# US 2019/0166947 A1 · Athletic gear or other devices comprising pads or other cushioning components > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0166947 A1 - Document ID: US20190166947A1 - Status: Published application - Kind: A1 - Application number: 16/206,112 - Filed: 2018-11-30 - Published: 2019-06-06 - Earliest claimed: 2017-11-30 - Assignees: Bauer Hockey, LLC - Applicants: Bauer Hockey Ltd. - Inventors: JEAN-FRANÇOIS LAPERRIÈRE; CHARLES-ANTOINE DESROCHERS - Web page: https://patentgrep.com/patent/US20190166947A1 ## CPC - A42B 3/128: {with zones of different density} - A43B 5/1625: {made from materials with different rigidities} - A43B 23/028: {Resilient uppers, e.g. shock absorbing} - A63B 59/20: having means, e.g. pockets, netting or adhesive type surfaces, for catching or holding a ball, e.g. for lacrosse or pelota - A63B 59/54: made of plastic - A63B 59/70: with bent or angled lower parts for hitting a ball on the ground, on an ice-covered surface, or in the air, e.g. for hockey or hurling - A63B 60/08: characterised by the material - A63B 71/12: for the body or the legs {, e.g. for the shoulders (A63B71/081 takes precedence)} - A63B 71/1225: {for the legs, e.g. thighs, knees, ankles, feet} - A63B 71/14: for the hands, e.g. baseball, boxing or golfing gloves (archer's finger tabs F41B5/1473) - A63B 71/141: {in the form of gloves} - B32B 1/00: Layered products having a non-planar shape - B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} - B32B 3/14: characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)} - B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} - B32B 5/022: {Non-woven fabric} - B32B 5/024: {Woven fabric} - B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder - B32B 5/32: {at least two} layers being foamed {and next to each other} - B32B 7/02: Physical, chemical or physicochemical properties - B32B 7/022: Mechanical properties - B32B 27/14: next to a particulate layer - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B32B 27/34: comprising polyamides - B32B 27/365: {comprising polycarbonates} - B32B 27/40: comprising polyurethanes - A42B 3/06: Impact-absorbing shells, e.g. of crash helmets - A42B 3/08: Chin straps or similar retention devices - A42B 3/324: {Adjustable helmets} - A63B 71/10: for the head ({A63B71/081 takes precedence } ; in the form of caps or hats A42B1/08; helmets A42B3/00) - A63B 2071/1208: {for the breast and the abdomen, e.g. breast plates} - A63B 2102/14: Lacrosse - A63B 2102/18: Baseball, rounders or similar games - A63B 2102/24: Ice hockey - A63B 2209/00: Characteristics of used materials - A63B 2209/02: with reinforcing fibres, e.g. carbon, polyamide fibres - B32B 27/065: {of foam} - B32B 2262/0207: Elastomeric fibres - B32B 2262/0253: Polyolefin fibres - B32B 2262/0261: Polyamide fibres - B32B 2262/0276: Polyester fibres - B32B 2266/0214: Materials belonging to B32B27/00 - B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF - B32B 2266/025: Polyolefin - B32B 2266/0278: Polyurethane - B32B 2307/51: Elastic - B32B 2307/536: Hardness - B32B 2307/54: Yield strength; Tensile strength - B32B 2307/558: Impact strength, toughness - B32B 2307/56: Damping, energy absorption - B32B 2307/72: Density - B32B 2307/722: Non-uniform density - B32B 2307/732: Dimensional properties - B32B 2437/04: Caps, helmets - B32B 2571/00: Protective equipment - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A device (e.g., an article of athletic gear) comprising a cushioning component for absorbing energy when the device is contacted (i.e., impacted or otherwise contacted), in which the cushioning component comprises a core comprising a plurality of zones of different materials (e.g., which may differ in one or more materials properties such as density, stiffness, resilience, etc.) and a covering disposed on the core. In some embodiments, a given one of the zones of different materials may be a zone of expanded microspheres. The cushioning component may provide enhanced protection, comfort, and/or vibration or other shock absorption while being relatively lightweight. ## Claims ### Claim 1 A cushioning component comprising: a core comprising a plurality of zones of different materials; and a covering disposed on the core; wherein a given one of the zones of different materials is a zone of expanded microspheres. ### Claim 2 (depends on 1) The cushioning component of claim 1, wherein a density of a first zone of the different materials is different from a density of a second one of the zones of different materials. ### Claim 3 (depends on 2) The cushioning component of claim 2, wherein the cushioning component is configured to protect a user, the second one of the zone of different materials is configured to be located closer to the user than the first one of the zones of different materials, and the density of the second one of the zones of different materials is less than the density of the first one of the zones of different materials. ### Claim 4 (canceled) ### Claim 5 (depends on 2) The cushioning component of claim 2, wherein the density of the second one of the zones of different materials is no more than 50% of the density of the first one of the zones of different materials. ### Claim 6 (canceled) ### Claim 7 (depends on 2) The cushioning component of claim 2, wherein a modulus of elasticity of a first zone of the different materials is different from a modulus of elasticity of a second one of the zones