Method for manufacturing flexible impact-resistant cushion
阅读说明:本技术 一种制造柔性抗冲击垫的方法 (Method for manufacturing flexible impact-resistant cushion ) 是由 D·S·泰勒 于 2018-12-05 设计创作,主要内容包括:一种制造主要用于防护服的物品中的柔性抗冲击垫(1)的方法,包括以下步骤。首先,提供冲击吸收材料的片材,例如闭孔泡沫。切割该片材以提供具有垫(1)所需的轮廓的部件(16),然后将该部件(16)切割成多个间隔开的独立的元件(2),将这些元件保持在垫(1)所需的轮廓内。提供第一柔性材料层(3),并且该材料层的一侧粘结到间隔开的独立的元件(2)。通过以下附加步骤使垫(1)的边缘流线型化,该附加步骤可以在将片材(16)切割成多个间隔开的独立的元件(2)之前或在将第一柔性材料层(3)粘结到间隔开的独立的元件(2)之后进行。首先,提供轮廓化的模具(8),该模具限定出具有与垫的一侧上所需的形状互补的形状的凹部(9),以及围绕其周边的至少一部分的流线型边缘(10)。加热冲击吸收材料或模具(8),然后将模具(8)压入其中,以在一侧上模制它以限定所需的形状。较佳地,该方法包括将第二柔性材料层(4)粘结到垫(1)的模制侧的另一步骤。在该第二柔性材料层(4)的粘结期间,垫(1)较佳地支承在屈服表面(23)上,以使垫(1)的模制侧在粘结期间变平。还提供了一种柔性抗冲击垫(1),该垫包括第一柔性材料层(3)和多个间隔开的独立的元件(2),每个元件由冲击吸收材料构成并且粘结到第一柔性材料层(3)的一侧。邻近垫(1)的边缘的至少一些元件(2)围绕垫(1)的周边的至少一部分流线型化。(A method of manufacturing a flexible impact-resistant pad (1) intended primarily for use in items of protective clothing, comprising the following steps. First, a sheet of impact absorbing material, such as a closed cell foam, is provided. The sheet is cut to provide a component (16) having the desired profile of the mat (1), and the component (16) is then cut into a plurality of spaced apart individual elements (2) which are held within the desired profile of the mat (1). A first layer of flexible material (3) is provided and one side of the layer is bonded to the spaced apart individual elements (2). The edges of the mat (1) are streamlined by an additional step which may be carried out before cutting the sheet (16) into a plurality of spaced-apart individual elements (2) or after bonding the first layer of flexible material (3) to the spaced-apart individual elements (2). First, a contoured mold (8) is provided, the mold defining a recess (9) having a shape complementary to the desired shape on one side of the pad, and a streamlined edge (10) around at least a portion of its perimeter. The impact absorbing material or mould (8) is heated and then the mould (8) is pressed into it to mould it on one side to define the desired shape. Preferably, the method comprises the further step of bonding the second layer of flexible material (4) to the moulded side of the mat (1). During the bonding of this second layer (4) of flexible material, the mat (1) preferably bears on the yielding surface (23) to flatten the molding side of the mat (1) during bonding. A flexible impact resistant pad (1) is also provided, the pad comprising a first layer of flexible material (3) and a plurality of spaced apart individual elements (2), each element being of impact absorbing material and bonded to one side of the first layer of flexible material (3). At least some of the elements (2) adjacent the edge of the mat (1) are streamlined around at least a portion of the perimeter of the mat (1).)
1. A method of manufacturing a flexible impact resistant pad comprising the steps of:
providing a sheet of impact absorbing material;
cutting the sheet to provide a part with a desired contour of the mat;
cutting the component into a plurality of spaced apart individual elements;
maintaining the plurality of spaced apart individual elements within a desired contour of the mat;
providing a first layer of flexible material;
bonding one side of the first layer of flexible material to the spaced apart individual elements;
characterized in that at least a part of the edges of the pad is streamlined by the following additional steps:
providing a contoured mold defining a recess having a three-dimensional shape complementary to the desired shape on one side of the pad and having a streamlined edge around at least a portion of its perimeter;
heating the impact absorbing material or the mold; and
pressing the mold into the impact absorbing material to mold the impact absorbing material on one side to define a desired shape.
2. A method according to claim 1, wherein the additional step is performed prior to cutting the sheet of shock absorbing material to provide the component with the desired contour of the pad.
3. A method according to claim 2, wherein the sheet of impact absorbing material is moulded to provide a plurality of moulded parts, and then the moulded parts are cut from the sheet to provide a plurality of parts having the desired profile of the plurality of pads.
4. A method as claimed in any one of claims 1 to 3, characterised by cutting each component having the required profile of the mat into a plurality of spaced individual elements using a cutter which is pressed into the impact absorbing material to cut therefrom, the cutter being fitted with an ejector present which causes the spaced individual elements to protrude from the surface of the cutter.
