Outdoor base layer including multi layer joint protection

Abstract

A base layer such as an undershirt or long underwear, for outdoor activities is described. The base layer includes an integrated joint protector. The protector includes foam padding realized as a collection of individual, mutually separated pads having a polygonal perimeter. The thickness of the pads decreases from a centerline of the protector to its medial and lateral edges. The medial and lateral edges have triangular individual pads with vertices facing out, which prevents binding or creasing of the protector under flexure. The base layer includes a rigid over-plate arranged over the foam padding having forward projecting unsupported projections that may deform when subject to shock.

Description

REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 18 / 737,902, entitled “Outdoor Base Layer Including Integrated Knee Protection”, filed on Jun. 7, 2024, and also claims the benefit of the U.S. Provisional Application No. 63 / 924,089 entitled “Outdoor Base Layer Including Multi Layer Joint Protection,” filed on Nov. 24, 2025, the entirety of which is incorporated herein by reference.FIELD OF THE INVENTION

[0002] This disclosure is related to a base layer wearable during strenuous outdoor activities including integrated knee protection.BACKGROUND

[0003] A base layer is a layer designed to be worn next to the skin during strenuous physical activity, particularly strenuous physical activity performed outdoors and especially during cold temperatures. Base layers are typically thin, stretchable and conformable and non-chafing when moist. Base layers typically provide minimal insulation, but are designed to wick moisture (i.e., sweat) from the surface of the skin to the outside surface of the base layer. A base layer's wicking action is provided by fibers arranged roughly normal to the surface of the wearer's skin, which fibers can transport moisture from a first, skin-facing surface of the garment to a second, outward facing surface of the garment by capillary action. From there, the moisture can be further wicked away from the body by additional clothing layers, or it evaporates due to body heat, and the resulting vapor is transported outward to the surrounding environment by a wearer's clothing system. Typical base layers are made of synthetic fabrics (e.g., polyester, nylon, elastane or polypropylene), wool (e.g., merino wool) or silk.

[0004] Base layers are typically worn as part of a clothing system including one or more other layers. Such a clothing system, at least for the upper body, may include a base layer and a waterproof or water-resistant outer shell (i.e., a jacket). The shell is typically capable of venting water vapor from the base layer through large vents (e.g., zippered openings under the arm pits or other openings) and / or though the shell fabric itself in cases where the shell comprises waterproof-breathable fabric. Waterproof-breathable materials typically have microscopic pores in the fabric. Warm water vapor evaporating from the base layer (or directly from the wearer's skin) is capable of passing through these small pores in the shell fabric, but liquid water on the outside cannot move through the same pores because of surface tension. Thus, the waterproof breathable shell is capable of venting water vapor while preventing rain, or the like, from penetrating the jacket. This sort of clothing system keeps the user relatively warm and dry despite high levels of physical exertion and sweating.

[0005] In some cases, a clothing system will also include an insulating middle layer, made of some wicking material, or including large gaps in body coverage, so as to not interfere with the passage of vapor from the base layer. Typical middle layers may include an insulated vest (e.g., filled with goose down or some synthetic, low-density material) or polyester fleece. For the lower body, where heat loss may be less of a concern, the outer layer may be a wind or water-resistant pant, and the base layer may be relied on for insulation. A clothing system like the one just described is typically worn during outdoor activities like backpacking, day hiking or hunting, because such a system enables a wearer to manage sweat and heat during periods of exertion while maintaining warmth during periods of rest.

[0006] When hunting, a hunter must frequently traverse rough, off-trail terrain, and must rapidly transition from walking or running, to a prone or kneeling position (e.g., in order to reduce visibility and prevent themselves from “sky lining” or to take a shot). While kneepads are available to protect a hunter's knees, these are unnecessarily bulky and tend to slip out of position. Certain pants (e.g., “tactical pants”) have pockets for receiving knee pads, but again, positioning and fit are problems, since pants that are suitable for hunting tend to be loose fitting, which allows the knee pad to move around with respect to the hunter's knee. Additionally, while there are products available that integrate a knee pad with a base layer the integrated kneepad is monolithic, being composed of a single piece of foam of uniform thickness, which adversely impact the comfort and flexibility of the kneepad. Improvement in these prior art systems would be desirable.BRIEF SUMMARY

[0007] Embodiments of the invention are directed a base layer with integrated knee protection. In one embodiment, the invention includes a base layer pant formed of a thin, elastic material such as polyester or elastane. The base layer is sized to be worn directly next to and tight to the skin. The knee area of the base layer has a knee protector incorporated within the fabric of the base layer on an anterior surface of the base layer. The knee protector, in one embodiment, comprises a plurality of discrete, discontinuous, polygonal padding sections arranged over the wearer's knee, and extending beyond the knee (dorsally, ventrically, medially and laterally). The padding sections may be any soft, conformable material such as closed or open cell foam, gel, non-Newtonian fluid cells, etc. In preferred embodiments, the discrete pads have non-uniform thicknesses, with thicker padding being located in the middle of the knee pad, and progressively thinner pads being located to the medial and lateral sides of the knee. In other embodiments, the knee protector comprises a plurality of non-polygonal padding sections (e.g., circles or ellipses).

[0008] In preferred embodiments, the knee protector also comprises a second protective layer over the padding sections. The second layer is a relatively hard plastic plate arranged on top of, or the anterior of the padding sections. The plate is preferably formed of a hard plastic material such as thermoplastic polyurethane, acrylic, polystyrene, polycarbonate, carbon fiber or the like. The plate is preferably sewn to the padding section and to the underlying elastic fabric of the base layer around its perimeter, either continuously or discontinuously, such that an air gap is formed between the bottom or posterior surface of the plate and the top or anterior surface of the padding section. On its posterior surface, the plate may include concave depressions of a size and shape to complement and receive the polygonal or non-polygonal individual pads that make up the padding section. On its top or anterior surface, the plate includes projections in an upper or anterior direction, over the positions of the polygonal or non-polygonal pads of the padding section beneath. These projections may be of any shape, but preferably have a circular cross section (e.g., they are preferably cylindrical, conical or frustoconical). The smooth perimeter provided by a circular cross section is advantageous because these projections interface directly with an interior surface of the pants being worn by the user, and this shape prevents snagging. The projections are hollow (i.e., they are shells) and can collapse upon the application of force to dissipate impulse force. Additionally, the rigid material of the plate distributes force against the underlying padded sections. These two features permit a user to quickly dropped to their knees while comfort is maintained.

[0009] Additionally, the plate may include vents in the form of holes, slots or other apertures extending from the plates anterior to the posterior side. These vents may be aligned to vents in the underlying pad, or they may be laterally offset and misaligned. Only attaching the plate to the pad at the edges to maintain an airgap enables the plate to flex relative to the pad, which creates a bellows action that flushes moist air and water vapor out of the space between the pad and the plate, which results in more efficient venting of moisture.

[0010] Inventive embodiments are advantageous over the prior art in that they provide knee protection in the layer that is immediately next to and tight to the skin, and so the knee protection is more likely to stay over the knee with movement of the leg and body. Providing the knee protector as an arrangement of discrete small pads aids in comfort, flexibility and conformability, and varying the thicknesses of the pads reduces the overall size of the pad and preserves its flexibility while still providing adequate padding for the user.

