementations, a portion of the wall segment 156 is an inwardly angled wall 158 (i.e., toward the channel 148 and the opposing cell wall 150), and a portion of the wall segment 156 is an outwardly angled wall 160 (i.e., away from the channel 148 and the opposing cell wall 150). In particular implementations, each cell 142 has four wall segments 156, including two inwardly angled walls 158 and two outwardly angled walls 160. In other implementations, the number of wall segments 156 is different (e.g., 3, 5, 6, etc.). Each inwardly angled wall 158 has an inner surface 164 facing the channel 148, and each outwardly angled wall 160 has an inner surface 162 facing the channel 148. In particular implementations, the inwardly angled wall 158, and particularly the inner surface 164, is angled at about 30 degrees (e.g., 30 degrees plus or minus 10 degrees) relative to an axial axis 166 of the cell 142.

[0046] In particular implementations, the cell wall 150 has a thickness T of 2 mm. In particular implementations, the cell 142 has a height H defined between the outer surface 144 and the inner surface 146. In particular implementations, H is about 17.5 mm (e.g., 17.5 mm plus or minus 5 mm). The cell 142 has an effective radius defined as a distance from a center of the cell to the cell wall 150. In particular implementations, the cell 142 has an effective radius R of 10 mm.

[0047] Referring to Figure 11 , a graph showing load versus deflection on the pad layer 140 is shown in accordance with an example implementation. Applicant has found that the pad layer 140 exhibits a relatively linear load deflection response within different regions of the pad layer 140.

[0048] Referring to Figure 12 , a graph showing load versus deflection on the pad layer 140 compared to a commercially available knee guard 170 (Milwaukee Tool Performance Knee Guard (48-73-6040)) is shown in accordance with an example implementation. The pad layer 140 tested had a thickness of 19 mm, and the prior art knee guard 170 had a thickness of 32 mm. As can be seen, the results are similar despite the pad layer being significantly thinner up to about 500 N or 12.5 mm of deflection.

[0049] Referring to Figure 13FIG. 6 shows a graph illustrating the stiffness of the cushion layer 140 compared to a commercially available knee brace 170, according to an example embodiment. The cushion layer 140 tested had a thickness of 19 mm, and the prior art knee brace 170 had a thickness of 32 mm. As shown in the graph of FIG. 6, the cushion layer 140 stiffness has a generally linear behavior up to about 500 N. The generally horizontal or plateaued portion of the data for the cushion layer 140 occurring around a load of 80 represents an ideal design. Figure 13

[0050] Referring to FIG. 8, a detailed view of a cell 242 of a cushion layer 240 is shown, according to another example embodiment. The cushion layer 240 can be used with the knee brace 110 and is substantially identical to the cushion layer 140 except for the differences discussed herein. Each cell 242 includes a cell wall 250 having a plurality of wall segments 256. In particular embodiments, the plurality of wall segments 156 are both angled relative to a longitudinal axis 258 of the cell 242 and / or the channel 248 and parallel to the longitudinal axis 258. In other words, some of the wall segments 256 are angled and some of the wall segments are generally vertical. Figure 14

[0051] Referring to FIG. 8, a detailed view of a cell 242 of a cushion layer 240 is shown, according to another example embodiment. The cushion layer 240 can be used with the knee brace 110 and is substantially identical to the cushion layer 140 except for the differences discussed herein. Each cell 242 includes a cell wall 250 having a plurality of wall segments 256. In particular embodiments, the plurality of wall segments 156 are both angled relative to a longitudinal axis 258 of the cell 242 and / or the channel 248 and parallel to the longitudinal axis 258. In other words, some of the wall segments 256 are angled and some of the wall segments are generally vertical. Figure 15

[0052] Referring to FIG. 9, a detailed view of a cell 342 of a cushion layer 340 is shown, according to another example embodiment. The cushion layer 340 can be used with the knee brace 110 and is substantially identical to the cushion layer 140 except for the differences discussed herein. Each cell 342 includes a cell wall 350 having a plurality of wall segments 356. In particular embodiments, the plurality of wall segments 256 includes an upper curved portion 360 and a lower curved portion 362. Both the upper curved portion 360 and the lower curved portion 362 curve inwardly or concave relative to the channel 348. Figure 16

