Improved knee pad

Abstract

A knee pad (1, 10) for protecting a wearer's knee is disclosed. The knee pad (1, 10) is arranged to protect the knee front in use. The knee pad comprises a central cup (E) contoured in complement with the knee, the cup (E) being constructed from a plurality of layers of material. The knee pad (1, 10) further comprises at least one strap (A) arranged to form a loop around a leg of the wearer. The at least one strap has a body substantially constructed from a material integral with an outer layer (E4) of the plurality of layers of material of the cup (E).

Description

[0001] Improved Knee Pad

[0002] Field of the invention

[0003] This invention comprises a knee pad that is capable of providing floor layers and other tradespeople and industry professionals with a durable and washable protective kneecovering whilst working that absorbs impact but does not lose its shape or function with use.

[0004] Background to the invention

[0005] The average floor-layer and tradesperson spends approximately 75% of their working day kneeling on the floor. Spending the majority of their time whilst working kneeling on the floor can have a physical and long-lasting effect on the professional should they not be wearing the necessary protection to prevent constant and intense impact of the floor on the small surface area of the knee, in which the bones and ligaments of the joint take the majority of any impact.

[0006] It is crucial for the longevity of such a tradesperson's career and continued profitability of their work, that such a tradesperson should have a durable and suitably protective kneecovering to decrease the impact of the floor on their knees whilst working.

[0007] The current market facilitates a number of knee pad varieties that attempt to protect the wearer's knees when the wearer is required to perform jobs in which kneeling may be necessary, including but not limited to gardening, carpet installation and tile-laying. The most common current design for knee pads is 'one size fits all' which includes dual nylon straps with adjustable buckles and plastic front faces, allowing the pad to be adjusted to the wearer's knee size. These knee pads tend to be uncomfortable for the user and can pinch their legs behind the knee.

[0008] The common hard-shell plastic pads within the form of the current knee pads that are available, can also scratch more delicate types of floor coverings. Current designs of knee pads that can be used to carry out high impact jobs include a hard-shell pad. But in some cases tradespeople will then need a separate pair of pads for the more delicate flooring, to avoid such flooring being damaged and scratched by the hard pad.

[0009] These current knee pad styles come in a front-adjustable strap design, whereby the user wraps the straps around the front of the knee pad face to meet the user's size requirements. Due to the large variation in the sizes of legs and knees of the potential wearers, these designs do not always fit the wearer tightly and comfortably and can become loose or move around on the wearer's knee. There is also the common issue that the materials can bulge and restrict the movement of the wearer or make the pad uncomfortable. Should the wearer attempt to remove the excess material, there is also the issue that the remaining strap will be likely to fray and any stitching that remains will be prone to coming loose. A user with smaller than average legs would kneel on the weaker and unprotected area of the knee pad. This would significantly reduce the lifespan of the pads.

[0010] The majority of soft-shell knee pads fray really easily on the edges after heavy use.

[0011] Front pad strap designs solve the solution in a 'one size fits all' design but cause alternative issues when in use. These issues include, but are not limited to, the front strap ripping due to the weaker nature of the strap, the strap limits on size adjustments and the straps therefore being too big or small for the wearer and the front strap becoming caught on materials on the floor and pulling the pad off the knee.

[0012] Many of the knee pads currently available have been designed for comfort and therefore lose their durability due to the use of ethylene-vinyl acetate (EVA) foam in their construction, because the EVA foam is too soft for the task which the knee pad is required to perform.

[0013] The majority of knee pads on the market slide off to the side of the knee as the wearer moves around the working space. Over time this will damage the wearer's knee and cause injury to the wearer.

[0014] The current knee pads on the market also use gel inserts that make knee pads unwashable, due to the risk of them bursting and they can also burst during heavy use. Although it is not essential to be able to wash the knee pad, nevertheless being on the floor in a variety of settings and completing manual work that may lead to perspiration, means that it is in the interests of cleanliness for both the tradesperson and the client that the knee pad be kept clean and be durable enough to be regularly cleaned if necessary. Washing the knee pad helps to keep its shape and restrict the stretching of the neoprene.

[0015] The currently available knee pad designs are unable to offer a solution to the known problems in providing a comfortable, safe 'one size fits all' knee pad. Therefore, there is a need for a knee pad that provides comfort and protection, without compromising on durability and adaptability.

[0016] It is against this background that the present invention has been conceived. of the invention

[0017] According to a first aspect of the present invention there is provided a knee pad. The knee pad may be configured for protecting a user's (or wearer's) knee front in use. Preferably, the knee pad comprises a central cup contoured in complement with the knee. The cup is ideally constructed from a plurality of layers of material.

[0018] Preferably, the knee pad comprises at least one strap arranged to form a loop around a leg of the wearer. Preferably, the at least one strap has a body substantially constructed from a material integral with an outer layer of the plurality of layers of material of the cup.

[0019] Preferably, the material of the body of the at least one strap and outer layer of the cup is a resilient and flexible fabric such as neoprene.

[0020] Preferably, an intermediate layer of the plurality of layers comprises a cushioning material that includes at least one of EVA foam, and SBR.

