Abstract: A protective undergarment, such as trousers or a shirt intended for use under other clothing, employs seamless welding to permanently affix one or more protective pad segments to the main body of material. An ultra-sonic welding process may be employed. Thus, a welding material, such as a suitable polymeric film, may be used to fuse a small-area fabric member to the main body material of the undergarment, so as to form a pocket for a pad segment. To ensure that the pad segment does not fold or otherwise move within the pocket, at least one channel may be formed within the pad segment to allow welding within the interior of the pad segment.

Abstract: A protective undergarment, such as trousers or a shirt intended for use under other clothing, employs seamless welding to permanently affix one or more protective pad segments to the main body of material. An ultrasonic welding process may be employed. Thus, a welding material, such as a suitable polymeric film, may be used to fuse a small-area fabric member to the main body material of the undergarment, so as to form a pocket for a pad segment. To ensure that the pad segment does not fold or otherwise move within the pocket, at least one channel may be formed within the pad segment to allow welding within the interior of the pad segment.

Abstract: A protective pad system having an exoskeletal shell assembly and an impact absorbing cushioning pad assembly releasably and mechanically attached to the inner surface of the exoskeletal shell assembly. The cushioning pad assembly includes a plurality of independent sub pad assemblies constructed of moisture and heat tolerant materials and adhesives to allow frequent laundering.

Abstract: A protective garment is provided for use in conjunction with an exoskeletal upper body pad system for a sport, such as American football. The protective garment includes a shirt formed of air-permeable, moisture-wicking fabric that stretches in all directions. A number of independent protective pad segments are integrated within the shirt and are arranged to enable flexible motion by the wearer of the shirt. The independent protective pad segments are positioned and dimensioned to enable the protective garment to be worn between the body of the wearer and the exoskeletal upper body pad system. A conventional exoskeletal shoulder pad system may be easily retrofit for use with the protective garment by attaching a pair of sub pad assemblies to the main arches of the system in order to provide localized compressible padding.