5. The method of claim 4, wherein the cutter comprises a plurality of cutter blades, each cutter blade having a polygonal or closed curve profile mounted on a plate, the ejector comprising a block within each cutter blade, each block defining an exposed surface at a higher level relative to the cutter blade than the plate surrounding the cutter blade.
6. A method as claimed in claim 5, wherein the overall profile produced by the cutter blades is similar to that required for the mat, and the ejectors of the cutter acting on elements around the periphery of the mat eject these peripheral elements to a greater extent than those acting on other elements, whereby the uppermost surface defined collectively by all elements projecting from the cutter surface is substantially flat.
7. The method of claim 5, wherein the overall profile produced by the cutter blades is similar to the desired profile of the mat, and the ejectors of the cutters are all of the same height.
8. A method according to any one of claims 1 to 7, wherein each element is spaced from an adjacent element 1 by between 1mm and 4mm and has a width of between 12mm and 25 mm.
9. A method as claimed in any one of claims 1 to 8, wherein at least one of the opposite faces of the sheet of impact absorbing material is covered with hot melt adhesive prior to cutting the sheet, the at least one adhesive covered face being the face bonded to the one side of the first layer of flexible material.
10. A method as claimed in any one of claims 1 to 9, wherein said one side of the first layer of flexible material is covered with hot melt adhesive prior to bonding said one side of the first layer of flexible material to said one face of impact absorbing material.
11. A method according to claim 9 or claim 10, wherein the one face of the impact absorbing material bonded to the first layer of flexible material is the face opposite the side of the pad moulded to streamline the pad.
12. A method according to any one of claims 1 to 11, including the further step of bonding a second layer of flexible material to the moulded side of the mat.
13. The method of claim 12, wherein the second layer of flexible material is bonded to the molded side of the mat in a heated press.
14. The method of claim 12 or claim 13, wherein during bonding of the second layer of flexible material to the mat, the mat is supported on a yielding surface to enable the molded side of the mat to flatten during bonding.
15. The method of claim 14, wherein the yielding surface comprises a sponge material.
16. The method of claim 13, wherein the heated press is provided with a forming platen that receives the molded side of the pad during bonding of the second layer of flexible material thereto.
17. A method according to any one of claims 1 to 16, wherein the impact absorbing material is a foam.
18. The method of claim 17, wherein the foam is a closed cell foam.
19. The method of any of claims 1 to 18, wherein the layer of flexible material to which the compression resistant material is bonded comprises at least one of an elastically stretchable fabric, a knitted fabric, a woven fabric, a plastic sheet.
20. A flexible impact resistant mat made in accordance with any one of claims 1 to 19.
21. A flexible impact pad comprising a first layer of flexible material and a plurality of spaced apart individual elements each comprising an impact absorbing material and bonded to one side of the first layer of flexible material, characterised in that at least some elements adjacent an edge of the pad are streamlined around at least a portion of the perimeter of the pad.
22. A flexible impact pad as claimed in claim 21 wherein a second layer of flexible material is bonded to a second side of said element opposite said one side.
Technical Field
The present invention relates to a method of manufacturing a flexible impact resistant mat and to a laminated mat manufactured by such a method.
Background
Flexible impact resistant laminates are widely used as protective materials, the pads of which are incorporated into garments and the like to form protective garments for human and animal bodies. Such protective garments are used during sports such as american football, football and equestrian sports, as well as in other activities where the wearer is at risk of injury, such as in the construction and other industries.
The pad may form an integral part of the garment and be sewn or bonded to the garment, for example a shoulder pad, or be provided separately to be secured in a pocket of the garment, or as a specific item of garment, for example a leg pad held in place by a sock.
In WO01/03530 a method of manufacturing a flexible laminate is described, the method comprising the steps of:
1. providing a sheet of resilient material, such as closed cell foam;
2. cutting the sheet into a plurality of spaced, individual elements using a cutter that is pressed into the sheet to cut therefrom;
3 projecting one side of the spaced elements beyond the surface of a clamp arranged to hold the elements in place;
4. removing excess resilient material from between the spaced, individual elements; and
5. the flexible, elastically stretchable substrate is bonded to one side of the individual element by heating the substrate to activate the adhesive applied between the one side of the individual element and the substrate or to fuse the element to the substrate.
One disadvantage of mats made by the foregoing methods is that they have square edges around the outline of the mat. When incorporated into a garment, this gives the garment an unaesthetic appearance, since the edges around the pads are not streamlined. The streamlined edges of the pad are more aesthetically pleasing and can also reduce air blocking and drag when the pad is worn.
Disclosure of Invention
It is an object of the present invention to provide a method of manufacturing a flexible impact resistant pad having at least one streamlined edge.