[0021] Preferably, an intermediate layer of the plurality of layers comprises a flexible protective shell. The shell may be constructed of plastic, a composite material, an aramid fibre such as Kevlar® or other suitable protective material. Preferably, the protective shell is substantially impervious to liquid.

[0022] Preferably, an inner layer of the plurality of layers is constructed from a resilient, flexible, breathable fabric such as neoprene.

[0023] Preferably, the at least one strap may be located on at least one of the top and bottom edges of the pad. Preferably, the at least one strap comprises two straps: a top strap and a bottom strap at the pads top and bottom edges respectively.

[0024] Preferably, the at least one strap comprises a set of interconnectable fastening materials. The fastening material may be hook and loop fastening materials. Preferably, the fastening materials are bonded to complementary strap portions of the at least one strap such that when the strap portions of a strap are overlapped, the fastening materials adhere to one another to form a loop around a user's leg for securing the knee pad to the user's leg.

[0025] Preferably, the at least one strap is positioned relative to the cup so that when the at least one strap forms a loop around the leg of the wearer, it does not encompass the region of the wearer's leg behind the knee.

[0026] Preferably, the at least one strap is configured to allow the user to customise its length. Preferably, the fastening materials are bonded to allow customisable shortening of strap portions of the at least one strap, for example via cutting of the distal ends of the strap portion, without losing the integrity of the bond between the fastening material and the strap portion to which it is bonded.

[0027] Preferably, bonding is achieved by stitching, and, for example, users can unpick stitching applied to bond the strap portion and the fastening material.

[0028] Preferably, the knee pad further comprises a locking assembly for forming a reinforcing lockable loop around the at least one strap. Preferably, the locking assembly comprises a buckle assembly having mating buckle clips that are lockable to one another. Preferably, the buckle clips are quick-release buckle clips.

[0029] Preferably, the locking assembly comprises at least one belt portion. Preferably, the at least one belt portion is aligned with the at least one strap.

[0030] Preferably, the knee pad comprises belt loops for maintaining the alignment between the at least one belt portions and the at least one strap.

[0031] Preferably, the knee pad comprises a pair of belt portions each connected at a proximal end to a body of the knee pad at a location either side of the cup.

[0032] Preferably, the knee pad comprises a bridge portion that interconnects between the belt portions, the bridge portion extending across the cup. Preferably, the bridge portion is of a thinner material than the belt portions. Preferably, the bridge portion is between the outer layer and an inner layer of the cup.

[0033] Preferably, the belt portions are constructed from a relatively inelastic material, such as nylon, to maintain cinching tension when locked around the at least one strap. Preferably, the at least one belt portion is connected at a distal end to a respective buckle clip.

[0034] Further aspects, advantages and variants of the invention are now described:

[0035] The knee pad may be designed to be worn over the knee and protect the entire front of the knee. The knee pad may be fastened by at least one strap. The at least one strap may be located on at least one of the top and bottom edges of the pad. Preferably, a bottom strap located at the bottom edge is designed to fasten at or towards the top of the calf of the user of the pad. Preferably, a top strap located at the top edge is designed to fasten at or towards the lower part of the thigh of the user. Advantageously, the straps do not interfere with the crease behind the knee, which would be uncomfortable for the wearer. Additionally, as the straps can be located above and below the knee (respectively), this reduces edge fraying of soft-shell style knee pads. Accordingly, the knee pad can have a much longer lifespan, especially with regard to shell edges of the knee pad.

[0036] The knee pad may be fabricated in a manner which can be adapted to fit any form or structure of knee. One way this is achieved is the at least one strap being configured to allow the user to customise the length of the at least one strap.

[0037] Preferably, both the outer length of each strap and an inner fastening material are capable of adjustment. Therefore, the wearer may adjust the straps to fit them comfortably, without any excess material restricting their movement.

[0038] The top strap of this invention assists in stopping the pad dropping down the leg. The bottom strap helps stop the pad from twisting round the leg.

[0039] Preferably, the at least one strap comprises a set of interconnectable fastening materials, such as hook and loop fastening materials.

[0040] The fastening materials are ideally bonded to complementary strap portions such that when the strap portions are overlapped, the fastening materials adhere to one another to form a loop around a user's leg for securing the knee pad to the user's leg.

[0041] Preferably, the fastening materials are bonded in a manner that allows customisable shortening of the strap portions, for example via cutting of the distal ends of the strap portions, without losing the integrity of the bond between the fastening material and the strap portion to which it is bonded. Bonding may be achieved by stitching and, for example, users can unpick stitching applied to bond the strap portion and the fastening material.

[0042] Preferably, the strap length is user-customisable by facilitating unpicking of stitching used at a working end and outside surface of the strap (i.e. surface furthest from the knee) (and holding in place a strip (Strip A) of fastening material on the working end and inside surface of the strap (i.e. the surface nearest the knee) consisting of a thin plastic sheet covered with a fastening material component, such as tiny loops, and designed to fasten the inside surface of the strap to a strip (Strip B) of fastening material attached to the outward facing surface of the knee pad, for example consisting of a thin plastic sheet covered with tiny flexible hooks, so that Strip A and Strip B adhere when pressed together and can be separated when pulled apart) and so allowing the user to trim the straps to their chosen length and shape to enable the pad to fit the user's knee without the straps fraying or losing the strong bind between the straps and the Strip A's in order to provide optimal protection and comfort for the user when wearing the pad.

