PROTECTION DEVICE AND PROCESS OF MAKING THE SAME

Description

RELATED APPLICATION

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

FIELD OF THE INVENTION

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.

BACKGROUND

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.

SUMMARY

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 (1) is provided, said protection device (1) comprising: at least one inflatable element (2) 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 (2) 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 (3) having a compartment (V) in which the plurality of segments is housed, wherein the case (3) comprises a first and second covers (4, 5) in sheet material, at least partially opposed to each other, wherein each segment is interposed between said first and second covers (4, 5).

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 (2) is fixed to, or in proximity to, at least one of said first and second covers (4, 5). In an aspect 2ter according to any one of the preceding aspects the inflatable element (2) 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 (2) 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 (4, 5).

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 (4, 5). In a 6th aspect according to any one of the preceding aspects each segment is fixed to the first and/or second cover (4, 5) 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 (2a) and a second wall (2b) in sheet material. In an 8th aspect according to the preceding aspect the first wall (2a) 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 (2b) 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 (2a, 2b) of each segment are engaged with each other at a peripheral edge (2c) 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 (2a, 2b) engaged with each other at a peripheral edge (2c) 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 (2a, 2b) 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 (4, 5).

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 (2c′, 2c″) opposite each other, joined at respective end portions by at least one connection tract (2c″), wherein the first and second tracts (2c′, 2c″) 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 (4, 5) at the first and second tract (2c′, 2c″) of the peripheral edge (2c).

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 (4), whereas at least a portion of the second tract of the same segment is fixed to the second cover (5). In a 16th aspect according to any one of the preceding six aspects each segment is fixed to the first and second covers (4, 5) 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 (4) 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 (5) 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 (4) 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 (5) 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 (4, 5) 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 (4) 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 (5) 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 (2) is made of a deformable material. In a 21st aspect according to any one of the preceding aspects the inflatable element (2) 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 (2) 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 (2a) of the inflatable element (2) is gas impermeable. In a 25th aspect according to any one of the preceding aspects from 7th to 24th the second wall (2b) of the inflatable element (2) is gas impermeable.

In a 26th aspect according to any one of the preceding aspects the inflatable element (2) 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 (2a, 2b) of the inflatable element (2) 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 (2a, 2b) of the inflatable element (2) 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 (2a, 2b) of said inflatable element (2) 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 (2a, 2b) of the inflatable element (2) 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 (2a, 2b) of the inflatable element (2) 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 (2) is elastically deformable. In a 33rd aspect according to any one of the preceding aspects the inflatable element (2) 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 (2a, 2b) 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 (2), to the length of said perimeter edge, in the deflated condition of the inflatable element (2), 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 (2a, 2b) are fluid-tightly engaged with each other at the peripheral edge (2c), 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 (2a, 2b) 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 (2a, 2b) 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 (2a, 2b) 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 (2) is directly fixed to, or in proximity to, at least one of said first and second covers (4, 5) 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 (4, 5). In a 42nd aspect according to any one of the preceding aspects, the first tract of the peripheral edge (2c) is fixed by sewing to the first cover (4) while the second tract of the peripheral edge is fixed by sewing to the second cover (5).

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 (2c′) of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (2), in the inflated condition of said segments, are placed at a predetermined distance (D1). In a 52nd aspect according to the preceding aspect said predetermined distance (D1) 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 (2c″) of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (2), in the inflated condition of said segments, are placed at a predetermined distance (D2). In an aspect 54 according to the preceding aspect, said predetermined distance (D2) 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 (D1) between two first tracts (2c′) is substantially equal to the predetermined distance (D2) of two second tracts (2c″).

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 (D1) between two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (2), 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 (D2) of two first tracts of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element (2), in the inflated condition of said segments, is equal to or greater than 1, optionally it is between 1 and 1.5.

In a 60th aspect according to any one of the preceding aspects, the inflatable element (2) 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 (2) 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 (2) are in fluid communication. In a 66th aspect according to any one of the preceding aspects, the inflatable element (2) comprises at least one connection section (20) 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 (20) of the inflatable element (2). In a 68th aspect according to 66th or 67th aspect, the inflatable element (2) comprises a connection section (20) 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 (20) is housed in the compartment (V) of the case (3). In a 70th aspect according to any one of the preceding aspects from 66th to 69th, the connection section (20) is interposed between said first and second covers (4, 5). In an 71st aspect according to any one of the preceding aspects from 66th to 70th, the connection section (20) 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 (20) comprises a respective first and second portions facing each other, wherein the connection section (20) further comprises one or more peripheral engagement portions. In a 72nd aspect according to the preceding aspect, the connection section (20) 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 (20) 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 (20) is fixed to, or in proximity to, at least one of said first and second covers (4, 5). 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 (20). 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 (4, 5). In a 77th aspect according to any one of the five preceding aspects, the connection section (20) is fixed to the first and/or second cover (4, 5) 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 (20) is engaged to the case.

In a 79th aspect according to any one of the preceding aspects, the first and second covers (4, 5) of the case (3), in the deflated condition of the inflatable element (2) 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 (4, 5) in the inflated condition of the inflatable element (2) 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 (4, 5) 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 (4, 5) of the case (3), 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 (4, 5) of the case (3), 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 (4, 5) of the case (3) 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 (4, 5) 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 (2) is fixed to the first and/or second cover (4, 5) at a distance from the joined (e.g., sewn) peripheral portions of said first and second covers (4, 5). In an aspect 85bis according to any one of the three preceding aspects, at least one peripheral portion of the first and second cover (4, 5) of the case (3) is fixed to each other by sewing, wherein each of said segments of the inflatable element (2) is sewn to the first and second cover (4, 5) at a distance from the seams joining said first and second cover (4, 5).

In an 86th aspect according to any one of the preceding aspects, the case (3) comprises a plurality of auxiliary covers (30) arranged in the compartment (V), wherein each auxiliary cover (30) is made of sheet material and defines within it a sub-chamber (C) in which the at least one segment of the inflatable element (2) is housed. In an 87th aspect according to the preceding aspect, each auxiliary cover (30) 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 (30) 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 (30) is fixed to at least one of: at least a peripheral engagement portion of the segment housed in the auxiliary cover (30), the first cover (4) of the case, or the second cover (5) of the case.