[0011] The incorporation of a hard plate with projections over the pads provides further advantages beyond those already mentioned. For example, incorporating a hard plate over the pads protects the pads from abrasion against the fabric of a user's pants during use. Additionally, the hard place may be configured with projections that better dissipate and distribute shock force when a user drops to a knee. Additionally, by maintaining an air gap between the hard plate and the underlying pads, venting of moisture is improved. Additionally, by configuring the posterior side of the plate to have concave depressions that are complementary to the pads, such that the pads nest into mating depressions in the plate, lateral movement of the plate relative to the pads and misalignment is minimized.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 depicts a base layer including left and right integrated joint protectors

[0013] FIG. 2 is an isometric view of one of the joint protectors depicted in FIG. 1.

[0014] FIG. 3 is a front elevation view of the joint protector depicted in FIG. 2.

[0015] FIG. 4 is a side view of the joint protector depicted in FIG. 2.

[0016] FIG. 5 is a sketch of an alternative embodiment of a joint protector.

[0017] FIG. 6 is a sketch of an alternative embodiment of a joint protector.

[0018] FIG. 7 is a sketch of an alternative embodiment of a knee protector showing placement of a lateral pad.

[0019] FIG. 8 is a drawing showing an improved knee protector incorporating a hard over plate according to an embodiment.

[0020] FIG. 9 is an oblique view of a hard over-plate according to an embodiment.

[0021] FIG. 10 is a top view, of an anterior surface of a hard over-plate according to an embodiment.

[0022] FIG. 11 is an oblique view of a hard over-plate arranged with an underlying pad.

[0023] FIG. 12 is a bottom view, of a posterior surface, of a hard over-plate.

[0024] FIG. 13 is a cross section of a knee protector showing a hard over-plate and an underlying pad.

[0025] FIG. 14 is a top view of an over-plate showing circular vent apertures.

[0026] FIG. 15 is a view of an over-plate showing slot vent apertures.DETAILED DESCRIPTION

[0027] The described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.

[0028] Reference throughout this specification to “one embodiment,”“an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrase “in one embodiment,”“in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0029] The example embodiments discussed below relate to a lower body base layer with an integrated and integral knee protector comprising plurality of discrete sub-pads of optionally varying thicknesses. This embodiment, however, should not be understood as limiting. The inventive joint protector configurations described may be applied to other areas of the body requiring padding and protection, such as elbows and hips. While the base layer described is a lower body base layer, an upper body base layer (i.e., a shirt) incorporating an elbow protector constructed according to the principals described below is also within the scope of the invention. Additionally, the inventive embodiments may be extended to non-base layers such as pants or over shirts which, themselves, are worn over base layers, or over the skin, but not in the tight-to the-skin, form fitting configuration of the base layer described below.

[0030] Referring now to FIG. 1, there is shown a base layer including left and right integrated joint protectors (e.g., right protector 105 and left protector 110) according to a first and preferred embodiment. In the example of FIG. 1 a garment 100 is provided, which is a base layer. Base layer is 100 is preferably formed of a multilayer fabric such that it includes a first, inside fabric layer that faces in and is in close contact with the skin of the wearer and a second, outside fabric layer that faces out. Both layers are preferably formed of an elastic fabric, and base layer 100 is sized such that it is form fitting. In cases where base layer 100 is a lower body base layer, it preferably extends from waist to ankle, as shown, but in other embodiments it may be shorter, i.e., a ¾ length pant that extends to just below the integrated joint protectors shown at 105, 110. Base layer 100, in other embodiments, may be full length and may include stirrups for the feet, or may be closed at the distal ends and include structures to receive the wearer's feet. In other embodiments, base layer may be an undershirt, configured to be worn on the upper body, in which case the joint protectors 105, 110 may be elbow protectors as opposed to the knee protectors shown in FIG. 1 and described in more detail below. In the case of elbow protectors, they are configured according to the design principles employed below for knee protectors.

[0031] Exemplary materials for base layer 100 include cotton, silk, polypropylene, polyester, nylon, and elastane, which is available under trade names such as LYCRA and SPANDEX. Preferably, the material of base layer 100 comprises more than one of the aforementioned or other materials, such as 90% polyester and 10% elastane.

[0032] Base layer 100 includes two joint protectors, which in the example of FIG. 1 are knee protectors 105, 110, that are integral to base layer 100 such that they will not slip with respect to the base layer with the wearer's motion. Knee protectors 105, 110 are arranged on an interior side of base layer 100 to cover and protect the knee of a wearer. In certain embodiments, a non-slip patch, strip or strips is arranged on an interior, posterior facing surface of an anterior portion of the base layer 100 (i.e., the inside surface of the front of the garment facing the front of the wearer's knee). Acceptable materials for this patch, strip or series of strips may include silicone, which helps to fix the knee protectors over the knee and prevent slippage. In one embodiment, knee protectors 105, 110 are arranged between a first anterior layer and a second posterior layer of the fabric making up the front of base layer 100 (the portion over the front of the knee) when that fabric is a two or more-layer fabric. In certain embodiments, protectors 105, 110 are arranged in a pocket or enveloped formed in a fabric layer making up the front of the base layer 100. In certain of these embodiments, the pocket or envelope that receives the protectors is sealed, e.g., by being sewn shut or with a layer of adhesive. In these embodiments, the protectors 105, 110 are not removable by the owner of the base layer 100 without cutting or otherwise creating an opening in the fabric of the base layer. In other embodiments, the pocket or envelope receiving the protectors is open (e.g., open to the top) such that a user insert or remove the protectors into the pocket without altering or destroying the base layer fabric itself.

[0033] In these embodiments where the protector is user insertable and removable, a flap of fabric may be arranged to cover a slit opening in the pocket.

[0034] The base layer 100 of FIG. 1 may include projecting tabs 112, which may be formed of a loops of flat, strong fabric. These tabs are centered on the knee protectors and located above and below the knee protectors. These tabs may be used by the wearer to finely adjust the position of the knee protectors during wear.

[0035] One embodiment of a left knee protector is shown in detail in FIGS. 2-4 and 7, however, it should be understood that in the inventive garments such as those shown in FIG. 1, the garment will have two such knee protectors, and the right knee protector will be a mirror image (reflected about a vertical line) of the left knee protector shown in FIGS. 2-4 and 7. Right knee protectors of a different embodiment are shown in FIGS. 5-6, but again, it should be understood that a complete garment will include corresponding, mirror-image left knee protectors for embodying garments with the right knee protectors of FIGS. 5-6.

[0036] Referring now to FIGS. 1-7, in preferred embodiments, knee protectors 105, 110 comprise a series of conformable and elastic (i.e., pads that deform under force, but then tend to return to their original shape in the absence of force) pads (e.g., 115), of various sizes and shapes. These pads 115 may be fixed to and optionally integral to a knee protector base 120. For example, knee protectors may be molded from closed or open cell foam material, and may be molded on top of base 120, which is also molded at the same time. Alternatively, pads 115 may be fabricated separately (e.g., by molding) and then fixed to base 120, e.g., by adhesive, hook and-loop fasteners, or the like. Acceptable materials for the pads 115 include closed cell foam (e.g., polyethylene foam, PVC foam, Neoprene, vinyl nitrile, and silicone foam), open cell foam (e.g., polyurethane, open cell rubber, etc.), gels and non-Newtonian fluid cells.

