Athletic protector cup

Abstract

An athletic protector cup is provided including a rigid cup-shaped base member and an impact resistant resilient body which is fixedly attached to an exterior surface and around a periphery of the base member. The resilient body includes a flange extending beyond portions of the base member edge and having a geometry for providing additional impact resistance.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to athletic protector cups, and more particularly to an athletic protector cup having a flexible resilient portion molded thereto for providing improved protection and comfort to the wearer.

2. Description of the Prior Art

Devices for the protection of the male groin region are extensively utilized in athletics. In athletic competition, particularly body contact sports such as football, baseball, hockey, soccer and the like, protective devices are worn by the players to avoid injury due to inadvertent blows to the groin area. The most common protective device includes a cup supported by a jockstrap. Protector cups of this character are usually formed from a plastic material, such as polypropylene or polyethylene, which is sufficiently rigid to retain its shape even when struck a relatively severe blow.

Historically, protector cups have been provided with a resilient padding about their periphery both for the comfort of the wearer and, in some measure, to absorb the impact of a blow to the protector cup. The resilient padding is usually formed from a soft, flexible foam-like material, such as foam rubber or polyurethane foam, and is usually provided in the form of a limited elongated strip manually attached to the peripheral edge of the cup with the aid of an adhesive. Such conventional padded cups suffer a number of disadvantages and limitations. For instance, the pad attachment procedure is both time consuming and costly, and the bond between the padding and the protector cup is often deficient. Separation of the padding and the protector cup typically occurs during repeated use of the protector when the padding is peeling away from the restricted area of attachment to the cup. Furthermore, such known structures, in view of the restricted extent of the padding, offer only limited impact absorption protection. Consequently, upon impact a significant portion of the blow is transferred to the body of the wearer. Examples of athletic protector cups incorporating such conventional peripheral padding are provided in U.S. Pat. Nos. 2,283,684; 3,782,375; 4,453,541 and 4,134,400.

U.S. Pat. No. 4,257,414 discloses an athletic protector cup having a resilient peripheral binding molded to a peripheral cup flange. The molded binding structure disclosed in the this patent provides some benefits vis-a-vis the aforementioned conventional padded cup structures. For instance, molding provides a more efficient and cost-effective means of attachment than a conventional adhesive foam strip. Furthermore, the disclosed binding is contoured to have a relatively thick outwardly-extending body portion for providing improved comfort to the wearer and improved impact absorption. However, the athletic cup structure disclosed in this patent has some significant drawbacks and limitations. For instance, to prevent separation of the molded binding from the cup over time, the cup must be manufactured having a series of perforations along the flange. In other words, to achieve adequate attachment of the binding to the cup flange, the binding material is required to flow through relatively small perforations during assembly. This is necessary to provide interlocks integrally connecting the portions of the binding lying on opposite sides of the flange. Furthermore, the relative increase in impact resistance provided by the disclosed flange geometry leaves significant room for improvement. This is because only a limited area of hard-shell is covered by soft binding. Additionally, the disclosed binding surface geometry of the outwardly extending body portion includes sharp edges which could result in chafing during frictional contact with the wearer's body.

Accordingly, there is an established need for an athletic protector cup overcoming the aforementioned drawbacks and limitations of the prior art.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an athletic protector cup including a rigid plastic base having a resilient body extending over a substantial portion or entire outer surface thereof for dampening the impact of a blow to the outer surface of the cup.

It is another object of the present invention to provide an athletic protector cup having a peripheral flexible flange for further dampening the impact of a blow to the outer surface of the cup.

It is a further object of the present invention to provide an athletic protector cup having a peripheral flexible flange geometry designed to collapse under forces applied by the cup to the wearer during various body movements, or under the force of a sudden impact, in such a manner as to create a cushioning barrier between the rigid plastic base and the wearer's body.

It is still a further object of the present invention to provide an athletic protector cup having a flexible flange incorporating a surface geometry for providing improved comfort to the wearer by minimizing frictional contact with the wearer's skin.

It is yet a further object of the present invention to provide an athletic protector cup incorporating a flexible resilient body portion molded to a rigid base in such manner as to minimize the risk of separation of the molded portion from the rigid base.

One aspect of the invention provides an athletic protector including a rigid cup-shaped member having interior and exterior surfaces defined along their peripheries by an edge having an upper segment and opposite side segments. A flexible resilient body covers a substantial portion of the exterior surface and extends around at least a portion of the peripheral edge. The resilient body is fixedly attached over at least a portion of the exterior surface of the base member.

