Resilient pad composite and process for making same

• US 8,980,412 B2
• Filed: 11/24/2009
• Issued: 03/17/2015
• Est. Priority Date: 11/24/2008
• Status: Active Grant

• Current Assignee: Applied Ft Composite Solutions Inc.
• Original Assignee: Applied Ft Composite Solutions Inc.
• Inventors: Kim, Daniel
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): Powers, Laura C
• Application Number:
  US12/624,881
• Publication Number:
  US 20100129573A1
• Time in Patent Office: 1,939 Days
• Field of Search: 245/5, 241/0, 245/9, 2 2/0, 2 4/94, 572/7, 428/71, 428/201, 156/300, 156/250
• US Class Current: 428/201
• CPC Class Codes: A41D 31/285 using layered materials
• CPC Class Codes: A63B 71/08 Body-protectors for players or sportsmen , i.e. body-protecting accessories affording protection of body parts against blows or collisions protective clothing or garments for sporting purposes A41D13/00
• CPC Class Codes: B32B 2038/047 Perforating
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/025 Polyolefin vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2437/00 Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 25/04 comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/10 characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/025 : comprising leather
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1074 : Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1093 : with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential

Abstract

The present application discloses a composite pad structure that includes a substrate bonded to a plurality of discrete, spaced-apart, resilient elements engaged to at least one reinforcing structure.

Claims

1. A composite pad structure, comprising a substrate bonded to a resilient material assembly comprising

a plurality of discrete, spaced-apart, resilient elements having opposite sides cut from a sheet of resilient material having opposite sides, which are at least partially surrounded by at least one removable reinforcing structure having holes, wherein holes in the reinforcing structure fit around selected resilient elements.

2. The composite pad structure according to claim 1, wherein the reinforcing structure comprises a lattice of reinforcing material.

3. The composite pad structure according to claim 2, wherein the lattice of reinforcing material engages all of the resilient elements.

4. The composite pad structure according to claim 2, wherein the lattice of reinforcing material engages some of the resilient elements.

5. The composite pad structure according to claim 2, wherein at least one lattice of reinforcing material engages all of the resilient elements, and additional lattice of reinforcing material engages some of the resilient elements.

6. The composite pad according to claim 1, wherein a second substrate is bonded on opposite side of the resilient elements.

7. The composite pad according to claim 1, wherein the resilient elements engaged to the reinforcing structure is positioned between a first and second substrates.

8. A support comprising the composite according to claim 1.

9. The support according to claim 8, which is an athletic garment, footwear, bag, backpack, sack, seating pads, or athletic equipment.

10. An athletic safety wear, comprising the composite according to claim 1.

11. The composite pad structure according to claim 1, wherein the resilient elements have a first side and a second side, wherein the first side of the resilient elements are bound to a first substrate.

12. The composite pad structure according to claim 11, wherein the second side of the resilient elements are bound to a second substrate.