of different materials. ### Claim 8 (canceled) ### Claim 9 (canceled) ### Claim 10 (canceled) ### Claim 11 (canceled) ### Claim 12 (depends on 1) The cushioning component of claim 1, wherein a resilience of a first zone of the different materials is different from a resilience of a second one of the zones of different materials. ### Claim 13 (canceled) ### Claim 14 (canceled) ### Claim 15 (canceled) ### Claim 16 (canceled) ### Claim 17 (depends on 1) The cushioning component of claim 1, wherein an elongation at break of a first zone of the different materials is different from an elongation at break of a second one of the zones of different materials. ### Claim 18 (canceled) ### Claim 19 (canceled) ### Claim 20 (canceled) ### Claim 21 (canceled) ### Claim 22 (depends on 1) The cushioning component of claim 1, wherein the given one of the zones of different materials is a first given one of the zones of different materials, the zone of expanded microspheres is a first zone of expanded microspheres, a second given one of the zones of different materials is a second zone of expanded microspheres, and a density of the first zone of expanded microspheres is different from a density of the second zone of expanded microspheres. ### Claim 23 (depends on 22) The cushioning component of claim 22, wherein the cushioning component is configured to protect a user, the second zone of expanded microspheres is configured to be located closer to the user than the first zone of expanded microspheres, and the density of the second zone of expanded microspheres is less than the density of the first zone of expanded microspheres. ### Claim 24 (canceled) ### Claim 25 (canceled) ### Claim 26 (canceled) ### Claim 27 (depends on 1) The cushioning component of claim 1, wherein the zone of expanded microspheres constitutes at least one-quarter of the core by weight. ### Claim 28 (canceled) ### Claim 29 (depends on 1) The cushioning component of claim 1, wherein the zone of expanded microspheres constitutes at least half of the core by weight. ### Claim 30 (depends on 1) The cushioning component of claim 1, wherein the given one of the zones of different materials is a first given one of the zones of different materials, the zone of expanded microspheres is a first zone of expanded microspheres, and a second given one of the zones of different materials is a second zone of expanded microspheres. ### Claim 31 (depends on 30) The cushioning component of claim 30, wherein a state of the first zone of expanded microspheres is different from a state of the second zone of expanded microspheres. ### Claim 32 (depends on 30) The cushioning component of claim 30, wherein the first zone of expanded microspheres is consolidated and the second zone of expanded microspheres is unconsolidated. ### Claim 33 (depends on 1) The cushioning component of claim 1, wherein expanded microspheres constitute at least one-quarter of the core by weight. ### Claim 34 (canceled) ### Claim 35 (depends on 1) The cushioning component of claim 1, wherein expanded microspheres constitute at least a majority of the core by weight. ### Claim 36 (depends on 1) The cushioning component of claim 1, wherein the given one of the zones of different materials is a first given one of the zones of different materials, and a second given one of the zones of different materials is not a zone of expanded microspheres. ### Claim 37 (depends on 1) The cushioning component of claim 1, wherein: the given one of the zones of different materials is a first given one of the zones of different materials; and a second given one of the zones of different materials is a zone of foam. ### Claim 38 (depends on 37) The cushioning component of claim 37, wherein the zone of foam is a first zone of foam, a third given one of the zones of different materials is a second zone of foam, and a density of the second zone of foam is different from a density of the second zone of foam. ### Claim 39 (canceled) ### Claim 40 (canceled) ### Claim 41 (canceled) ### Claim 42 (depends on 1) The cushioning component of claim 1, wherein the zones of different materials include at least three zones of different materials. ### Claim 43 (depends on 1) The cushioning component of claim 1, wherein a peripheral one of the zones of different materials comprises a projection projecting from an adjacent part of a surface of the core. ### Claim 44 (depends on 1) The cushioning component of claim 1, wherein a peripheral one of the zones of different materials comprises a plurality of projections projecting from an adjacent part of a surface of the core and spaced from one another. ### Claim 45 (depends on 1) The cushioning component of claim 1, wherein a thickness of the zone of expanded microspheres corresponds to at least one-quarter of a thickness of the core. ### Claim 46 (canceled) ### Claim 47 (depends on 1) The cushioning component of claim 1, wherein a thickness of the zone of expanded microspheres corresponds to at least a majority of a thickness of the core. ### Claim 48 (canceled) ### Claim 49 (canceled) ### Claim 50 (depends on 1) The cushioning component of claim 1, wherein a particular one of the zones of different materials and an adjacent one of the zones of different materials are interlocked by an interlocking part of the particular one of the zones of different materials extending into an interlocking void of the adjacent one of the zones of different materials. ### Claim 