WO2017211597A1

WO2017211597A1 - Personal protection device

Info

Publication number: WO2017211597A1
Application number: PCT/EP2017/062772
Authority: WO
Inventors: Antti PÄRSSINEN; Ian Campbell; Eija Pirhonen
Original assignee: Onbone Oy
Priority date: 2016-06-10
Filing date: 2017-05-26
Publication date: 2017-12-14
Also published as: GB2551329A; GB201610139D0

Abstract

The present invention provides a personal protection device (e.g. an arm guard or a hip guard) for protecting a portion of a wearer's body (e.g. their arm or hip) from injuries arising from hazardous occupations or from trips and falls by elderly or infirm individuals. The personal protection device comprises a lining layer for facing the wearer's body and an opposing composite layer superimposed on said lining layer. The composite layer comprises wood particles within a thermoplastic polymer matrix. The lining and composite layers are shaped to substantially match the contour of the portion of the wearer's body (shin). A moldable blank for forming a sports protection device is also provided. Also provided is a support device (e.g. a back rest/lumbar support) comprising a composite layer formed of wood particles within a thermoplastic polymer matrix.

Description

PERSONAL PROTECTION DEVICE

Field of the Invention

The present invention relates to a protection device for providing protection to an individual's body whilst participating in hazardous occupational activities and/or for providing protection to a vulnerable individual's body whilst participating in everyday activities. In particular, the present invention relates to a customizable personal protection device that is moldable to fit a portion of the individual's body to provide shock, impact, friction and puncture protection. The present invention also relates to a support device for providing support to an individual's body whilst in a rest position. Background of the Invention

Many occupational activities such as construction work, factory machine operation, chainsaw operation (e.g. in forestry/gardening work), heavy vehicle operation, mining, mechanical work (e.g. in garages), metal work and rescue operations present opportunities for an individual to sustain serious injury e.g. through impact arising from falls or falling/flying objects and equipment malfunction or misuse. Such injuries typically include bruising/contusion, abrasions, lacerations and bone fractures.

It is known (and, indeed required by law in many countries) to provide personal protection equipment (PPE) for use during hazardous occupational activities to protect vulnerable areas of the individual body. For example, it is known to provide protective hats, gloves, gauntlets, safety boots and chaps.

Vulnerable individuals such as the elderly, mobility-impaired and young children are prone to injury arising from trips and falls arising during the course of their normal/everyday activities and/or from fits/seizures arising from medical conditions. Elderly individuals are especially prone to bone breakages such as hip fractures arising from falls and such individuals often require extended stays in hospital. Many elderly individuals fail to make a full recovery from such injuries. It is known to provide PPE such as helmets and hip-guards to help mitigate the effects of such trips and falls. Known hip guards are typically formed of padded plastic shields which fit into specially designed underwear.

It is obviously a requirement for PPE that it is both lightweight so as not to impede the activities of the wearer and highly shock absorbent/puncture resistant. It is also a requirement that it is comfortable as the individual will need to wear the PPE for considerable periods of time. Many individuals report high levels of discomfort when wearing the known PPE and there have been numerous incidences of workplace injuries and even fatalities when individuals provided with PPE have failed to wear it owing to the high levels of discomfort they have experienced. Long term compliance of elderly individuals wearing known hip guards is low - discomfort is identified as the main reason for the lack of compliance.

Known PPE is generally provided in standard sizes/shapes devised to fit an average individual. Such standard-sized PPE typically provides an imperfect fit for the majority of individuals thus leading to the discomfort experienced by the wearer. Accordingly, there is a need to provide a device for providing protection to an individual's body whilst participating in hazardous occupational activities and/or for providing protection to a vulnerable individual's body whilst participating in everyday activities that is both lightweight and comfortable whilst still affording a high level of shock, impact, friction and puncture resistance. Many individuals will adopt a prone or seated position to rest e.g. on a bed or chair. A seated rest position is also adopted for extended periods of time by individuals engaged in a sedentary occupation such as office work. Poor posture, especially by individuals in a seated position can lead to significant back-ache and/or neck-ache which can be very debilitating for the individual. Chairs typically comprise a backrest for supporting the individual's back and arm rests for supporting the individual's arms. The back/arms rests are typically provided in a standard shape/size designed to fit an average individual. In fact, this typically provides an imperfect fit for the majority of individuals thus leading to poor support, poor posture and, consequentially, back-ache/neck-ache for the individual. It is known to provide a lumbar support which straps onto the backrest of a chair, the lumbar support resting in the small of the individual's back. This provides extra support and posture control for the individual. Again, such lumbar supports are typically provided in a standard shape/size designed to fit an average individual which provides an imperfect fit for the majority of individuals.

Accordingly, there is a need to provide a support device for supporting an individual whilst in a rest position that provides optimal support for the individual in order to improve the individual's posture and thus reduce instances of back-/neck-ache. Summary of the Invention

In a first aspect, the present invention provides a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the personal protection device comprising:

a lining layer for facing the wearer's body; and

an opposing composite layer superimposed on said lining layer, the composite layer comprising wood particles within a thermoplastic polymer matrix,

the lining and composite layers being shaped to substantially match the contour of the portion of the wearer's body.

In a second aspect, the present invention provides a moldable blank for forming a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the moldable blank comprising:

a lining layer for facing the wearer's body; and

the lining and composite layers being moldable to substantially match the contour of the portion of the wearer's body. The present inventors have found that a composite layer comprising a thermoplastic polymer and wood particles can be used to provide a personal protection device and a moldable blank for forming a personal protection device having a high shock absorbance whilst being lightweight and unbulky. Combined with a liner layer facing the wearer's body, the present invention provides a comfortable, customizable, highly effective personal protection device which can be formed from a moldable blank or can be provided pre-formed.

Optional features of the invention will now be set out. These are applicable singly or in any combination with any aspect of the invention.

The term "personal protection device" is intended to cover a device worn by an individual to maintain their safety and prevent injury arising from hazardous occupational activities and/or a device worn by a vulnerable individual (e.g. a young child, an elderly individual, a physically- /mobility-impaired individual) to maintain their safety and prevent injury arising from trips and falls occurring during their everyday/normal activities. It is not intended to cover sports protection devices won by an individual to maintain their safety and prevent injury arising from sport/recreation.

In a third aspect, the present invention provides a support device for supporting a portion of an individual's body whilst in a rest position, the support device comprising:

a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being shaped to substantially match the contour of the portion of the individual's body.

In some embodiments, the support device further comprises a lining layer for facing the individual's body with the composite layer superimposed on said lining layer, both layers being shaped to substantially match the contour of the portion of the individual's body.

In a fourth aspect, the present invention provides a moldable blank for forming a support device for supporting a portion of an individual's body whilst in a rest position, the moldable blank comprising:

a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being moldable to substantially match the contour of the portion of the individual's body.

In some embodiments, the moldable blank further comprises a lining layer for facing the individual's body with the composite layer superimposed on said lining layer, both layers being moldable to substantially match the contour of the portion of the individual's body.

The present inventors have found that a composite layer comprising a thermoplastic polymer and wood particles can be used to provide a support device and a moldable blank for forming a support device having a moldability to conform with the individual's body portion that providing for optimal support and optimal posture thus reducing incidences of back-/neck- ache. Combined with a liner layer facing the individual's body, the present invention provides a comfortable, customizable, highly effective support device which can be formed from a moldable blank or can be provided pre-formed.

