Segmented custom-molded protective device

Abstract

A protective pad, for example, a shin guard, for being custom-fitted to a body member to be protected, and including a first flexible cushion layer for being placed against the body member in a first orientation and an initially flexible intermediate layer having a first side positioned adjacent to the first layer. The intermediate layer includes a fabric impregnated with a moisture-curable resin which hardens upon curing to form a rigid structure of the fabric which retains a body part-defined shape into which it is molded during curing, thereby also holding the first flexible cushion layer in the same body-part defined shape, the intermediate layer defining at least first and second adjacent segments for overlying adjacent body parts of the wearer. A second flexible layer is positioned adjacent a second side of the intermediate layer for being held by the intermediate layer in the same body-part defined shape as the intermediate layer and for being placed against the body part to be protected in a second orientation. A connector is provided for connecting together the first and second flexible cushion layers and the intermediate layer sandwiched therebetween to form the protective pad into a unitary structure. Hinge means are provided for forming a hinge area of increased flexibility in the shin guard along a line extending between adjacent side edges of the first and second intermediate layer segments.

Dependencies are inferred from the claim text.