WO2008044007A1 - Procédé de fabrication d'un stratifié flexible, résistant au choc - Google Patents

Procédé de fabrication d'un stratifié flexible, résistant au choc Download PDF

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Publication number
WO2008044007A1
WO2008044007A1 PCT/GB2007/003836 GB2007003836W WO2008044007A1 WO 2008044007 A1 WO2008044007 A1 WO 2008044007A1 GB 2007003836 W GB2007003836 W GB 2007003836W WO 2008044007 A1 WO2008044007 A1 WO 2008044007A1
Authority
WO
WIPO (PCT)
Prior art keywords
tessellating
cutter
flexible
sheet
patterns
Prior art date
Application number
PCT/GB2007/003836
Other languages
English (en)
Inventor
David Stirling Taylor
Original Assignee
Stirling Moulded Composites Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB0620110A external-priority patent/GB0620110D0/en
Application filed by Stirling Moulded Composites Limited filed Critical Stirling Moulded Composites Limited
Priority to EP20070824090 priority Critical patent/EP2084004B1/fr
Priority to US12/294,869 priority patent/US20100285299A1/en
Publication of WO2008044007A1 publication Critical patent/WO2008044007A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2459/00—Nets, e.g. camouflage nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details

Definitions

  • the present invention relates to a method of manufacturing a flexible, impact-resistant laminate and to a laminate produced by such a method.
  • Such laminates are widely used as protective material which is incorporated into clothing and the like to fashion protective wear for human and animal bodies.
  • Such protective wear is used during sport, rugby for example and equestrian sports and in other activities where a person runs a risk of injury, for example building and other trades.
  • Conventional protective wear may form an integral part of an item of clothing, for example a shoulder pad, or be provided separately, for example a shin pad.
  • EP 1194050 is described a method of manufacturing a flexible laminate comprising the following steps:-
  • a sheet of a resilient material such as a closed cell foam
  • the cutter acts as the jig after cutting through the resilient foam to hold the elements in place while the substrate layer is applied thereto. Prior to this, excess material from between the elements is removed before the bonding of the spaced elements to the substrate. Such excess material is then scrapped.
  • the object of the present invention is to provide an improved method of manufacturing the flexible material.
  • a method of manufacturing a flexible, impact-resistant material comprising the steps of providing a sheet of a closed-cell foam material; cutting the sheet into at least two tessellating patterns; differentially moving the tessellating patterns relative to one another such that the surface of one of the tessellating patterns stands proud of the surface of the other tessellating patterns; providing a first, flexible layer of material; and bonding a first of said tessellating patterns to one side of the first layer of material.
  • the sheet of closed-cell foam is cut into the tessellating patterns using a cutter which is pressed into the foam to cut therethrough.
  • the cutter is adapted so that after the sheet of closed- cell foam has been cut all of the tessellating patterns stand proud of the surface of the cutter grid.
  • a block arrangement is located within the cutter that causes the tessellating patterns to move relative to one another after the sheet of foam has been cut.
  • the cutter comprises a plurality of cutter blades each with a polygonal or closed curve profile that are mounted on a board, a block being located within each of the cutter blades that defines an exposed surface at a level higher, relative to the cutter blades, than the level of the board surrounding the cutter blades.
  • the cutter is adapted so that after the sheet of closed- cell foam has been cut all of the tessellating patterns stand proud of the cutter.
  • opposing faces of the sheet of closed-cell foam material are coated with a hot-melt adhesive prior to the sheet being cut into said tessellating patterns.
  • the method comprises the additional step of bonding the closed-cell foam comprising one of the tessellating patterns to one side of a second flexible layer of material on the other side of the laminate to the first layer of material after the foam material defining said one tessellating pattern has been removed from contact with the other tessellating patterns.
  • the method comprises the additional steps of providing a third flexible layer of material and bonding a second tessellating pattern to one side of the third layer of material after the foam material - A -
  • the flexible layers of material to which the closed-cell foam is bonded comprise at least one of the following, namely a resiliently stretchable fabric, a knitted fabric, a woven fabric, a plastics sheeting.
  • Fig. l is a perspective view of a flexible, impact-resistant laminate manufactured in accordance with the method of the present invention.
  • Fig. 2 is a plan view of a sheet of closed-cell foam cut into two tessellating patterns in accordance with the method of the present invention
  • Fig. 3 is a plan view of a cutter for use in the method according to the present invention.
  • Fig. 4 is a vertical cross-section, to an enlarged scale, through part of the cutter as shown in Fig. 3;
  • Figs. 5 to 8 are a series of diagrams showing various stages during the manufacture of a laminate as shown in Fig. i.
  • a flexible, impact resistant laminate manufactured according to the present invention comprises a plurality of elements i of a resilient closed-cell foam fused to or joined by an adhesive to a flexible layer of material 2.
  • the elements 1 are evenly arranged, each element 1 being spaced from adjacent elements 1 by between 1 mm and 4 mm.