[0037] Preferably, pads 115 are mutually discontinuous along their front facing surface, that is to say, knee protectors 105, 110 may not formed of a single piece of foam or cushioning material, but instead, are formed of discrete, small pads separated from one another by gaps, such as the straight line channels 122 depicted in the figures, or alternatively, non-straight channels. By realizing the knee protectors as assemblies of discrete, separated pads, flexibility is increased because the pads may tilt toward and away from one another without interference as the base 120 flexes with the user's motion. Additionally, if the knee protector was formed of a continuous cushion, it would tend to crease or bulge with motion in certain places, which is avoided by providing discrete pads separated by gaps or channels 122. In cases where the individual pads 105, 110 and base 120 are integrally formed in a single process, e.g., by molding or by machining the pads out of a larger piece of material where the base is retained, the channels do not extend through the base, but instead, may extend 50% of the total thickness of the knee protector or more from the front facing surface. The width of the channels separating individual pads may vary, but in preferred embodiments, is between 0.5 and 20 mm. The widths of the channels 122 may be non-uniform or uniform along their length. While the width of all the channels may be the same, preferably, the width of the channels separating vertical columns of individual pads is less than the width of channels separating horizontal rows. This enables more flexure for the protector about a horizontal axis (i.e., the knee's bend axis), than a vertical axis.

[0038] While pads 115 may have any shape in certain embodiments (e.g., circles, ellipses or irregular shapes having curved perimeters), preferably, pads 115 have polygonal perimeters. This is advantageous because, under certain flexure conditions, it enables the edges of adjacent pads to meet along a continuous line such that the two pads form a continuous uninterrupted surface. In the arrangement of the Figures, the perimeters of the pads 115 are defined by the straight-line channels 122. In preferred arrangements, horizontal channels are mutually parallel and run substantially horizontally when the knee protector is in a flat, unflexed configuration. This can best be seen in FIG. 3. The horizontal channels permit flexure about horizontal axes, as rows of pads 115 separate from one another at horizontal channels. As noted above, this is advantageous because it allows the pad to flex with direction of motion of the knee joint. Substantially vertical channels (i.e., channels with a vertical component, or non-horizontal channels) run transverse to the horizontal channels. These substantially vertical channels tend to converge toward a point below the knee protector, which results in the knee protector having an overall shape that tapers toward the bottom. The substantially vertical channels 122 allow the pads to flex and separate from one another along the channels. This is advantageous because it allows the protector 105 to be bent into a curve, such that it takes on a conical shape, with a wide, superior opening (to accommodate a wearer's lower thigh, above the knee), and a narrower, inferior opening (to accommodate the thinner upper shin, below the knee). The result is that the pad wraps around the front of the knee, such that the pad is convex towards the wearer's anterior direction, and concave towards the wearer's posterior direction.

[0039] In the preferred embodiments of the Figures, individual pads 115 are arranged in substantially horizonal rows, and in columns with a substantial vertical component. As seen best in FIG. 3, there is a first, central column 125 of pads 115 that is centered over the centerline of a wearer's knee, and specifically the centerline of the wearer's kneecap. The preferred embodiments also include a first pair of flanking columns of pads 130a, b arranged on either side of the central column 125. The preferred embodiments also include a second pair of flanking columns 135a, b located to the outsides of the first pair of flanking columns 130a, b. This second pair of flanking columns includes columns located on a medial and lateral edge of the protector 105.

[0040] In the illustrated embodiments, the individual pads 115 in the central column of pads 125 have a first thickness, the pads in the first flanking columns 130a, b have a second thickness and the pads in the second pair of flanking columns 135a, b have a third thickness. More generally, the pads 115 of the protector 105 are arranged in groups, where a first group has a first pad thickness, a second group has a second pad thickness and a third group has a third pad thickness. These groups are preferably arranged with the first group along a vertical centerline of the wearer's knee, the second group arranged a first range of distance from the vertical centerline of the wearer's knee, and the third group arranged yet farther from the vertical centerline of the wearer's knee. In certain embodiments, the first, second and third thicknesses are the same. However, in a preferred embodiment, the first thickness is greater than the second or third thicknesses. In another preferred embodiment the first thickness is greater than the second thickness, and the second thickness is greater than the third thickness. In one embodiment, the first thickness (of the central column of pads) is between 15 and 23 mm, with a preferred thickness of between 17 and 21 mm, and an especially preferred thickness of between 18 and 20 mm. In one embodiment, the thickness of the central pads is about 19 mm or ¾″. The thickness of the flanking pads, on either side of the central column of pads is between 12 and 20 mm, with a preferred thickness of between 14 and 18 mm, and an especially preferred thickness of between 15 and 16.5 mm. In one embodiment, the thickness of the central pads is about 15.9 mm or ⅝″. In one embodiment, the thickness of the outside most columns of pads is between 9 and 17 mm, with a preferred thickness of between 11 and 15 mm, with an especially preferred thickness of between 12 and 14 mm. In one embodiment, the outermost columns of pad have pads with a thickness of about 12.7 mm or 0.5″.

[0041] The decreasing thickness in the pads as they move from the vertical centerline of the protector, horizontally, to the medial and lateral edges of the protector is seen easily in the side view of an exemplary protector in FIG. 4. Decreasing the effective thickness of the knee protector, from the centerline, to its medial and lateral edges, has significant advantages. First, because of the decreased thickness of the pads on the medial and lateral edges, the overall protector is more flexible along the medial and lateral edges. The overall weight and bulk of the protector is decreased, and good padding is provided over the centerline of the knee, which will experience pressure when a wearer is kneeling, but some padding is provided on the edges of the front of the knee and along the sides. This side and edge padding is helpful to protect the knee from obstacles encountered while walking (e.g., tree branches). Additionally, the decreased bulk at the edge of the protector reduces the likelihood of bulges or creases when the protector is flexed with the joint, as shown in FIG. 7.

[0042] Another advantage of inventive embodiments comes from the unique shape of the various individual pads 115. Referring still to FIGS. 1-7, and in particular to FIG. 3, the central pads, along the knee vertical centerline (column 125) and in the immediately adjacent pads (flanking columns 130a, b) are preferably large in area relative to other pads, and are separated from adjacent pads with narrow channels 122. Additionally, these more central pads preferably have quadrilateral shapes. The combination of these features ensures good coverage across the central portion of the knee, where good padding is advantageous when a wearer is kneeling.

[0043] Pads on the medial and lateral vertical edges of the protector (i.e., in columns 135a, b), may have triangular shapes (145), where a vertex of each triangle points out in a medial or lateral direction. The consequence of arranging triangular shapes at the medial and lateral vertical edges of the protector is that the channels or space between the individual triangular pads is increased. There is less coverage in these areas, but less is needed since these areas are unlikely to fully bear the weight of the wearer, and the open structure provided by the triangular edge pads is still sufficient to protect the wearer against blows to the sides of the knee. This is the case because these triangular edge pads will tend to bend back around the knee and be arranged on the sides of the knee when the protector is worn. This can be seen in FIG. 7. The open gaps between the medial and lateral pointing vertices of the triangles allow prevents the knee protector from bulging or creasing when the along those sides when the knee is flexed, because there is space that allows the pointed ends of the edge pads to converge toward one another without interference. Some embodiments may include pads that include both quadrilateral and triangular sub-portions, such as pad 150.

[0044] Other configurations and arrangements of individual pads are possible and within the scope of the invention. FIGS. 5-7 illustrate alternative configurations of individual pads.

[0045] As discussed above, one advantage of knee protectors within the scope of the invention is ability to protect the knee against lateral blows or contact with objects to the side of the knee. To this end, preferred embodiments include a lateral pad that wraps around to be arranged on a lateral side of the knee. Preferably, the joint axis of the knee passes through this pad when the base layer including the protector is worn. The lateral pad is shown as 155 in FIGS. 3, and 5-7, but it is visible in FIGS. 2-3 and 7 (which show left knee protectors) and FIGS. 5-6 (which show right knee protectors). By providing wrap around protection to the joint axis on the lateral sides of the knee, knee protectors within the scope of the invention protect the knee from objects or blows to the side of the knee that may occur while walking.