As to another aspect of the invention, the flexible resilient body is molded over substantially the entire exterior surface of the rigid cup base member and around the length of peripheral edge. The flexible resilient body can also be molded over substantially the entire interior and exterior surface of the rigid cup-shaped base member.

A further embodiment of the invention provides an athletic protector wherein the upper segment of the peripheral edge terminates at a first integral lip and the lower segment of the peripheral edge terminates at a second integral lip. The flexible resilient body envelopes the first and second integral lips. The opposite side segments of the rigid cup peripheral edge have an inwardly stepped surface forming an exterior leading edge. The flexible resilient body is molded around the leading edge.

Still another aspect of the invention provides the flexible resilient body having a cup-shaped portion overlying substantially the entire exterior surface of the rigid cup-shaped base member. The cup-shaped portion of the flexible-resilient body has a thickened flange portion extending around substantially its entire periphery. The thickened flanges portion terminates at a rounded end having generally crescent-shaped cross-section geometry. The rounded end has a convex outer surface and a concave inner surface. Upon application of a force to an exterior surface of the athletic protector, the thickened flange portion collapses inwardly in such a manner as to form a cushion barrier between the rigid peripheral edge of the base member and the body of the wearer.

Still further aspect of the invention provides the athletic protector in which the resilient flexible body is made of an elastomer and the resilient flexible body is injection molded to the rigid cup-shaped base.

These and other objects and aspects of the invention are achieved by the athletic protector cup which is described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:

FIG. 1 is a perspective view of a rigid cup-shaped body portion of an athletic protector cup in accordance with the present invention;

FIG. 2 is a front elevational view of the rigid cup-shaped body of FIG. 1, viewed from lower end 12;

FIG. 3 is a cross-sectional view according to section line 3-3 of FIG. 2;

FIG. 4 is a top plan view of the rigid-cup shaped body depicted in FIG. 1;

FIG. 5 is a cross-sectional view according to section line 5-5 of FIG. 4;

FIG. 6 is a side view elevational of the rigid cup-shaped body depicted in FIG. 1;

FIG. 7 is a perspective view of a resilient body portion of an athletic protector cup in accordance with the present invention;

FIG. 8 is a top plan view of the molded body portion depicted in FIG. 7;

FIG. 9 is a cross-sectional view according to section line 9-9 of FIG. 8;

FIG. 10 is a side elevational view of the molded body portion depicted in FIG. 7;

FIG. 11 is a top plan view of a completely constructed athletic protector cup in accordance with the present invention;

FIG. 12 is a cross-sectional view according to section line 12-12 of FIG. 11;

FIG. 13 is a cross-sectional view according to section line 13-13 of FIG. 11;

FIG. 14 is a partially fragmented perspective view of the molded body portion of FIG. 7;

FIG. 15 is a partially fragmented perspective view of a completely assembled athletic protector cup in accordance with a preferred embodiment of the present invention;

FIG. 16a is identical to the cross-sectional view depicted in FIG. 12 and provided to illustrate the relative horizontal cross-sectional shape of the cup in a non-deflected equilibrium state; and

FIG. 16b illustrates the deflection of thickened section 62 of molded body 10 40, thereby forming an interlocking structure for enhancing the stability of rigid cup 10 within molded body 40. As best illustrated in FIG. 13, in this embodiment of the invention, portion 68 of thickened flange 60 completely envelops the integral upper and lower lips 22 and 20 of rigid cup base 10. In a manner similar to the interlocking structure described above, this mating structure further reduces the potential for interfacial separation by maintaining rigid cup 10 and resilient body 40 in a fixed position relative to each other.

The overmolded resilient body structure of the present invention provides numerous significant advantages over the prior art flange structures. For instance, in contrast to known athletic protector cups which provide a resilient body restricted to a peripheral portion of the cup, the resilient elastomer structure of the present invention is molded over the outer surface 16 of the rigid cup to provide an impact resistant barrier. In this manner, the magnitude of a blow to the exterior surface of the protector cup is significantly reduced, or dampened, before being transferred to the rigid plastic inner cup layer. As a result of this improved dampening, the athletic protector cup of the present invention can be constructed using a thinner rigid cup base 10, providing a corresponding weight reduction of approximately 20-30% compared to conventional athletic protector cups.