[0043] Preferably, the stitching made through the pad from the inside surface of the strap to affix the fastening material on the working end and outside surface of the strap is covered on the outside surface by a protective layer of material to reduce the effect of friction causing such stitching to become damaged and / or suffer wear.

[0044] Preferably, the straps can be adjusted by means of a fastening mechanism in which each strap is looped around the knee, fastened by means of Strip A and Strip B adhering when pressed together with the preference of the user as to the degree of tightness and comfort required by them when wearing the protective pad.

[0045] Preferably, by such means, the knee pad removes or avoids any bulge of material caused by unwanted excess material of the straps protruding across the front of the knee when so adapted and / or adjusted.

[0046] Preferably, the body of the pad comprises a number of layers of material of which the outer layer consists of material that is thicker and harder than the inner layer or layers (comprising neoprene or other form of flexible material) and so protects the front part of the knee from potential impact and the inner layer or layers consist of thinner and softer material than the outer layer enabling the pad to mould to the form or structure of the knee.

[0047] Preferably, the outer layer is covered by a protective coating to extend the durability of the pad and is supported by a plastic shell located underneath the top layer of the pad that enables the knee pad to cushion the knee whilst moulding to its form or structure.

[0048] Advantageously, the materials and layering of those materials allows the knee pad to be shaped to each individual user's knee for the most effective comfort while working.

[0049] Preferably, the knee pad comprises an inner plastic shell for safety and a protective coated softer outer face, to allow the knee pad to be used in carrying out a very wide range of jobs. Preferably, the knee pad does not include gel inserts, meaning the invention is machine-washable and will withstand the harsher impact that may be required of it within the industry of floor-laying when worn by tradespeople.

[0050] Aspects of the invention can be applicable to a wide range of different situations and conditions of use. Preferably, the knee pad is configured to allow the user to unpick the stitching used on the working end and outside surface of the strap (and holding in place a strip (Strip A) of fastening material on the working end and inside surface of the strap consisting of a thin plastic sheet covered with tiny loops and designed to fasten the inside surface of the strap to a strip (Strip B) of fastening material consisting of a thin plastic sheet covered with tiny flexible hooks attached to the outward facing surface of the knee pad (with the Strip B attached to the bottom of the knee pad being attached to the side to avoid the fastened material causing discomfort to the user and getting caught or damaged whilst the pad is in use) and so that Strip A and Strip B adhere when pressed together and can be separated when pulled apart) and so allowing the user to trim the straps to their chosen length and shape to enable the pad to fit the user's knee in order to provide optimal protection and comfort for the user when wearing the pad.

[0051] Preferably, the straps can be adjusted by means of a fastening mechanism in which each strap is fastened by means of a strip (e.g. strip A) of fastening material on the working end and inside surface of the strap.

[0052] Preferably, the knee pad can be adjusted or adapted to remove or avoid any bulge of material caused by unnecessary excess material of such strap protruding across the front of the knee.

[0053] Preferably, stitching made through the pad to affix the fastening material on the working end is covered on the outside surface by means of a protective layer of material to reduce the effect of friction causing such stitching to become damaged and / or suffer wear.

[0054] Preferably, the body of the pad comprises a number of layers of material of which the outer layer consists of thicker and harder material than the inner layer or layers and so protects the front part of the knee from potential impact and the inner layer or layers consist of thinner and softer material than the outer layer enabling the pad to mould to the form or structure of the knee; and the outer layer is covered by a protective coating to extend the durability of the pad and is supported by a plastic shell located underneath the top layer of the pad that enables the knee pad to cushion the knee whilst moulding to its form or structure.

[0055] Preferably, the combination of materials used in formulating the knee pad allows the knee pad to be washable by way of a washing machine or otherwise.

[0056] Preferably, the knee pad is a soft-shell knee pad with an inner hard shell for safety and the outer layer comprises a clear face and fully protective coating, that covers the whole pad face. The knee pad ideally comprises user adjustable straps located respectively above and below the knee whereby the wearer can completely adjust both the length of each strap and the inner loop fastening material of each strap. The knee pad is designed with an enlarged knee-protecting area, made from multiple layers of materials, to create a safe and comfortable kneeling platform.

[0057] Advantageously, the knee pad redevelops the structure of the common EVA pad by layering the materials to provide the softest feel on the knee, while maintaining the durability of the pad thickness. This therefore also allows the pad to disperse the weight of the user through the pad during a working day, thereby reducing knee injury.

[0058] Preferably, the layer of material closest to the knee is between 4.5mm and 6-millimetre neoprene. This layer can provide a gel-like comfort feel to the wearer, without using gel. This layer, used instead of any gel inserts, makes the knee pad machine-washable and less at risk of damage when required for high impact tasks.

[0059] Preferably, the second layer, moving away from the knee, is an EVA pad which has been designed specifically to curve with the curve of the knee of the wearer. The curve of the knee pad using the EVA allows the knee pad to fit any knee size and shape without the wearer feeling uncomfortable. This layer can also prevent the knee pad from sliding or moving when on the knee.

