Protection Device and Process of Making the Same

This application incorporated by reference and claims priority to Italian Patent Applications 102024000009331 and 102024000009340 both of which were filed Apr. 23, 2024.

The present invention relates to a protection device and a process of making the same. The protection device may be of the wearable type, which can be used in the sports or work field to protect a user's body from impacts, for example in the event of an accident. The protection device may be inserted into or engaged with technical sports clothing, for example jackets, vest, tracksuits for motorcycling and motorsport fields, or be an integral part thereof. The protection device of the present invention may also define protection accessories, such as knee pads, back protectors, head protectors, neck protectors and chest protectors.

Wearable protection devices with an inflatable bag that can be activated under specific conditions to protect the user's body from shocks or falls are known. The inflatable bag consists of two layers in sheet material constrained at a peripheral edge.

In a first example, the bag is directly housed in a pocket of a garment such that, in its deflated condition, one layer of the bag directly faces an inner layer of the garment while the opposite layer of the bag directly faces the outer layer of the garment. The bag is generally engaged in the garment to protect vital parts of the human body (e.g., cervical, hip, thorax and spinal column) and placed in fluid communication with a gas generator configured to inflate the bag in 30-50 milliseconds. To enable the bag to maintain its position in the garment, it is known to provide two or more portions of the bag attachment constrained at the seams of the garment. See for example the following patent applications: WO2011/148354A1, WO2015181734A1, WO2020/115158A1, WO2021/083877A1.

In a second example, the protection devices comprise a case comprising a plurality of side-by-side chambers, delimited by longitudinal ties, inside which segments of an inflatable bag are positioned. Following activation of the bag, each segment of the bag is configured to expand and occupy the entire internal volume of the respective chamber; the ties of the case, in the inflated condition of the bag, are configured to limit the expansion of the bag and determine the shape of the protection device. See, for example, the PCT patent Application no. WO2021/260002A1.

Although the known protection devices described above are used today to protect users, the Applicant noted that they could be improved in several aspects.

The present invention may be embodied to solve at least one of the drawbacks and/or limitations of the previous solutions.

The present invention may provide an extremely safe protection device, capable of providing a user with excellent impact protection; in particular, it is further an object of the present invention to provide a protection device having a structure such as to ensure its correct positioning when worn by a user or when engaged to a garment and therefore its correct operation. It is further an object of the present invention to provide a protection device having a simple structure which can be quickly made with low production costs, but which is structurally robust. It is also an object of the present invention to provide a protection device which is flexible in use and can be used for the proper protection of different parts of a user's body. It is a further scope of the present invention to provide a simple and quick process for making a protection device, but which at the same time may guarantee the correct assembly of the protection device to prevent failures.

These purposes and others, which will become more apparent from the following description, are substantially achieved by a protection device and a process of making the same according to one or more of the attached claims.

In a 1st aspect a wearable protection device () is provided, said protection device () comprising: at least one inflatable element () comprising a plurality of side-by-side segments each extending along a respective extension trajectory, wherein each segment comprises at least one wall in sheet material delimiting an internal volume and having a first and second portions facing each other, wherein the inflatable element () is configurable between: a deflated condition where the first and second portions of at least one wall of each segment, for a preponderant part of its surface extension, are close and at least partially in contact with each other, an inflated condition where the first and second portions of the at least one wall of each segment, for a preponderant portion of its surface extension, are spaced apart, wherein said at least one wall, in the inflated condition, defines an internal volume greater than the internal volume defined by the same wall in the deflated condition, at least one case () having a compartment (V) in which the plurality of segments is housed, wherein the case () comprises a first and second covers (,) in sheet material, at least partially opposed to each other, wherein each segment is interposed between said first and second covers (,).

In a 2nd aspect according to the preceding aspect, at least one of said segments further comprises one or more peripheral engagement portions. In an aspect 2bis according to the preceding aspect at least one part of the peripheral engagement portion of at least one segment of the inflatable element () is fixed to, or in proximity to, at least one of said first and second covers (,). In an aspect 2ter according to any one of the preceding aspects the inflatable element () is fixed to the case by means of a seam. In a 2quater aspect according to any one of the preceding aspect the segments, in the inflated condition, exhibit substantially parallel extension trajectories.

