Flexible Cushioning Pads, Items Incorporating Such Pads, and Methods of Making and Using

Abstract

Disclosed herein are conformable protection pads, which can be integrated into articles such as clothing and protective cases.

What is claimed is: 
     
         1 . A cushioning pad section, comprising:
 a hinge comprising a thickness and a width, the hinge comprising a continuous upper layer and a continuous lower layer, the continuous upper layer at least partially bonded to the continuous lower layer; and   a cushioning region adjacent to the hinge, the cushioning region having a thickness greater than the thickness of the hinge, the cushioning region further comprising a cushioning material disposed between and bonded to the continuous upper layer and the continuous lower layer.   
     
     
         2 . The cushioning pad section of  claim 1 , wherein the continuous upper layer is at least partially bonded to the continuous lower layer in the hinge by a plurality of portions of cushioning material disposed between and bonded to the continuous upper and lower layers. 
     
     
         3 . The cushioning pad section of  claim 1 , wherein the hinge has a width ranging from about 1 mil to about 10 mils. 
     
     
         4 . The cushioning pad section of  claim 1 , wherein the hinge has a thickness ranging from about 1 mil to about 10 mils. 
     
     
         5 . The cushioning pad section of  claim 1 , wherein the hinge has a thickness ranging from about 1 mil to about 10 mils. 
     
     
         6 . The cushioning pad section of  claim 1 , wherein the hinge has a thickness of about ranging from about 5 mil to about 8 mils. 
     
     
         7 . The cushioning pad section of  claim 1 , wherein the cushioning material comprises a density ranging from about 10 to about 30 pounds per cubic foot. 
     
     
         8 . The cushioning pad section of  claim 1 , wherein the cushioning material comprises a density ranging from about 15 to about 25 pounds per cubic foot. 
     
     
         9 . The cushioning pad section of  claim 1 , wherein the cushioning material is a rate dependent foam. 
     
     
         10 . The cushioning pad section of  claim 1 , further comprising a garment, wherein the cushioning pad is attached to the garment by stitching. 
     
     
         11 . The cushioning pad section of  claim 10 , wherein the garment is a compression sleeve, and the cushioning medallion is configured to correspond to an elbow joint. 
     
     
         12 . The cushioning pad section of  claim 10 , wherein the garment is a compression leg sleeve, and the cushioning medallion is configured to correspond to a knee joint. 
     
     
         13 . The cushioning pad section of  claim 1 , wherein the continuous upper and lower layers are thermoplastic elastomer (TPE) layers. 
     
     
         14 . The cushioning pad section of  claim 1 , wherein the continuous upper and lower layers are TPE layers bonded to a layer of spandex fabric, and the TPE layers are disposed adjacent to the cushioning material. 
     
     
         15 . The cushioning pad section of  claim 1 , wherein the cushioning material is a cellular material comprising a plurality of cells having a minimum cell diameter, and the thickness of the cushioning material between the inner layer and the outer layer is less than the minimum cell diameter. 
     
     
         16 . A cushioning pad section, comprising:
 a perimeter hinge comprising a thickness and a width, the perimeter hinge comprising a continuous upper layer and a continuous lower layer, the continuous upper layer at least partially bonded to the continuous lower layer;   a cushioning region adjacent to the perimeter hinge, the cushioning region having a thickness greater than the thickness of the perimeter hinge, the cushioning region further comprising a cushioning material disposed between and bonded to the continuous upper layer and the continuous lower layer; and   a perimeter flange spaced apart from the cushioning region by the width of the perimeter hinge, the perimeter hinge having a thickness approximately equal to the combined thickness of the inner layer and the outer layer.   
     
     
         17 . The cushioning pad section of  claim 1 , further comprising a groove defined in the upper surface of the cushioning region, the groove comprising a thickness less than the thickness of the cushioning region and greater than the thickness of the hinge. 
     
     
         18 . The cushioning pad section of  claim 1 , wherein the perimeter hinge has a width ranging from about 1 mil to about 10 mils. 
     
     
         19 . The cushioning pad section of  claim 1 , wherein the perimeter hinge has a thickness ranging from about 1 mil to about 10 mils. 
     
     
         20 . The cushioning pad section of  claim 1 , wherein the perimeter hinge has a thickness of about ranging from about 5 mil to about 8 mils.