In a 90th aspect according to any one of the four preceding aspects, each auxiliary coating (30) comprises one or more peripheral engagement portions, wherein at least one peripheral engagement portion of each auxiliary coating (30) is fixed to, or in proximity to, at least one of said first and second covers (4, 5). In a 91st aspect according to any one of the preceding five aspects, each auxiliary cover (30) is interposed between said first and second cover (4, 5). In a 92nd aspect according to any one of the preceding six aspects, each auxiliary cover (30) is fixed to: at least a peripheral engagement portion of the segment housed in the auxiliary cover itself, the first cover (4) of the case, or the second cover (5) 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 (30). In a 94th aspect according to any one of the preceding aspects from 86th to 93rd, each auxiliary cover (30) 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 (30) 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 (30), 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 (30) 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 (4, 5).

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 (30) comprises a first wall (30a) and a second wall (30b) in sheet material, respectively facing and at least partially in contact with the first wall (2a) and the second wall (2b) of a segment of the inflatable element.

In a 100th aspect according to the preceding aspects, the first and second walls (30a, 30b) of each auxiliary cover (30) are fixed to at least one tract of the peripheral edge (2c) of a segment as well as to the first and second covers (4, 5) of the case. In a 101st aspect according to any one of the preceding two aspects, the first and second walls (30a, 30b) 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 (30a, 30b) of each auxiliary cover (30) are fixed, for example by seam, to the first cover (4) of the case, to the second cover (5) of the case, to the first and second tracts (2c′, 2c″) 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 (30a, 30b) of an auxiliary cover extends in heights between a first and second longitudinal portions (30a′, 30a′, 30b′), wherein the first and second longitudinal portions (30a′, 30b′) of the first and second walls (30a, 30b) of the auxiliary cover (30) are fixed, optionally sewn, to the first cover (4) 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 (4),

• • wherein the second longitudinal portions (30a″, 30b″) of the first and second walls (30a, 30b) of the auxiliary cover (30) are fixed, optionally sewn, to the second cover (5) of the case (3) and to at least one tract of the peripheral engagement portion of a segment which is also fixed, optionally sewn, to the second cover (5).

In an aspect 102bis according to any one of the preceding aspects, the first cover (4), 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 (5), 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 (4, 5), 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 (4, 5) 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.

In a 103rd aspect according to any one of the preceding aspects, the case (3) is made at least in part, optionally entirely, of gas permeable sheet material. In a 104th aspect according to any one of the preceding aspects, the case (3) is made of perforated sheet material. In a 105th aspect according to any one of the preceding aspects, the case (3) is made at least in part, optionally entirely, of woven material. In a 106th aspect according to any one of the preceding aspects, the case (3) is made at least in part, optionally entirely, of at least one of the following materials: polyester, nylon, cotton. In an aspect 106bis according to any one of the preceding aspects, the case (3) is made of deformable material.

In a 107th aspect according to any one of the preceding aspects, the inflatable element (2), in the inflated condition, is configured to occupy a predetermined volume lower than the internal volume of the case (3). In a 108th aspect according to any one of the preceding aspects, the ratio between the internal volume of the case (3) and the predetermined volume defined by the inflatable element, in the inflated condition, is equal to or greater than 1,1, optionally between 1,2 and 1,5.

In a 109th aspect according to any one of the preceding aspects, two immediately adjacent segments of the inflatable element (2) delimit in cooperation with at least one of the first cover (4) and the second cover (5), in the inflated condition and according to a section orthogonal to the extension trajectory of at least one of said segments, at least one empty zone. In a 110th aspect according to the preceding aspect, the at least one empty zone is not occupied by the inflatable element (2). In a 111th aspect according to any one of the two preceding aspects, the empty zone is present for a preponderant part (optionally at least 80%, even more optionally 90%) of the total longitudinal extension of said segments. In a 112th aspect according to any one of the three preceding aspects, the empty zone, in the inflated condition and at a longitudinal centreline of the two adjacent segments delimiting said empty zone, has a predetermined area, wherein the ratio between said predetermined area and the area of one of the segments delimiting said empty zone-in the inflated condition, in section along a plane orthogonal to the extension trajectory of the respective segment, at a longitudinal centreline zone of said segment-is between 0,05 and 0,3, optionally between 0,06 and 0,1.

In a 113th aspect according to any one of the three preceding aspects, the at least one empty zone comprises: a first empty zone (E1) delimited between two immediately adjacent segments of the inflatable element (2) and the first cover (4), a second empty zone (E2) delimited between two immediately adjacent segments of the inflatable element (2) and the second cover (5).

In a 114th aspect according to any one of the preceding aspect the at least one empty zone, optionally each of the said first and second empty zones has, in cross-section, a substantially triangular outline.

In a 115th aspect according to any one of the preceding aspects, the protection device (1) comprises an actuator (15) configured to allow the inflatable element (2) to switch from the deflated condition to the inflated condition. In a 116th aspect according to any one of the preceding aspects, the actuator (15) comprises a pressure vessel. In a 117th aspect according to any one of the preceding aspects, the protection device (1) further comprises: an activator configured to activate the actuator to allow the inflatable element to switch from the deflated to the inflated condition, a control unit connected to and active on the activator, wherein the control unit is configured to send a command signal to the activator to activate the actuator.

In a 118th aspect according to any one of the preceding aspects, the activator comprises at least one of: a pyrotechnic charge, a perforator. In an 119th aspect according to any one of the preceding two aspects, the protection device (1) further comprises at least one sensor configured to emit a signal representative of a condition of the user, wherein the control unit is configured to: receive the signal from the sensor, compare the received signal with at least one threshold value of a control parameter, determine, based on the comparison, the presence of an accident condition for the user, and if an accident condition is determined, send the command signal to the activator to determine the inflated condition of the inflatable element.