[0046] FIGS. 8-15 show an improved joint protector design, and in particular, an improved knee protector design. In the examples shown in FIG. 8-15 a hard over-plate preferably formed of TPU, acrylic, polystyrene, carbon fiber or some other rigid plastic material is provided. The over-plate is usable with any of the knee protector embodiments described in FIGS. 1-7 to form an improved knee protector. The over-plate alone is shown in FIGS. 9, 10, 12, and 14-15. The over-plate is arranged on top of the pad assembly described above in reference, for example to FIG. 1. On a bottom side (i.e., a posterior side that will face the wearer's knee and the pads) (visible in FIG. 12), a posterior surface of the plate defines concave depressions 1105. These are shaped and sized to be of a complementary shape to pads (e.g., 115), such that the depressions can receive and have a nesting engagement with the pads (best seen in FIGS. 8 and 13). To this end, the perimeter or outline of the depressions will have the same shape as the underlying pads (e.g., squares, trapezoids, triangles or other polygonal shapes). The depressions are separated by posteriorly projecting ridges 1110 that fit into the channels 122 that separate the foam pads in the knee protector. The height of the ridges 1110 is preferably equal to or less than the depth of the channels 122 (as best seen in the cross section of FIG. 13). This ensures that when pressure is applied to an anterior surface of the over-plate, that pressure is distributed widely to the foam pads by surface contact between the posterior surfaces of the over-plate that are within depressions 1105 and the corresponding anterior surfaces of the pads. The nesting engagement between the over-plate and the underlying pads can be best seen in the cross section of FIG. 13 and in FIGS. 8 and 11. On an anterior facing surface of the over-plate, the structures are the inverse. Thus on this surface the depressions 1105 correspond to projections that accommodate the underlying foam pad, and the separating ridges correspond to channels.

[0047] The over-plate also includes further projections 1115 on the top, forward facing or anterior surface (i.e., the surface facing away from the user's knee). These correspond to depressions from the perspective looking at the posterior surface of the plate. These projections, like depressions / projections 1105, are hollow (i.e., are unsupported). The depressions / projections 1105 are hollow to accommodate the underlying foam pads. The further projections 1115 are hollow to allow them to deform under pressure from, for example, impact with the ground when a user drops to their knee(s). The further projections 1115 may temporarily collapse when loaded from the front. The further projections 1115 preferably have a circular cross section, which prevents snagging on the user's pants, but this is not limiting. The projections 1115 preferably are conical, cylindrical, frustoconical, or partially spherical (e.g., hemispherical).

[0048] An over-plate such as been described assembled to an underlying pad may be seen in FIGS. 8 and 11. Here it can be seen that the foam pads (e.g., 115) nest into the depressions defined by the over-plate, which itself provides further projections outward to absorb force. Preferably, the over-plate is attached to the base layer garment around its perimeter, by sewing, adhesive, ultrasonic welding, etc. This perimeter attachment may be continuous around the entirety of the perimeter or may be discontinuous. The over-plate may be attached directly to the fabric layer of the garment, or may be attached to both the fabric layer of the garment and the perimeter of the pad assembly, e.g., by sewing. Perimeter attachment (i.e., without continuous or discontinuous bonding of the over-plate to the underlying foam pads) ensures an air gap between the over-plate and the underlying foam pads, which may have some advantages. In this arrangement, the over-plate can flex somewhat with respect to the pad assembly, which increases flexibility of the entire assembly. Additionally, this flexing acts as a bellows, which tends to draw air and water vapor out of the foam layer where it can vented through apertures in the plate, as will be discussed relative to FIGS. 14 and 15. At the same time, the nesting arrangement between the foam pads and the depressions or sockets in the over-plate prevents lateral movement between the two parts and prevents misalignment.

[0049] Referring now to FIGS. 14 and 15, venting apertures may be provided in the over-plate between its bottom (anterior) and top (posterior) surfaces. These apertures may be circular, e.g., holes at the anterior ends of the further projections as shown in FIG. 14. They may also be slots in the channels that separate the depressions as shown in FIG. 15. The vents in the over-plate may be aligned over corresponding vends in the underlying foam pad layer, but this is not a requirement. Indeed, by laterally misaligning the vents, airflow is encouraged along the anterior facing surface of the padding layer, which may improve the venting of water vapor.

[0050] The improved embodiment including the over-plate has certain advantages. The over-plate, which preferably has a smooth surface finish (e.g., from the thermoplastic molding process), which reduces snagging or friction with the inside of the user's pants. The over-plate serves to protect the underlying foam layer, which tends to be more delicate and vulnerable to abrasion. The further projections (i.e., the frustoconical projections shown in the figures) serve to absorb and dissipate shock forces that may be created when a user rapidly drops to their knees. This force is absorbed by deformation of the projections (further projections 1115), which are not supported by the underlying foam layer. Additionally, the plate itself, which is rigid plastic, distributes the total absorbed force uniformly over the underlying foam layer. This is ensured by the ridges 1110 in the over-plate being shorter than the corresponding channels that separate the foam pads. This means that when the over-plate presses against the foam pads, engagement occurs all across the posterior facing surfaces of the bottoms of the over-plate depressions as they press against the anterior facing surfaces on the tops of the corresponding pads. These two effects work together to make the user very comfortable when dropping to their knees or otherwise experiencing a sudden force on the anterior side of the protector.

[0051] It should be understood that, unless explicitly stated or otherwise required, the features disclosed in embodiments explicitly described herein and elsewhere in this disclosure may be used in any suitable combinations. Other embodiments and uses of the above inventions will be apparent to those having ordinary skill in the art upon consideration of the specification and practice of the invention disclosed herein. It should be understood that features listed and described in one embodiment may be used in other embodiments unless specifically stated otherwise. The specification and examples given should be considered exemplary only, and it is contemplated that the appended claims will cover any other such embodiments or modifications as fall within the true scope of the invention.

Examples

Embodiment Construction

[0027]The described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.

[0028]Reference throughout this specification to “one embodiment,”“an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrase “in one embodiment,”“in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0029]The example embodiments discussed below relate to a lower body base layer with an integrated and integral knee protecto...

REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 18 / 737,902, entitled “Outdoor Base Layer Including Integrated Knee Protection”, filed on Jun. 7, 2024, and also claims the benefit of the U.S. Provisional Application No. 63 / 924,089 entitled “Outdoor Base Layer Including Multi Layer Joint Protection,” filed on Nov. 24, 2025, the entirety of which is incorporated herein by reference.FIELD OF THE INVENTION

[0002] This disclosure is related to a base layer wearable during strenuous outdoor activities including integrated knee protection.BACKGROUND

[0003] A base layer is a layer designed to be worn next to the skin during strenuous physical activity, particularly strenuous physical activity performed outdoors and especially during cold temperatures. Base layers are typically thin, stretchable and conformable and non-chafing when moist. Base layers typically provide minimal insulation, but are designed to wick moisture (i.e., sweat) from the surface of the skin to the outside surface of the base layer. A base layer's wicking action is provided by fibers arranged roughly normal to the surface of the wearer's skin, which fibers can transport moisture from a first, skin-facing surface of the garment to a second, outward facing surface of the garment by capillary action. From there, the moisture can be further wicked away from the body by additional clothing layers, or it evaporates due to body heat, and the resulting vapor is transported outward to the surrounding environment by a wearer's clothing system. Typical base layers are made of synthetic fabrics (e.g., polyester, nylon, elastane or polypropylene), wool (e.g., merino wool) or silk.