[0060] Preferably, the third layer is a plastic safety shell mould included to ensure the EVA holds its shape for longer and provides greater protection for the knee in rough, sharp terrain. This layer can minimise penetration and in turn restricts the impact on the knee. This layer can also prevent water from soaking through to the EVA pad and further to the knee when the wearer is required to work in such conditions. This layer can also add extra protection when the wearer is working with potentially dangerous material.

[0061] Preferably, a final outer layer is an additional layer of neoprene which allows for the hard shell layer to be contained and ensure that the surfaces on which the wearer is kneeling are protected from scratching and spoiling.

[0062] The knee pad is arranged with the curve of the cup of the knee pad to fit the knee cap as effectively as possible. The knee pad ideally includes extra-wide straps (e.g. greater than 2.5cm, more preferably greater than 5cm), located respectively above and below the knee. These have the combined effect of hugging the knee, so stopping any movement of the pad around the knee. Most soft-shell knee pads have a front strap that fastens across the face of the knee pad.

[0063] These front straps on knee pads get in the way or become caught on sharp or other objects on the floor, which has the effect of either ripping the strap or pulling the pad off.

[0064] Advantageously, the knee pad can be configured so the bottom strap is located completely on the side of the knee, removing any bulging of material and any chances of ripping, or causing other damage to the strap. The top strap can be configured to fasten at the middle of the thigh just above the knee, allowing it to adjust to any shape or size of leg. The strap can be designed to be minimalistic, so it doesn't get in the way while working, or get caught on clothing constantly when going from kneeling to standing, as do many knee pads on the market.

[0065] The fastening material on the straps ideally include a large amount of tiny hooks, that link to similar fastening material on the body of the knee pad. This material can ensure that the straps fasten securely to ensure the pad is firmly in place for high impact tasks, as well as being durable material that can withstand great manipulation, so as to ensure the pad is durable and does not require replacement with frequent use.

[0066] Preferably, the straps are adjustable, to avoid the bunching of excess material when the straps are required to be tightened for maximum comfort. Ideally, both straps, that include one strip of the fastening material, are made from neoprene, meaning that when the material is cut to size, it will not fray or become weak.

[0067] On the external side of the strap, facing away from the knee, the strap may be covered with a protective material to provide further support to the strap in ensuring it is not easily damaged by the impact that is required through use in the industrial requirements of tradespeople.

[0068] The fastening strips on the inside facing the knee and protective sheet of material on the outer layer of the knee straps may be attached to the straps using a specific stitch which includes a number of square shaped areas being sown into the strap. Preferably, these stitches are in place so that when the strap is cut to size the stitching remains intact on the remaining strap and does not fray or come un-done, meaning that the bond between the fastener and strap remains strong.

[0069] According to a second aspect of the present invention there is provided a method of manufacturing a knee pad. Preferably, the method is for manufacturing a knee pad according to a first aspect of the present invention. The method may generally comprise at least one of the following steps: cutting an outer layer of resilient fabric, such as neoprene; printing marking, such as logos; applying reinforcing material, such as PVC leather, fastening layers (e.g. hook- and-loop) and sewing to the outer layer; applying a bridge portion, such as Oxford fabric, and sewing; coating the outer layer with a protective coating, such as TPU; applying a buckle and belt webbing; sewing belt webbing; applying an inner layer of resilient breathable fabric, such as neoprene; sewing the inner layer to the outer layer to form a pocket; forming a cushioning layer, such as by glueing an EVA and SBR layer together; inserting the cushioning layer into the pocket; inserting a protective shell into the pocket; sewing at least one of the cushioning layer and the protective shell between the inner and outer layers; and sewing a woven label.

[0070] More specifically, the method may comprise at least one of the following steps: cutting an outer neoprene layer; printing marking, such as logos; applying PVC leather, fastening layers (e.g. hook-and-loop) and sewing; applying Oxford fabric (20) and sewing; coating the outside with TPU which adds protection for the stitching; applying the buckle and belt webbing; sewing belt webbing; applying the inner neoprene layer; sewing the inner neoprene to the outer layer to form a pocket glueing the EVA and SBR layers together; inserting into the pocket, and sewing the EVA, SBR and plastic shell between the inner and outer neoprene layers; and sewing a woven label.

[0071] It will be understood that features and advantages of different aspects of the present invention may be combined or substituted with one another where context allows.

[0072] For example, the features of the device described in relation to the first aspects of the present invention may be provided as part of a method of manufacturing of the second aspect. Furthermore, such features may themselves constitute further aspects of the present invention. For example, the features of the cup and layers of material may themselves constitute further aspects of the present invention.

[0073] Brief description of the drawings

[0074] In order for the invention to be more readily understood, embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0075] Figure 1 is a front view of a knee pad according to a first embodiment of the invention. The knee pad is shown splayed out and in isolation;

[0076] Figure 2 is a front view of the knee pad of Figure 1 shown attached to a wearer's leg;

[0077] Figure 3 is a side view of the knee pad of Figure 2 in place around a wearer's leg;

[0078] Figure 4 is a partial view of the knee pad of Figure 1 ;

[0079] Figure 5 is an enlarged partial view of Figure 4;

[0080] Figure 6 is a schematic sectional view of the knee pad of Figure 1 ;

[0081] Figure 7 is a front view of a knee pad according to a second embodiment of the invention. The knee pad is shown in isolation;

[0082] Figure 8 is a schematic sectional view of the knee pad of Figure 7 according to the second embodiment; and

[0083] Figure 9 is a side view of the knee pad of Figure 7 in place around a wearer's leg.