The support device may be a back rest or an arm rest for a chair. It may be integrated into the structure of the chair or it may be an insert which is positionable against a standard back rest /arm rest of a chair. In a fifth aspect, the present invention provides a back support device for supporting an individual's back whilst in a rest position, the support device comprising:

a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being shaped to substantially match the contour of the individual's back.

In some embodiments, the back support device (back rest) further comprises a lining layer for facing the individual's back with the composite layer superimposed on said lining layer, both layers being shaped to substantially match the contour of the individual's back.

In some embodiments, the back support device is a lumbar support device and the composite layer is shaped to substantially match the contour of the individual's lumbar region.

In a sixth aspect, the present invention provides a moldable blank for forming a back support device for supporting an individual's back whilst in a rest position, the moldable blank comprising:

a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being moldable to substantially match the contour of the individual's back.

In some embodiments, the moldable blank further comprises a lining layer for facing the individual's back with the composite layer superimposed on said lining layer, both layers being moldable to substantially match the contour of the individual's back.

In some embodiments, the back support device is a lumbar support device and the composite layer is moldable to substantially match the contour of the individual's lumbar region.

The lining layer (in any of the aspects of the present invention) may be formed of a textile material. The textile material may be formed by weaving, knitting, crocheting, knotting, bonding or felting natural fibres such as cotton, hemp, jute, flax or artificial fibres such as polyester, polyamide, polyurethane, polynitrile, ABS, polyolefin (such as polypropylene) fibres.

Performance/technical fabrics including such as COOLMAX®, DRYROAD®, DRI-FIT® or CLIMACOOL® i.e. fabrics that wick moisture away from the wearer's skin are particularly preferred.

The lining layer may be formed of a 3D spacer fabric such as those manufactured by Baltex or Apex Mills which provide effective heat and moisture transfer. A 3D spacer fabric typically comprises a three-dimensional knitted/woven fabric comprising two knitted/woven substrates separated by spacer yarns. The spacer yarns allow air and moisture flow through the fabric between the knitted/woven substrates. The 3D spacer fabric may be formed of polyester, polyamide of polypropylene for example. The lining layer e.g. the 3D spacer may have a thickness of between 1 - 5 mm e.g. around 3 mm for the personal protection device. It may be thicker for the support device.

The lining layer e.g. the 3D spacer fabric may have a weight of between 200 -500 g/m² e.g. around 350 g/m².

The lining layer may comprise a foam. The foam may be provided instead of or as well as the textile material described above. The foam may be provided between the textile material and the composite layer. The foam may be a shock-absorbing foam such as a polyurethane foam e.g. Poron ® XRD® foam.

The foam may have a thickness of between 1 -20 mm e.g. between 3-8 mm.

The lining layer e.g. the 3D spacer fabric and/or the foam may comprise an anti-bacterial and/or anti-odour composition. The composition may be coated onto or impregnated into the fabric/foam. For example, the lining layer may comprise silver ions e.g. such as those provided in Polygiene® or Microban®.

The material used to form the composite layer may be as described in WO2010/103186 herein incorporated by reference. The thermoplastic polymer (in any of the aspects of the present invention) is preferably a biodegradable polymer (only) but also non-biodegradable polymers may be utilized.

Examples of polymers include polyolefins, e.g. polyethylene (HD or LD), polypropylene, and polyesters, e.g. poly(ethylene terephthalate) and poly(butylenes terephthalate), polystyrene homopolymer and copolymers including acrylonitrile-butadiene-styrene (ABS), polycarbonates, polyethers, polyetheresters, polyamides e.g. nylon, lactic or butyric acid derivatives, polybenzimidazole (PBI), polyethersulfones (PES), polyvinyl alcohols (PVA), ethyl vinyl acetates (EVA), polyether ether ketones (PEEK), polyetherimides (PEI), polyphenylene oxide (PPO), polyphenylene sulphide (PPS), polyvinyl chloride (PVC) and acrylic polymers. Copolymers, blends and mixtures of polymers may also be used. The thermoplastic polymer may also be any cross-linked polymers manufactured prior to processing or in situ during the compounding process for example by means of ionizing radiation or chemical free-radical generators. Examples of such polymers are cross-linked polyesters, such as polycaprolactone (PCL). Generally, the weight ratio of biodegradable polymer to any non-biodegradable polymer is 100:1 to 1 :100, preferably 50:50 to 100:1 and in particular 75:25 to 100:1 .

The thermoplastic polymer may comprise a biodegradable polymer i.e. a polymer which can degrade into natural by-products such as carbon dioxide, nitrogen, water, biomass and inorganic salts. By using a biodegradable polymer in combination with the wood particles for the composite layer, the personal protection device/(back/lumbar) support device can be made substantially biodegradable offering environmental advantages after disposal.

For example, the thermoplastic polymer may be a thermoplastic polyester e.g. a biodegradable thermoplastic polyester. Suitable examples for the thermoplastic polymer are polylactide, polyglycolide, polycaprolactone (PCL), mixtures/blends thereof and copolymers thereof.

The thermoplastic polymer may comprise a mixture/blend of 5-99 wt%, in particular 40 to 99 wt%, of a caprolactone homopolymer and 1 -95 wt%, in particular 1 to 60 wt%, of another thermoplastic polymer e.g. another biodegradable or non-biodegradable thermoplastic polymer. Copolymers of caprolactone include copolymers formed with caprolactone, lactic acid and/or glycolic acid monomers. The copolymer may contain at least 80 % by volume of (epsilon) caprolactone monomer, in particular at least 90 % by volume and in particular about 95 to 100 % epsilon caprolactone monomer. The copolymer may contain 5 to 99 wt% and especially 40 to 99 wt% of repeating units derived from (epsilon) caprolactone monomer with 1 to 95 wt% and especially 1 to 60 wt% of repeating units derived from another polymerisable monomer.

The thermoplastic polymer (e.g. the polycaprolactone polymer) may have a molecular weight of between 60,000 g/mol and 500,000 g/mol. For example, the thermoplastic polymer may have a molecular weight between 65,000 - 300,000 g/mol, preferably above 70,000 g/mol such as between 75,000 g/mol and 100,000 or 200,000 g/mol. This has been found to be advantageous both in terms of resultant properties and cost. The thermoplastic polymer is preferably selected such that it softens when it is heated to a temperature of approximately 50 to 70 °C, after which the blank can be molded directly on the wearer to create a form that closely matches the anatomical contours of the portion of the wearer's/individual's body. PCL has a unique melting behavior: The polymer crystals only start melting when a temperature of approximately 60 °C is reached yet the polymer crystals start re-forming when temperature is decreased down to 37 °C. This hysteresis property together with insulating wood particles in the composite layer of preferred embodiments enables a molding time for the blank which facilitates use in "field situations" and by users without any special competence working with materials.

The molding properties of the present invention can be determined by the average molecular weight (Mn) of the polymer, such as epsilon caprolactone homo- or copolymer. A particularly preferred molecular weight range for the Mn value of PCL is from about 75,000 to about 100,000 g/mol, e.g. around 80,000 g/mol. The number average molar mass (Mn) and the weight average molar mass (Mw) as well as the polydispersity (PDI) were measured by gel permeation chromatography. Samples for GPC measurements were taken directly from the polymerization reactor and dissolved in tetrahydrofuran (THF). The GPC was equipped with a Waters column set styragel HR(1 , 2 and 4) and a Waters 2410 Refractive Index Detector. THF was used as eluent with a flow rate of 0,80 ml/min at a column temperature of 35°C. A conventional polystyrene calibration was used. In determination of the water content of the monomer at different temperatures a Metroohm 756 KF Coulo meter was used.