[0004] Base layers are typically worn as part of a clothing system including one or more other layers. Such a clothing system, at least for the upper body, may include a base layer and a waterproof or water-resistant outer shell (i.e., a jacket). The shell is typically capable of venting water vapor from the base layer through large vents (e.g., zippered openings under the arm pits or other openings) and / or though the shell fabric itself in cases where the shell comprises waterproof-breathable fabric. Waterproof-breathable materials typically have microscopic pores in the fabric. Warm water vapor evaporating from the base layer (or directly from the wearer's skin) is capable of passing through these small pores in the shell fabric, but liquid water on the outside cannot move through the same pores because of surface tension. Thus, the waterproof breathable shell is capable of venting water vapor while preventing rain, or the like, from penetrating the jacket. This sort of clothing system keeps the user relatively warm and dry despite high levels of physical exertion and sweating.

[0005] In some cases, a clothing system will also include an insulating middle layer, made of some wicking material, or including large gaps in body coverage, so as to not interfere with the passage of vapor from the base layer. Typical middle layers may include an insulated vest (e.g., filled with goose down or some synthetic, low-density material) or polyester fleece. For the lower body, where heat loss may be less of a concern, the outer layer may be a wind or water-resistant pant, and the base layer may be relied on for insulation. A clothing system like the one just described is typically worn during outdoor activities like backpacking, day hiking or hunting, because such a system enables a wearer to manage sweat and heat during periods of exertion while maintaining warmth during periods of rest.

[0006] When hunting, a hunter must frequently traverse rough, off-trail terrain, and must rapidly transition from walking or running, to a prone or kneeling position (e.g., in order to reduce visibility and prevent themselves from “sky lining” or to take a shot). While kneepads are available to protect a hunter's knees, these are unnecessarily bulky and tend to slip out of position. Certain pants (e.g., “tactical pants”) have pockets for receiving knee pads, but again, positioning and fit are problems, since pants that are suitable for hunting tend to be loose fitting, which allows the knee pad to move around with respect to the hunter's knee. Additionally, while there are products available that integrate a knee pad with a base layer the integrated kneepad is monolithic, being composed of a single piece of foam of uniform thickness, which adversely impact the comfort and flexibility of the kneepad. Improvement in these prior art systems would be desirable.BRIEF SUMMARY

[0007] Embodiments of the invention are directed a base layer with integrated knee protection. In one embodiment, the invention includes a base layer pant formed of a thin, elastic material such as polyester or elastane. The base layer is sized to be worn directly next to and tight to the skin. The knee area of the base layer has a knee protector incorporated within the fabric of the base layer on an anterior surface of the base layer. The knee protector, in one embodiment, comprises a plurality of discrete, discontinuous, polygonal padding sections arranged over the wearer's knee, and extending beyond the knee (dorsally, ventrically, medially and laterally). The padding sections may be any soft, conformable material such as closed or open cell foam, gel, non-Newtonian fluid cells, etc. In preferred embodiments, the discrete pads have non-uniform thicknesses, with thicker padding being located in the middle of the knee pad, and progressively thinner pads being located to the medial and lateral sides of the knee. In other embodiments, the knee protector comprises a plurality of non-polygonal padding sections (e.g., circles or ellipses).

[0008] In preferred embodiments, the knee protector also comprises a second protective layer over the padding sections. The second layer is a relatively hard plastic plate arranged on top of, or the anterior of the padding sections. The plate is preferably formed of a hard plastic material such as thermoplastic polyurethane, acrylic, polystyrene, polycarbonate, carbon fiber or the like. The plate is preferably sewn to the padding section and to the underlying elastic fabric of the base layer around its perimeter, either continuously or discontinuously, such that an air gap is formed between the bottom or posterior surface of the plate and the top or anterior surface of the padding section. On its posterior surface, the plate may include concave depressions of a size and shape to complement and receive the polygonal or non-polygonal individual pads that make up the padding section. On its top or anterior surface, the plate includes projections in an upper or anterior direction, over the positions of the polygonal or non-polygonal pads of the padding section beneath. These projections may be of any shape, but preferably have a circular cross section (e.g., they are preferably cylindrical, conical or frustoconical). The smooth perimeter provided by a circular cross section is advantageous because these projections interface directly with an interior surface of the pants being worn by the user, and this shape prevents snagging. The projections are hollow (i.e., they are shells) and can collapse upon the application of force to dissipate impulse force. Additionally, the rigid material of the plate distributes force against the underlying padded sections. These two features permit a user to quickly dropped to their knees while comfort is maintained.

[0009] Additionally, the plate may include vents in the form of holes, slots or other apertures extending from the plates anterior to the posterior side. These vents may be aligned to vents in the underlying pad, or they may be laterally offset and misaligned. Only attaching the plate to the pad at the edges to maintain an airgap enables the plate to flex relative to the pad, which creates a bellows action that flushes moist air and water vapor out of the space between the pad and the plate, which results in more efficient venting of moisture.

[0010] Inventive embodiments are advantageous over the prior art in that they provide knee protection in the layer that is immediately next to and tight to the skin, and so the knee protection is more likely to stay over the knee with movement of the leg and body. Providing the knee protector as an arrangement of discrete small pads aids in comfort, flexibility and conformability, and varying the thicknesses of the pads reduces the overall size of the pad and preserves its flexibility while still providing adequate padding for the user.

[0011] The incorporation of a hard plate with projections over the pads provides further advantages beyond those already mentioned. For example, incorporating a hard plate over the pads protects the pads from abrasion against the fabric of a user's pants during use. Additionally, the hard place may be configured with projections that better dissipate and distribute shock force when a user drops to a knee. Additionally, by maintaining an air gap between the hard plate and the underlying pads, venting of moisture is improved. Additionally, by configuring the posterior side of the plate to have concave depressions that are complementary to the pads, such that the pads nest into mating depressions in the plate, lateral movement of the plate relative to the pads and misalignment is minimized.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 depicts a base layer including left and right integrated joint protectors

[0013] FIG. 2 is an isometric view of one of the joint protectors depicted in FIG. 1.

[0014] FIG. 3 is a front elevation view of the joint protector depicted in FIG. 2.

[0015] FIG. 4 is a side view of the joint protector depicted in FIG. 2.

[0016] FIG. 5 is a sketch of an alternative embodiment of a joint protector.

[0017] FIG. 6 is a sketch of an alternative embodiment of a joint protector.

[0018] FIG. 7 is a sketch of an alternative embodiment of a knee protector showing placement of a lateral pad.

[0019] FIG. 8 is a drawing showing an improved knee protector incorporating a hard over plate according to an embodiment.

[0020] FIG. 9 is an oblique view of a hard over-plate according to an embodiment.

[0021] FIG. 10 is a top view, of an anterior surface of a hard over-plate according to an embodiment.

[0022] FIG. 11 is an oblique view of a hard over-plate arranged with an underlying pad.

[0023] FIG. 12 is a bottom view, of a posterior surface, of a hard over-plate.

[0024] FIG. 13 is a cross section of a knee protector showing a hard over-plate and an underlying pad.

[0025] FIG. 14 is a top view of an over-plate showing circular vent apertures.

[0026] FIG. 15 is a view of an over-plate showing slot vent apertures.DETAILED DESCRIPTION

[0027] The described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.