In a 3rd aspect according to any one of the preceding aspects, the inflatable element () comprises at least two peripheral engagement portions opposite to each other with respect to the internal volume of the respective segment. In a 4th aspect according to any one of the preceding aspects at least one of said segments is fixed, at opposing peripheral engagement portions with respect to the internal volume of the respective segment, to the first and second covers (,).

In a 5th aspect according to any one of the preceding aspects each segment is fixed, at opposing peripheral engagement portions with respect to the internal volume of said segment, to the first and second covers (,). In a 6th aspect according to any one of the preceding aspects each segment is fixed to the first and/or second cover (,) only at at least one of said peripheral engagement portions.

In a 7th aspect according to any one of the preceding aspects the at least one wall of each segment comprises a first wall () and a second wall () in sheet material. In an 8th aspect according to the preceding aspect the first wall () has a central area defining said first portion of the at least one wall. In a 9th aspect according to any one of the preceding two aspects the second wall () has a central area defining said second portion of the at least one wall.

In a 10th aspect according to any one of the three preceding aspects the first and second walls (,) of each segment are engaged with each other at a peripheral edge () to define a single peripheral engagement portion. In an 11th aspect according to any one of the preceding four aspects, each segment comprises only the first and second walls (,) engaged with each other at a peripheral edge () to define a single peripheral engagement portion. In a 12th aspect according to any one of the preceding five aspects the first and second walls (,) delimit the internal volume of the respective segment.

In a 13th aspect according to any one of the three preceding aspects, each segment is fixed at opposing portions of the peripheral edge to the first and second covers (,).

In a 14th aspect according to any one of the four preceding aspects, the peripheral edge of each segment has a first and a second tract (′,″) opposite each other, joined at respective end portions by at least one connection tract (″), wherein the first and second tracts (′,″) of the peripheral edge develop substantially along the extension trajectory of the respective segment, wherein each segment is fixed to at least one of the first and second cover (,) at the first and second tract (′,″) of the peripheral edge ().

In a 15th aspect according to any one of the five preceding aspects at least a portion of the first tract of a segment is fixed to the first cover (), whereas at least a portion of the second tract of the same segment is fixed to the second cover (). In a 16th aspect according to any one of the preceding six aspects each segment is fixed to the first and second covers (,) at the first and second tracts of the peripheral edge, respectively.

In a 17th aspect according to any one of the preceding seven aspects each segment is fixed to: the first cover () at the first tract of the peripheral edge for at least 50% of a total longitudinal extension of said first tract, substantially defined along the extension trajectory of the respective segment, and/or the second cover () at the second tract of the peripheral edge for at least 50% of a defined total longitudinal extension of said second tract, substantially defined along the extension trajectory of the respective segment.

In a 18th aspect according to any one of the preceding aspects, each segment is fixed to: the first cover () at the first tract of the peripheral edge for at least 70%, optionally at least 80%, of a total longitudinal extension of said first tract, defined substantially along the extension trajectory of the respective segment, and the second cover () at the second tract of the peripheral edge for at least 70%, optionally at least 80%, of a total longitudinal extension of said second tract, defined substantially along the extension trajectory of the respective segment.

In a 19th aspect according to any one of the preceding nine aspects, each segment is fixed to the first and/or second cover (,) only at at least one of said first and second tracts of the peripheral edge. In an aspect 19bis according to any one of the preceding aspects from 14th to 19th each segment is fixed to, or in proximity of, the first cover () at: a single continuous portion of the first tract, or one or more spaced portions of the first tract.

In an aspect 19ter according to any one of the preceding aspects 14 to 19bis each segment is fixed to, or in proximity of, the second cover () at: a single continuous portion of the second tract, or one or more spaced portions of the second tract.