In a 120th aspect according to the preceding aspect, the at least one sensor comprises at least one of: a gyroscope, an accelerometer, a GPS.

In an 121st aspect a process of making the protection device (1) according to any one of the preceding aspects is provided. In a 122nd aspect according to the preceding aspect, the process comprises the steps of: arranging the inflatable element (2) with said one or more peripheral engagement portions, optionally in the deflated condition, fixing the inflatable element (2) to the case (3).

In a 123rd aspect according to the preceding aspect, the phase of fixing the inflatable element to the case comprises the following sub-phases: spreading a semi-finished product sheet material on a single plane, overlapping the inflatable element (2) on said semi-finished product, fixing and wrapping said semi-finished product to the inflatable element in such a way that said semi-finished product may define the case (3).

In a 124th aspect according to any one of the preceding aspects, the step of fixing the semi-finished product to the inflatable element comprises at least one seam step. In a 125th aspect according to any one of the preceding two aspects, the semi-finished product comprises at least one sheet of gas permeable material. In a 126th aspect according to any one of the preceding three aspects, the semi-finished product is in a monolayer sheet material. In a 127th aspect according to any one of the four preceding aspects, the semi-finished product is made at least in part, optionally entirely, of woven material. In a 128th aspect according to any one of the five preceding aspects, the semi-finished product is made at least in part, optionally entirely, of at least one of the following materials: polyester, nylon, cotton.

In a 129th aspect according to any one of the preceding aspects from 121st to 128th, the step of arranging the inflatable element (2) comprises the sub-steps of: arranging a first sheet, overlapping a second sheet on the first sheet, fluid-tightly joining the first and second sheets at a peripheral zone to define said inflatable element (2).

In a 130th aspect according to any one of the preceding aspects, the first and second sheets have a gas impermeable structure. In a 131st aspect according to any one of the preceding two aspects, the first and second sheets are at least partially made of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene, silicone rubber, rubber. In a 132nd aspect according to any one of the preceding three aspects, the step of joining the first and second sheets comprises at least one of the following processes: gluing, seam, welding. In a 133rd aspect according to any one of the four preceding aspects, the first and second sheets are welded, optionally heat-sealed, together to define the peripheral edge of the inflatable element. In a 134th aspect according to any one of the five preceding aspects, the first and second sheets 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 135th aspect a use of said protection device (1) according to any one of the preceding aspects is provide to define at least one of: an integral part of a garment wearable by a user, an integral part of a protection accessory for a user's body (optionally at least one of: a back protector, a chest protector, a shoulder protector, a neck protector, a head protector, a pelvic protector, a leg protector), a device that may be coupled (fixable or detachably engageable) to a garment, a device that may be coupled (fixable or detachably engageable) to a protection accessory for a user.

In a 136th aspect a garment (100) wearable by a user comprising at least one protection device (1) according to any one of the preceding aspects is provided. In a 137th aspect according to the preceding aspect, the garment (100) comprises at least one of: a jacket, a gilet, a tracksuit (optionally a motorbike tracksuit or a motorsport tracksuit), technical sportswear. In a 138th aspect according to any one of the preceding two aspects, the garment comprises an outer layer and an inner layer, wherein the protection device (1) is: directly engaged at the inner layer to define a part of an inner surface of the garment, or engaged between the inner and outer layers of the garment.

In a 139th aspect according to any one of the preceding aspects, the protection device (1) is fixed to the inner layer of a garment. In a 140th aspect according to any one of the preceding two aspects, the protection device (1) is sewn to the inner layer of a garment. In a 141st aspect according to any one of the three preceding aspects, the protection device is sewn to the inner layer of the garment. In a 142nd aspect according to any one of the four preceding aspects, the case (optionally only the case of the protective device) is directly fixed (optionally sewn) to the inner layer. In a 143rd aspect according to any one of the preceding five aspects, the case (3) of the protection device is sewn to the inner layer of the garment at the peripheral engagement portion between the first and second covers (4, 5).

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments and aspects of the invention will be described below with reference to the accompanying drawings, which are provided for illustrative purposes only and are therefore not limiting, wherein:

FIGS. 1 and 2 are schematic views of a garment comprising a protection device according to the present invention;

FIG. 3 is a perspective view of a protection device according to the present invention, for example usable on the garment of FIGS. 1 and 2;

FIGS. 4 and 5 are schematic views of a further garment comprising a protection device according to the present invention;

FIG. 6 is a perspective view of an inflatable element usable in a protection device;

FIG. 7 is a sectional view of a protection device according to a first embodiment, in a deflated condition;

FIG. 8 is a sectional view of the protection device of FIG. 7, in an inflated condition;

FIGS. 9 and 10 are perspective views of a protection device according to a second embodiment, in a deflated condition and an inflated condition, respectively;

FIGS. 11 and 12 are sectional views of the protection device of FIGS. 9 and 10, in a deflated condition and an inflated condition, respectively.

CONVENTIONS AND DEFINITIONS

In the present detailed description, corresponding parts illustrated in the various figures are indicated by the same numerical references. The figures may illustrate the subject-matter of the invention by means of representations that are not to scale; therefore, parts and components illustrated in the figures may relate only to schematic representations.

The term ‘sheet material’ refers to a structure with two dimensions (e.g., length and width) strongly overriding a third dimension (the thickness). The sheet material extends in thickness between a first and a second main surface and may be a single-layer or multi-layer.

For example, as will be better described below, the protection device object of the present invention comprises at least one inflatable element, which may be made of sheet material. In particular, the inflatable element may comprise at least one wall, optionally a first and a second wall, made of sheet material, capable of substantially defining a fluid-tight bag. The inflatable element may have a first and second walls joined in a fluid-tight way to define substantially a bag.

The sheet (or foil) material of at least one wall, optionally of the first and second wall, of the inflatable element may be monolayer or multilayer. In the case of a monolayer sheet, this may substantially comprise a plastic film, in particular a material that is substantially impermeable to gases. In detail, the first and second walls may be of a heat-sealable type to allow said walls to be welded together; in particular, the first and second walls may be engaged with each other by means of heat pressing, high frequency welding or ultrasonic welding.

