The present invention provides a shoulder pad for use in a contact sport, such as football, hockey or lacrosse, that is formed from a consolidated polymer fiber composite material, such as polypropylene tape yarn that reduces the overall weight of the shoulder pad. The shoulder pad includes a pair of arch members, each having an upper portion, a front portion depending from the upper portion, and a rear portion depending from the upper portion. The shoulder pad further includes at least one side pad assembly having an epaulet and a shoulder cap, wherein the shoulder cap overlies the wearer's shoulder region and the epaulet overlies both the arch member and the shoulder cap. The side pad assembly is operably secured to the body arch member by a fastening assembly that includes a flexible single band. Unlike conventional designs, the single band secures both the epaulet and the shoulder cap to the upper portion of the arch member. The shoulder pad further includes a pair of interior pad assemblies wherein each interior pad assembly is removably connected to an arch member. The interior pad assembly is an integrated unit formed from a front pad, an intermediate pad, and a rear pad joined together to form distinct air management chambers.
1. A football shoulder pad worn by a player, the shoulder pad comprising:
a pair of continuous arch members joined together to define a central opening, each arch member having a front arch portion depending from an upper arch portion and a rear arch portion depending from the upper arch portion, wherein each arch member is a unitary piece formed from a consolidated polymer fiber composite material and that extends continuously over the player's shoulder and between the player's chest region and back region;
a side pad assembly operably connected to each arch member by a single flexible band to substantially overlie the player's shoulder region, the side pad assembly comprising an epaulet and a shoulder cap that are both formed from a consolidated polymer fiber composite material, wherein the shoulder cap resides external to the arch member and the epaulet resides above and against the shoulder cap;
an internal padding assembly removably connected to and extending along each arch member.
2. The football shoulder pad of claim 1 , wherein the consolidated polymer fiber composite material used to form the arch members, the epaulet and the shoulder cap is fabricated from a polyolefin tape yarn.
3. The football shoulder pad of claim 2 , wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other and then consolidated with heat and pressure to form a rigid sheet.
4. The football shoulder pad of claim 3 , wherein the rigid sheet is cut into shapes and molded into the arch members, the epaulet and the shoulder cap.
5. The football shoulder pad of claim 2 , wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other in a mold and then consolidated with heat and pressure to form one of the arch members, the epaulet and the shoulder cap.
6. The football shoulder pad of claim 1 , wherein the consolidated polymer fiber composite used to form the arch members, the epaulet and the shoulder cap is fabricated from a coextruded polyolefin tape yarn with a highly drawn core residing within a polymer matrix, wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other and then consolidated with heat and pressure to form one of the arch members, the epaulet and the shoulder cap through a molding process.
7. The football shoulder pad of claim 1 , wherein the consolidated polymer fiber composite used to form the arch members, epaulets and shoulder caps is polypropylene with a tensile modulus ranging from 5 to 6 GPa and a tensile strength of 205 MPa, both under ASTM D638 test standard.
8. The football shoulder pad of claim 1 , wherein the consolidated polymer fiber composite used to form the arch members, epaulets and shoulder caps is polypropylene with a flexural modulus of 5-6 GPa ranging from 5 to 6 GPa and a flexural strength of 65 MPa, both under ASTM D790 test standard.
9. The football shoulder pad of claim 1 , wherein the consolidated polymer fiber composite used to form the arch members, epaulets and shoulder caps is polypropylene with a Gardner Dart Impact of 24.7 J at −40° C. and 24.5 J at 20° C. with a 1.25 mm sample thickness, both under ASTM D5420 test standard.
10. The football shoulder pad of claim 2 , wherein the side pad assembly is connected to the arch member by the band proximate a raised front segment of the arch member, the raised front segment being defined by opposed sidewalls that extend transversely from the front arch portion.
11. A shoulder pad worn by a player engaged in a contact sport, the shoulder pad comprising:
a pair of curvilinear, continuous arch members operatively joined together to define a central opening, wherein each arch member is a unitary piece formed from a consolidated polymer fiber composite material and that continuously extends over the player's shoulder and between the player's chest region and back region, wherein each arch member has both a raised front segment extending along a substantial extent of a front arch portion and a raised rear segment extending along a substantial extent of a rear arch portion, wherein the raised front and rears segments are defined by a pair of opposed sidewalls that extend transversely from an outer surface of the respective arch portion;
a side pad assembly operably connected to each arch member between the raised front and rear segments, the side pad assembly comprising an epaulet and a shoulder cap formed from a consolidated polymer fiber composite material and, wherein the shoulder cap resides external to the arch member and the epaulet resides above and against the shoulder cap; and,
an internal padding assembly removably connected to and extending along each arch member.
12. The football shoulder pad of claim 11 , wherein the consolidated polymer fiber composite material used to form the arch members, the epaulet and the shoulder cap is fabricated from a polyolefin tape yarn.
13. The football shoulder pad of claim 12 , wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other and then consolidated with heat and pressure to form a rigid sheet, and then the rigid sheet is cut into shapes and molded into the arch members, the epaulet and the shoulder cap.
14. The football shoulder pad of claim 13 , wherein the rigid sheet is cut into shapes and molded into the arch members, the epaulet and the shoulder cap.
15. The football shoulder pad of claim 12 , wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other in a mold and then consolidated with heat and pressure to form one of the arch members, the epaulet and the shoulder cap.
16. The football shoulder pad of claim 11 , wherein the consolidated polymer fiber composite used to form the arch members, the epaulet and the shoulder cap is fabricated from a coextruded polyolefin tape yarn with a highly drawn core residing within a polymer matrix, wherein the polyolefin tape yarn is woven into a fabric, and multiple layers of the fabric are stacked upon each other and then consolidated with heat and pressure to form one of the arch members, the epaulet and the shoulder cap through a molding process.
17. The football shoulder pad of claim 11 , wherein the consolidated polymer fiber composite material used to form the arch members, epaulets and shoulder caps is polypropylene with a tensile modulus ranging from 5 to 6 GPa and a tensile strength of 205 MPa, both under ASTM D638 test standard.
18. The football shoulder pad of claim 11 , wherein the polypropylene composite material used to form the arch members, epaulets and shoulder caps is polypropylene with a flexural modulus of 5-6 GPa ranging from 5 to 6 GPa and a flexural strength of 65 MPa, both under ASTM D790 test standard.
19. The football shoulder pad of claim 11 , wherein the polypropylene composite material used to form the arch members, epaulets and shoulder caps is polypropylene with a Gardner Dart Impact of 24.7 J at −40° C. and 24.5 J at 20° C. with a 1.25 mm sample thickness, both under ASTM D5420 test standard.
20. The football shoulder pad of claim 12 , wherein the pad assembly is operably connected to each arch member by a single flexible band secured between the raised front and rear segments.