In a 20th aspect according to any one of the preceding aspects the inflatable element () is made of a deformable material. In a 21st aspect according to any one of the preceding aspects the inflatable element () is made at least in part of a plastic material, optionally a plastic film material. In a 22nd aspect according to any one of the preceding aspects the inflatable element () defines a gas impermeable structure. In a 23rd aspect according to any one of the preceding aspects the at least one wall is gas impermeable. In a 24th aspect according to any one of the preceding aspects from 7th to 23rd the first wall () of the inflatable element () is gas impermeable. In a 25th aspect according to any one of the preceding aspects from 7th to 24th the second wall () of the inflatable element () is gas impermeable.

In a 26th aspect according to any one of the preceding aspects the inflatable element () is made at least in part of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene, silicone rubber, rubber. In a 27th aspect according to any one of the preceding aspects from 7th to 26th at least part of the first and second walls (,) of the inflatable element () is made at least in part of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene, silicone rubber, rubber.

In a 28th aspect according to any one of the preceding aspects from 7th to 27th, each of said first and second walls (,) of the inflatable element () comprises a single monolayer plastic film. In a 29th aspect according to any one of the preceding aspects from 7th to 28th, each of said first and second walls (,) of said inflatable element () is entirely made of polyurethane, PVC, EVA, polyethylene, polypropylene, silicone rubber, rubber.

In a 30th aspect according to any one of the preceding aspects from 7th to 27, each of said first and second walls (,) of the inflatable element () is made of a multilayer material. In a 31st aspect according to any one of the preceding aspects from 7th to 27th or according to the 30th aspect, each of said first and second walls (,) of the inflatable element () comprises: a first layer defined by a plastic film, a second woven layer attached to the first layer, and optionally fixed by glue.

In a 32nd aspect according to any one of the preceding aspects the inflatable element () is elastically deformable. In a 33rd aspect according to any one of the preceding aspects the inflatable element () is configured to deform substantially elastically during the transition from the deflated condition to the inflated condition. In a 34th aspect according to any one of the preceding aspects from 7th to 33rd the first and second walls (,) of the inflatable element are configured to deform substantially elastically during the transition from the deflated condition to the inflated condition.

In a 35th aspect according to any one of the preceding aspects the at least one wall of the inflatable element, according to a section along a plane orthogonal to the extension trajectory of the respective segment and at the peripheral engagement portion, substantially defines a closed perimeter edge having a predetermined length, wherein the ratio of said length of the perimeter edge, in the inflated condition of the inflatable element (), to the length of said perimeter edge, in the deflated condition of the inflatable element (), is equal to or greater than 1, optionally is between 1 and 1.4 including extremes.

In a 36th aspect according to any one of the preceding aspects from 7th to 35th the first and second walls (,) are fluid-tightly engaged with each other at the peripheral edge (), in particular the peripheral edge is configured to substantially prevent the passage of gas. In a 37th aspect according to any one of the preceding aspects from 7th to 36th the first and second walls (,) of the inflatable element are engaged to each other at respective free edge portion by at least one of: gluing, welding, sewing. In a 38th aspect according to any one of the preceding aspects from 7th to 37th the first and second walls (,) of the inflatable element are welded, optionally heat-sealed, to each other to define the peripheral edge. In a 39th aspect according to any one of the preceding aspects from 7th to 38th the first and second walls (,) of the inflatable element are engaged to each other at the peripheral edge by at least one of the following processes: hot pressing, high frequency welding, ultrasonic welding.

In a 40th aspect according to any one of the preceding aspects, the peripheral engagement portion of at least one segment of the inflatable element () is directly fixed to, or in proximity to, at least one of said first and second covers (,) by means of a seam. In a 41st aspect according to any one of the preceding aspects, the peripheral engagement portion of each segment is sewn to at least one of said first and second covers (,). In a 42nd aspect according to any one of the preceding aspects, the first tract of the peripheral edge () is fixed by sewing to the first cover () while the second tract of the peripheral edge is fixed by sewing to the second cover ().

In a 43rd aspect according to any one of the preceding aspects, each segment has an elongated conformation, optionally developing along the extension trajectory. In a 44th aspect according to any one of the preceding aspects, two immediately adjacent segments have substantially the same length; optionally said length is measured along the extension trajectory.