The properties of moldability of the present composition can also be determined by the viscosity value of the polymer. For an epsilon caprolactone homopolymer: when the inherent viscosity (IV) -value of PCL is less than 1 dl/g the composite is sticky, flows while formed and forms undesired wrinkles while cooling. When PCL having IV-value closer to 2 dl/g is used the composite maintains its geometry during molding on the wearer and it may be handled without adhesive properties. Thus, IV values in excess of 1 dl/g are preferred, values in excess to 1.2 dl/g are preferred and values in excess of 1.3 dl/g are particularly suitable. Advantageously the values are in the range of about 1.5 to 2.5 dl/g, for example 1 .6 to 2.1 dl/g. Inherent Viscosity values were determined by LAUDA PVS 2.55d rheometer at 25 °C. The samples were prepared by solvating 1 mg of PCL in 1 ml chloroform (CH3CI). The viscosity of the thermoplastic polymer may be relatively high, typically at least 1 ,800 Pas at 70 °C, 1/10 s. The viscosity can be of the order of 8,000 to 13,000 Pas at 70 °C, 1/10 s (dynamic viscosity, measured from melt phase).

The modulus (Young's modulus) at ambient temperature of the thermoplastic polymer component may be greater than 300 MPa. By compounding the thermoplastic polymer with the wood particles, the modulus will increase to about 350 to 2000 MPa for the composite material.

The thermoplastic polymer may have a melt flow index of between 0.3 to 2.3 g/min (at 80°C; 2.16 kg). The thermoplastic polymer may be present in the composite layer in an amount of 5 to 99 wt% (based on the amount of thermoplastic polymer and wood particles). It may be present in an amount between 40 to 99 wt%.

In some preferred embodiments showing particularly good shock absorption, the thermoplastic polymer is present in an amount of around 60 wt% i.e. the weight ratio of wood particles to thermoplastic polymer in the composite layer may be 2:3.

Preferably, the wood particles have a granular or a generally plate-like structure. Typically, the wood particles are greater in size than a powder.

Particulate or powdered material is characterised typically as material of a size in which the naked eye can no longer distinguish unique sides of the particle. Plate-like particles are easily recognizable as one dimension is recognizable by the naked eye as being larger than another. Granular particles, while having substantially equal dimensions, are of such dimension that their unique sides can be determined by the naked eye and oriented.

More particularly, particulate or powdered materials are of such a small or fine size that they cannot be easily oriented with respect to their neighbors. Granular and plate-like particles are of such a size that their sides are recognizable and can be orientated.

The wood particles orientate in two dimensions in the thermoplastic polymer matrix and provide a self-reinforcement effect. As a result, the composite layer of the personal protection device/(back/lumbar) support device provides a good dimensional stability, good shock absorbance and good puncture resistance. The wood particles may be present in the composite material forming the composite layer in an amount of 1 to 95 wt% (based on the amount of thermoplastic polymer and wood particles). They may be present in an amount between 1 to 70 wt% or 1 to 60 wt% or 10 to 60 wt% or 20 to 60 wt%. In some preferred embodiments showing particularly good shock absorption, the wood particles may be present in an amount of around 40 wt% i.e. the weight ratio of wood particles to thermoplastic polymer in the composite material forming the composite layer may be 2:3.

The wood particles may be present in the composite material forming the composite layer in an amount of 15 to 50 % (based on the volume of thermoplastic polymer and wood particles). They may be present in an amount between 25 to 50 %, by volume.

Before the wood particles are mixed with the thermoplastic polymer they can be surface treated, e.g. sized, with agents, which modify their properties of hydrophobicity/- hydrophobicity and surface tension. Such agents may introduce functional groups on the surface of the wood particles to provide for covalent bonding to the matrix. The wood particles can also be surface treated with polymer e.g. PCL.

The wood particles can be also coated or treated with anti-rot compound e.g. vegetable oil to improve its properties against aging and impurities.

The wood particles can be dehydrated to make them lighter before mixing with thermoplastic polymer. The mechanical and chemical properties of the wood particles can be improved with heat treatment, which is known to decrease swelling and shrinkage.

The size and the shape of the wood particles may be regular or irregular. Typically, the particles have an average size (of the smallest dimension) in excess of 0.02 mm, advantageously in excess of 0.1 mm, 0.4 mm or 0.5 mm, for example in excess of 0.6 mm or 1 mm, suitably about 0.6 to 40 mm, in particular about 1 .2 to 20 mm, preferably about 1 .5 to 10 mm, for example about 1 to 7 mm. For the plate-like wood particles having a length, width and thickness, the smallest dimension will be the thickness.

The length of the particles (longest dimension of the particles) can vary from a value of greater than 0.6 mm (e.g. greater than 0.75 mm or 1 mm or 1 .8 mm or 3mm) to value of up to about 200 mm, for example up to about 50 mm or 21 mm. The wood particles can be granular i.e. having a substantially cubic shape, plate-like or a mixture of both. Wood particles considered to be granular have a cubic shape whose ratio of general dimensions are on the order of thickness : width : length = 1 : 1 : 1. In practice it is difficult to measure each individual particle to determine if it is a perfect cube. Therefore, in practice, particles considered to be granular are those where one dimension is not substantially different than the other two.

Wood particles considered to be plate-like means that they have generally a plate-shaped character. The ratio of the thickness of the plate to the smaller of the width or length of the plate's edges is generally 1 :2 to 1 :500 or 1 :100 or 1 :20 such that the thickness of the plate- like particles is smaller than the width/length.

The plate-like wood particles may have at least two dimensions greater than 1 mm and one greater than 0.02 mm (e.g. greater than 0.1 mm), the average volume of the wood particles being generally at least 0.02 mm³ (e.g. at least 0.1 mm³ or at least 1 mm³). Suitable wood particles have typical dimensions of 2mm x 2mm x 1 mm, for example. The specific weight of the wood particles may be between 180-200 kg/m³.

"Derived from platy wood particles" designates that the wood particles may have undergone some modification during the processing of the composition. For example, if blending of the thermoplastic polymer and wood particles is carried out with a mechanical melt processor, some of the original plate-like wood particles may be deformed to an extent. Typically more than 70 % and preferably up to 100% of the wood particles are greater in size than powder, which particles may be granular or platy.

The wood species can be freely selected from deciduous and coniferous wood species alike: beech, birch, alder, aspen, poplar, oak, cedar, Eucalyptus, mixed tropical hardwood, pine, spruce and larch tree for example. The wood particles can be derived from wood raw-material typically by cutting or chipping of the raw-material. Wood chips of deciduous or coniferous wood species are preferred.

The desired composition of the wood particles can be achieved by sifting wood particles through one or more meshes having one or more varying qualities. The desired composition can also be accomplished by other well-known techniques in the art for sorting and separating particles in to desired categories. The desired composition may be the resultant composition of one sifting or separating process. The desired composition may also be a mixture of resultant compositions from several sifting or separation processes.

