Protective padding layer
A flexible padding layer for use during competitive sports is provided. The flexible padding layer is comprised of a plurality of individual padding elements each joined on multiple sides with an adjacent padding element via a thin, connecting section. Each padding element further comprises openings and a three-dimensional surface configuration to allow for consistent mechanical properties throughout the padding layer as a whole.
1. A flexible padding layer, comprising a section of resilient sheet material, having an upper surface and an opposing lower surface, said sheet material formed with repetitive composite pattern of surface features, said repetitive composite pattern comprising a geometric array of a plurality of structural elements, at least one structural element of each surface feature being shared with an adjoining surface feature, each surface feature further comprising:
a polygonal perforation surrounded by a plurality of sides joined at corners; and
a contoured crown surrounding said polygonal perforation, said crown including at each said corner an angular section having a first surface forming said upper surface, said angular sections being separated by a plurality of shoulders extending along said sides, said plurality of shoulders each integrally joining a pair of said plurality of angular sections to form said crown,
wherein each shoulder tapers from said first surface between adjoining angular sections in an arc-shaped concavity; and
wherein said surface patterns and perforations collectively providing consistent flexibility in multiple directions.
2. The flexible padding layer according to claim 1 , wherein said angular sections have an opposing second surface forming said lower surface, wherein each shoulder tapers from said second surface at said opposing edges such that an opposing cross-section adjoining angular sections is also an arc-shaped concavity.
3. The flexible padding layer according to claim 2 , wherein each shoulder tapers to a first thickness, and said plurality of angular sections are of a greater thickness between said first and second surfaces than said first thickness.
4. The flexible padding layer according claim 3 , wherein said greater thickness is a uniform thickness.
5. The flexible padding layer according to claim 1 , wherein the arc-shaped concavity is symmetrical.
6. The flexible padding layer according to claim 1 , wherein said shoulders extend along the entirety of said sides.
7. The flexible padding layer according to claim 1 , wherein said polygonal perforation is hexagonal.
8. The flexible padding layer according to claim 7 , further comprising six radially-arrayed shoulders.
9. The flexible padding layer according to claim 8 , wherein said angular sections are triangular.
10. The flexible padding layer according to claim 9 , further comprising six triangular angular sections.
11. The flexible padding layer according to claim 1 , wherein each said structural element overlaps an adjacent structural element by sharing at least one shoulder.
12. The flexible padding layer according to claim 11 , wherein each said structural element overlaps an adjacent structural element by sharing one shoulder and two angular sections.
13. A flexible padding layer, comprising:
a resilient sheet material, having an upper surface and an opposing lower surface, said sheet material defined by a composite pattern of surface features, said composite pattern comprising a repeating array of structural elements, each said structural element in said array comprising,
a geometric perforation through said sheet material,
a plurality of polygonal sections radially arrayed around said geometric perforation, said polygonal sections having a first surface forming said upper surface, each polygonal section having a plurality of sides connected by vertices,
a plurality of shoulders integrally attached to each of said polygonal section sides, wherein each shoulder extends between a pair of opposing sides and are tapered at said opposing sides from said first surface such that a cross-section between opposing sides is an arc-shaped concavity,
wherein said array of surface features collectively provides consistent flexibility in multiple directions.
14. The flexible padding layer according to claim 13 , wherein said polygonal sections have an opposing second surface forming said lower surface, wherein each shoulder tapers from said second surface at said opposing edges such that an opposing cross-section between opposing edges is also an arc-shaped concavity.
15. The flexible padding layer according to claim 14 , wherein each shoulder tapers to a first thickness, and said plurality of polygonal sections are of a greater thickness between said first and second surfaces than said first thickness.
16. The flexible padding layer according claim 15 , wherein said greater thickness is a uniform thickness.
17. The flexible padding layer according to claim 13 , wherein the arc-shaped concavity is symmetrical.
18. The flexible padding layer according to claim 13 , wherein each of said shoulders abuts a side of said geometric perforation, wherein said geometric perforation is a polygon surrounded by a plurality of sides joined at corners.
19. The flexible padding layer according to claim 18 , wherein said polygonal perforation is hexagonal.
20. The flexible padding layer according to claim 19 , further comprising six radially-arrayed shoulders.
21. The flexible padding layer according to claim 20 , wherein said polygonal sections are triangular.
22. The flexible padding layer according claim 21 , further comprising six triangular sections.
23. The flexible padding layer according to claim 18 , wherein each said structural element overlaps an adjacent structural element.
24. The flexible padding layer according to claim 23 , wherein each said structural element overlaps an adjacent structural element by sharing at least one shoulder.
25. The flexible padding layer according claim 24 , wherein each said element overlaps an adjacent structural element by sharing at least one polygonal section.
26. The flexible padding layer according claim 25 , wherein each said element overlaps an adjacent structural element by sharing one shoulder and two polygonal sections.