Further advantages result from the self-collapsing design of the integral flange structure. Referring now to FIGS. 16a and 16b, under the impact of an external force, F, upon outer surface 46, flexible flange portion 62 deflects, or folds, inwardly. At least two significant advantages accrue from this self-collapsing design. First, the inwardly folding flange portion 62 forms a barrier between the rigid perimeter side edges 24 of inner cup 10 and the wearer's body to provide enhanced comfort during the application of a force, F, on the cup. Such force may result from a blow to the cup. Alternatively, such force may result from various bodily movements, such as bending, while wearing the cup. As a consequence of the significant improvements in comfort to the wearer, the athletic protector cup of the present invention lends itself to use by certain athletes, such as soccer players, who commonly play without a protector cup to avoid the discomfort associated with existing cup structures. Second, the inwardly collapsing structure provides enhanced impact resistance in situations where the force results from a blow to the cup, further minimizing the transmission of the force to the wearer's body.

As best illustrated in FIG. 10, in the central region of the athletic protector (commonly engaging the body of the wearer) the rigid peripheral edges of the cup (shown in phantom) are remote from the outer surface 61 of the resilient body portion. Thus, in the assembly of the invention, a substantial portion of the rigid plastic is substituted by a soft plastic of the resilient body, further enhancing comfort to the wearer.

The smooth rounded convex outer surface 61 provides a comfortable, low friction, contact region between the flange and the body of the wearer. Concave inner surface 63 defines an integral channel 70 which extends completely around the lower interior of thickened flange 60.

The resilient body 40 and rigid cup base 10 are fixedly connected. Outer surface 16 of rigid cup 10 is bonded over substantially its entire surface area to interior surface 48 of impact resistant body 40. The surfaces 27, 28 and 29 of rigid cup 10 are attached to corresponding surfaces 65, 64 and 66 of rigid cup 10, thereby forming an interlocking structure. This enables the invention to enhance the stability of rigid cup 10 within body 40.

The flexible end portion 68 of the flexible resilient body envelops the integral upper and lower ends of rigid cup base 10. This mating structure further reduces the potential for interfacial separation by maintaining rigid cup 10 and resilient body 40 in a fixed position relative to each other.

Under the impact of an external force, outer surface of the flexible resilient body 46 40, its flexible end flange portion 62 deflects, or folds, inwardly, thereby forming a barrier between the rigid perimeter side edges of cup shaped base member 10 and the wearer's body. This provides enhanced comfort during the application of a force, on the cup. Furthermore, the inwardly collapsing structure enhances impact resistance of the structure when the force of a blow is applied to the cup.

While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions and equivalents will be apparent to those skilled in the art without departing from the spirit and scope of the present invention as described in the claims. For example, resilient body 40 can be further extended over the entire inner surface 18 of rigid cup-shaped base member 10, thereby completely encapsulating the hard cup. The rigid cup-shaped base member can be formed having smooth outer surface and inner surface 18, without lip portions 20 and 22, etc.,.

Claims

1. An athletic protector, comprising:

a rigid cup-shaped base member having interior and exterior surfaces defined along their peripheries by an outer edge having an anchor formation;

an integral resilient flexible body comprising: a cup-shaped portion, a thickened flanged portion and a transition portion between said cup-shaped portion and said thickened flanged portion;

wherein said cup-shaped portion enveloping substantially the entire exterior surface of said cup-shaped base member, said entire outer edge including the anchor formation is enveloped by said transition portion, and an inner surface of the transition portion and the interior surface of the cup-shaped base member facing a body of a wearer form a continuous smooth internal surface.

2. An athletic protector as recited in claim 1, wherein said integral resilient flexible body is molded over the exterior surface of said rigid cup-shaped base member.

3. An athletic protector as recited in claim 1, wherein said integral resilient flexible body is molded over substantially the entire exterior surface of said rigid cup-shaped base member.

4. An athletic protector as recited in claim 3, further comprising one or more apertures extending through said rigid base member and said resilient body.

5. An athletic protector as recited in claim 3, wherein an upper segment of said rigid cup peripheral edge terminates at an upper integral lip and a lower segment of said peripheral edge terminates at a lower integral lip, said integral resilient flexible body enveloping said upper and lower integral lips.

6. An athletic protector as recited in claim 1, wherein said integral resilient flexible body comprises an elastomer.

7. An athletic protector as recited in claim 1, wherein said resilient flexible body is injection molded to said rigid cup-shaped base.