A particularly interesting raw-material comprises wood particles, chips or granules, of any of the above mentioned wood species having a screened size of greater than 0.6 mm up to about 3.0 mm, in particular about 1 to 2.5 mm on an average.

In addition to wood particles and thermoplastic polymer, the composite layer can contain reinforcing fibrous material, for example cellulose fibers, such as flax or seed fibers of cotton, wood skin, leaf or bark fibers of jute, hemp, soybean, banana or coconut, stalk fibers (straws) of hey, rice, barley and other crops and plants including plants having hollow stem which belong to main class of Tracheobionta and e.g. the subclass of meadow grasses (bamboo, reed, scouring rush, wild angelica and grass).

In addition, inorganic particulates or powdered materials such as mica, silica, silica gel, calcium carbonate and other calcium salts such as tricalcium orthophosphate, carbon, clays and kaolin may be present or added. In some embodiments, the composite layer further comprises an elastic or soft polymer. Such a polymer can be homogenously distributed within the composite layer or can be concentrated within regions of the composite layer. For example, the elastic/soft polymer may be provided at a hinge portion of the personal protection device.

This improves the fit and comfort of the personal protection device. "Soft" when used in the context of a polymer means that the polymer, either a thermoplastic or thermosetting polymer, has Shore D hardness 27 or less at ambient temperature. "Ambient temperature" stands for a temperature of about 10 to 30 °C, in particular about 15 to 25 °C.

"Region" when used in connection of elasticity or softness of the composite layer denotes a portion of the composite layer. The region may extend only to a limited depth of the composite layer or it may extend through the composite layer in at least one dimension. The region may comprise an elongated, essentially integral area. The region may also comprise one or several isolated portions of, for example, material different from the material surrounding the isolated portion(s). "Region" may also be a portion evenly distributed throughout the composite layer. Thus, a soft or elastic polymer can be homogeneously blended or mixed with the thermoplastic polymer to extend the region of elasticity or softness to cover essentially the whole superficial area of the personal protection/ (back/lumbar) support device formed by the composite layer.

A property of "elasticity" or "softness" can be measured by a ring stiffness test, and such a property will be manifested in a greatly reduced stiffness. Typically the stiffness will be at least 20 % lower, preferably at least 30 % lower than for a corresponding material, wherein the same (± 10 %) volume as taken up by the soft or flexible polymer is formed by the thermoplastic polymer, for example and typically by the thermoplastic polyester or other polymer having melting point or softening point below 70 °C and higher or equal to about 55 °C. The elastic/soft polymer is a different polymer than the thermoplastic polymer. The elastic/soft polymer can be thermoplastic or thermosetting polymer. The elastic/soft polymer can be used to partly replace the thermoplastic polymer to maintain the total volume of polymer in the composite layer at least essentially unaltered.

In a personal protection/ (back/lumbar) support device/blank having a longitudinal and lateral axis, the soft (or elastic) polymer rich regions are generally unidirectional either along the longitudinal or lateral axis. The soft (or elastic) polymer rich regions can also be in form of a grid, mesh or web.

Typically, the soft/elastic polymer is a polymer having a Shore D hardness of 27 or less, in particular 25 or less, at ambient temperature or a thermoplastic elastomer. Other examples of soft polymers include polymers exhibiting Shore A of 0 to 70 and Shore OO of 0 to 90.

The soft/elastic polymer can be formed by a polymer selected from the group of thermoplastic polyolefin blends; polyurethanes; co-polyesters; polyamides; unsaturated or saturated rubbers, including natural rubber, silicone, and copolymers of olefins; and natural or synthetic soft material, including soft gelatin, hydrogels, hydrocolloids and modified cellulose.

The elastic or soft polymer does not need to have melting range in same range as the thermoplastic polymer. Typically, the soft/elastic polymer has a melting range outside that of the thermoplastic polymer, in particular the melting point of the soft/elastic polymer is higher than the melting point of the thermoplastic polymer. In one embodiment, the soft/elastic polymer is miscible with thermoplastic polymer forming a homogenous matrix when processed at elevated temperatures. In another embodiment, the soft/elastic polymer is immiscible with the thermoplastic polymer forming phase-separated zones or regions within the thermoplastic polymer. Based on the above, in one embodiment, the composite material comprises:

- 10 to 70 parts by weight of thermoplastic polymer e.g. a biodegradable polyester;

- 25 to 60 parts by weight of wood particles; and

- 5 to 40 parts by weight of a soft or elastic polymer.

Preferably the soft or elastic polymer together with the thermoplastic polymer (e.g. biodegradable polyester) make up a majority of the composite layer (i.e. more than 50 % by weight of the total weight of the composite layer).

In a particular preferred embodiment, the soft or elastic polymer together with the thermoplastic polymer (e.g. biodegradable polyester) make up at least 53 % and up to 70 %, for example 55 to 70 %, by weight of the total weight of the composite layer. The soft or elastic polymer generally forms 5 to 50 %, in particular 10 to 40 %, for example 15 to 30 %, by weight of the total weight of the thermoplastic polymer (e.g. biodegradable polyester) together with the soft or elastic polymer.

It is possible to incorporate further polymers into the composite layer. In one embodiment, the composition comprises 3 to 30 parts by weight, of a further polymer comprising a thermoplastic polymer different from that of the first and the soft/elastic polymer. Such a component can be used for achieving improved mechanical properties of the composite layer. It is also possible to use a fourth polymer to modify the surface properties (for example properties of adhesion) of the composition.

Suitable polymers for the soft/elastic polymer and the further polymer are as described in WO2015/059354.

In some embodiments, it may be desirable to include reinforcing fibres either within the composite layer or superimposed onto the composite layer e.g. between the composite layer and lining layer. For example, reinforcing metallic fibres or reinforcing synthetic fibres such as aramid fibres (e.g. Kevlar®) fibres may be used. The reinforcing fibres may be substantially aligned with one another e.g. in devices having a longitudinal and lateral axis, reinforcing fibres may be unidirectional either along the longitudinal or lateral axis. The reinforcing fibres may also be in form of a grid, mesh or web.

The composite and lining layers be affixed directly to one another with no interposing layer (other than the optional reinforcing fibres described above if desired).

They may be affixed directly to one another by bonding e.g. bonding using an adhesive. For example, the lining layer may be pre-impregnated with adhesive prior to affixing to the composite layer.

The lining layer may be affixed to the composite layer by heat bonding i.e. by pressing the lining layer onto the composite layer when the composite layer is tacky due to heating e.g. during extrusion of the composite layer.

The lining layer may be affixed to the composite layer by stitching or mechanical locking.

The personal protection/(back/lumbar) support device or blank may further comprise an edging layer which may extend at least partly (and preferably entirely) around the peripheral edges of at least the composite layer and preferably both the lining/composite layers. The edging layer may provide a smooth edge to the personal protection/(back/lumbar) support device or blank to prevent irritation of the portion of the wearer's/individual's body against which the personal protection/(back/lumbar) support device fits/rests.

The edging layer may be formed of a textile material or textile string e.g. a fleece material. The textile material may have a width of between 2-6 mm e.g. around 3 mm. It may have a thickness of between 0.5-3 mm, e.g. around 1.5mm.

The edging layer may be joined around the peripheral edges of the composite layer or lining/composite layers using adhesive e.g. adhesive that is pre-impregnated into the edging layer. The edging layer may be stitched around the peripheral edges of the composite layer or lining/composite layers.