[0028] Reference throughout this specification to “one embodiment,”“an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrase “in one embodiment,”“in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0029] The example embodiments discussed below relate to a lower body base layer with an integrated and integral knee protector comprising plurality of discrete sub-pads of optionally varying thicknesses. This embodiment, however, should not be understood as limiting. The inventive joint protector configurations described may be applied to other areas of the body requiring padding and protection, such as elbows and hips. While the base layer described is a lower body base layer, an upper body base layer (i.e., a shirt) incorporating an elbow protector constructed according to the principals described below is also within the scope of the invention. Additionally, the inventive embodiments may be extended to non-base layers such as pants or over shirts which, themselves, are worn over base layers, or over the skin, but not in the tight-to the-skin, form fitting configuration of the base layer described below.

[0030] Referring now to FIG. 1, there is shown a base layer including left and right integrated joint protectors (e.g., right protector 105 and left protector 110) according to a first and preferred embodiment. In the example of FIG. 1 a garment 100 is provided, which is a base layer. Base layer is 100 is preferably formed of a multilayer fabric such that it includes a first, inside fabric layer that faces in and is in close contact with the skin of the wearer and a second, outside fabric layer that faces out. Both layers are preferably formed of an elastic fabric, and base layer 100 is sized such that it is form fitting. In cases where base layer 100 is a lower body base layer, it preferably extends from waist to ankle, as shown, but in other embodiments it may be shorter, i.e., a ¾ length pant that extends to just below the integrated joint protectors shown at 105, 110. Base layer 100, in other embodiments, may be full length and may include stirrups for the feet, or may be closed at the distal ends and include structures to receive the wearer's feet. In other embodiments, base layer may be an undershirt, configured to be worn on the upper body, in which case the joint protectors 105, 110 may be elbow protectors as opposed to the knee protectors shown in FIG. 1 and described in more detail below. In the case of elbow protectors, they are configured according to the design principles employed below for knee protectors.

[0031] Exemplary materials for base layer 100 include cotton, silk, polypropylene, polyester, nylon, and elastane, which is available under trade names such as LYCRA and SPANDEX. Preferably, the material of base layer 100 comprises more than one of the aforementioned or other materials, such as 90% polyester and 10% elastane.

[0032] Base layer 100 includes two joint protectors, which in the example of FIG. 1 are knee protectors 105, 110, that are integral to base layer 100 such that they will not slip with respect to the base layer with the wearer's motion. Knee protectors 105, 110 are arranged on an interior side of base layer 100 to cover and protect the knee of a wearer. In certain embodiments, a non-slip patch, strip or strips is arranged on an interior, posterior facing surface of an anterior portion of the base layer 100 (i.e., the inside surface of the front of the garment facing the front of the wearer's knee). Acceptable materials for this patch, strip or series of strips may include silicone, which helps to fix the knee protectors over the knee and prevent slippage. In one embodiment, knee protectors 105, 110 are arranged between a first anterior layer and a second posterior layer of the fabric making up the front of base layer 100 (the portion over the front of the knee) when that fabric is a two or more-layer fabric. In certain embodiments, protectors 105, 110 are arranged in a pocket or enveloped formed in a fabric layer making up the front of the base layer 100. In certain of these embodiments, the pocket or envelope that receives the protectors is sealed, e.g., by being sewn shut or with a layer of adhesive. In these embodiments, the protectors 105, 110 are not removable by the owner of the base layer 100 without cutting or otherwise creating an opening in the fabric of the base layer. In other embodiments, the pocket or envelope receiving the protectors is open (e.g., open to the top) such that a user insert or remove the protectors into the pocket without altering or destroying the base layer fabric itself.

[0033] In these embodiments where the protector is user insertable and removable, a flap of fabric may be arranged to cover a slit opening in the pocket.

[0034] The base layer 100 of FIG. 1 may include projecting tabs 112, which may be formed of a loops of flat, strong fabric. These tabs are centered on the knee protectors and located above and below the knee protectors. These tabs may be used by the wearer to finely adjust the position of the knee protectors during wear.

[0035] One embodiment of a left knee protector is shown in detail in FIGS. 2-4 and 7, however, it should be understood that in the inventive garments such as those shown in FIG. 1, the garment will have two such knee protectors, and the right knee protector will be a mirror image (reflected about a vertical line) of the left knee protector shown in FIGS. 2-4 and 7. Right knee protectors of a different embodiment are shown in FIGS. 5-6, but again, it should be understood that a complete garment will include corresponding, mirror-image left knee protectors for embodying garments with the right knee protectors of FIGS. 5-6.

[0036] Referring now to FIGS. 1-7, in preferred embodiments, knee protectors 105, 110 comprise a series of conformable and elastic (i.e., pads that deform under force, but then tend to return to their original shape in the absence of force) pads (e.g., 115), of various sizes and shapes. These pads 115 may be fixed to and optionally integral to a knee protector base 120. For example, knee protectors may be molded from closed or open cell foam material, and may be molded on top of base 120, which is also molded at the same time. Alternatively, pads 115 may be fabricated separately (e.g., by molding) and then fixed to base 120, e.g., by adhesive, hook and-loop fasteners, or the like. Acceptable materials for the pads 115 include closed cell foam (e.g., polyethylene foam, PVC foam, Neoprene, vinyl nitrile, and silicone foam), open cell foam (e.g., polyurethane, open cell rubber, etc.), gels and non-Newtonian fluid cells.

[0037] Preferably, pads 115 are mutually discontinuous along their front facing surface, that is to say, knee protectors 105, 110 may not formed of a single piece of foam or cushioning material, but instead, are formed of discrete, small pads separated from one another by gaps, such as the straight line channels 122 depicted in the figures, or alternatively, non-straight channels. By realizing the knee protectors as assemblies of discrete, separated pads, flexibility is increased because the pads may tilt toward and away from one another without interference as the base 120 flexes with the user's motion. Additionally, if the knee protector was formed of a continuous cushion, it would tend to crease or bulge with motion in certain places, which is avoided by providing discrete pads separated by gaps or channels 122. In cases where the individual pads 105, 110 and base 120 are integrally formed in a single process, e.g., by molding or by machining the pads out of a larger piece of material where the base is retained, the channels do not extend through the base, but instead, may extend 50% of the total thickness of the knee protector or more from the front facing surface. The width of the channels separating individual pads may vary, but in preferred embodiments, is between 0.5 and 20 mm. The widths of the channels 122 may be non-uniform or uniform along their length. While the width of all the channels may be the same, preferably, the width of the channels separating vertical columns of individual pads is less than the width of channels separating horizontal rows. This enables more flexure for the protector about a horizontal axis (i.e., the knee's bend axis), than a vertical axis.

[0038] While pads 115 may have any shape in certain embodiments (e.g., circles, ellipses or irregular shapes having curved perimeters), preferably, pads 115 have polygonal perimeters. This is advantageous because, under certain flexure conditions, it enables the edges of adjacent pads to meet along a continuous line such that the two pads form a continuous uninterrupted surface. In the arrangement of the Figures, the perimeters of the pads 115 are defined by the straight-line channels 122. In preferred arrangements, horizontal channels are mutually parallel and run substantially horizontally when the knee protector is in a flat, unflexed configuration. This can best be seen in FIG. 3. The horizontal channels permit flexure about horizontal axes, as rows of pads 115 separate from one another at horizontal channels. As noted above, this is advantageous because it allows the pad to flex with direction of motion of the knee joint. Substantially vertical channels (i.e., channels with a vertical component, or non-horizontal channels) run transverse to the horizontal channels. These substantially vertical channels tend to converge toward a point below the knee protector, which results in the knee protector having an overall shape that tapers toward the bottom. The substantially vertical channels 122 allow the pads to flex and separate from one another along the channels. This is advantageous because it allows the protector 105 to be bent into a curve, such that it takes on a conical shape, with a wide, superior opening (to accommodate a wearer's lower thigh, above the knee), and a narrower, inferior opening (to accommodate the thinner upper shin, below the knee). The result is that the pad wraps around the front of the knee, such that the pad is convex towards the wearer's anterior direction, and concave towards the wearer's posterior direction.