8. An athletic protector as recited in claim 1, wherein said thickened flanged portion terminates at a rounded end having a generally crescent-shaped cross-sectional geometry, said rounded end having a convex outer surface and a concave inner surface.

9. An athletic protector as recited in claim 1, wherein upon application of a force to an exterior surface of said athletic protector, said thickened flange portion collapses inwardly in such a manner as to form a cushioning barrier between the rigid peripheral edges of said base member and the body of a wearer.

10. An athletic protector as recited in claim 1, further comprising said anchor formation of the outer edge having an outwardly extending solid leading portion; the exterior surface of the cup-shaped base member and an exterior surface of the solid leading portion forming an integral smooth external surface, wherein an interior surface of the solid leading portion has a stepped-shaped configuration.

11. An athletic protector as recited in claim 10, wherein said transition portion is formed with a continuous substantially uninterrupted channel enveloping said solid leading portion and said integral, external smooth surface.

12. An athletic protector, comprising:

a unitary rigid cup-shaped base member having interior and exterior surfaces defined along their peripheries by an outer edge, the edge having upper and lower segments joined by opposite side segments, said upper and lower segments terminating at corresponding upper and lower lips, said opposite side segments having an outer edge with an anchor formation;

an integral resilient body comprising:

a cup-shaped portion, a thickened flanged portion and a transition portion between said cup-shaped portion and said thickened flanged portion;

wherein said cup-shaped portion being molded over so as to envelope substantially the entire exterior surface of said cup-shaped base member, said outer edge including said anchor formation is enveloped by said transition region, and an inner surface of the resilient transition region and the interior surface of the rigid cup-shaped base member facing a body of a wearer form a continuous smooth internal surface.

13. An athletic protector having an upper, central and lower region and having a first and second sidewall, said protector comprising:

a rigid cup-shaped base member having interior and exterior surfaces defined along their peripheries by an outer edge;

an integral flexible body comprising: a cup-shaped portion, a flanged portion and a transition portion between said cup shaped portion and said flanged portion;

wherein said outer edge is covered by said transition portion; and

wherein said first and second sidewalls are substantially comprised of said integral flexible body at said central region.

14. The athletic protector as recited in claim 13, wherein said cup-shaped portion substantially covers one of said interior or said exterior surfaces.

15. The athletic protector as recited in claim 14, wherein the other of said exterior or said interior surface form a continuous surface with said integral flexible body.

16. The athletic protector as recited in claim 13, wherein said upper region is capable of being positioned against the side of a wearer's body while said lower region is capable of being positioned beneath the wearer's body.

17. The athletic protector as recited in claim 13, wherein said cup shaped portion substantially covers said cup-shaped base member.

18. An athletic protector having upper, central and lower region and a first and second sidewall, said protector comprising:

a unitary rigid cup-shaped base member;

an integral flexible body comprising: a cup-shaped portion, a flanged portion and a transition portion between said cup shaped portion and said flanged portion;

wherein said cup-shaped portion substantially covers said cup-shaped base member; and

wherein said first and second sidewalls are substantially comprised of said integral flexible body at said central region.

19. The athletic protector as recited in claim 18, wherein one of said interior surface or said exterior surface forms a continuous surface with said integral flexible body.

20. An athletic protector having upper, central and lower segments and first and second sidewalls, comprising:

a rigid cup-shaped base member having interior and exterior surfaces defined along its periphery by an outer edge having an anchor formation;

an integral flexible body comprising: a cup-shaped portion, a thickened flanged portion and a transition portion between said cup shaped portion and said thickened flanged portion;

wherein said cup shaped portion substantially covers one of said interior or said exterior surfaces and said anchor formation; and the other of said exterior or said interior surface forms a continuous surface with said integral flexible body; and

wherein at least a portion of said first and second sidewalls comprise a portion of said integral flexible body.

21. An athletic protector having an upper, central and lower segments and a first and second sidewall, comprising:

a unitary rigid cup-shaped base member having interior and exterior surfaces;

an integral flexible body comprising: a cup shaped portion, a flanged portion and a transition portion between said cup shaped portion and said flanged portion; and

wherein said first and second sidewalls are substantially comprised of said integral flexible body at said central region; and

wherein said one of said interior or said exterior surfaces form a continuous surface with said integral flexible body.