In detail, the at least one wall, optionally the first and second wall, of the inflatable element may be made of at least one of the following material: polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The thickness of the single plastic film may be between 0,05 mm and 0,4 mm, optionally 0,1 mm and 0,25 mm.

In the case of a multilayer sheet, this may comprise at least a first gas barrier layer coupled with a second layer configured to increase the sheet's mechanical properties.

The first gas barrier layer may comprise a plastic film, e.g., polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The first layer is coupled with the second layer, e.g., by means of glue. As mentioned above, the second layer substantially defines the structural element of the multilayer sheet configured to increase the mechanical properties of the sheet with respect to a sheet having the same thickness made solely of the material of the first layer. The second layer may be made of woven material, e.g., nylon or polyester.

In this way, the first layer of the multilayer sheet ensures gas impermeability, while the second layer ensures resistance during inflation. In the case of an inflatable element with a first and second wall, these are placed in contact with each other on the side of the first layer in such a way that said first and second walls may be welded together in a fluid-tight manner, e.g., by hot pressing, high-frequency welding or ultrasonic welding.

When engaged with each other, the first and second walls of multilayer material substantially define a bag wherein the first layer defines the inner surface while the second layer defines an outer surface of said bag.

The term ‘impermeable’ refers to the ability of a body or material to prevent the passage of fluids. The wall, optionally the first and second wall, of the inflatable element is substantially impermeable to gas, i.e., it does not allow a gas (optionally air or nitrogen) to pass through the thickness of the sheet material.

The term ‘breathable’ indicates the permeability of a body or material to a gas, e.g., air.

The term ‘actuator’ refers to any device capable of causing a movement on a body, e.g., upon command from the control unit (reception by the actuator of a command sent by the control unit). The actuator may comprise a gas generator, such as a pressure vessel.

The protection device may comprises/use at least one control unit for controlling the operating conditions of the protection device. The control unit may be a single unit or consist of several separate control units, depending on the design choices and operational requirements.

By ‘control unit’ is meant a component of electronic type, which may comprise at least one of: a digital processor (CPU), an analogue type circuit, or a combination of one or more digital processors with one or more analogue type circuits. The control unit may be “configured” or “programmed” to perform certain steps: this may be achieved in practice by any means that allows the control unit to be configured or programmed. For example, in the case of a control unit comprises one or more CPUs and one or more memories, one or more programs may be stored in appropriate memory banks attached to the CPU(s); the program(s) contain instructions which, when executed by the CPU(s), program or configure the control unit to perform the operations described in relation to the control unit. Alternatively, if the control unit is or comprises analogue type circuitry, then the circuitry of the control unit may be designed to include circuitry configured, in use, to process electrical signals to perform the steps related to the control unit.

At least part of the operation of the protection device described may be performed by a data processing unit, or control unit, technically substitutable for one or more computers designed to execute a portion of a software programme or firmware loaded onto a storage medium. Such a software programme may be written in any known programming language.

The data processing unit, or control unit, may be a general purpose processor configured to perform one or more of the steps of the operating process identified in this disclosure through the software or firmware programme, or be an ASIC or dedicated processor or FPGA, specifically programmed to perform at least part of the operations of the operating process.

The memory medium may be non-transitory and may be internal or external to the processor, or control unit, or data processing unit. The memory medium may also be physically divided into several portions.

DETAILED DESCRIPTION

Protection Device

Reference 1 indicates a wearable protection device configured to protect a user's body from impact, e.g., in the event of an accident. For example, the protection device 1 may be used in the sport field and may be inserted or engaged in technical clothing, such as jackets, gilet, tracksuits for the motorcycling and motorsport fields. In fact, as will be better described below, the protection device 1 of the present invention may be insertable/coupled to a garment or be an integral part of a garment; further, the protection device 1 may be used as a stand-alone protection, for example a knee pad, a back protector, a head, neck and chest protector of a user. As will be better described below, the protection device 1 is configured to inflate by means of pressurised gas to define a kind of bag configured to absorb shocks.

The protection device 1 comprises a case 3 made of sheet material, defining a compartment V, which, as will be further described below, is configured to house at least one inflatable element 2. The case 3 is made of a deformable material, e.g., it is at least partly made of at least one of the following materials: polyester, nylon, cotton. In fact, the case 3 is configured to be arranged in a stretched or taut configuration, depending on the stresses/strains applied to the material. Additionally, the case may be made at least in part, optionally entirely, of gas-permeable sheet material. In particular, the material itself or the case structure may be gas permeable. For example, in a non-limiting way, the sheet material from which the case 3 is made may be of a woven type which, due to its structure, may provide a certain breathability in itself; further, the sheet material from which the case 3 is made may have a perforated structure. In fact, gas permeability may be achieved due to the type of material used and/or the presence of openings through the thickness of the sheet that allow gas to pass through.

The case 3 with a perforated woven structure was illustrated in the accompanying figures. Such a configuration ensures the passage of air through the case 3 and thus a certain breathability.

As mentioned above, the case 3 is made of deformable sheet material. For example, the woven structure ensures a certain deformability of the sheet material capable of moving according to applied stresses. The thickness of the sheet material forming the case 3 may be between 0,05 mm and 2,5 mm, optionally between 0,1 mm and 1 mm.

The case 3 may comprise a first and second cover 4, 5 made of sheet material at least partially facing each other so as to delimitate, in interposition between said covers 4, 5, a compartment V which, as will be better described below, is configured to house at least one inflatable element 2. The first and second covers 4, 5 may have respective peripheral portions 3c fixed to each other, for example by means of sewing (FIG. 3), to substantially define one at least partially closed bag. The first and second covers may be fixed (e.g., sewn), in a non-limiting way, for substantially the entire extension of the peripheral portion 3c to define substantially a fully closed pouch (FIG. 3). The type of engagement between the first and second covers may depend on the type of material used for the case 3; for example, if a woven material is used, the first and second covers may be fixed by means of a seam. The possibility of joining covers 4, 5 by means of glue or a heat-sealing process is not excluded. In a different embodiment, the first and second covers 4, 5 faces each other but are spaced to substantially define an open type compartment V.