In a 45th aspect according to the 43rd or 44th aspect, each segment has a length measured along the extension trajectory. In a 46th aspect according to the preceding aspect the length of each segment is greater than 50 mm, optionally between 100 and 350 mm. In a 47th aspect according to any one of the preceding aspects the at least one wall of each segment of the inflatable element, according to a section along a plane orthogonal to the extension trajectory of the respective segment and at the peripheral engagement portion, substantially defines a closed perimeter edge having a predetermined length. In a 48th aspect according to the preceding aspect, said length of the closed perimeter edge is between 45 and 345 mm, optionally between 70 and 300 mm. In a 49th aspect according to the 47th or 48th aspect, the length of a segment measured along the extension trajectory is greater than the length of the closed perimeter edge of the same segment. In a 50th aspect according to any one of the preceding aspects from 47th to 49th, the ratio between the length of a segment, measured along the extension trajectory, and the length of the closed perimeter edge of the same segment is greater than 1,1, optionally between 1,2 and 1,6.

In a 51st aspect according to any one of the preceding aspects, two first tracts (′) of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (), in the inflated condition of said segments, are placed at a predetermined distance (D). In a 52nd aspect according to the preceding aspect said predetermined distance (D) is equal to or greater than 25 mm, optionally between 30 mm and 80 mm. In a 53rd aspect according to any one of the preceding aspects, two second tracts (″) of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (), in the inflated condition of said segments, are placed at a predetermined distance (D). In an aspectaccording to the preceding aspect, said predetermined distance (D) is equal to or greater than 25 mm, optionally between 30 mm and 80 mm. In a 55th aspect according to the 53rd or 54th aspect the predetermined distance (D) between two first tracts (′) is substantially equal to the predetermined distance (D) of two second tracts (″).

In a 56th aspect according to any one of the preceding aspects, the first and second tracts of the peripheral edge of a segment are placed, in the inflated condition of the inflatable element, at a minimum distance (Dm) from each other. In a 57th aspect according to the preceding aspect, said minimum distance (Dm) is 25 mm or more, optionally it is between 30 mm and 120 mm, even more optionally between 40 mm and 80 mm. In a 58th aspect according to the 56th or 57th aspect, the ratio between the minimum distance (Dm) between the first and second tracts of the peripheral edge of a segment and the distance (D) between two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (), in the inflated condition of said segments, is equal to or greater than 1, optionally it is between 1 and 1.5. In a 59th aspect according to the 56th or 57th or 58th aspect, the ratio between the minimum distance (Dm) between the first and second tracts of the peripheral edge of a segment and the distance (D) of two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (), in the inflated condition of said segments, is equal to or greater than 1, optionally it is between 1 and 1.5.

In ath aspect according to any one of the preceding aspects, the inflatable element () comprises a number of segments equal to or greater than 2, optionally between 2 and 20 inclusive. In an 61st aspect according to any one of the preceding aspects the inflatable element () comprises: at least a first series of segments comprises two or more side-by-side segments, at least a second series of segments comprises two or more side-by-side segments.

In a 62nd aspect according to the preceding aspect, the segments of the first series of segments, in the inflated condition, have substantially parallel extension trajectories. In a 63rd aspect according to the 61st or 62nd aspect, the segments of the second series of segments, in the inflated condition, have substantially parallel extension trajectories. In a 64th aspect according to any one of the preceding aspects from 61st to 63rd, the first series segments and the second series segments, in the inflated condition of the segments of both series, are spaced apart from each other.

In a 65th aspect according to any one of the preceding aspects, the plurality of segments of the inflatable element () are in fluid communication. In a 66th aspect according to any one of the preceding aspects, the inflatable element () comprises at least one connection section () which places the plurality of side-by-side segments in fluid communication. In a 67th aspect according to any one of the preceding aspects, the plurality of side-by-side segments emerge from the same side of the connection section () of the inflatable element (). In a 68th aspect according to 66th or 67th aspect, the inflatable element () comprises a connection section () for each of the series of segments. In a 69th aspect according to any one of the preceding aspects from 66th to 68th, the connection section () is housed in the compartment (V) of the case (). In a 70th aspect according to any one of the preceding aspects from 66th to 69th, the connection section () is interposed between said first and second covers (,). In an 71st aspect according to any one of the preceding aspects from 66th to 70th, the connection section () comprises at least one wall in sheet material delimiting an internal volume in fluid communication with the internal volume of a plurality of segments, wherein the connection section () comprises a respective first and second portions facing each other, wherein the connection section () further comprises one or more peripheral engagement portions. In a 72nd aspect according to the preceding aspect, the connection section () is inflatable and configurable between: a deflated condition where the first and second portions of at least one wall of the connection section, for a preponderant part of their surface extension, are close and at least partially in contact with each other, an inflated condition where the first and second portions of the at least one wall the connection section, for a preponderant part of its surface extension, are spaced apart, wherein said at least one wall, in the inflated condition, defines an internal volume greater than the internal volume defined by the same wall of the connection section in the deflated condition.