[0084] Specific description of the preferred embodiments

[0085] Figure 1 is a front view of a knee pad 1 according to a first embodiment of the invention. The knee pad 1 is shown splayed out and in isolation. The pad 1 generally comprises straps (A) including a top strap (A1) and a bottom strap (A2), fastening material (B), protective layering (C), stitching (D), and a cup (E).

[0086] The cup (E) acts as a support that covers the knee when worn. The fastening materials (B) on the straps (A) are located on the reverse face of the straps (A). They are complementary with, and are detachably engageable with the fastening materials (B) on the front face of the pad (1). The fastening materials in this first embodiment are in the form of hook-and-loop fasteners, but in alternative embodiments may be of a different fastening material. Specifically, a hook component of the fastening materials are located on the front surface, and a loop component of the fastening materials are located on the reverse surface. This aids in the comfort of the wearer as the hook component is of texture that more readily scratches the skin, and so by positioning it on the front face, it is directed away from the skin.

[0087] Figure 2 is a front view of the knee pad of Figure 1 shown attached to a wearer's leg 2. The strap at a top edge of the pad (A1) fastens towards the bottom part of the thigh of the wearer / user with the fastening material (B1) on the reverse surface of the top strap (A1) engaging with the fastening material adjoined to the top of the knee pad (B2).

[0088] Figure 3 is a side view of the knee pad of Figure 2 in place around a wearer's leg. The strap at a bottom edge of the pad (A2) fastens towards the top of the calf of the user with the fastening material (B3) on the reverse surface of the strap (A2) engaging with the fastening material adjoined to the bottom side of the knee pad (B4).

[0089] Figures 4 and 5 are partial front views of the knee pad of Figure 1. Protective layering (C1 and C2) is provided on the outside edge of the straps (A1 and A2). Stitching (D1) and (D2) affixes the fastening material (B1-4) and the protective layer (C1 and C2) to both straps (A1 and A2).

[0090] Figure 6 is a schematic sectional view of the knee pad of Figure 1. The cup (E) of the knee pad is made up of four different layers including: an inner layer of 6-millimetre neoprene (E1), an EVA pad (E2), a plastic safety shell mould (E3) and an outer layer of neoprene (E4).

[0091] With continued reference to Figures 1 to 6, the knee pad 1 is a soft-shell knee pad with an inner hard shell (E3) for safety. The outer layer (E4) comprises a clear face and fully protective coating that covers the whole pad face. In particular, in certain embodiments, the outer layer (E4) may be coated with TPU (thermoplastic polyurethane) which protects the underlying neoprene and presents a durable but soft surface. This can be advantageous for delicate work where, for example, a worker wearing the knee pads desires to avoid scratching or otherwise damaging a floor surface being laid.

[0092] In alternatives, a different coating or additional layer may be used, such as leather or Hypalon. Preferably, the coating or layer should be machine washable without losing its integrity - the same as the rest of the knee pad. The knee pad 1 of the first embodiment has adjustable straps located respectively above and below the knee whereby the wearer can completely adjust both the length of each strap and the inwardly-facing loop fastening material of each strap.

[0093] The knee pad is designed with an enlarged knee-protecting area, made from multiple layers of materials, to create a safe and comfortable kneeling platform.

[0094] This is a redevelopment of the structure of a common EVA pad as the materials are layered to provide the softest feel on the knee of the user, while maintaining the durability of the pad thickness. This therefore also allows the pad to disperse the weight of the user through the pad during a working day, thereby reducing knee injury.

[0095] In the region of the cup (E) the layer of material closest to the knee when worn is 6- millimetre neoprene (E1). This layer provides a gel-like comfort feel to the wearer, without using gel. This layer, used instead of any gel inserts, makes the knee pad 1 machine- washable and less at risk of damage when required for high impact tasks.

[0096] The second layer, moving away from the knee, is then the EVA pad (E2) which has been ergonomically designed specifically to curve with the curve of the knee of most wearers. The curve of the knee pad using the EVA allows the knee pad to fit any knee size and shape without the wearer feeling uncomfortable. This layer also prevents the invention from sliding or moving when on the knee. In alternatives, the EVA may be substituted with a similar cushioning material such as polyurethane, although EVA is preferred.

[0097] The third layer is a plastic safety shell mould (E3) included to ensure the EVA holds its shape for longer and provides greater protection for the knee in rough, sharp terrain. This layer minimises penetration and in turn restricts the impact on the knee. This layer is substantially waterproof, and so prevents water from soaking through to the EVA pad and further to the knee when the wearer is required to work in such conditions. This layer also adds extra protection when the wearer is working with potentially dangerous material.

[0098] In variants, the plastic safety shell may be constructed from another hard protective material, such as Kevlar® and the like.