[0039] In the preferred embodiments of the Figures, individual pads 115 are arranged in substantially horizonal rows, and in columns with a substantial vertical component. As seen best in FIG. 3, there is a first, central column 125 of pads 115 that is centered over the centerline of a wearer's knee, and specifically the centerline of the wearer's kneecap. The preferred embodiments also include a first pair of flanking columns of pads 130a, b arranged on either side of the central column 125. The preferred embodiments also include a second pair of flanking columns 135a, b located to the outsides of the first pair of flanking columns 130a, b. This second pair of flanking columns includes columns located on a medial and lateral edge of the protector 105.

[0040] In the illustrated embodiments, the individual pads 115 in the central column of pads 125 have a first thickness, the pads in the first flanking columns 130a, b have a second thickness and the pads in the second pair of flanking columns 135a, b have a third thickness. More generally, the pads 115 of the protector 105 are arranged in groups, where a first group has a first pad thickness, a second group has a second pad thickness and a third group has a third pad thickness. These groups are preferably arranged with the first group along a vertical centerline of the wearer's knee, the second group arranged a first range of distance from the vertical centerline of the wearer's knee, and the third group arranged yet farther from the vertical centerline of the wearer's knee. In certain embodiments, the first, second and third thicknesses are the same. However, in a preferred embodiment, the first thickness is greater than the second or third thicknesses. In another preferred embodiment the first thickness is greater than the second thickness, and the second thickness is greater than the third thickness. In one embodiment, the first thickness (of the central column of pads) is between 15 and 23 mm, with a preferred thickness of between 17 and 21 mm, and an especially preferred thickness of between 18 and 20 mm. In one embodiment, the thickness of the central pads is about 19 mm or ¾″. The thickness of the flanking pads, on either side of the central column of pads is between 12 and 20 mm, with a preferred thickness of between 14 and 18 mm, and an especially preferred thickness of between 15 and 16.5 mm. In one embodiment, the thickness of the central pads is about 15.9 mm or ⅝″. In one embodiment, the thickness of the outside most columns of pads is between 9 and 17 mm, with a preferred thickness of between 11 and 15 mm, with an especially preferred thickness of between 12 and 14 mm. In one embodiment, the outermost columns of pad have pads with a thickness of about 12.7 mm or 0.5″.

[0041] The decreasing thickness in the pads as they move from the vertical centerline of the protector, horizontally, to the medial and lateral edges of the protector is seen easily in the side view of an exemplary protector in FIG. 4. Decreasing the effective thickness of the knee protector, from the centerline, to its medial and lateral edges, has significant advantages. First, because of the decreased thickness of the pads on the medial and lateral edges, the overall protector is more flexible along the medial and lateral edges. The overall weight and bulk of the protector is decreased, and good padding is provided over the centerline of the knee, which will experience pressure when a wearer is kneeling, but some padding is provided on the edges of the front of the knee and along the sides. This side and edge padding is helpful to protect the knee from obstacles encountered while walking (e.g., tree branches). Additionally, the decreased bulk at the edge of the protector reduces the likelihood of bulges or creases when the protector is flexed with the joint, as shown in FIG. 7.

[0042] Another advantage of inventive embodiments comes from the unique shape of the various individual pads 115. Referring still to FIGS. 1-7, and in particular to FIG. 3, the central pads, along the knee vertical centerline (column 125) and in the immediately adjacent pads (flanking columns 130a, b) are preferably large in area relative to other pads, and are separated from adjacent pads with narrow channels 122. Additionally, these more central pads preferably have quadrilateral shapes. The combination of these features ensures good coverage across the central portion of the knee, where good padding is advantageous when a wearer is kneeling.

[0043] Pads on the medial and lateral vertical edges of the protector (i.e., in columns 135a, b), may have triangular shapes (145), where a vertex of each triangle points out in a medial or lateral direction. The consequence of arranging triangular shapes at the medial and lateral vertical edges of the protector is that the channels or space between the individual triangular pads is increased. There is less coverage in these areas, but less is needed since these areas are unlikely to fully bear the weight of the wearer, and the open structure provided by the triangular edge pads is still sufficient to protect the wearer against blows to the sides of the knee. This is the case because these triangular edge pads will tend to bend back around the knee and be arranged on the sides of the knee when the protector is worn. This can be seen in FIG. 7. The open gaps between the medial and lateral pointing vertices of the triangles allow prevents the knee protector from bulging or creasing when the along those sides when the knee is flexed, because there is space that allows the pointed ends of the edge pads to converge toward one another without interference. Some embodiments may include pads that include both quadrilateral and triangular sub-portions, such as pad 150.

[0044] Other configurations and arrangements of individual pads are possible and within the scope of the invention. FIGS. 5-7 illustrate alternative configurations of individual pads.

[0045] As discussed above, one advantage of knee protectors within the scope of the invention is ability to protect the knee against lateral blows or contact with objects to the side of the knee. To this end, preferred embodiments include a lateral pad that wraps around to be arranged on a lateral side of the knee. Preferably, the joint axis of the knee passes through this pad when the base layer including the protector is worn. The lateral pad is shown as 155 in FIGS. 3, and 5-7, but it is visible in FIGS. 2-3 and 7 (which show left knee protectors) and FIGS. 5-6 (which show right knee protectors). By providing wrap around protection to the joint axis on the lateral sides of the knee, knee protectors within the scope of the invention protect the knee from objects or blows to the side of the knee that may occur while walking.

[0046] FIGS. 8-15 show an improved joint protector design, and in particular, an improved knee protector design. In the examples shown in FIG. 8-15 a hard over-plate preferably formed of TPU, acrylic, polystyrene, carbon fiber or some other rigid plastic material is provided. The over-plate is usable with any of the knee protector embodiments described in FIGS. 1-7 to form an improved knee protector. The over-plate alone is shown in FIGS. 9, 10, 12, and 14-15. The over-plate is arranged on top of the pad assembly described above in reference, for example to FIG. 1. On a bottom side (i.e., a posterior side that will face the wearer's knee and the pads) (visible in FIG. 12), a posterior surface of the plate defines concave depressions 1105. These are shaped and sized to be of a complementary shape to pads (e.g., 115), such that the depressions can receive and have a nesting engagement with the pads (best seen in FIGS. 8 and 13). To this end, the perimeter or outline of the depressions will have the same shape as the underlying pads (e.g., squares, trapezoids, triangles or other polygonal shapes). The depressions are separated by posteriorly projecting ridges 1110 that fit into the channels 122 that separate the foam pads in the knee protector. The height of the ridges 1110 is preferably equal to or less than the depth of the channels 122 (as best seen in the cross section of FIG. 13). This ensures that when pressure is applied to an anterior surface of the over-plate, that pressure is distributed widely to the foam pads by surface contact between the posterior surfaces of the over-plate that are within depressions 1105 and the corresponding anterior surfaces of the pads. The nesting engagement between the over-plate and the underlying pads can be best seen in the cross section of FIG. 13 and in FIGS. 8 and 11. On an anterior facing surface of the over-plate, the structures are the inverse. Thus on this surface the depressions 1105 correspond to projections that accommodate the underlying foam pad, and the separating ridges correspond to channels.

