Molded Foam-Island Dorsal Padding for Flexible Sports Gloves

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Solution Overview

Problem

Conventional stitched dorsal padding in protective sports gloves compromises flexibility and tactile feel while providing inadequate protection, complicating manufacturing and increasing costs.

Innovation Solution

A unitary dorsal panel with a molded array of discrete foam protective pads separated by minimal interstitial channels, integrated with a scrim material, allowing for increased flexibility and protection without stitching, and facilitating easier manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional stitched dorsal padding is used, then protection is provided, but flexibility and tactile feel are compromised

Engineering Contradiction:

ImproveprotectionVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Multiple foam pads and fabric layers are merged into a single unitary dorsal panel structure. The foam pads are molded directly onto the scrim material, eliminating the need for separate stitching operations. This integration maintains protection while improving flexibility because the entire panel moves as one unit rather than multiple stitched components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical stitching process is replaced with a molding process. Instead of sewing foam pads to fabric layers, the foam is molded directly onto the scrim material in a single forming operation. This substitution eliminates the rigid stitching constraints and allows for greater flexibility and tactile feel while maintaining protective function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If conventional stitched dorsal padding is used, then protection is provided, but tactile feel is compromised

Engineering Contradiction:

ImproveprotectionVSAvoidtactile feel

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The foam pads and scrim material are merged into a single integrated structure where the foam is molded directly onto the scrim. This eliminates the layered stitched construction that creates bulk and reduces tactile sensitivity. The unified structure provides a smoother, more responsive surface that enhances tactile feel while maintaining protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The construction method changes from mechanical stitching to molded integration. This parameter change in the manufacturing process eliminates the rigidity introduced by stitching and creates a more compliant, tactilely responsive surface. The molded structure allows for finer detail and better touch feedback to the wearer.

Inventive Principle:

Principle #35Parameter changes

3Strength

If conventional stitched dorsal padding is used, then protection is provided, but device complexity is increased

Engineering Contradiction:

ImproveprotectionVSAvoidconstruction complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple separate components (foam pads, fabric layers, scrim material) are merged into a single unitary dorsal panel. This consolidation reduces the number of parts and assembly steps while maintaining the protective function. The simplified construction reduces manufacturing complexity and time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The complex mechanical stitching process is replaced with a single molding operation. Instead of sewing multiple layers together, the foam is molded directly onto the scrim material in one step. This substitution dramatically simplifies the manufacturing process and reduces both time and complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If conventional stitched dorsal padding is used, then protection is provided, but manufacturing time is increased

Engineering Contradiction:

ImproveprotectionVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Multiple assembly steps are merged into a single molding operation. The foam pads, scrim material, and any necessary reinforcements are all formed together in one molding cycle, eliminating the time required for separate stitching operations. This significantly reduces manufacturing time while maintaining protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The time-consuming mechanical stitching process is replaced with a faster molded formation process. The foam is molded directly onto the scrim material in a single operation rather than requiring multiple sewing steps. This substitution reduces manufacturing time and increases production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250262511A1Stitchless dorsal padding for protective sports gloves and other protective gear

Publication Date: 2025.08.21 WM T BURNETT IP LLC

AI summary

A protective glove can include a unitary dorsal panel formed from an inner scrim material and a plurality of protective elements molded directly to an exterior surface of the inner scrim. Two or more protective elements can be formed as an array of discrete islands each separated by substantially zero-elevation interstitial spaces. The unitary dorsal panel can be sewn or otherwise attached circumferentially to the palmer sections of the glove. This array of protective elements can provide increased protection to the user's fingers, hands, wrists, and lower forearms while maintaining flexibility and tactile feel on both palmar and dorsal sides of the glove, increasing flexibility where needed without compromising protection.