[0099] The final outer layer (E4) is an additional layer of neoprene which allows for the hard (third) layer (E3) to be contained and ensure that the surfaces on which the wearer is kneeling are protected from scratching and spoiling, especially when coated with a protective coating such as TPU. A main body of the knee pad 1 is formed from this outermost neoprene layer, in that the straps and the outermost layer of the cup (E) is constructed from an integral layer of neoprene.

[0100] The curve of the knee pad is designed to fit the knee cap as effectively as possible. The straps are wider than normal, located respectively above and below the knee. These have the combined effect of hugging the knee, so stopping any movement of the pad around the knee, but do so in a manner that is comfortable for the user. Furthermore, as the underlying body of material that forms the straps is neoprene - which is integral with the outer layer (E4) - the strap material is resilient, and so can stretch slightly to conform with the leg of the wearer. At the same time, this maintains evenly-distributed tension around the leg adding to comfort and also the security of the fit.

[0101] Front straps that fasten across the face of the knee pad can get in the way or become caught on sharp objects on the floor, which has the effect of either ripping the strap or pulling the pad off. Accordingly, the bottom strap (A2) is located on the side of the knee, removing any bulging of material and any chances of ripping, or causing other damage to the strap.

[0102] The top strap (A1) fastens at the middle of the thigh just above the knee, allowing it to adjust to any shape or size of leg. The strap has been designed to be minimalistic, so it doesn't get in the way while working, or get caught on clothing constantly when going from kneeling to standing, as do many knee pads on the market.

[0103] As described above, the fastening material on the straps of this embodiment include hook- and-loop fasteners. This material ensures that the straps fasten securely to ensure the pad is firmly in place for high impact tasks, as well as being durable material that can withstand great manipulation, so as to ensure the pad is durable and does not require replacement with frequent use. This material can also be washed without deterioration.

[0104] The straps are adjustable to avoid the bunching of excess material when the straps are required to be tightened for maximum comfort. Both straps, that include one strip of the fastening material, are made from neoprene, meaning that when the material is cut to size, it will not fray or become weak. On the external side of the strap, facing away from the knee, the strap is covered with a protective material to provide further support to the strap in ensuring it is not easily damaged by the impact that is required through use in the industrial requirements of tradespeople.

[0105] The fastening strips on the inside, facing the knee, and protective sheet of material on the outer layer of the knee straps are attached to the straps using a specific stitch pattern which includes a number of square-shaped areas being sown into the strap. These stitches are in place so that when the strap is cut to size the stitching remains intact on the remaining strap, meaning that the bond between the fastener and strap remains strong.

[0106] For other embodiments, a different stitching pattern may be used. In general, it is preferred that the stitching pattern defines a group of cells that are self-supporting such that when the strap is cut to size the stitching remains intact on the remaining strap and does not fray or come undone.

[0107] In use of the knee pad according to the first embodiment, a wearer stretches the straps around their leg as shown in Figures 2 and 3 to generate compressive tension that holds the knee pad in place.

[0108] However, over time and in use, especially when the wearer's knee is bent when kneeling, the fabric of the straps, and the top strap in particular, becomes overstretched. This can lead to a loss of elasticity and a reduction in the compressive force that is needed to hold the knee pad in place. A wearer of the knee pad may need to undo and redo the strap to retighten it several times throughout the course of a work day.

[0109] An additional challenge arises in situations where knee pads are used in wet trades where products such as adhesive and grout are used. Such products can become lodged within the hook and loop structures of the fastening material reducing their efficacy.

[0110] A knee pad 10 according to a second embodiment of the present invention seeks to address these inconveniences via the addition of a locking assembly in combination with the bottom strap. This combination improves the reliability of the bottom strap without sacrificing comfort.

[0111] It will be understood that the knee pad 10 of the second embodiment contains the same features and advantages of the first embodiment, apart from the differences described as follows and with reference to Figures 7 to 9.

[0112] The locking assembly comprises a male buckle clip 12 connected to a first belt portion 14 which extends along the length of the bottom strap A2, and a female buckle clip 22 connected to a second belt portion 24.

[0113] The first belt portion 14 is looped through the male buckle clip 12 such that the effective length of the first belt portion 14 can be customised by the user by feeding the first belt portion 14 through the buckle clip 12. A proximal end of the first belt portion 14 is sewn to one side of the cup E. A proximal end of the second belt portion 24 is sewn to the other side of the cup E. A distal end of the second belt portion 24 is looped into the female buckle clip 22 and sewn, and so is not adjustable in length.

[0114] The belt portions 14, 24 are constructed from nylon which is a relatively inelastic material compared to the underlying neoprene body of the knee pad 10. In alternatives, a different suitable material may be used for the belt webbing, such as polyester or polypropylene. The relative inelasticity of the belt webbing ensures that a secure cinching force can be applied to keep the knee pad in place around the wearer's leg. This increases the reliability of the knee pad 10 when used for wet trades, as the buckle clips are significantly less likely than hook and loop fasteners to be adversely affected by the presence of products such as grout. Furthermore, overstretching of the neoprene bottom strap A2 is prevented.

[0115] The first belt portion 14 is threaded through a series of belt loops 16 sewn to the lower strap A2 that restrains the movement of the first belt portion 14 relative to the lower strap A2, keeping them aligned. Moreover, the first belt portion can slide through the loops during tightening or adjustment, but the belt loops 16 prevent misalignment and twisting of the belt portion 14.