[0053] Referring to FIG. 9, a detailed view of a cell 342 of a cushion layer 340 is shown, according to another example embodiment. The cushion layer 340 can be used with the knee brace 110 and is substantially identical to the cushion layer 140 except for the differences discussed herein. Each cell 342 includes a cell wall 350 having a plurality of wall segments 356. In particular embodiments, the plurality of wall segments 256 includes an upper curved portion 360 and a lower curved portion 362. Both the upper curved portion 360 and the lower curved portion 362 curve inwardly or concave relative to the channel 348. Figure 17 ​​​​The diagram shows a detailed view of a unit 442 of a padding layer 440 according to another exemplary embodiment. The padding layer 440 can be used with a knee brace 110 and is substantially the same as the padding layer 140 except for the differences discussed herein. Each unit 442 includes a unit wall 450. In a specific embodiment, the plurality of walls 450 form a generally hexagonal shape. In other words, the channel 448 is shaped to resemble a hexagonal prism.

[0054] Reference Figures 18-21 The illustration shows details of a method 500 for manufacturing a liner layer, such as liner layer 140, for protective equipment. In a first step, a geometry is defined. The geometry 502 of the illustrated embodiment is shown as a black outer area. The geometry can be defined using a program, such as CAD, a graphics program, a presentation program, etc.

[0055] In the second step, the user inputs, for example, a smoothed pressure map 504 of knee pressure obtained from a kneeling individual. In other embodiments, the user input may be based on other user data (e.g., scans), bone location, known impact points, etc. The pressure map 504 is customizable. In the illustrated embodiment, color or grayscale is used to define different zones. The pressure map 504 includes a first outer zone 506, a second zone 508, a third zone 510, a fourth zone 512, and a middle or central zone 514. A boundary 516 is defined between the second zone 508 and the first outer zone 506. Cells formed on the left side of the boundary 516 will have a smaller size and / or dimension compared to cells formed on the right side of the boundary 516.

[0056] In the third step, an algorithm is used to convert the pressure map 504 into a definition map or group 520 of multiple elements. In a specific implementation, the Flat Voronoi stacking algorithm and... Figure 18 pressure Figure 1 Its use is for creating such Figure 19 Multiple cells 522 are shown. As will generally be understood, the algorithm determines the size and / or dimensions of each cell 522, including the number of walls 524. The walls 524 of the cell 522 are shown in black, and the center 526 of each cell is indicated by a point located within each set of cell walls 524. In various other embodiments, different algorithms or methods may be used to create multiple cells for the padding layer. For example, a tessellation method with selected shapes (e.g., hexagons, squares, etc.) may be used.

[0057] In the fourth step, select the geometry of wall 524. For example, angled or zigzag walls can be used (see example). Figure 10 In various embodiments, spaces are inserted between adjacent units 522 to avoid overlap. For example... Figure 20As shown, in the fifth step, a 3D model 530 of element 520 is created. In a specific embodiment, a computer-aided design or CAD program is used. In the sixth step, the 3D model 530 is used to create a curved 3D padding layer 540. In a specific embodiment, the padding layer 540 is molded into a curved shape. The applicant believes that there are many advantages to using a bending molding process. In contrast to flat molding, which may wrinkle, crease, or twist when bending flat-molded elements, the bending molding process allows multiple elements 522 to maintain the desired structure (see, for example...). Figure 8 The curved three-dimensional padding layer 540 can then be used with a knee brace shell to complete a knee brace, such as knee brace 110. In other embodiments, different methods, such as additive manufacturing (e.g., 3D printing), are used to create the three-dimensional padding layer.

[0058] Reference Figure 22 An exploded view of a helmet 610 according to an exemplary embodiment is shown. The helmet 610 includes an outer shell 612 formed of a rigid material, such as a rigid polymer material. The outer shell 612 includes a crown portion 613 and a bottom or edge portion 615 defining the lower circumference of the helmet 610. The helmet 610 includes a padding layer 614 supported within the outer shell 612. The helmet 610 includes a suspension system 616 and a chin strap 618 for supporting and securing the helmet 610 to the user's head. In a specific embodiment, the helmet 610 also includes various padding layers 620 for providing increased comfort to the wearer.