The composite layer may a thickness of about 1 to 50 mm, in particular about 1 .5 to 30 mm, for example 1 .5 to 20 mm. The composite layer may have a thickness greater than 1 .5 mm. A typical thickness for the personal protection device is about 2 to 6 mm, for example between 2 and 4 mm. It may be thicker for the support device.

With a typical thickness of the composite layer being 2-4 mm and a typical thickness of the lining layer being 1 -5 mm, the typical thickness of the personal protection device is around 3- 9 mm making the personal protection device considerably less bulky than the known PPE.

The thickness of the composite layer may vary over the personal protection/ (back/lumbar) support device/blank. For example, the composite layer may be increase in thickness from its periphery to its centre. For example, the composite layer may have a thickness of between 4-6 mm e.g. around 4 mm at its centre decreasing to between 2-4 mm e.g. around 2 mm at its peripheral edges.

The length and the width of the personal protection/(back/lumbar) support device and the blank for forming the personal protection/(back/lumbar) support device can vary in the range of about 1 to 150 cm (length) and 1 to 50 cm (width). The length and width will vary depending on the body portion requiring protection/support. The blank may have a substantially planar profile i.e. it may be in the form of a plate or sheet. The plate or sheet may have, for example, a rectangular, square, triangular, H-shaped or I- shaped profile. Any apices may be rounded.

The blank and/or the personal protection/(back/lumbar) support device may have at least a portion having a substantially curved profile. For example, where the blank or personal protection/support device is for protecting/supporting the wearer's/individuals arms, the blank and/or personal protection/support device may have a substantially U-shaped curved profile. The curvature may be constant or may vary along its length. For example, the curvature may decrease along its length.

The composite layer may comprise at least one region of non-rigidity to provide for flexibility and/or aeration in the personal protection/(back/lumbar) support device. For example, the composite layer may comprise a region of non-rigidity at a hinge portion.

The or each region of non-rigidity may be formed by perforations in the composite layer for example in the form of incisions, in particular unidirectional incisions. By introducing lengthwise/longitudinal incisions in regions of the composite layer, aeration and flexibility can be achieved by merely widening the composite layer in widthwise direction e.g. during the formation of the personal protection/(back/lumbar) support device from the blank.

The incisions are located such that they are kept "closed" in the areas of the personal protection/(back/lumbar) support device requiring maximum strength so as not to impair mechanical strength.

Typically the areas requiring maximal strength are subjected to longitudinal forces, i.e. forces which act along the length of the device. Thus, in one preferred embodiment, the incisions are longitudinally directed, and they will therefore not be opened by the action of such longitudinal force. By orientating the incisions longitudinally, the incisions will remain closed under the influence of longitudinal forces, and the material will exhibit mechanical strength and rigidity directly derivable from the structure of the composite layer.

Wearer comfort is improved by providing some flexibility of the material, to allow for some movement, and the composite layer can yield to forces perpendicular to the general orientation of the incisions by opening the closed incisions.

In the context of the present technology, the pattern and the shape of the incisions in the composite material have been studied in particular for planar composite materials having a thickness in the range of 2 to 4 mm.

The incisions studied are formed by straight (linear) incisions or cuts. Preferably there are lines formed with a plurality of incisions. In particular there is a plurality of such lines, which preferably are parallel.

In a particular embodiment, the incisions in adjacent lines are off-set such that no two adjacent incisions are located along the same transversal line. Examples of suitable perforations are shown in WO2015/059355. When subjected to the stretching laterally, the incisions will form apertures. Typically, the perforated composite layer will allow stretching at least 5 %, typically up to 75 %, in particular about 10 to 50 %.

During stretching, the non-rigid region of the composite layer will have pore area which is 2x to lOOx, typically 2.5x to 15x greater that than pore area of the corresponding non-stretched, non- incised composite layer. The pore area can be about 2.5 to 30 % of the total area of the non-rigid region, for example about 3 to 20 %, for example about 5 to 15 %.

It has been found that incisions having a length of generally more 20 mm may cause tearing of the material when exposed to strong twisting and strain. On the other hand, incisions which are less than 5 mm in length do not sufficiently open during molding the material around a human limb to allow for proper aerating.

Further, the space between each incision in longitudinal direction must exceed 5 mm to avoid tearing of the material and be less than 20 mm to achieve sufficient level of aerating.

The space between each incision line transversally to the linear incision must exceed 10 mm to avoid tearing and be less than 25 mm to achieve sufficient level of aerating. The incisions may be manufactured into the composite profile with an incision device, examples of suitable equipment include a rolling cylinder or a press equipped with blades, water jet, and laser cutting.

Typically, the incisions have a width of 0.1 to 1 mm, preferably 0.3 to 0.8 mm, and a length of 4 to 20 mm.

The incisions can be made with a blade, the surface area of which incisions being on the blade ingoing side about 1 to 10 mm², preferably 2.5 to 8 mm². The number of incisions per 10 cm² may be generally 20 to 100, preferably 30 to 70.

The particular advantage of incorporating incisions into the composite layer is that upon forming the personal protection/(back/lumbar) support device e.g. by molding the blank, the incisions will yield openings which give the composite layer properties of breathability and flexibility in the non-rigid region(s) e.g. at a hinge portion.

The shape of the openings or apertures formed by stretching of the incisions can be, for example, round, rectangular, square, diamond, hexagonal, oval, slot or ornamental perforation. The surface area of one hole should be generally about 3 to 30 mm² and the number of the holes is kept between 20 holes / 10 cm² and 100 holes / 10 cm². The total open area is less than 10 percentage of the whole surface area.

In a seventh aspect, the present invention provides a method of manufacturing a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the method comprising:

providing a lining layer for facing the wearer's body;

superimposing a composite layer on said lining layer, the composite layer comprising wood particles within a thermoplastic polymer matrix,

shaping said layers to substantially match the contour of the portion of the wearer's body.

In an eighth aspect, the present invention provides a method of manufacturing a moldable blank for forming a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the method comprising:

providing a lining layer for facing the wearer's body;

superimposing a composite layer on said lining layer, the composite layer comprising wood particles within a thermoplastic polymer matrix. In a ninth aspect, the present invention provides a method of manufacturing a support device for supporting a portion of an individual's body whilst in a rest position, the method comprising: providing a composite layer comprising wood particles within a thermoplastic polymer matrix,

shaping the composite layer to substantially match the contour of the portion of the individual's body.

In some embodiments, the method further comprises providing a lining layer for facing the individual's body, superimposing the composite layer on said lining layer, and shaping both layers to substantially match the contour of the portion of the individual's body.

In a tenth aspect, the present invention provides a method of manufacturing a moldable blank for forming a support device for supporting a portion of an individual's body whilst in a rest position, the method comprising:

providing a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being moldable to substantially match the contour of the portion of the individual's body. In some embodiments, the method further comprises providing a lining layer for facing the individual's body, superimposing the composite layer on said lining layer, both layers being moldable to substantially match the contour of the portion of the individual's body.

In an eleventh aspect, the present invention provides a method of manufacturing a back support device for supporting an individual's back whilst in a rest position, the method comprising:

providing a composite layer comprising wood particles within a thermoplastic polymer matrix; and

shaping the composite layer to substantially match the contour of the individual's back. In some embodiments, the method further comprises providing a lining layer for facing the individual's back, superimposing the composite layer on said lining layer, shaping both layers to substantially match the contour of the individual's back.

