초록

An impact absorbing composite structure (10), the impact absorbing composite structure including a plurality of impact absorbing members (18) and a flexible layer (16), each impact absorbing member (18) integral with the flexible layer (16).

대표청구항 ▼

1. A method of forming an impact absorbing composite, the method comprising:placing a flexible layer into a molding apparatus, the molding apparatus having a plurality of first surfaces that define a plurality of first mold cavity portions and a second surface that defines a second mold cavity porti

1. A method of forming an impact absorbing composite, the method comprising:placing a flexible layer into a molding apparatus, the molding apparatus having a plurality of first surfaces that define a plurality of first mold cavity portions and a second surface that defines a second mold cavity portion and, the flexible layer positioned between the first mold cavity portions and the second mold cavity portion, and the first mold cavity portions and the second mold cavity portion collectively forming a mold cavity;placing polymeric resin in the mold cavity;expanding the polymeric resin in the mold cavity to form an impact absorbing composite intermediate, the impact absorbing composite intermediate comprising expanded polymeric resin and the flexible layer; andfinishing the impact absorbing composite intermediate to form the impact absorbing composite.2. The method of claim 1 wherein:placing polymeric resin in the mold cavity comprises placing the polymeric resin in the first mold cavity portions and the second mold cavity portion; andexpanding the polymeric resin in the mold cavity comprises expanding the polymeric resin in the first mold cavity portions and expanding the polymeric resin in the second mold cavity portion.3. The method of claim 2 wherein:the flexible layer has a first major surface and a second major surface that are located on opposing sides of the flexible layer and has internal surfaces that define a plurality of holes that extend through the flexible layer from the first major surface to the second major surface; andplacing polymeric resin in the mold cavity comprises placing the polymeric resin in the second mold cavity portion and allowing the polymeric resin to pass through the holes of the flexible layer and into the first mold cavity portions.4. The method of claim 2 wherein the flexible layer has internal surfaces that define a plurality of holes in the flexible layer, the method further comprising securing the expanded polymeric resin within the holes of the flexible layer.5. The method of claim 4 wherein:the flexible layer has a first major surface and a second major surface, the first major surface and the second major surface located on opposing sides of the flexible layer; andthe holes of the flexible layer extend through the first major surface, through the second major surface, or through both the first major surface and the second major surface.6. The method of claim 1 wherein the impact absorbing composite intermediate comprises a plurality of first impact absorbing members, the first impact absorbing members formed in the first mold cavity portions, and adjacent first impact absorbing members are discrete and individually distinct from each other.7. The method of claim 6 wherein:the flexible layer has internal surfaces that define a plurality of holes in the flexible layer;the first impact absorbing members comprise the expanded polymeric resin; andthe expanded polymeric resin of the first impact absorbing members extends into and is fixed within the holes of the flexible layer.8. The method of claim 1 wherein the expanded polymeric resin comprises closed cell polymeric foam.9. The method of claim 8 wherein the closed cell polymeric foam comprises polymeric material that is selected from the group consisting of polystyrene, polyethylene, polypropylene, and any combination of any of these.10. The method of claim 1 wherein the impact absorbing composite comprises:a plurality of first impact absorbing members attached to the flexible layer; anda plurality of second impact absorbing members attached to the flexible layer, the first impact absorbing members and the second impact absorbing members attached to opposing sides of the flexible layer.11. The method of claim 10 wherein the first impact absorbing members are free of voids.12. The method of claim 10 wherein adjacent first impact absorbing members are discrete and individually distinct from each other.13. The method of claim 10 wherein the first impact absorbing members are movable independently with respect to each other.14. The method of claim 1 wherein the flexible layer comprises a net or open-meshed fabric.15. The method of claim 1 wherein:the impact absorbing composite intermediate comprises a plurality of first impact absorbing members, the first impact absorbing members formed in the first mold cavity portions; andfinishing the impact absorbing composite intermediate comprises:removing excess expanded polymeric resin to form a plurality of second impact absorbing members, the first impact absorbing members and the second impact absorbing members located on opposing sides of the flexible layer.16. The method of claim 15 wherein:removing excess expanded polymeric resin means thermally cutting excess expanded polymeric resin, mechanically cutting or routing excess expanded polymeric resin, vaporizing excess expanded polymeric resin, or any of these in any combination.17. An impact absorbing composite, the impact absorbing composite comprising:a plurality of impact absorbing members, each impact absorbing member being solid and predominantly free of voids; anda flexible layer comprising a net or open-meshed fabric, each impact absorbing member attached to the flexible layer, wherein:adjacent impact absorbing members are in contact with each other; andthe majority of the impact absorbing members are surrounded by at least three adjacent impact absorbing members.18. An impact absorbing composite, the impact absorbing composite comprising:a plurality of first impact absorbing members, the first impact absorbing members being solid and predominantly free of voids;a plurality of second impact absorbing members attached in working relation with the first impact absorbing members; anda flexible layer, the first impact absorbing members attached to the flexible layer, wherein:adjacent first impact absorbing members are in contact with each other; andthe first impact absorbing members and the second impact absorbing members are located on opposite sides of the flexible layer.19. A method of making an impact absorbing composite, the method comprising:attaching a plurality of impact absorbing members to a flexible layer that comprises a net or open-meshed fabric, the impact absorbing members being solid and predominantly free of voids;placing adjacent impact absorbing members in contact with each other, the majority of the impact absorbing members surrounded by at least three adjacent impact absorbing members.20. A method of making an impact absorbing composite, the method comprising:attaching a plurality of first impact absorbing members to a flexible layer, the first impact absorbing members being solid and predominantly free of voids and adjacent first impact absorbing members in contact with each other;attaching a plurality of second impact absorbing members in working relation with the first impact absorbing members, the first impact absorbing members and the second impact absorbing members located on opposite sides of the flexible layer.21. The method of claim 6 wherein each impact absorbing member is directly attached to, and in contact with, the flexible layer.22. The method of claim 6 wherein the impact absorbing members and the flexible layer are formed of different materials.23. The method of claim 10 wherein each first impact absorbing member is directly attached to, and in contact with, the flexible layer.24. The method of claim 10 wherein the first impact absorbing members and the flexible layer are formed of different materials.25. The method of claim 10 wherein the flexible layer comprises a net or open-meshed fabric.26. The impact absorbing composite of claim 17 wherein each impact absorbing member is directly attached to, and in contact with, the flexible layer.27. The impact absorbing composite of claim 17 wherein the impact absorbing members and the flexible layer are formed of different materials.28. The impact absorbing composite of claim 18 wherein each first impact absorbing member is attached to, and in contact with, the flexible layer.29. The impact absorbing composite of claim 18 wherein the first impact absorbing members and the flexible layer are formed of different materials.30. The impact absorbing composite of claim 18 wherein the flexible layer comprises a net or open-meshed fabric.31. The method of claim 19 wherein each impact absorbing member is attached to, and in contact with, the flexible layer.32. The method of claim 19 wherein the impact absorbing members and the flexible layer are formed of different materials.33. The method of claim 20 wherein each first impact absorbing member is attached to, and in contact with, the flexible layer.34. The method of claim 20 wherein the first impact absorbing members and the flexible layer are formed of different materials.35. The method of claim 20 wherein the flexible layer comprises a net or open-meshed fabric.