In a 73rd aspect according to the preceding aspect, the connection section () extends along a respective extension trajectory which is transversal, optionally orthogonal, to the extension trajectory of the segments emerging directly from said connection section.

In a 74th aspect according to any one of the preceding two aspects, the at least one peripheral engagement portion of the connection section () is fixed to, or in proximity to, at least one of said first and second covers (,). In a 75th aspect according to any one of the three preceding aspects, the connection section comprises at least two peripheral engagement portions opposite each other with respect to the internal volume of the respective connection section (). In a 76th aspect according to any one of the four preceding aspects, the connection section is fixed, at peripheral engagement portions opposite to each other with respect to the internal volume of the respective connection section, to the first and second covers (,). In ath aspect according to any one of the five preceding aspects, the connection section () is fixed to the first and/or second cover (,) only at at least one of said peripheral engagement portions. In a 78th aspect according to any one of the six preceding aspects, a preponderant portion (optionally at least 70%, even more optionally at least 80%) of the peripheral engagement portion of the connection section () is engaged to the case.

In a 79th aspect according to any one of the preceding aspects, the first and second covers (,) of the case (), in the deflated condition of the inflatable element () and at the zone where said segments are fixed to the case, are spaced apart from each other up to a maximum distance (DM), wherein said first and second covers (,) in the inflated condition of the inflatable element () and at the zone where said segments are fixed to the case, are arranged at an operating distance (Dp) less than said maximum distance (DM). In an 80th aspect according to the preceding aspect, the ratio between said maximum distance (DM) and said operating distance (Dp) between the first and second cover (,) is equal to or greater than 1.1, optionally between 1.1, and 1.8.

In an 81st aspect according to any one of the preceding aspects, the first and second covers (,) of the case (), in the inflated condition and in the deflated condition, are kept at a distance, for a preponderant part of the surface extension of said covers, by interposition of the plurality of segments. In an 82nd aspect according to any one of the preceding aspects the first and second cover (,) of the case (), in the inflated condition and in the deflated condition and for at least 70% of their surface extension (optionally for at least 80%) are spaced from each other.

In an 83rd aspect according to any one of the preceding aspects, at least one peripheral portion of the first and second cover (,) of the case () is fixed to each other. In an 84th aspect according to any one of the preceding aspects the peripheral portions of the first and second covers (,) are fixed to each other by seams. In an 85th aspect according to any one of the preceding aspects, each of said segments of the inflatable element () is fixed to the first and/or second cover (,) at a distance from the joined (e.g., sewn) peripheral portions of said first and second covers (,). In an aspect 85bis according to any one of the three preceding aspects, at least one peripheral portion of the first and second cover (,) of the case () is fixed to each other by sewing, wherein each of said segments of the inflatable element () is sewn to the first and second cover (,) at a distance from the seams joining said first and second cover (,).

In an 86th aspect according to any one of the preceding aspects, the case () comprises a plurality of auxiliary covers () arranged in the compartment (V), wherein each auxiliary cover () is made of sheet material and defines within it a sub-chamber (C) in which the at least one segment of the inflatable element () is housed. In an 87th aspect according to the preceding aspect, each auxiliary cover () comprises at least one wall in sheet material delimiting the sub-chamber. In an 88th aspect according to the 86th or 87th aspect, the auxiliary cover () is configured to contain the expansion of the at least one segment during the transition from the deflated to the inflated condition. In an 89th aspect according to any one of the three preceding aspects, each auxiliary cover () is fixed to at least one of: at least a peripheral engagement portion of the segment housed in the auxiliary cover (), the first cover () of the case, or the second cover () of the case.