According to a first aspect of the present invention there is provided a method of manufacturing a flexible impact pad, the method comprising the steps of:
providing a sheet of impact absorbing material;
cutting the sheet to provide a part with the desired contour of the mat;
cutting the part into a plurality of spaced apart individual elements;
maintaining the plurality of spaced apart individual elements within a desired contour of the pad;
providing a first layer of flexible material;
bonding one side of the first layer of flexible material to the spaced apart individual elements;
characterised in that at least a part of the edges of the pad is streamlined by the following additional steps:
providing a contoured mold defining a recess having a three-dimensional shape complementary to the desired shape on one side of the pad and having a streamlined edge around at least a portion of its perimeter;
heating the impact absorbing material or the mold; and
a mold is pressed into the impact absorbing material to mold the impact absorbing material on one side to define a desired shape.
The streamlined edges include rounded, tapered or chamfered edges and are shaped to reduce the resistance to air or water flowing over the pad. When incorporated into a garment, such pads may increase the speed or ease of movement of the person wearing the garment.
Preferably, an additional step is performed prior to cutting the sheet of impact absorbing material to provide the component with the desired contour of the pad. This enables the use of large sheets of impact absorbing material and the use of dies to define a plurality of individual dies, each die defining a recess, so that a plurality of parts can be moulded in a single press. After pressing, the molded sheet is cut to form individual molded parts, which may then be individually subjected to the other steps of the method.
It is also preferred that each section having the desired profile of the mat is cut into a plurality of spaced individual elements using a cutter pressed into the section to cut through the section, the cutter being fitted with an ejector present by the spaced individual elements projecting from the cutter surface.
Also preferably, the cutter comprises a plurality of cutter blades, each cutter blade having a polygonal or closed curve profile mounted on a plate, the ejector comprising a block located within each cutter blade, each block defining an exposed surface at a level relative to the cutter blade higher than the level of the plate surrounding the cutter blade.
Advantageously, the overall profile made by the cutter blades is similar to that required for the mat, and the ejectors of the cutters acting on elements around the periphery of the mat eject these peripheral elements to a greater extent than those acting on other elements, whereby the uppermost surface defined collectively by all elements projecting from the cutter surface is substantially flat.
It is also preferred that at least one of the opposite faces of the sheet of impact absorbing material is covered with hot melt adhesive prior to cutting the sheet. The at least one adhesive covered face is a surface adhered to the one side of the first layer of flexible material. Alternatively, a hot melt adhesive is applied to the one side of the first layer of flexible material prior to bonding the one side of the first layer of flexible material to the one face of the impact absorbing material. In either case, the one face of the impact absorbing material bonded to the first layer of flexible material is preferably the face opposite the side of the pad that is moulded to streamline the pad. This means that if the additional steps described above are performed before cutting the sheet of shock absorbing material, the moulded side of the pad is the side which is placed adjacent the cutter.
Also preferably, the method includes the further step of bonding a second layer of flexible material to the moulded side of the mat.
Also preferably, the second layer of flexible material is bonded to the molding side of the pad in a heated press.
It is also preferred that during bonding of the second layer of flexible material to the mat, the mat is supported on the yielding surface to enable the molded side of the mat to flatten during bonding. Advantageously, the yielding surface is constituted by a sponge material. During bonding, the planarization of the molding side of the pad ensures that the second layer of flexible material is uniformly bonded to the component. Alternatively, the heated press is provided with a forming platen which receives the molded side of the pad during bonding of the second layer of flexible material thereto.
Also preferably, the impact absorbing material is a foam. Advantageously, the foam is a closed cell foam.
Also preferably, the layer of flexible material to which the compression resistant material is bonded comprises at least one of an elastically stretchable fabric, a knitted fabric, a woven fabric, a plastic sheet.
According to a second aspect of the present invention there is provided a flexible impact pad manufactured according to the first aspect of the present invention.
According to a third aspect of the present invention there is provided a flexible impact pad comprising a first layer of flexible material and a plurality of spaced apart individual elements each comprising an impact absorbing material and bonded to one side of the first layer of flexible material, characterised in that at least some of the elements adjacent an edge of the pad are streamlined around at least a portion of the periphery of the pad.
Drawings
Various aspects of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic cross-sectional view of a mat made by a method according to the present invention;
FIG. 2 is a perspective view of a cut and molded part of flexible impact resistant material;
FIG. 3 is a side view of the pad shown in FIG. 2;
FIG. 4 is a perspective view of a mold used in the method of the present invention;
FIG. 5 is a perspective view of a cutter used in the method of the present invention;
FIG. 6 is a view showing the use of a cutter as shown in FIG. 5 to cut a sheet of impact absorbing material into a plurality of spaced apart individual elements;
FIG. 7 is a view showing one side of bonding a first layer of flexible material to spaced apart individual elements produced as shown in FIG. 6;
FIG. 8 is a view showing the first layer of flexible material and the elements bonded thereto removed from the cutter; and
figure 9 is a view showing the bonding of a second layer of flexible material to the other side of the spaced apart individual elements.
