Apparel – Guard or protector – Leg
Reexamination Certificate
2000-06-07
2001-08-07
Calvert, John J. (Department: 3765)
Apparel
Guard or protector
Leg
C602S006000, C602S008000
Reexamination Certificate
active
06269485
ABSTRACT:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a custom-fitted batter's lower leg protector, and is specifically intended to protect a baseball or softball batter's leg, including the ankle bones, against being directly struck by a pitched or foul-tipped ball. This type of impact has a high probability of causing severe bruising, broken or chipped bones of the lower leg, ankle or foot. A variation of the invention therefore includes a detachable foot protector, and a pair of optionally-detachable ankle flap protectors which are hinged to the bottom of the lower leg protector. The foot protector and one or both of the ankle flap protectors may be detached from the lower leg protector at the option of the batter.
The lower leg protector according to the invention takes advantage of polymer chemistry to permit quick and easy molding of the protector to the ankle. Shock attenuation is increased since the custom fit spreads contact between the protector and the lower leg over a wider surface area. Similarly, the close, custom fit achieved when the protector is properly applied to the lower leg is in distinct contrast to so-called “one size fits all” protectors now commonly used by baseball and softball players and umpires.
The protector is particularly useful with young players, whose relatively low skill level makes wild pitches more frequent and more difficult to avoid.
Prior art leg protectors include numerous types of devices which typically include a soft component to place near the skin and a hard, shell-like performed outer cover having a shape approximating the shape of the lower leg. The soft component, for example, fiber padding or foam, is intended not only to provide a cushion, but also to accommodate itself to the varying configurations of differing sized and shaped body lower legs. For this reason, the cushioned part is substantially greater in thickness than required merely to provide the required amount of shock attenuation and protection from the rigid substrate.
Other prior art batter's leg protectors include products which are constructed of thermosetting materials which are heated and then formed to the lower leg while heated. These products require a source of heat, and are susceptible to either over-or-underheating. In addition, body heat itself can soften or increase the flexibility of the protector, thereby decreasing the effectiveness of the protection offered by the protector.
The present invention permits quick and easy application of a protector to the lower leg in such a way as to achieve a true custom fit. The moisture curable resin system used results in a very rigid protector which holds the shape of the leg to which it was molded permanently and to a very high degree. No heat is required, and a source of water is the only additional material necessary to achieve a cure. Atmospheric moisture alone will cure the protector into its hardened position in a relatively short period of time, but in practice the resin in or on the protector will typically be activated by dipping in water and then removing the excess by rolling the protector in a towel immediately before application. This can be easily done by an equipment manager or trainer as an integral part of properly equipping a player. The custom-molded protector becomes part of the equipment, together with gloves and batting hats which protect the batter against injury.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a custom-moldable batter's lower leg protector.
It is another object of the invention to provide a protector which can be molded to the lower leg of a batter for protecting the batter's lower leg while permitting inversion, eversion, dorsiflexion and planoflexion necessary during batting and running the bases.
It is another object of the invention to provide a lower leg protector which can be custom-fitted to a particular player.
It is another object of the invention to provide a lower leg protector which hardens in the presence of moisture to form a very rigid but very lightweight protector.
It is another object of the invention to provide a lower leg protector in combination with a removable foot protector for protecting the top of the foot against pitched and foul-tipped baseballs and softballs.
It is another object of the invention to provide a lower leg protector in combination with a foot protector which is releasably and adjustably hinged to the leg protector.
It is another object of the invention to provide a lower leg protector which includes a leg portion in combination with optionally-detachable ankle flap portions integrally formed with a bottom edge of the leg portion and shaped to provide protection to the lateral and medial ankle bones.
These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a batter's lower leg protector product, including a lower leg protector for being custom-formed to the shape of a batter's lower leg while flexible and upon hardening providing a rigid, supporting custom fit. The lower leg protector product comprises an outer container formed of moisture-impervious material. A flexible lower leg protector is positioned in the container in substantially moisture-free conditions and sealed therein against entry of moisture until use. The lower leg protector includes a leg portion shaped to provide, when in place on a batter's leg, protection to the front, lateral and medial aspects of the leg above the ankle and optionally-detachable ankle flap portions integrally formed with a bottom edge of the leg portion shaped to provide protection to the lateral and medial ankle bones. The lower leg protector comprises a substrate and a reactive system impregnated into or coated onto the substrate, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to moisture to form a rigid, self supporting structure. A flexible protective pad is positioned on one side of the substrate to provide cushioning between the substrate and the batter when the lower leg protector is being worn. An outer cover covers the substrate on the side opposite the protective pad. The substrate, protective pad and outer cover are connected together into a unitary structure for being molded while flexible to the lower leg and ankle of the batter. Complementary fasteners are attached to opposing side edges of the lower leg protector for retaining the lower leg protector in place on the batter's leg while being worn.
Preferably, the complementary fasteners comprise patches of hook-and-loop material.
According to one preferred embodiment of the invention, the container is fabricated of an aluminum foil laminate having an outer tear resistant layer, a central aluminum foil layer and an inner heat sealable plastic layer.
According to another preferred embodiment of the invention, the substrate comprises a plurality of knitted or woven fabric layers and the protective pad comprises a foam material.
According to another preferred embodiment of the invention, the foam material is chosen from the group consisting of open or closed cell EVA or polyurethane.
According to yet another preferred embodiment of the invention, the outer cover is formed of a synthetic, hydrophobic fabric.
According to yet another preferred embodiment of the invention, the reactive system comprises a blended polyisocyanate, polyol, catalyst and stabilizer.
According to yet another preferred embodiment of the invention, the protective padding, substrate and outer cover are sandwiched together in overlying layers and joined together around their respective peripheral edges by sewing stitches to form a unitary structure.
According to yet another preferred embodiment of the invention, the optionally-detachable ankle flap portions are defined by an area along the bottom of the leg portion. The area is devoid of the substrate and separates the optionally-detachable ankle flap portions from the leg portion for form
Adams, Schwartz & Evans P.A.
Calvert John J.
Parker Athletic Products, LLC
Patel Tejash
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