In a 90th aspect according to any one of the four preceding aspects, each auxiliary coating () comprises one or more peripheral engagement portions, wherein at least one peripheral engagement portion of each auxiliary coating () is fixed to, or in proximity to, at least one of said first and second covers (,). In a 91st aspect according to any one of the preceding five aspects, each auxiliary cover () is interposed between said first and second cover (,). In a 92nd aspect according to any one of the preceding six aspects, each auxiliary cover () is fixed to: at least a peripheral engagement portion of the segment housed in the auxiliary cover itself, the first cover () of the case, or the second cover () of the case.

In a 93rd aspect according to any one of the preceding aspects from 86th to 92nd, a preponderant portion (optionally at least 70%, even more optionally 80%) of each segment is housed in the sub-chamber (C) of an auxiliary cover (). In a 94th aspect according to any one of the preceding aspects from 86th to 93rd, each auxiliary cover () is substantially countershaped to the segment that is housed in the sub-chamber (C) of the respective auxiliary cover. In a 95th aspect according to any one of the preceding aspects from 86th to 94th, each auxiliary cover () is of an elongated type and extends along a predetermined extension trajectory parallel to the extension trajectory of the segment housed in the sub-chamber of the respective auxiliary cover. In a 95th aspect according to the preceding aspect, the length of an auxiliary cover (), measured along the respective extension trajectory, is substantially equal to the length of the segment housed in the sub-chamber of the respective auxiliary cover.

In a 97th aspect according to any one of the preceding aspects from 86th to 96th, each auxiliary cover () comprises at least two peripheral engagement portions opposite each other with respect to the internal volume of the respective auxiliary cover. In a 98th aspect according to any one of the preceding aspects from 86th to 97th, each auxiliary cover is fixed at peripheral engagement portions opposite each other with respect to the internal volume of the respective auxiliary cover to opposite portions of a segment and/or to the first and second covers (,).

In a 99th aspect according to any one of the preceding aspects from 86th to 98th, the at least one wall of each auxiliary cover () comprises a first wall () and a second wall () in sheet material, respectively facing and at least partially in contact with the first wall () and the second wall () of a segment of the inflatable element.

In a 100th aspect according to the preceding aspects, the first and second walls (,) of each auxiliary cover () are fixed to at least one tract of the peripheral edge () of a segment as well as to the first and second covers (,) of the case. In a 101st aspect according to any one of the preceding two aspects, the first and second walls (,) of an auxiliary cover delimit the sub-chamber of said auxiliary cover. In a 101bis aspect according to any one of the preceding three aspects, the first and second walls (,) of each auxiliary cover () are fixed, for example by seam, to the first cover () of the case, to the second cover () of the case, to the first and second tracts (′,″) of the peripheral edge of a segment.

In a 102nd aspect according to any one of the four preceding aspects, each of said first and second walls (,) of an auxiliary cover extends in heights between a first and second longitudinal portions (′,′,′), wherein the first and second longitudinal portions (′,′) of the first and second walls (,) of the auxiliary cover () are fixed, optionally sewn, to the first cover () of the case and to at least one tract of the peripheral engagement portion of a segment which is also fixed, optionally sewn, to the first cover (),

In an aspect 102bis according to any one of the preceding aspects, the first cover (), in the inflated condition and at a tract connecting substantially two immediately adjacent segments, exhibits a substantially flat conformation. In an aspect 102ter according to any one of the preceding aspects the second cover (), in the inflated condition and at a tract connecting substantially two immediately adjacent segments, exhibits a substantially flat conformation. In an aspect 102quater according to any one of the preceding aspects, two opposite portions of the first and second covers (,), in the inflated condition and at a tract connecting substantially two immediately adjacent segments, are substantially parallel to each other. In an aspect 102quinques according to any one of the preceding aspects, the first and second covers (,) of the case, in the deflated condition of the inflatable element, are arranged in a non-tensioned condition while, in the inflated condition of the inflatable element, they are in tension.