In some embodiments, the back support device is a lumbar support device and the composite layer is shaped to substantially match the contour of the individual's lumbar region. In a twelfth aspect, the present invention provides a method of manufacturing a moldable blank for forming a back support device for supporting an individual's back whilst in a rest position, the method comprising:

providing a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being moldable to substantially match the contour of the individual's back.

In some embodiments, the method further comprises providing a lining layer for facing the individual's back, superimposing the composite layer on said lining layer, both layers being moldable to substantially match the contour of the individual's back.

The lining layer and composite layer may be as described above for the previous aspects.

The composite layer can be manufactured by mixing the thermoplastic polymer with the wood particles. The thermoplastic polymer may be provided in the form of pellets. The method may comprise the steps of mixing together 10 to 100 parts, preferably 50 to 100 parts by weight of the thermoplastic polymer and 1 to 100 parts, preferably 10 to 50 parts, by weight of wood particles. In some embodiments, the method comprises mixing together the thermoplastic polymer and wood particles in a ratio of 3:2 (by weight). The thermoplastic polymer (pellets) and wood particles may be mixed using melt mixing/processing e.g. in a heatable vessel having a mechanical stirrer.

The mixing can be melt mixing carried out at a temperature sufficient for melting the thermoplastic polymer, e.g. at about 50 to 150 °C. Alternatively, the temperature can be in the range of about 80 to 190 °C, preferably about 100 to 150 °C. The uniformity of the composite layer can be increased by using an extruder, kneader or any device suitable for mixing thermoplastic polymers.

By using an extruder mixing apparatus, two hoppers, each containing one of the two components of the composite layer, can deposit the desired amount of each component (thermoplastic polymer and wood particles) in to the mixing chamber of the apparatus. Alternatively, the wood chips and polymer granules may mixed to form a uniform blend before pouring into the feed hopper of an extruder. Then, by way of the stirrer/agitator in the mixing apparatus, there is formed a homogeneous mixture of the thermoplastic and wood particles prior to the formation of the composite layer.

One advantage to the material being formed by such a homogeneous mixture of the components is that the forces necessary to form a substantially homogeneous material are reduced. Therefore, little or no compression force is necessary to facilitate mixing of the components in a material formation step. The importance of this factor is that, by way of the homogeneous mixture, larger particles of each component can be used which would otherwise have been destroyed when subjected to high compression forces. The composite layer can be formed, for example, by extruding the mixture of thermoplastic polymer and wood particles using an appropriate nozzle e.g. to form a sheet or plate. The extruder may be a single screw extruder. The nozzle is selected to give the desired thickness and profile of the composite layer including a composite layer of varying thickness as described above. In the compounding process the profile of the extruder screw is preferably such that its dimensions will allow relatively large wood chips to move along the screw without crushing them. Thus, the channel width and flight depth are selected so that the formation of excessive local pressure increases, potentially causing crushing of the wood particles, are avoided. The temperature of the cylinder and the screw rotation speed are also selected such as to avoid decomposition of wood chip structure by excessively high pressure during extrusion. For example a suitable barrel temperature can be in the range of about 1 10 to 150 °C from hopper to die, while the screw rotation speed may be between 25-50 rpm. These are, naturally, only indicative data and the exact settings will depend on the actual apparatus used.

The molten thermoplastic polymer containing the wood particles can be subjected to tensile forces to achieve a desired orientation of the thermoplastic polymer and, in particular, the wood particles.

The desired 2D profile for the composite layer for the personal protection/(back/lumbar) support device/blank can be obtained from the extruded sheet or plate with e.g. laser cutting, water jet cutting, eccentric pressing or with any tool capable for producing regular shape profiles.

The composite layer with the appropriate 2D profile can also be formed by compression molding, injection molding, die-casting, pressure die-casting or manual shaping.

A particular advantage of the present invention is that the composite layer and lining layer forming the blank can be cut to its 2D profile using scissors i.e. without any specialist cutting tools.

Other features of the steps of manufacturing the composite layer may be as described in WO2010/103188 incorporated herein by reference.

At least one region of non-rigidity can be provided e.g. at a hinge portion of the personal protection device by forming incisions or by using polymer mixtures with more elasticity as described above. The incisions can be formed into the composite layer during or subsequent to extrusion of the composite layer e.g. using a rolling cylinder or a press equipped with blades, water jet or laser cutting. The composite and lining layers be affixed directly to one another with no interposing layer. They may be affixed before or after the formation of the personal protection/(back/lumbar) support device/blank into the desired 2D profile.

In some embodiments, the method comprises including reinforcing fibres either within the composite layer or superimposing reinforcing fibres onto the composite layer e.g. between the composite layer and lining layer. For example, reinforcing metallic fibres or reinforcing synthetic fibres such as aramid fibres (e.g. Kevlar®) fibres may be used.

The reinforcing fibres may be substantially aligned with one another e.g. in devices having a longitudinal and lateral axis, reinforcing fibres may be unidirectional either along the longitudinal or lateral axis. The reinforcing fibres may also be in form of a grid, mesh or web.

The layers may be affixed directly to one another by bonding e.g. bonding using an adhesive. For example, the lining layer may be pre-impregnated with adhesive prior to affixing to the composite layer.

The method may further comprise affixing an edging layer which may extend at least partly (and preferably entirely) around the peripheral edges of at least the composite layer and preferably both layers. The edging layer may provide a smooth edge to the composite layer to prevent irritation of the portion of the wearer's/individual's body against which the personal protection/(back/lumbar) support device fits/rests. The edging layer may be affixed using adhesive and/or stitching, for example.

To form the 3D profile of the personal protection/(back/lumbar) support device and/or to mold the blank, the composite/lining layers are heated to the desired operating temperature by a heating device.

Once the composite/lining layers are heated to the desired temperature, then the layers can be formed into the desired profile. For example, the blank can be placed on the wearer/individual in the desired location to form the personal protection/(back/lumbar) support device. The advantage of the present material is that it can be handled by hand without any protective requirement such as gloves. Equally important is that the material can be formed directly against the wearer's skin. The wood particles form insulating regions within the thermoplastic polymer (which is moldable at low temperature) such that the composite layer is comfortable to touch with bare hands. With the composite material still pliable and moldable, it can be contoured to fit the wearer's/individual's body part (e.g. hip, arm/wrist or back) nearly or exactly. Additionally, if the initial placement is not desirable, the blank can be moved while still moldable to a more desirable location. If the composite layer has lost its desired moldability, then it can be reheated and likewise moved to the new location. A blank formed of PCL and wood particles typically remains moldable for up to 5 minutes. One of the particular advantages of the present material is that it can be heated and cooled many times without degrading its mechanical properties.

When the blank is located properly and molded to the desired form, then it can be allowed to cool to a temperature where it can be removed but maintain its shape. The cooling may be accomplished by allowing the ambient conditions to reduce the temperature of the material or the cooling may be aided by spraying the material with water or another chemical to speed up the cooling. Additionally, solid cooling means can be used to cool the material such as a cold pack or ice place directly against the composite material.

The personal protection/support device may be contoured or the blank may be moldable to fit against the wearer's limb.