51 (depends on 1) The cushioning component of claim 1, wherein the core comprises a first side and a second side opposite to the first side of the core and the first side of the core is uneven. ### Claim 52 (depends on 1) The cushioning component of claim 1, wherein the first side of the core is concave. ### Claim 53 (depends on 1) The cushioning component of claim 1, wherein the core comprises a first side and a second side opposite to the first side of the core and the covering covers at least part of the first side of the core and at least part of the second side of the core. ### Claim 54 (depends on 53) The cushioning component of claim 53, wherein the covering covers at least a majority of the first side of the core and at least a majority of the second side of the core. ### Claim 55 (depends on 54) The cushioning component of claim 54, wherein the covering covers an entirety of the first side of the core and an entirety of the second side of the core. ### Claim 56 (depends on 1) The cushioning component of claim 1, wherein the covering covers at least a majority of a periphery of the core. ### Claim 57 (depends on 1) The cushioning component of claim 1, wherein the covering envelops the core. ### Claim 58 (depends on 1) The cushioning component of claim 1, wherein the covering is molded to conform to the core. ### Claim 59 (depends on 58) The cushioning component of claim 58, wherein at least part of the covering is vacuum-formed. ### Claim 60 (depends on 1) The cushioning component of claim 1, wherein the covering comprises a layer of polymeric material molded to conform to the core. ### Claim 61 (depends on 60) The cushioning component of claim 60, wherein the layer of polymeric material is a layer of polyurethane. ### Claim 62 (depends on 1) The cushioning component of claim 1, wherein the covering comprises a layer of fabric molded to conform to the core. ### Claim 63 (depends on 1) The cushioning component of claim 1, wherein the covering comprises a layer of a first material molded to conform to a first side of the core and a layer of a second material different from the first material molded to conform to a second side of the core opposite to the first side of the core. ### Claim 64 (depends on 1) The cushioning component of claim 1, wherein the first material is a polymeric material and the second material is a fabric. ### Claim 65 (depends on 1) The cushioning component of claim 1, wherein the covering is bonded to the core. ### Claim 66 (canceled) ### Claim 67 (canceled) ### Claim 68 (canceled) ### Claim 69 (canceled) ### Claim 70 (canceled) ### Claim 71 (depends on 1) The cushioning component of claim 1, wherein the core comprises a hole extending through the core and defined by an internal surface of the core, and the covering extends into the hole and covers at least part of the internal surface of the core. ### Claim 72 (depends on 1) A device comprising the cushioning component of claim 1. ### Claim 73 (depends on 72) The device of claim 72, wherein the device is an article of athletic gear for a user. ### Claim 74 (depends on 73) The device of claim 73, wherein the article of athletic gear is an article of protective athletic gear wearable by the user and the cushioning component is a pad to protect the user. ### Claim 75 (depends on 74) The device of claim 74, wherein the article of protective athletic gear is a helmet for protecting a head of the user. ### Claim 76 (depends on 75) The device of claim 75, wherein the helmet comprises an outer shell and an inner liner that includes the pad. ### Claim 77 (depends on 72) The device of claim 72, wherein the device is an article of personal protective gear wearable by a user and the cushioning component is a pad to protect the user. ### Claim 78 (canceled) ### Claim 79 (canceled) ### Claim 80 (canceled) ### Claim 81 (canceled) ### Claim 82 (canceled) ### Claim 83 (canceled) ### Claim 84 (depends on 73) The device of claim 73, wherein the article of athletic gear is a sports implement for handling by the user. ### Claim 85 (depends on 84) The device of claim 84, wherein the sports implement is a hockey stick. ### Claim 86 (depends on 84) The device of claim 84, wherein the sports implement is a lacrosse stick. ### Claim 87 (depends on 84) The device of claim 84, wherein the sports implement is a ball bat. ### Claim 88 (depends on 1) A device comprising the cushioning component of claim 1, wherein the device comprises a first side and a second side opposite to the first side, the core comprises a first side facing towards the first side of the device and a second side facing towards the second side of the device, and the core occupies a majority of a thickness of the device from the first side of the device to the second side of the core. ### Claim 89 (depends on 1) A device comprising a plurality of cushioning components as claimed in claim 1. ### Claim 90 A cushioning component comprising: a core comprising a zone of expanded microspheres and a zone materially different from the zone of expanded microspheres; and a covering disposed on the core. ### Claim 91 An article of athletic gear for a user, the article of athletic gear comprising a cushioning component that comprises: a core comprising a plurality of zones of different materials; and a covering disposed on the core; wherein a given one of the zones of different materials is a zone of expanded microspheres. ### Claim at position 92 -166. (canceled)