[0047] The over-plate also includes further projections 1115 on the top, forward facing or anterior surface (i.e., the surface facing away from the user's knee). These correspond to depressions from the perspective looking at the posterior surface of the plate. These projections, like depressions / projections 1105, are hollow (i.e., are unsupported). The depressions / projections 1105 are hollow to accommodate the underlying foam pads. The further projections 1115 are hollow to allow them to deform under pressure from, for example, impact with the ground when a user drops to their knee(s). The further projections 1115 may temporarily collapse when loaded from the front. The further projections 1115 preferably have a circular cross section, which prevents snagging on the user's pants, but this is not limiting. The projections 1115 preferably are conical, cylindrical, frustoconical, or partially spherical (e.g., hemispherical).

[0048] An over-plate such as been described assembled to an underlying pad may be seen in FIGS. 8 and 11. Here it can be seen that the foam pads (e.g., 115) nest into the depressions defined by the over-plate, which itself provides further projections outward to absorb force. Preferably, the over-plate is attached to the base layer garment around its perimeter, by sewing, adhesive, ultrasonic welding, etc. This perimeter attachment may be continuous around the entirety of the perimeter or may be discontinuous. The over-plate may be attached directly to the fabric layer of the garment, or may be attached to both the fabric layer of the garment and the perimeter of the pad assembly, e.g., by sewing. Perimeter attachment (i.e., without continuous or discontinuous bonding of the over-plate to the underlying foam pads) ensures an air gap between the over-plate and the underlying foam pads, which may have some advantages. In this arrangement, the over-plate can flex somewhat with respect to the pad assembly, which increases flexibility of the entire assembly. Additionally, this flexing acts as a bellows, which tends to draw air and water vapor out of the foam layer where it can vented through apertures in the plate, as will be discussed relative to FIGS. 14 and 15. At the same time, the nesting arrangement between the foam pads and the depressions or sockets in the over-plate prevents lateral movement between the two parts and prevents misalignment.

[0049] Referring now to FIGS. 14 and 15, venting apertures may be provided in the over-plate between its bottom (anterior) and top (posterior) surfaces. These apertures may be circular, e.g., holes at the anterior ends of the further projections as shown in FIG. 14. They may also be slots in the channels that separate the depressions as shown in FIG. 15. The vents in the over-plate may be aligned over corresponding vends in the underlying foam pad layer, but this is not a requirement. Indeed, by laterally misaligning the vents, airflow is encouraged along the anterior facing surface of the padding layer, which may improve the venting of water vapor.

[0050] The improved embodiment including the over-plate has certain advantages. The over-plate, which preferably has a smooth surface finish (e.g., from the thermoplastic molding process), which reduces snagging or friction with the inside of the user's pants. The over-plate serves to protect the underlying foam layer, which tends to be more delicate and vulnerable to abrasion. The further projections (i.e., the frustoconical projections shown in the figures) serve to absorb and dissipate shock forces that may be created when a user rapidly drops to their knees. This force is absorbed by deformation of the projections (further projections 1115), which are not supported by the underlying foam layer. Additionally, the plate itself, which is rigid plastic, distributes the total absorbed force uniformly over the underlying foam layer. This is ensured by the ridges 1110 in the over-plate being shorter than the corresponding channels that separate the foam pads. This means that when the over-plate presses against the foam pads, engagement occurs all across the posterior facing surfaces of the bottoms of the over-plate depressions as they press against the anterior facing surfaces on the tops of the corresponding pads. These two effects work together to make the user very comfortable when dropping to their knees or otherwise experiencing a sudden force on the anterior side of the protector.

[0051] It should be understood that, unless explicitly stated or otherwise required, the features disclosed in embodiments explicitly described herein and elsewhere in this disclosure may be used in any suitable combinations. Other embodiments and uses of the above inventions will be apparent to those having ordinary skill in the art upon consideration of the specification and practice of the invention disclosed herein. It should be understood that features listed and described in one embodiment may be used in other embodiments unless specifically stated otherwise. The specification and examples given should be considered exemplary only, and it is contemplated that the appended claims will cover any other such embodiments or modifications as fall within the true scope of the invention.

Examples

Embodiment Construction

[0027]The described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.

[0028]Reference throughout this specification to “one embodiment,”“an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrase “in one embodiment,”“in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0029]The example embodiments discussed below relate to a lower body base layer with an integrated and integral knee protecto...

Claims

1. An athletic base layer garment comprising:a garment comprising one or more elastic fabric layers, sized to fit tightly to a portion of the body of a wearer;a padded joint protector integrated into a fabric layer of the garment over a joint of the wearer, wherein the padded joint protector comprises a plurality of individual, conformable pads mutually separated from adjacent pads by open channels;a rigid over-plate arranged over the padded joint protector, the rigid over-plate having a plurality of depressions on a bottom sur face configured to accept conformable pads in a nesting arrangement, wherein the over-plate further comprises a plurality of unsupported projections extending from a top surface, and wherein the over-plate is secured to the garment at its perimeter such that an airspace exists between a top surface of the conformable pads and the bottom surface of the over-plate.

2. The garment of claim 1, wherein the unsupported projections have a circular cross section.

3. The garment of claim 2, wherein the unsupported projections have a conical or frustoconical shape.

4. The garment of claim 1, wherein the over-plate includes vent apertures.

5. The garment of claim 4, wherein the vent apertures are located on a distal end of one or more of the projections.

6. The garment of claim 4, wherein the vent apertures are slots located between one or more of the depressions.

7. The garment of claim 1, wherein at least some of the pads have a polygonal perimeter.

8. The garment of claim 7, wherein at least of the pads have a triangular perimeter.

9. The garment of claim 7, wherein at least some of the pads have a quadrilateral perimeter.

10. The garment of claim 1, wherein the pads are attached to a common, flexible base layer of the joint protector.

11. The garment of claim 1, wherein the joint protector is a knee protector arranged over the knee of a wearer when the garment is worn.

12. The garment of claim 11, wherein the joint protector comprises a center column of pads that cover a vertical centerline of the knee of a wearer, and wherein at least one pad in the center column of pads covers the wearer's kneecap.

13. The garment of claim 12, wherein the joint protector further comprises flanking columns of pads on either side of the center column.

14. The garment of claim 11, wherein the joint protector further comprises medial and lateral columns of pads on either side of the flanking columns.

15. The garment of claim 14, wherein the medial and lateral columns of pads include pads having a triangular perimeter.

16. The garment of claim 15, wherein the pads having a triangular perimeter are arranged with each pad having a vertex that points out in a medial or lateral direction relative to a vertical centerline of the knee protector.

17. The garment of claim 14, wherein the pads in the central column have a first thickness, the pads in the flanking columns have a second thickness, and the pads in the medial and lateral columns have a third thickness, and wherein the first thickness is greater than the second and third thicknesses.

18. The garment of claim 17 wherein the first thickness is greater than the second thickness and the second thickness is greater than the third thickness.

19. The garment of claim 11, wherein the joint protector includes a lateral pad arranged on the lateral side of the knee when the garment is worn.

20. The garment of claim 19, wherein the lateral pad is arranged to be on the wearer's knee's bend axis when the garment is worn.

21. The garment of claim 11, wherein the joint protector is configured to taper in width from an upper side to a downward side.

22. The garment of claim 1, one or more of the elastic fabric layers includes one or more of the following materials: polyester, nylon, elastane, polypropylene, wool or silk.

23. The garment of claim 1, wherein the padded joint protector comprises one or more of the following materials: polyethylene foam, PVC foam, Neoprene, vinyl nitrile foam, silicone foam, polyurethane, open cell rubber, gels and non-Newtonian fluid cells.

24. The garment of claim 1, wherein the over-plate comprises TPU or carbon fiber.

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