In fact, in a first embodiment, the case 3 consists only of the first and second covers 4, 5 which may be joined at peripheral portions 3c or, as mentioned above, may be two entirely unattached layers.

FIGS. 7 and 8 show a different embodiment of the case 3 which further includes, in a non-limiting way, a plurality of auxiliary covers 30 arranged in the compartment V in interposition between the first and second covers 4, 5; each auxiliary cover 30 defines within it a sub-chamber C, in which the inflatable element 2 is housed, in particular at least one segment of the inflatable element (a component better described below). Each auxiliary cover 30 comprises at least one wall made of sheet material, which may be made of the same material as the first and second covers 4, 5. Each auxiliary cover 30 may be directly fixed to at least one of: the inflatable element (optionally directly to the segment of the inflatable element housed in the respective auxiliary cover 30), the first cover 4, the second cover 5.

In further detail, each auxiliary cover 30 comprises one or more peripheral engagement portions fixed to, or in proximity to, at least one of said first and second covers 4, 5. In still greater detail, each auxiliary cover 30 is fixed at its peripheral engagement portion to: the inflatable element 2 (optionally directly to the segment of the inflatable element 2 housed in the respective auxiliary cover 30), to the first cover 4, to the second cover 5. In fact, each auxiliary cover 30 comprises at least two peripheral engagement portions opposite each other with respect to the internal volume defined by the sub-chamber C of the respective auxiliary cover 30; each auxiliary cover is therefore fixed at opposing peripheral engagement portions of the inflatable element and/or to the first and second cover 4, 5.

The peripheral engagement portion of an auxiliary cover 30 may be defined by a protruding band in sheet material; depending on the material used, this portion may be sewn, glued or heat-sealed to at least one of: the first cover, the second cover, the inflatable element.

FIGS. 7 and 8 show a case 3 having, in a non-limiting way, two auxiliary covers 30 fixed to both the first cover 4 and the second cover 5. The at least one wall of each auxiliary cover 30 comprises a first wall 30a and a second wall 30b in sheet material facing each other and movable with respect to each other due to the deformable structure thereof. The first and second walls of each auxiliary cover 30 delimits a respective sub-chamber C configured to house one or more segments of the inflatable element.

Each auxiliary cover 30 extends longitudinally along an extension trajectory to define a length of said auxiliary cover. The length may be between 50 and 350 mm, optionally between 100 and 300 mm, and be defined substantially according to the structure and size of the inflatable element 2. For example, each auxiliary cover 30 may cover only a portion of the length of a segment or wrap around the segment entirely. Further, each of said first and second walls 30a, 30b of an auxiliary cover extends, orthogonally to the extension trajectory, between a first and second longitudinal portions (see references 30a′, 30a″, 30b′, 30b″ in FIGS. 7 and 8) opposite to each other to substantially define a wall height. A non-limiting configuration of the case 3 is shown in the attached figures where the first longitudinal portions 30a′, 30b′ of the first and second walls 30a, 30b are both fixed, optionally sewn, to a same portion of the first cover 4 while the second longitudinal portions 30a″, 30b″ of the first and second walls 30a, 30b are both fixed, optionally sewn, to a same portion of the second cover 5.

As mentioned above, the protection device 1 further comprises at least one inflatable element 2 comprising a plurality of side-by-side segments each extending along a respective extension trajectory. As mentioned above, the inflatable element 2 is housed in the compartment V of the case, in particular interposed between the first and second covers 4, 5. The inflatable element 2 is made of deformable sheet material, for example it is at least partly made of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber. In fact, the inflatable element 2 is configured to arrange itself in a stretched or taut configuration depending on the stresses/strains applied to the material. Further, the inflatable element 2 has a gas-tight structure such that the same element may switch from a deflated condition (relaxed condition of the inflatable element) to an inflated condition where the sheet material of the inflatable element is substantially stretched (in tension).

The sheet material of the inflatable element 2 may be, for example, a monolayer plastic film, which is gas-tight and deformable. In the case of monolayer plastic film, this may define an elastically deformable inflatable element structure. Alternatively, the sheet material of the inflatable element 2 may be a multi-layered material; for example, the sheet material defining the inflatable element may comprises: a first layer in plastic film, and a second woven layer coupled with the first layer, optionally fixed by glue or heat-sealing.

The first layer may be of a gas impermeable layer and define a gas barrier layer such that the inflatable element 2 can be inflated; for example, the first layer may comprise a plastic film, e.g., polyurethane, PVC, EVA, polyethylene, polypropylene, rubber, silicone rubber or similar materials. The second layer may substantially define the structural element of the multilayer sheet, e.g., configured to prevent the inflatable element from bursting during its transition from a deflated to an inflated (operational) condition; for example, the second layer may be made of woven material, e.g., nylon or polyester. In the case of multilayer sheet material, this may be deformable but substantially non-elastically deformable.

Each segment may have an elongated conformation, optionally extending along the extension trajectory T (see FIG. 6). Two immediately side-by-side segments may present substantially the same length, which is measured along their respective extension trajectories. For example, each segment may have a length measured along the extension trajectory of greater than 50 mm, optionally between 100 and 350 mm. Further, the at least one wall of each segment, 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 (or extension), which may be between 45 mm and 345 mm, optionally between 70 mm and 300 mm. In fact, 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 particular, 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 may be greater than 1,1, optionally between 1,2 and 1,6.

As described above, the inflatable element 2 and thus each segment is of a deformable type and may deform elastically. In a non-limiting way, the ratio between the length of the perimeter edge of each segment, in the inflated condition of the inflatable element 2, and the length of the same perimeter edge in the deflated condition of the inflatable element 2 is equal to or greater than 1, optionally being between 1 and 1,4 including extremes. In particular, it is possible to obtain an elastic deformation of the inflatable element by means of the engagement of a monolayer sheet material made of plastic film, for example polyurethane, while it is possible to obtain a change of shape of the inflatable element without, a plastic or elastic deformations by means of the engagement of a multilayer sheet material (reinforced sheet), for example made of nylon and polyurethane.