[0059] Reference Figure 23 A perspective view of a padding layer 614 according to an exemplary embodiment is shown. The padding layer 614 includes a plurality of units 642 having a size and / or dimension selected to reduce pressure on the head of a user wearing the helmet 610.

[0060] Reference Figure 24 The illustration shows a glove, exemplified as an impact protection glove 700, according to an exemplary embodiment. The glove 700 includes a liner layer 714 that surrounds and encloses it (see, for example...). Figure 25 ) outer surface or cover 702.

[0061] Reference Figure 25 Details of a padding layer 714 according to an exemplary embodiment are shown. The padding layer 714 includes a plurality of units 742 having channels 748 that extend between and connect the outer surface 744 and the inner surface 746 of the padding layer 714. Each channel 748 is surrounded or enclosed by a unit wall 750.

[0062] The method 500 of manufacturing a cushion layer for a protective device can similarly be used for the cushion layers 614 and 714. Moreover, the method can be used for additional types of protective devices and / or layers, such as elbow guards, padded sleeves, insoles, outsoles, etc. As will generally be understood, different types of protective devices will each have their own design objectives or geometries 502.

[0063] It is to be understood that the drawings detail exemplary implementations and that the application is not limited to the details of description or the details of the drawings. It is also to be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0064] In light of this description, other modifications and alternative embodiments of the various aspects of this disclosure will be apparent to those of ordinary skill in the art. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the present disclosure. The structures and arrangements of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as separate can be implemented in a single element, and vice versa. The position, number, and configuration of elements can be varied and still be consistent with the teachings and advantages of the subject matter described herein. The order or sequence of any process, logical algorithm, or method steps can be varied or re-sequenced without materially affecting the underlying teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes, and omissions can also be made in the design, operating conditions, and arrangement of the various example embodiments without departing from the scope of the present disclosure.

[0065] Unless specifically stated otherwise, and as apparent from the preceding description, it is not intended that any of the methods described herein be construed as requiring their steps to be carried out in a particular order. Accordingly, unless specifically stated otherwise, it is not intended that any particular order of steps be inferred. Furthermore, as used herein a singular article (e.g., an or the) is intended to include the plural (e.g., one or more) unless the context clearly indicates otherwise.

[0066] For purposes of this disclosure, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining can be stationary or moveable in nature. Such joining can be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members and any additional intermediate members being attached to one another. Such joining can be permanent in nature or alternatively can be removable or releasable in nature. As used herein, "rigidly coupled" means that two members are coupled such that the members move together in a fixed positional relationship when acted upon by forces.

[0067] While the present application describes particular combinations of features in the claims appended hereto, various embodiments of the present inventive concept relate to any combination of any of the features described herein, whether or not such combination is presently claimed, and any such combination of features can be claimed in this application or in a future application. Any of the features, elements or components of any of the above-discussed example embodiments can be used alone or in combination with any of the features, elements or components of any of the other above-discussed embodiments.

[0068] In various example embodiments, relative dimensions including angles, lengths and radii as shown in the drawings are drawn to scale. Actual measurements of the drawings disclose relative dimensions, angles and proportions of various example embodiments. Various example embodiments extend to various ranges of absolute dimensions and relative dimensions, angles and proportions that can be determined from the drawings. Various example embodiments include any combination of one or more relative dimensions or angles that can be determined from the drawings. Furthermore, actual dimensions not explicitly stated in the description can be determined by using the scale of the dimensions measured in the drawings in combination with explicit dimensions stated in the description.

Claims

1. A knee brace, characterized by, The knee brace comprises: an upper support configured to couple to a user's leg above a knee; a lower support configured to couple to the user's leg below the knee; a shell coupled to the upper support and the lower support and positioned between the upper support and the lower support; and a single, unitary pad layer comprising: an outer surface engaged against the shell; an inner surface; and a plurality of cells, each cell of the plurality of cells extending between the outer surface and the inner surface, each cell of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis extending along the channel; and a cell wall enclosing the channel, the cell wall comprising a plurality of segments angled relative to the longitudinal axis.