[0116] Advantageously, when secured, the first belt portion 14 compresses the material of the lower strap A2 into the leg of the wearer, leading to both greater comfort and security of fit than can be achieved with either the belt alone or the strap alone.

[0117] To this end, in alternative embodiments, the top strap A1 may be omitted entirely as the security of the fit provided by the combination of the bottom strap A2 and the locking assembly is sufficient to keep the knee pad in place.

[0118] A user of the knee pad 10 according to the second embodiment can adjust the length of the lower strap A2 by cutting it as in the first embodiment, and also can adjust the length of the locking assembly via the adjustment of the first belt portion 14.

[0119] With reference to Figure 8, the layers of material in the cup part of the knee pad 10 are slightly different from the first embodiment. The layers, from the outer layer (i.e. furthest from the knee when in use) inwards are:

[0120] A TPU coating (E6)

[0121] An outer neoprene layer (E4) A hard protective shell (E3) EVA foam (E2) Styrene-Butadiene Rubber - SBR (E5)

[0122] An inner neoprene layer (E1)

[0123] The outer neoprene is of a thickness of approximately 4mm, the plastic shell is of a thickness of approximately 3mm, the EVA layer has a thickness of approximately 22mm, the SBR layer has a thickness of approximately 10mm and the inner neoprene has a thickness of approximately 4.5mm. At least the neoprene layers are constructed from a sheet material, reducing the cost and complexity of manufacturing.

[0124] In alternatives, the thickness of each of the layers may vary plus or minus 50%, more preferably 25%. In general, the overall thickness of the cup of the knee pad is approximately 44mm. In variants to the present embodiment, this thickness may vary between a range of 25mm and 75mm, more preferably 35mm to 55mm. If layers such as the shell (E3) are omitted, then the overall thickness is reduced by a corresponding amount.

[0125] One key difference from the first embodiment is the addition of the SBR layer. This further increases the comfort and durability of the knee pads 10. It has been determined during testing that knee pads, such as that of the first embodiment, that contains only EVA or Pll foam as the primary cushioning material start off soft, but over time with continuous heavy use can flatten and become a lot denser and harder. This adds a gel-like feel to the knee pad 10 but, unlike gel, allows the pad 10 to be washable without deterioration of the pad. Additionally, gel layers can burst, and so the SBR does not have this drawback. The SBR layer reforms back to its original shape after use, and particularly after washing.

[0126] The SBR and EVA layers are cut or formed individually and glued together prior to fitting within the neoprene layers. The SBR and EVA layers predominantly set the contour of the cup E of the knee pad 10.

[0127] As with the first embodiment, a main body of the knee pad 10 is formed from the outermost neoprene layer, with the straps A1 , A2 and the outermost neoprene layer of the cup E being constructed from an integral piece of neoprene material.

[0128] This enhances the performance of the knee pads of both the first and second embodiments relative to alternatives that have straps stitched to a central cup. The knee pads can have a higher strength to weight ratio, and a failure point in the form of the interface between the straps and the cup is eliminated. Furthermore, use of neoprene straps that are integral with a layer of the cup promotes evenness of the cinching force when the straps are looped around the leg of a wearer. The sandwiching of the hard protective shell (E3) ensures that whilst the knee pad 10 protects against sharp objects, and presents a liquid barrier between a floor and the wearer's knee, the hard shell (E3) does not present an exterior surface that may scratch or damage delicate flooring. Whilst being hard enough to be resistant to puncturing, the shell is nonetheless able to flex with the other layers during tightening of the lower strap A2 and locking assembly so that the cup E of the knee pad 10 can curve into the shape of the knee.

[0129] The innermost layer (E1) of neoprene is thicker than the outermost neoprene layer (E4). In alternatives, other fabrics may be used, but neoprene is preferred due to its cushioning effect, good breathability and sweat wicking, while maintaining comfort on the skin.

[0130] The knee pad 10 also includes a support patch 26 in the form of a sheet of PVC leather that is situated between the second belt portion 24 and the underlying neoprene body of the knee pad 10. The fastening material B4 and the second belt portion 24 are sewn into the body via the support patch, which provides a strengthening interface and distributes cinching forces more evenly that can be achieved via stitching into the neoprene alone.

[0131] The knee pad 10 also comprises a bridge portion 20, in the form of a strip of Oxford cloth. The bridge portion is provided beneath the outer neoprene layer and bridges between the first belt portion 14 and the second belt portion 24. The two belt portions 14, 24 are sewn to the outer layer either side of the cup E with the stitching extending into the bridge portion 20. This gives the belt portions 14, 24 a better fixing and increases the durability of the knee pad 10.

[0132] Moreover, the use of the bridge portion 20 ensures that as tension is applied along the belt portions during tightening of the belt and in use (e.g. when kneeling), the tension does not cause deterioration or delamination of the layers of material. The bridge portion is constructed from a material that is thinner than the belt portions (i.e. under 1mm), and so is more comfortable across the front face of the knee in use than, for example, if the belt portion extended all the way between the male and female buckle clips 12, 22. Also, as the bridge portion 20 is underneath the outer layer E4 and protective coating E6, delicate flooring on which a tradesperson is working is not liable to scratching or other damage. The TPU coating E6 also coats the stitching applied around the cup E. This further improves the reliability of the stitching, preventing slippage.