As mentioned above, the inflatable element 2 comprises a plurality of segments. Each segment comprises at least one wall in sheet material delimiting an internal volume and having a first and second portion facing each other; the inflatable element 2 is configurable between: a deflated condition (see, for example, FIGS. 7, 9 and 11) where the first and second portions of at least one wall of each segment, for a preponderant part of their surface extension, are close together and at least partially in contact with each other, and an inflated condition (see, for example, FIGS. 8, 10 and 12) where the first and second portions of at least one wall of each segment, for a predominant part of its surface extension, are spaced apart.

Each segment, in the inflated condition, defines an internal volume greater than the internal volume defined by the same segment when placed in the deflated condition. Further, in the inflated condition, the segments present substantially parallel extension trajectories. In each case, the first and second covers 4, 5 of the case 3, in the inflated condition and in the deflated condition, are maintained at a distance, for a preponderant portion of the surface extension of said covers (e.g., at least 70%, optionally at least 80%, of the surface extent of said covers 4, 5) by interposition of the plurality of segments.

FIGS. 7 and 11 show the portions of the at least one wall that are substantially separated in the inflated condition. These portions have been presented separately from each other for the sake of simplicity and to allow a better identification of the same in the attached figures; however, these walls are, in the deflated condition in contact with each other, also at a central area of these portions.

At least one of said segments, optionally all segments, further comprises one or more peripheral engagement portions 2c fixed to, or in proximity to, at least one of said first and second covers 4, 5, e.g., by one or more seams.

In detail, the at least one wall of each segment comprises a first wall 2a and a second wall 2b in sheet material: the first wall 2a has a central area, which defines said first portion of the at least one wall whereas the second wall 2b has a respective central area, which defines said second portion of the at least one wall. The first and second walls 2a, 2b of each segment are engaged with each other at a peripheral edge 2c to define a single peripheral engagement portion. The peripheral engagement portion substantially defines a fluid-tight band of union between the walls 2a, 2b which are also engaged to the case 3. Depending on the sheet material of the walls, these may be joined together to define the peripheral edge 2c by at least one of: glue, weld, seam. In an embodiment, the first and second walls 2a, 2b of the inflatable element 2 are fixed to each other by at least one of the following processes: hot pressing, high frequency welding, ultrasonic welding.

As shown in FIG. 3, each of said segments of the inflatable element 2 is fixed to the first and/or second covers 4, 5 at a distance from the joined peripheral portions 3c of said first and second covers 4, 5: in fact, each of said segments of the inflatable element 2 is sewn to the first and second covers 4, 5 at a distance from the seams joining the first and second covers 4, 5.

In detail, the peripheral edge 2c of each segment substantially has a first and a second tract 2c′, 2c″ opposite to each other with respect to the internal volume defined by the segment itself and joined at the end portions by at least one connection tract 2c″ (see, for example, FIG. 11). The first and second tracts 2c′, 2c″ of the peripheral edge extend substantially along the extension trajectory of the respective segment whereas the connecting edge 2c″ substantially defines a section extending transversely to the extension trajectory T of the respective segment. Each segment may define a distinct component and thus a kind of single fluid-tight bag closed at opposite longitudinal end portions; in such a configuration, each segment comprises the first and second tracts 2c′, 2″ joined at two end portions by two respective connection tracts 2c″. FIG. 3, on the other hand, illustrates an inflatable element 2 having a plurality of segments which protrude transversally (optionally orthogonally) from a connection section 20 of the inflatable element 2; the plurality of segments emerges from the same side of the connection section 20 and are placed in fluid communication with each other by said connection section 20. Also in such a configuration, each segment substantially has the first and second segments 2c′, 2c″ joined at a longitudinal end opposite to the connection section 20 by means of a single connecting segment 2c″ of the peripheral edge 2c.

The connection section 20 is part of the inflatable element 2 and is also housed in the compartment V of the case 3: the connection section may be also fixed to at least one of said first and second covers 4, 5. The connection section 20 may be a single tubular element joined to a plurality of segments, or it may have substantially the same double-wall structure as the segments, and thus move from an inflated to a deflated condition.

At least one of the first and second tracts 2c′, 2c″ of the peripheral edge 2c of each segment may be fixed to at least one of the first and second covers 4, 5. In more detail, in a non-limiting way, at least a part of the first tract 2c′ of a segment is fixed to the first cover 4, whereas at least a part of the second tract 2c″ of the same segment is fixed to the second cover 5; in this way, each segment is substantially fixed, e.g., sewn, to the case 3 at two opposing tracts with respect to the internal volume defined by the same segment. In greater detail, each segment may be fixed: to the first cover 4 at the first tract 2c′ for at least 50%, optionally 70%, of a total longitudinal extension of said first tract 2c′, substantially defined along the extension trajectory of the respective segment, and to the second cover 5 at the second tract 2c″ of the peripheral edge for at least 50%, optionally 70%, of a total longitudinal extension of said second tract, substantially defined along the extension trajectory of the respective segment.

The peripheral edge 2c of each segment fixed, optionally sewn, to case 3 may define a single continuous tractor define two or more discrete portions.

In dimensional terms, two first tracts 2c′ of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element 2, in the inflated condition of said segments, are placed at a predetermined distance D1, which may be equal to or greater than 25 mm, optionally between 30 mm and 80 mm; similarly, two second tracts 2c″ of two distinct peripheral edges of two immediately side-by-side segments of the inflatable element 2, in the inflated condition of said segments, are placed at a predetermined distance D2 (see FIGS. 8 and 12), which may be equal to or greater than 25 mm, optionally between 30 mm and 80 mm. In fact, the predetermined distance D1 between two first tracts 2c′ may be substantially equal to the predetermined distance D2 between two second tracts 2c″.