2. The knee brace of claim 1, wherein, A portion of the plurality of segments is angled inward toward the channel and a portion of the plurality of segments is angled outward away from the channel.

3. The knee brace of claim 2, wherein, Half of the plurality of segments are angled inward and half of the plurality of segments are angled outward.

4. The knee brace of claim 1, wherein, A thickness of the pad layer is defined between the outer surface and the inner surface, and wherein the thickness is less than 40 mm.

5. The knee brace of claim 4, wherein, The thickness is less than 25 mm.

6. The knee brace of claim 1, wherein, The shell further comprises: a front wall; and a pair of side walls, each side wall extending from opposite sides of the front wall.

7. The knee brace of claim 6, wherein, The pad layer further comprises: a central section positioned against the front wall of the shell; and side sections positioned against the pair of side walls of the shell.

8. The knee brace of claim 7, wherein, The plurality of cells in the central section have a first size and the plurality of cells in the side sections have a second size, and wherein the first size is greater than the second size.

9. A knee brace characterized by, The knee brace comprises: an upper support; a lower support; a shell coupled to the upper support and the lower support, the shell positioned between the upper support and the lower support; and a single, unitary pad layer comprising: an outer surface positioned along the shell; an inner surface; and a plurality of cells, each cell of the plurality of cells extending between the outer surface and the inner surface, each cell of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis; and a cell wall enclosing the channel, the cell wall comprising: an inwardly angled segment; and an outwardly angled segment; wherein the inwardly angled segment and the outwardly angled segment are each angled relative to the longitudinal axis.

10. The knee brace of claim 9, wherein, The inwardly angled segment is angled inward toward an opposite portion of the cell wall, and wherein the outwardly angled segment is angled outward away from an opposite cell wall.

11. The knee brace of claim 9, wherein, The cell wall comprises two inwardly angled segments and two outwardly angled segments.

12. The knee brace of claim 9, wherein, An inner surface of the inwardly angled segment is angled at 30 degrees relative to an axial axis of the cell.

13. The knee brace of claim 9, wherein, Each cell wall has a thickness defined between an outer surface of the cell wall and an inner surface of the cell wall, wherein the thickness is 2 mm.

14. The knee brace of claim 13, wherein, The spacer layer has a thickness of less than 25 mm.

15. The knee brace of claim 9, wherein, Each cell has a height defined between the outer surface and the inner surface of the spacer layer, and wherein the height is about 17.5 mm.

16. A knee brace, characterized in that The knee brace comprises: an upper support; a lower support; a shell coupled to the upper support and the lower support, the shell positioned between the upper support and the lower support; and a single, unitary spacer layer comprising: an outer surface positioned along the shell; an inner surface; and a plurality of cells, each cell of the plurality of cells extending between the outer surface and the inner surface, each cell of the plurality of cells comprising: a channel connecting the outer surface and the inner surface; a longitudinal axis; and a cell wall surrounding the channel, the cell wall comprising: a pair of inwardly angled segments; and a pair of outwardly angled segments; wherein the pair of inwardly angled segments and the pair of outwardly angled segments are each angled relative to the longitudinal axis.

17. The knee brace of claim 16, wherein, One outwardly angled segment of the pair of outwardly angled segments is positioned between the pair of inwardly angled segments.

18. The knee brace of claim 16, wherein, The shell further comprises: a front wall; and a pair of side walls, each side wall extending from opposite sides of the front wall; and wherein the spacer layer further comprises: a central segment positioned against the front wall of the shell; and side segments positioned against the pair of side walls of the shell.

19. The knee brace of claim 18, wherein, The plurality of cells in the central segment have a first size, and the plurality of cells in the side segments have a second size, and wherein the first size is greater than the second size.

20. The knee brace of claim 16, wherein, The spacer layer is formed from a thermoplastic elastomer.

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