For example, the personal protection device may comprise or the blank may be moldable to form a hip guard, a shin pad, an elbow pad, a knee pad, an ankle guard, a shoulder pad/guard or a wrist guard. In these embodiments, the personal protection device may be contoured/dimensioned to only partly encircle the wearer's limb so that weight of the device is minimised and ease of fitting is optimised.

For example, an arm guard may have a substantially U-shaped profile. A blank for an arm guard may have a substantially rectangular shape that is moldable into a U-shaped profile. The curvature of the U-shaped profile may be constant or may vary along its length. For example, the curvature may decrease along its length. The blank may have a cut-out portion at one end - this cut-out portion may provide for flexing of the wearer's wrist once the blank has been moulded into the arm guard. A blank for a wrist or an arm guard (e.g. for use in protecting against incisions when using cutting tools and/or for protecting from wrist fracture during falls by the infirm, especially by infirm individuals suffering with osteoporosis) may have a planar substantially rectangular shape with optionally rounded apices. The arm guard may be a half arm guard/wrist guard e.g. having a length of around 20-30 cm (e.g. 25 cm) and a width (of the blank) of between 10-20 cm e.g. between 10-15 cm. The arm guard may be a full arm guard e.g. having a length of around 45-55 cm (e.g. around 50 cm) and a width (of the blank) of between 10-20 cm e.g. between 10-15 cm.

In other embodiments, the personal protection device may be contoured or the blank may be moldable to fit against the wearer's face/head (e.g. nose/forehead). The personal protection device may be a helmet for protecting the wearer's head from occupational risks or from trip/falls by vulnerable wearer's e.g. the elderly, young and infirm.

In some embodiments, as described above, the support device may be contoured or the blank may be moldable to fit against the individual's back or lumbar region. In these embodiments, the support device/blank may have an H-shaped profile and the support device may be positionable on a chair with the central bar of the H-shaped profile transverse to or aligned with the individual's spine.

In other embodiments, the support device/blank may have a rectangular profile and the support device may be positionable on a chair with the longer axis of the central bar of the rectangular-shaped profile transverse to or aligned with the individual's spine.

In some embodiments, the maximum width of the support device/blank (e.g. the back/lumbar support device/blank) may be between 30-50 cm, e.g. around 40 cm. The height of the support device (e.g. the back/lumbar support device) may be around 10-30 cm, e.g. around 15 cm. The depth of the support device (e.g. the back/lumbar support device) may be around 5-10 cm, e.g. around 8 cm.

In some embodiments, the personal protection device may comprise at least one fastener for affixing the personal protection device to the portion of the wearer's body. The at least one fastener may comprise a strap e.g. a strap that is securable to a further strap or to the personal protection device using a hook/loop connection (e.g. Velcro™). In other embodiments, the personal protection device may not include any fastener. For example, the composite layer has been found to have a sufficiently rough surface (owing to the presence of wood particles) that it can frictionally engage with the wearer's clothing e.g. underwear, to maintain its position against the portion of the wearer's body e.g. hip. This provides for secure affixing of the personal protection device without the need for fasteners (which complicate the manufacturing process).

In some embodiments, the support device may comprise at least one fastener for affixing the support device to a chair. For example, the back/lumbar support may comprise at least one fastener for affixing the back/lumbar support device to the backrest of a chair. The at least one fastener may be adapted to encircle the backrest of a chair. The at least one fastener may comprise a strap e.g. a strap that is securable to a further strap or to the support device using a hook/loop connection (e.g. Velcro™).

In a thirteenth aspect, the present invention provides a hip pad for protecting a wearer's hip, the hip pad comprising:

a lining layer for facing the wearer's hip; and

the lining and composite layers being shaped to substantially match the contour of the wearer's hip. In a fourteenth aspect, the present invention provides a moldable blank for forming a hip pad for protecting a wearer's hip, the moldable blank comprising:

a lining layer for facing the wearer's hip; and

the lining and composite layers being moldable to substantially match the contour of the wearer's hip.

The lining layer and composite layers may be as described above and may be joined as described above. The hip pad/blank may further comprise the edging layer as described above. The hip pad/blank may be manufactured as described above. With a typical thickness of the composite layer being 2-4 mm and a typical thickness of the lining layer being 1-5 mm, the typical thickness of the hip pad is around 3-9 mm making it considerably less bulky than the known hip pads.

A typical length for a hip pad will be around 15-50 cm, e.g. around 30 cm in length. A typical width for a hip pad will be around 15 to 40 cm e.g. around 25 cm.

The blank and/or the hip pad may have at least a portion having a substantially curved profile. The curvature may be constant or may vary along its length. For example, the curvature may decrease along its length (e.g. towards a lower end).

Alternatively, the blank may have a substantially planar e.g. planar rectangular shape for molding into the curved profile.

The hip pad may not include any fastener. For example, the composite layer has been found to have a sufficiently rough surface (owing to the presence of wood particles) that it can frictionally engage with the wearer's clothing e.g. underwear, to maintain its position against the wearer's hip. This provides for secure affixing of the hip pad without the need for fasteners (which complicate the manufacturing process).

Example - Comparative Shock absorption test

Test specimens with dimensions of 50 mm x 50 mm were cut from the plastic shell of three commercially available shin guards (after separation of the shell from the associated foam/textile layers). Additionally three sets of 50 mm x 50 mm test samples were cut from a composite layer having a thickness of 4 mm and a composite layer having a thickness of 2 mm. The composite layer was formed from a 3:2 ratio of PCL and wood particles. The wood particles were aspen wood particles having an average size of 2 x 2 x 1 mm. The PCL had an Mn of 80,000g/mol.

The composite layers were heated and formed to have identical shape as the comparative shin guard specimens to exclude the effect of shape in results. The thickness of each test specimen was measured with calliper at both ends of the specimen, to calculate average thickness.

A blunt impact test set up was used to assess the impact absorbing properties of the test specimens and composite layer samples by dropping a 2.5 kg mass from 47 mm distance, positioned vertically over the top of the test specimen/samples. The amount of force that was transmitted through the guard onto the fiat anvil was measured (Kistler9065) and recorded. The lower the transmitted force the better the shock absorption property of the sample.

Three measurements were performed for each test specimen/sample.

Transmitted force averages and standard deviations were calculated for each test specimen/sample. An independent paired two-tailed t-test was used to test the hypothesis that there is a difference between two materials. A value of P < 0.05 indicates a statistically significant difference between the two materials.

The transmitted force values (averages from three measurements) are shown in Table 1 .

Table 1 The 4 mm composite layer clearly provides the best shock absorption amongst the specimens/samples tested. The 2 mm composite later has only approximately 2/3 of the thickness of the test specimens, however the shock absorption property was either higher (Test specimen 1 ; P=0.009 and Test specimen 2; P=0.048) or around the same level (Test specimen 3; P=0.171 ), in this test. The composite layer can be used to provide a personal protection/(back/lumbar) support device having high shock absorbance but with a narrow profile, reduced buikiness and lower weight compared to known products. The lining layer provides comfort for the wearer/individual. The 3D moldability of the composite layer in the blanks further improves comfort and shock absorbency.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

All references referred to above are hereby incorporated by reference.

Claims

1. A personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the personal protection device comprising:

a lining layer for facing the wearer's body; and

2. A moldable blank for forming a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the moldable blank comprising:

a lining layer for facing the wearer's body; and

the lining and composite layers being moldable to substantially match the contour of the portion of the wearer's body.