Further, the first and second tracts 2c′, 2c″ of the peripheral edge 2c of a segment are placed, in the inflated condition of the inflatable element 2, at a minimum distance Dm, which may be equal to or greater than 25 mm, optionally between 30 mm and 120 mm, even more optionally between 40 mm and 80 mm. In detail, the ratio between the minimum distance Dm of a segment and the distance D1 between the first tract 2c′ of the same segment and a tract 2c′ of an immediately adjacent segment is equal to or greater than 1, optionally it is between 1 and 1,5. Similarly, the ratio of the minimum distance Dm between the first and second tracts of the peripheral edge of a segment and the distance D2 between the second tract 2c″ of the peripheral edge of the same segment and a second tract of an immediately adjacent segment is equal to or greater than 1, optionally it is between 1 and 1,5.

The distances D1, D2 and Dm may be defined based on the size, in terms of perimeter edge, of the segments of the inflatable element 2. In fact, as mentioned above, each segment has a perimeter edge having a predetermined length; the ratio between the minimum distance Dm between the first and second tracts 2c′ and 2c″ of a segment and the length of the perimeter edge of the same segment is equal to or less than 1, optionally it is between 0,75 and 0,95. The length of the perimeter edge of a segment may further be related to the distances D1 and D2. In fact, the ratio between the distance D1 (between the first tract 2c′ of a first segment and a first tract 2c′ of a second immediately adjacent segment) and the length of the perimeter edge of the first segment is equal to or less than 0,9, optionally between 0,45 and 0,75. Similarly, the ratio of the distance D2 (between the second tract 2c′ of a first segment and a second tract 2c′ of a second immediately adjacent segment) and the length of the perimeter edge of the first segment is equal to or less than 0,9, optionally between 0,45 and 0,75.

Similar relations may be defined between the peripheral engagement portions of the walls 30a, 30b of each auxiliary cover 30 which, as schematically shown in the accompanying figures, is substantially countershaped to the segment of the inflatable element 2 housed in the respective auxiliary cover 30. As mentioned above, each auxiliary cover 30 is configured to contain the expansion of a segment, for example to prevent it from bursting, during the transition of the inflatable element from the deflated condition to the inflated condition. Therefore, in the inflated condition the auxiliary cover 30 when fixed to the peripheral edge 2c of a segment defines, in the inflated condition, a kind of cover adhered to the wall of the segment; therefore, said auxiliary cover 30, when joined to the peripheral edge 2c of a segment substantially shares the same dimensions and ratios between the various distances D1, D2 and Dm.

As described above, the case 3 has the first and second covers 4, 5 to which the segments of the inflatable element are fixed. This configuration allows the first and second covers 4, 5 to substantially act as a cover for the segments of the inflatable element 2 but also defines a constrained shape configured to guide the correct inflation of the protection device 1 during the transition of the inflatable element between the deflated and inflated condition. Additionally, the presence of the case 3 allows an optimised overall shape of the protection device 1 to be defined, a condition that maximises its effectiveness.

For example, the first and second covers 4, 5 of the case 3, in the deflated condition of the inflatable element 2 and in the area where said segments are fixed to the case 3, are spaced apart from each other up to a maximum distance DM; the first and second covers 4, 5, in the inflated condition of the inflatable element 2 and always in the area where said segments are fixed to the case 3, are instead arranged at an operating distance Dp, which is less than said maximum distance DM. In detail, the ratio between the maximum distance DM and the operating distance Dp between the first and second covers 4, 5 is equal to or greater than 1, optionally between 1,1, and 1,8.

As shown in FIGS. 8 and 12, the configuration of the case 3 and the inflatable element 2 defines, in the inflated condition of inflatable element 2, one or more empty zones. In fact, the inflatable element 2, in the inflated condition, is configured to occupy a prefixed volume which is lower than the internal volume of the compartment V definable by the case 3; for example, the ratio between the internal volume of the compartment V and the prefixed volume defined by the inflatable element 2, in the inflated condition, may be equal to greater than 1,1, optionally between 1,2 and 1,5.

In detail, the structure of the inflatable element 2 and the attachment structure between said inflatable element 2 and the case 3 allows defining between two immediately adjacent segments of the inflatable element 2, in cooperation with at least one of the first cover 4 and the second cover 5, in the inflated condition and according to a section orthogonal to the extension trajectory of at least one of said segments, at least one empty zone. The empty zone may be present for a preponderant part (optionally at least 80%, even more optionally 90%) of the overall longitudinal extension of said segments. In greater detail, such empty zone is present at least in the portions wherein the segments are fixed to the case 3.

In greater detail still, the empty zone has a predefined area; the ratio between said area and the area of one of the segments delimiting said empty zone—in the inflated condition, in section along a plane orthogonal to the extension trajectory of the respective segment at a longitudinal centreline of said segment-—is between 0,05 and 0,3, optionally between 0,06 and 0,1. As visible, for example, in FIGS. 8 and 12, the at least one empty zone comprises: a first empty zone E1 delimited between two immediately adjacent segments of the inflatable element 2 and the first cover 4, a second empty zone E2 delimited between two immediately adjacent segments of the inflatable element 2 and the second cover 5.

Each of said first and second empty zones E1, E2 has, in cross-section along a plane orthogonal to the extension trajectory of a segment delimiting said empty zone, a substantially triangular outline. These zones are opposite to each other and define a sort of bridge between two segments, a condition which allows the first and second covers 4, 5 to stretch and thus define an auxiliary zone of protection for the user.

Further, such a structure allows the first and second covers 4, 5 at least between two peripheral edges 2c of two immediately adjacent segments to define a substantially flat surface. This condition maximizes the width extension of the protection device to provide maximum protection to the user.

As mentioned above, the inflatable element 2 comprises a plurality of segments. In particular, the inflatable element 2 may comprise a number of segments equal to or greater than 2, optionally between 2 and 20 including extremes. The segments of said plurality of segments may all be placed side-by-side to substantially define a single group of segments. Alternatively, as shown in FIGS. 3 to 5, the inflatable element 2 may comprise: at least a first series of segments comprises two or more segments placed side-by-side, or at least a second series of segments comprises two or more segments placed side-by-side.