22. An athletic protector having upper, central and lower regions and having first and second sidewalls, said protector comprising:

a rigid cup-shaped base member defined along its periphery by an outer edge, said cup-shaped base member having interior and exterior surfaces; and

an integral flexible body comprising a cup-shaped portion, a flanged portion and a transition portion between said cup-shaped portion and said flanged portion;

wherein at least a portion of said outer edge is covered by said transition portion; and

wherein at least a portion of said first and second sidewalls comprise a portion of said integral flexible body.

23. The athletic protector according to claim 22, wherein said flanged portion terminates at a rounded end having a generally crescent-shaped cross-sectional geometry.

24. The athletic protector according to claim 22, wherein said cup-shaped portion of said integral flexible body covers at least a portion of said interior surface of said rigid cup-shaped base member.

25. The athletic protector according to claim 22, wherein said cup-shaped portion of said integral flexible body covers at least a portion of said exterior surface of said rigid cup-shaped base member.

26. The athletic protector according to claim 22, wherein said portion of said integral flexible body comprising at least a portion of the first and second sidewalls comprises said flanged portion.

27. An athletic protector having upper, central and lower regions and first and second sidewalls, said protector comprising:

a unitary rigid cup-shaped base member; and

an integral flexible body comprising a cup-shaped portion, a flanged portion and a transition portion between said cup-shaped portion and said flanged portion;

wherein said cup-shaped portion is contiguous with at least a portion of said cup-shaped base member; and

wherein at least a portion of said first and second sidewalls comprise a portion of said integral flexible body.

28. The athletic protector according to claim 27, wherein the unitary rigid cup-shaped base member has interior and exterior surfaces.

29. The athletic protector according to claim 28, wherein said cup-shaped portion of said integral flexible body is contiguous with at least a portion of said interior surface of said unitary rigid cup-shaped base member.

30. The athletic protector according to claim 28, wherein said cup-shaped portion of said integral flexible body is contiguous with at least a portion of said exterior surface of said unitary rigid cup-shaped base member.

31. The athletic protector according to claim 27, wherein said portion of said integral flexible body comprises said flanged portion.

32. The athletic protector according to claim 27, said flanged portion terminates at a rounded end having a generally crescent-shaped cross-sectional geometry.

33. An athletic protector having upper, central and lower regions and first and second sidewalls, said protector comprising:

a rigid cup-shaped base member defined along its periphery by an outer edge having an anchor formation, said cup-shaped base member having interior and exterior surfaces; and

an integral flexible body comprising a cup-shaped portion, a flanged portion and a transition portion between said cup-shaped portion and said flanged portion;

wherein said transition portion is contiguous with said anchor formation;

wherein said cup-shaped portion is contiguous with at least a portion of one of said interior or exterior surfaces;

wherein the other of said exterior or said interior surfaces forms a continuous surface with said integral flexible body; and

wherein at least a portion of said first and second sidewalls comprise a portion of said integral flexible body.

34. The athletic protector according to claim 33, wherein said portion of the integral flexible body comprising at least a portion of the first and second sidewalls comprises said flanged portion.

35. The athletic protector according to claim 33, wherein said flanged portion terminates at a rounded end having a generally crescent-shaped cross-sectional geometry.

36. An athletic protector having upper, central and lower segments and first and second sidewalls, comprising:

a unitary rigid cup-shaped base member having at least one surface; and

an integral flexible body comprising a cup-shaped portion, a flanged portion and a transition portion between said cup-shaped portion and said flanged portion;

wherein at least a portion of said first and second sidewalls comprise a portion of said integral flexible body; and

wherein said at least one surface of the unitary rigid cup-shaped base member forms a continuous surface with said integral flexible body.

37. The athletic protector according to claim 36, wherein the unitary rigid cup-shaped base member has interior and exterior surfaces.

38. The athletic protector according to claim 37, wherein the interior surface of the unitary rigid cup-shaped base member forms the continuous surface with said integral flexible body.

39. The athletic protector according to claim 37, wherein the exterior surface of the unitary rigid cup-shaped base member forms the continuous surface with said integral flexible body.

40. The athletic protector according to claim 36, wherein said flanged portion terminates at a rounded end having a generally crescent-shaped cross-sectional geometry.

41. The athletic protector according to claim 36, wherein said portion of said integral flexible member comprising at least a portion of said first and second sidewalls comprises said flanged portion.