3. A support device for supporting a portion of an individual's body whilst in a rest position, the support device comprising:

4. A device according to claim 3 wherein the device is a back/lumbar support device for supporting an individual's back/lumbar region whilst in a rest position, the composite layer being shaped to substantially match the contour of the individual's back/lumbar region.

5. A device according to claim 3 or 4 further comprising a lining layer for facing the individual's body/back/lumbar region with the composite layer superimposed on said lining layer, both layers being shaped to substantially match the contour of the portion of the individual's body/back/lumbar region.

6. A moldable blank for forming a support device for supporting a portion of an individual's body whilst in a rest position, the moldable blank comprising:

7. A blank according to claim 6 wherein the blank is for forming a back/lumbar support device for supporting an individual's back/lumbar region whilst in a rest position, the composite layer being moldable to substantially match the contour of the individual's back/lumbar region.

8. A blank according to claim 6 or 7 further comprising a lining layer for facing the individual's body/back/lumbar region with the composite layer superimposed on said lining layer, both layers being moldable to substantially match the contour of the portion of the individual's body/back/lumbar region.

9. A device or blank according to any one of claims 1 , 2, 5 or 8 wherein the lining layer is formed of a 3D spacer fabric.

10. A device or blank according to any one of claims 1 , 2, 5, 8 or 9 wherein the lining layer has a thickness of between 1 - 5 mm.

1 1 . A device or blank according to any one of claims 1 , 2, 5 or 8 to 10 wherein the lining layer comprises an anti-bacterial and/or anti-odour composition.

12. A device or blank according to any one of the preceding claims wherein the thermoplastic polymer is a polyester.

13. A device or blank according to any one of the preceding claims wherein the thermoplastic polymer is polycaprolactone.

14. A device or blank according to any one of the preceding claims wherein the wood particles are plate-like or granular and have at least two dimensions greater than 1 mm and one greater than 0.02 mm.

15. A device or blank according to claim 14 wherein the wood particles are plate-like and have dimensions or around 1 mm x 2mm x 2mm.

16. A device or blank according to any one of the preceding claims wherein the composite layer contains around 40 wt% wood particles.

17. A device or blank according to any one of the preceding claims comprising at least one region of increased flexibility.

18. A device or blank according to claim 17 wherein the region of increased flexibility is provided at a hinge portion.

19. A device or blank according to claim 17 or 18 wherein said composite layer further comprises a soft or elastic polymer in the region of increased flexibility.

20. A device or blank according to claim 19 wherein the soft or elastic polymer is selected from the group of thermoplastic polyolefin blends; polyurethanes; co-polyesters; polyamides; unsaturated or saturated rubbers, including natural rubber, silicone, and copolymers of olefins; and natural or synthetic soft material, including soft gelatin, hydrogels, hydrocolloids and modified cellulose.

21 . A device or blank according to any one of claims 17 to 20 wherein said composite layer further comprises incisions in the region of increased flexibility.

22. A device or blank according to claim 21 wherein said incisions are spaced in a series of longitudinal parallel lines.

23. A device or blank according to any one of the preceding claims further comprising an edging layer extending at least partly around the peripheral edges of the composite layer.

24. A device or blank according to any one of the preceding claims wherein the composite layer has a thickness of between 2 to 6 mm.

25. A device or blank according to any one of the preceding claims wherein the composite has a central portion that is thicker than a peripheral portion.

26. A device or blank according to any one of the preceding claims having at least a portion having a substantially curved profile.

27. A device or blank according to any one of the preceding claims further comprising reinforcing fibres contained within or superimposed onto the composite layer.

28. A device or blank according to claim 27 wherein the fibres are metallic fibres.

29. A device or blank according to any one of the preceding claims wherein the device is a hip pad for protecting a wearer's hip, the hip pad comprising:

a lining layer for facing the wearer's hip; and

the lining and composite layers being shaped or being moldable to substantially match the contour of the wearer's hip.

30. A method of manufacturing a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the method comprising:

providing a lining layer for facing the wearer's body;

31 . A method of manufacturing a moldable blank for forming a personal protection device for protecting a portion of a wearer's body whilst participating in hazardous occupational activities and/or for protecting a portion of a vulnerable wearer's body whilst participating in everyday activities, the method comprising:

providing a lining layer for facing the wearer's body;

superimposing a composite layer on said lining layer, the composite layer comprising wood particles within a thermoplastic polymer matrix.

32. A method of manufacturing a support device for supporting a portion of an individual's body whilst in a rest position, the method comprising:

providing a composite layer comprising wood particles within a thermoplastic polymer matrix,

33. A method according to claim 32 wherein the device is a back/lumbar support device for supporting an individual's back/lumbar region whilst in a rest position, the method comprising shaping the composite layer to substantially match the contour of the individual's back/lumbar region.

34. A method according to claim 32 or 33 further comprising providing a lining layer for facing the individual's body/back/lumbar region, superimposing the composite layer on said lining layer, and shaping both layers to substantially match the contour of the individual's body/back/lumbar region.

35. A method of manufacturing a moldable blank for forming a support device for supporting a portion of an individual's body whilst in a rest position, the method comprising: providing a composite layer comprising wood particles within a thermoplastic polymer matrix, the composite layer being moldable to substantially match the contour of the portion of the individual's body.

36. A method according to claim 35 wherein the support device is a back/lumbar region support device for supporting an individual's back/lumbar region whilst in a rest position, the composite layer be moldable to substantially match the contour of the individual's back/lumbar region.

37. A method according to claim 35 or 36 further comprising providing a lining layer for facing the individual's body/back/lumbar region, superimposing the composite layer on said lining layer, both layers being moldable to substantially match the contour of the portion of the individual's body/back/lumbar region.

38. A method according to any one of claims 30, 31 , 34 or 37 comprising affixing a lining layer formed of a 3D spacer fabric to said composite layer.

39. A method according to any one of claims 30 to 38 comprising mixing the thermoplastic polymer with the wood particles in a melt mixing apparatus to produce a compounded melt mixture and extruding the melt mixture.

40. A method according to any one of claims 30 to 39 wherein the thermoplastic polymer is polycaprolactone.

41 . A method according to any one of claims 30 to 40 wherein the wood particles are platelike or granular and have at least two dimensions greater than 1 mm and one greater than 0.02 mm.

42. A method according to any one of claims 30 to 41 comprising mixing around 40 wt% wood particles with said thermoplastic polymer.

43. A method according to any one of claims 30 to 42 comprising providing at least one region of increased flexibility at a hinge portion.

44. A method according to any one of claims 30 to 43 comprising mixing a soft or elastic polymer with the thermoplastic polymer in the region of increased flexibility.

45. A method according to any one of claims 30 to 44 comprising providing incisions in the region of increased flexibility.

46. A method according to any one of claims 30 to 45 further comprising applying an edging layer extending at least partly around the peripheral edges of the composite layer.

47. A method according to any one of claims 30 to 46 further comprising including reinforcing fibres within or superimposed onto the composite layer.

48. A method according to claim 47 wherein the fibres are metallic fibres.

49. A personal protection device substantially as any one embodiment described herein.

50. A blank substantially as any one embodiment described herein.

51 . A method substantially as any one embodiment described herein.