US 6,269,485 B1 · Custom-fitted batter's lower leg protector

Abstract

A batter's lower leg protector product, including a lower leg protector for being custom-formed to the shape of a batter's lower leg while flexible and upon hardening providing a rigid, supporting custom fit. The lower leg protector product includes an outer container formed of moisture-impervious material. A flexible lower leg protector is positioned in the container in substantially moisture-free conditions and sealed therein against entry of moisture until use. The lower leg protector includes a leg portion shaped to provide, when in place on a batter's leg, protection to the front, lateral and medial aspects of the leg above the ankle and optionally-detachable ankle flap portions integrally formed with a bottom edge of the leg portion and shaped to provide protection to the lateral and medial ankle bones. The lower leg protector includes a substrate and a reactive system impregnated into or coated onto the substrate, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to moisture to form a rigid, self supporting structure. A flexible protective pad is positioned on one side of the substrate to provide cushioning between the substrate and the batter when the lower leg protector is being worn. An outer cover covers the substrate on the side opposite the protective pad. The substrate, protective pad and outer cover are connected together into a unitary structure for being molded while flexible to the lower leg and ankle of the batter. Complementary fasteners are attached to opposing side edges of the lower leg protector for retaining the lower leg protector in place on the batter's leg while being worn. A foot protector having an construction optionally provides protection to the top of the foot.

Claims20

Dependent claims

A batter's lower leg protector product including a lower leg protector for being custom-formed to the shape of a batter's lower leg while flexible and upon hardening providing a rigid, supporting custom fit, said lower leg protector product comprising:

(a) an outer container formed of moisture-impervious material;
(b) a flexible lower leg protector positioned in the container in substantially moisture-free conditions and sealed therein against entry of moisture until use, the lower leg protector including a leg portion shaped to provide, when in place on a batter's leg, protection to the front, lateral and medial aspects of the leg above the ankle and optionally-detachable ankle flap portions integrally formed with a bottom edge of said leg portion and shaped to provide protection to the lateral and medial ankle bones, said lower leg protector comprising:
(i) a substrate;
(ii) a reactive system impregnated into or coated onto the substrate, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to moisture to form a rigid, self-supporting structure;
(iii) a flexible protective pad positioned on one side of the substrate to provide cushioning between the substrate and the batter's lower leg when the lower leg protector is being worn;
(iv) an outer cover covering the substrate on the side opposite the protective pad;
(v) said substrate, protective pad and outer cover connected together into a unitary structure for being molded while flexible to the lower leg and ankle of the batter;
and
(c) complementary fasteners attached to opposing side edges of the lower leg protector for retaining the lower leg protector in place on the batter's leg while being worn.

6 more elements

A method for custom-fitting a lower leg protector to the shape of a batter's lower leg comprising the steps of:

(a) providing a lower leg protector product comprising:
(i) an outer container formed of moisture-impervious material;
(ii) a flexible lower leg protector positioned in the container in substantially moisture-free conditions and sealed therein against entry of moisture until use, the lower leg protector including a leg portion shaped to provide, when in place on a batter's leg, protection to the front, lateral and medial aspects of the leg above the ankle and optionally-detachable ankle portions integrally formed with a bottom edge of said leg portion and shaped to provide protection to the lateral and medial ankle bones, said lower leg protector comprising:
(aa) a substrate;
(bb) a reactive system impregnated into or coated onto the substrate, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to moisture to form a rigid, self-supporting structure;
(cc) a flexible protective pad positioned on one side of the substrate to provide cushioning between the substrate and the batter's lower leg when the lower leg protector is being worn;
(dd) an outer cover covering the substrate on the side opposite the protective pad;
(ee) said substrate, protective pad and outer cover connected together into a unitary structure for being molded while flexible to the lower leg and ankle of the batter, and
(iii) complimentary fasteners attached to opposing side edges of the lower leg protector for retaining the lower leg protector in place on the batter's leg while being worn;
(b) when the lower leg protector is to be applied, removing the lower leg protector from the outer container;
(c) removing the protective outer cover from the leg portion and optionally-detachable ankle flap portions;
(d) wetting the leg portion and optionally-detachable ankle flap portions;
and
(e) molding the leg portion and optionally-detachable ankle flap portions to the lower leg and lateral and medial ankle bones, respectively.

11 more elements

Dependencies are inferred from the claim text.

Custom-fitted batter's lower leg protector

Life of this patent

Custom-fitted batter's lower leg protector

Life of this patent

Abstract

Claims20