Detailed Description
The flexible impact pad 1 made in accordance with the present invention is a laminate comprising a plurality of spaced apart individual elements 2 of impact absorbing material located between and bonded to first and
The element 2 is made of an impact absorbing material, preferably foam and advantageously closed cell foam. Such a closed cell foam may be a polyethylene foam and the elements 2 may comprise a polygonal shape, with 100 to 8000 elements/m2The density between them is uniformly distributed. For some applications, the density may be lower than the density used for the pads 1 used in protective garments, since the greater the density, the greater the flexibility of the pad. For use in protective clothing, the density is 2000 to 6000 elements/m2The density in between is preferred because it allows the pad to flex easily in all directions without "locking" or preventing movement in a particular direction. Preferably, the elements 2 are arranged uniformly, each element 2 being spaced from the adjacent element 1 by between 1mm and 4 mm. In most, but not all, pads 1 for clothing, the width of the element 2 will be between 12mm and 25 mm.
The
Fig. 4 is a perspective view of an embodiment of a mold 6 used in the method of the present invention described below. The shown mould 6 comprises a back plate 7 to which back plate 7 a number of separate individual moulds 8 are fixed, each mould 8 being intended to mould a part of the impact absorbing material cut into elements 2. As indicated above, the use of a mould 6 comprising a plurality of individual moulds 8 increases the efficiency of the method as it enables the use of large sheets of impact absorbing material and moulding them into a plurality of parts in a single press. The individual moulds 8 may all have the same shape and size or may be varied as desired, for example several different sizes and shapes of parts may be moulded in one operation for a single or different garment. In all cases, however, each die 8 is profiled to define a recess 9, the recess 9 having a streamlined edge 10 around at least a portion of its periphery.
Fig. 5 shows a perspective view of an embodiment of a
Preferably, as shown in fig. 6, within each
The steps involved in the manufacture of the pad 1 using the above-described die 6 and
In order to make the pad 1, it is necessary to produce a piece 16 of impact absorbing material which has been cut and moulded to the desired contour of the pad, as shown in figures 2 and 3. This can be achieved as follows. First, a sheet of impact absorbing material such as closed cell foam is coated on both sides with a layer 17 of hot melt adhesive. Such binders are known to those skilled in the art and typically have an activation temperature of about 130 ℃. The adhesive layer 17 may be applied to the sheet in liquid, powder or film form, but if applied in liquid form, the adhesive layer 17 must be dried before the other steps of the method are performed. The next step is to mold the sheet using mold 6 to produce the part 16. First, however, the mold 6 or sheet is heated to a temperature below the activation temperature of the adhesive 17, but this temperature may be up to about 125 ℃, for example. In other methods, the temperature may be higher, but then the surface of the mold is preferably provided with a non-stick coating. Preferably, however, the sheet is heated and then the die 6 is cold pressed into one side of the sheet 16. This molds the material on this side of the sheet so that it defines a plurality of shapes having contours complementary to the shapes of the recesses 9 defined by the respective molds 8. These shapes are now cut from the sheet to provide individual components 16, each having on one side the shape required for the pad 1 under manufacture. As mentioned above, it should be understood that the mould 6 may be provided with only one or more separate tools 8 as required.
The molded part 16 of impact absorbing material now has a flat surface 18 and a molded surface 19 with
As mentioned above, the first layer of
It is now possible to trim away the
As shown in fig. 9, to bond the second layer of material 4 to the element, the
In addition to the foregoing alternatives, alternatives for other portions of the manufacturing method will now be described. However, as will also be described, each of these alternatives has disadvantages compared to the above-described methods.
First, instead of covering both sides of the sheet of impact absorbing material 16 with the hot melt adhesive layer 17, hot melt adhesive is applied to one side of each of the first and second
Second, the impact absorbing material may be molded by a single mold 8 to form a streamlined edge after bonding the first layer of
Finally, as an addition to all the aforementioned methods, one or both of the first layer of
Alternatively, an additional step is performed after bonding the one side of the first layer of flexible material to the spaced apart individual elements. However, this alternative has several disadvantages. In particular, molding of the impact absorbing material tends to shrink and/or deform the elements and change the spacing between them. In particular, the impact absorbing material of the elements around the periphery of the pad tends to deform so that it bulges out sideways in all directions. This means that some of the impact absorbing material around the edges of the pad is not bonded to the first layer of flexible material. Furthermore, it tends to melt or lock together adjacent elements around the periphery of the mat, which reduces the flexibility of the mat in use. If the first flexible material layer is permeable, the breathability of the pad is also reduced.
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