[0133] Manufacturing of the knee pad 10 comprises the following steps: cutting an outer neoprene layer; printing marking, such as logos; applying PVC leather, fastening layers (e.g. hook-and-loop) and sewing; applying Oxford fabric (20) and sewing; coating the outside with TPU which adds protection for the stitching; applying the buckle and belt webbing; sewing belt webbing; applying the inner neoprene layer; sewing the inner neoprene to the outer layer to form a pocket glueing the EVA and SBR layers together; inserting into the pocket, and sewing the EVA, SBR and plastic shell between the inner and outer neoprene layers; and sewing a woven label.

[0134] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art.

[0135] Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the scope of the appended claims.

Claims

CLAIMS1. A knee pad for protecting a wearers knee front in use, the knee pad comprising: a central cup contoured in complement with the knee, the cup being constructed from a plurality of layers of material; and at least one strap arranged to form a loop around a leg of the wearer; wherein the at least one strap has a body substantially constructed from a material integral with an outer layer of the plurality of layers of material of the cup.

2. The knee pad of claim 1 , wherein the material of the body of the at least one strap and outer layer of the cup is a resilient and flexible fabric such as neoprene.

3. The knee pad of claim 1 or 2, wherein an intermediate layer of the plurality of layers comprises a cushioning material that includes at least one of EVA foam, and SBR.

4. The knee pad of any preceding claim, wherein an intermediate layer of the plurality of layers comprises a flexible protective shell.

5. The knee pad of claim 4, wherein the protective shell is substantially impervious to liquid.

6. The knee pad of any preceding claim, wherein an inner layer of the plurality of layers is constructed from a resilient, flexible, breathable fabric such as neoprene.

7. The knee pad of any preceding claim, wherein the at least one strap may be located on at least one of the top and bottom edges of the pad.

8. The knee pad of any preceding claim, wherein the at least one strap comprises a top strap and a bottom strap at the pads top and bottom edges respectively.

9. The knee pad of any preceding claim, wherein the at least one strap comprises a set of interconnectable fastening materials, such as hook and loop fastening materials, the fastening materials being bonded to complementary strap portions of the at least one strap such that when the strap portions are overlapped, the fastening materials adhere to one another to form a loop around a user's leg for securing the knee pad to the user's leg.

10. The knee pad of any preceding claim, wherein the at least one strap is positioned relative to the cup so that when the at least one strap forms a loop around the leg of the wearer, it does not encompass the region of the wearer's leg behind the knee.

11. The knee pad of any preceding claim, wherein the at least one strap is configured to allow the user to customise its length.

12. The knee pad of any preceding claim, wherein the fastening materials are bonded to allow customisable shortening of strap portions of the at least one strap, for example via cutting of the distal ends of the strap portion, without losing the integrity of the bond between the fastening material and the strap portion to which it is bonded.

13. The knee pad of claim 12, wherein bonding is achieved by stitching, and, for example, users can unpick stitching applied to bond the strap portion and the fastening material.

14. The knee pad of any preceding claim, the knee pad further comprises a locking assembly for forming a reinforcing lockable loop around the at least one strap.

15. The knee pad of claim 14, wherein the locking assembly comprises a buckle assembly having mating buckle clips that are lockable to one another.

16. The knee pad of claim 15, wherein the buckle clips are quick-release buckle clips.

17. The knee pad of any one of claims 14 to 16, wherein the locking assembly comprises at least one belt portion that is aligned with the at least one strap.

18. The knee pad of claim 17, wherein the locking assembly comprises belt loops for maintaining the alignment between the at least one belt portions and the at least one strap.

19. The knee pad of claim 17 or 18, comprising a pair of belt portions each connected at a proximal end to a body of the knee pad at a location either side of the cup.

20. The knee pad of claim 19, further comprising a bridge portion that interconnects between the belt portions, the bridge portion extending across the cup and being of a thinner material than the belt portions.

21. The knee pad of claim 20, wherein the bridge portion is between the outer layer and an inner layer of the cup.

22. The knee pad of any one of claims 17 to 21, wherein the belt portions are constructed from a relatively inelastic material, such as nylon, to maintain cinching tension when locked around the at least one strap.

23. The knee pad of any one of claims 17 to 22, wherein the at least one belt portion is connected at a distal end to a respective buckle clip.

24. A method of manufacturing a knee pad according to any preceding claim, comprising at least one of the steps of: cutting an outer layer of resilient fabric, such as neoprene; printing marking, such as logos; applying reinforcing material, such as PVC leather, fastening layers (e.g. hook- and-loop) and sewing to the outer layer; applying a bridge portion, such as Oxford fabric, and sewing; coating the outer layer with a protective coating, such as TPU; applying a buckle and belt webbing; sewing belt webbing; applying an inner layer of resilient breathable fabric, such as neoprene; sewing the inner layer to the outer layer to form a pocket; forming a cushioning layer, such as by glueing an EVA and SBR layer together; inserting the cushioning layer into the pocket; inserting a protective shell into the pocket; sewing at least one of the cushioning layer and the protective shell between the inner and outer layers; and sewing a woven label.

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