FIGS. 4 and 5 show an inflatable element 2 presenting two series of segments. A first series used to define a protection device for a user's chest and a second series used to protect the user's back. The two series are placed in fluid communication with each other by means of a sort of manifold 40. The manifold may, for example, be placed in direct fluid communication with the connection sections 20 of the two series. FIG. 3, on the other hand, illustrates, in a non-limiting way, a protection device with three series of segments. Also in such a configuration, two manifolds are configured to place the connection sections of the various series in fluid communication.

The segments of each series, in the inflated condition, have substantially parallel extension trajectories T; as can be seen, the segments of the different series, at least in the inflated condition, are spaced apart.

The protection device 1 may further comprise at least one actuator 15 configured to be placed in fluid communication with the inflatable element 2 to allow it to switch from the deflated to the inflated condition. The actuator 15 may comprise a pressure vessel. The protection device 1 may further comprise: an activator including, for example, a pyrotechnic charge and/or a perforator configured to activate the actuator 15 to allow the inflatable element to switch from the deflated to the inflated condition, and a control unit connected to and active on the activator, wherein the control unit is configured to send a command signal to the activator for activation (e.g., opening) of the actuator 15.

The protection device 1 may additionally comprise at least one sensor configured to emit a signal representative of a user condition.

The control unit is configured to: receive the signal from the sensor, compare the received signal with at least one threshold value of a control parameter, determine, based on the comparison, the presence of an accident condition for the user, and if the accident condition is determined, send the command signal to the activator to determine the inflated condition of the inflatable element 2.

At least one sensor may comprise at least one of: a gyroscope, an accelerometer, a GPS.

Making Process

It is also an object of the present invention a process of making a protection device 1 according to the attached claims. The process comprises a step of arranging the inflatable element 2 having said one or more peripheral engagement portions, arranged in the deflated condition. The step of arranging the inflatable element 2 comprises the sub-phases of: preparing a first sheet, overlapping a second sheet on the first sheet, and fluid-tight joining the first and second sheets at a peripheral area to define said inflatable element 2.

The first and second sheets may in a single piece to define a single semi-finished product or they may be two separate elements. The first and second sheets have substantially the same shape and size so that when overlapped the perimeter edge of the first sheet substantially coincides with the perimeter edge of the second sheet. The first and second sheets have a gas impermeable structure; for example, the first and second sheets are made at least in part of at least one of the following materials: polyurethane, PVC, EVA, polyethylene, polypropylene. Instead, the step of joining the first and second sheet may comprise at least one of the following processes: gluing, seam, welding; in particular, the welding sub-step may comprise at least one of the following processes: hot pressing, high frequency welding, ultrasonic welding. The joining of the first and second sheets defines the entire inflatable element 2, comprising at least the plurality of segments each comprising the first and second walls 2a, 2b joined together at the peripheral edge 2c. Depending on the shape of the first and second sheets, following the overlapping and joining steps, said first and second sheets may further define one or more connection sections 20.

The process further comprises a step of fixing the inflatable element 2 to the case 3. The step of fixing the inflatable element to the case 3 comprises the following sub-steps: spreading a semi-finished product in sheet material on a single plane, and fixing and wrapping said semi-finished product to the inflatable element 2 in such a way that said semi-finished product may define the case 3.

The phase of fixing the semi-finished product may be carried out following the formation of the inflatable element 2 or at the same time as this phase. For example, in a first embodiment, the process may comprise forming the inflatable element and then overlapping the semi-finished product; following the overlapping step, the process may comprise the step of fixing said semi-finished product to the peripheral edge 2c of the inflatable element, for example by means of a seam.

Alternatively, the semi-finished product may be joined, e.g., by seam, during the formation phase of the inflatable element 2, to at least one of said first and second sheets. In this way, case 3 and inflatable element 2 are formed simultaneously.

The semi-finished product may comprise at least one sheet of gas-permeable material, e.g., a mono-layer sheet. In further detail, the semi-finished product may be made at least in part, optionally entirely, of optionally perforated woven material. In still further detail, the semi-finished product may be made at least in part, optionally entirely, from at least one of the following materials: polyester, nylon, cotton.

Use of the Protection Device

It is also an object of the present invention to use protection device 1 to protect parts of a user's body. The protection device 1 may be directly used as a garment, e.g., as an integral part of a suit (see, for example, FIGS. 1 and FIG. 2), a jacket or a gilet (FIGS. 4 and FIG. 5), or it may be an integral part of an accessory for the protection of a user's body (optionally at least one of: a back protector, a chest protector, a shoulder protector, a neck protector, a head protector, a pelvis protector, a leg protector).

Alternatively, the protection device 1 may be of the type that can be coupled (fixed or detachable) to a garment or a protection device for a user.

Advantages

The present invention has important advantages over the state of the art. In fact, the attachment (e.g., the seams) of the segments to the first and/or cover 4, 5 of the case 3 allows the inflatable element to be attached and to be kept in the correct position in the compartment V of the case 3, for example during the use of the protection device 1 as an integral part or accessory of a garment 100; in this way, the protection of the user is ensured and problems of breakage of the inflatable element 2 due to incorrect positioning are avoided.

Additionally, the fixed (e.g., sewn) structure of the inflatable element 2 and the case 3 greatly simplifies the manufacturing process of the same. For example, the protection device 1 of the present invention eliminates the complex and delicate operation of inserting the inflatable element into the already formed case 3. For example, the fact of providing segments of the inflatable element sewn to the case 3 facilitates the positioning of the inflatable element 2 itself, solving possible positioning problems.

Additionally, the way the inflatable element is engaged to the case allows, in the deflated condition of the inflatable element, improves air passage, thus ensuring the provision of highly breathable clothing.

Furthermore, the way the inflatable element is engaged to the case 3 makes it possible, in the inflated condition, to obtain a protection device presenting extensive planar surfaces that allow for the adequate protection of a user's body, a condition to which is added the additional protection guaranteed by the empty zones between two immediately consecutive segments and the case 3, which allow the case and the segments to deform sufficiently to absorb shocks adequately and thus effectively protect a user's body.

While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both, unless the disclosure states otherwise. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.