  • a margin of material 2 is provided around the periphery of the elements 1 and along the edges of the material at opposite ends respectively there are strips 3 of VELCRO (registered trade mark), only one of which is shown. These strips 3 can be used to join a piece of the laminate together, for example to for a wrist band or shin pad.
  • edges of the laminate can be sewn or otherwise secured to clothing parts or other material dependent on the use to which it is to be put.
  • the closed-cell foam is a polyethylene foam and the elements 1 comprise cubes which are evenly distributed with a density of between 100 and 8000 cells or elements/m 2 .
  • the density can be lower than for protective wear as the greater the density, the greater the flexibility of the laminate.
  • For protective wear a density between 2000 and 6000 elements/m 2 is preferable as it allows the laminate to flex easily in all directions without “locking up” or preventing movement in a particular direction. Also, it enables the laminate to be cut into small pieces, for example to form protective wear of different sizes, without significantly affecting its ability to flex.
  • the elements 1 are shown as cubes in Fig. 1, the foam can be cut into other shapes, an hexagonal shape being preferable for some applications.
  • the material 2 is preferably made of a resiliently stretchable knitted fabric, advantageously one comprising polyester or elastane fibres.
  • the material 2 can be made of a hard- wearing knitted or woven fabric or film, that does not need to be stretchable. Suitable films include plastics films such as sheets of polyethylene or polyurethane.
  • a second layer of flexible material is bonded over the elements i so that they are sandwiched between two layers. In this case, if the first layer of material is resiliently stretchable or elastic, this helps to prevent puckering of one side of the laminate when it is flexed.
  • both the outer layers of material are resiliently stretchable.
  • the laminate is preferably arranged so that the stretchable material layer lies on the outside surface of the curve.
  • Fig. 3 shows a plan view of a first embodiment of cutter io used in the manufacture of the material shown in Fig. l.
  • the cutter io comprises a plurality of blades ii with a polygonal or closed curve profile that are mounted on a board 12.
  • the blades 11 each define a rectangular profile which determines the size of the elements 1. If the laminate material is for use in protective wear, for example, the blades 11 may have sides that are 12 mm long with corners of radius 2.5 mm. However, it will be appreciated that any appropriate blade profile 11 could be used.
  • the height of the blades 11 of the cutter 10 are arranged to be slightly smaller than the thickness of foam sheet with which the cutter 10 is to be used. This means that when the cutter 10 is used to cut a sheet of foam as shown in Fig. 2, the foam is cut into two tessellating patterns comprising a cellular matrix 8 and a regular series of elements 9 comprising blocks or cubes 18.
  • Fig. 4 is a diagram showing a vertical section through one of the blades 11 and the surrounding board 12. It can be seen that within each of the cutter blades 11 is a block 13 which has an exposed surface at a level higher relative to the blades 11 than the level of the board 12 surrounding the blades 11. This means that after cutting of the sheet of foam, the foam cubes 18 within the blades 11 are raised above the level of the matrix 8 after cutting. The reason for this will now be explained and the steps involved in manufacturing a laminate using the cutter shown in Figs. 3 and 4 will now be described with reference to the sequence of drawings as shown in Figs. 5 to 8.
  • both sides of a sheet 15 of closed cell foam are coated on both sides with a hot melt adhesive 16.
  • the foam 15 is then placed over a cutter 10, of the type shown in Figs. 3 and 4, and either pressed down with a press 17, as shown in Fig. 5, or passed through nip rollers (not shown) so that the cutter 10 cuts through the foam 15 to form a cellular matrix 8, as shown in Fig. 2, and a plurality of separate cubes 18.
  • the press 17 is removed, owing to its springy nature the foam 15 will tend to spring back slightly so that its upper surface stands proud above the upper surface of the cutter 10 as defined by the edges of the blades 11.
  • the cutter 10 therefore acts as a jig, holding the cut foam in position during the next stage of the manufacturing process.
  • a first layer of material 19 is placed over the foam 15 and the cutter 10.
  • the inner surface of the material 19 only contacts the upper surface of the cubes 18.
  • a heated platen 20 is now brought into contact with outer surface of the material 19 and heat is conducted through the material 19 to the foam of the cubes 18 which activates the adhesive coating 16. This bonds the material 19 to the cubes 18 but not to the cellular matrix 8. Heated nip rollers (not shown) could be used in place of the platen 20.
  • the cutter 10 is adapted to cut the foam sheet 15 into two tessellating patterns which are both suitable for use in the production of a useable laminate, each pattern having foam regions that are neither too small nor too narrow to be practical.
  • the patterns may comprise one which forms a cellular matrix and the other foam elements, as in the illustrated embodiment, or both could form elements in a chequerboard pattern or similar with square or other polygonal shapes.
  • the patterns may also define stripes or swirling patterns.
  • the patterns could also be specially adapted and bespoke for particular applications of the laminate as such a laminate will have different properties in different areas and when flexed in different directions.
  • a second layer of a flexible material 22 can be then bonded to the other side of the foam by supporting the laminate on a board 21 and using a heated platen 20 or heated nip rollers
  • the closed- cell foam may be fused to the layers 19 and 22 by the application of heat so that it partially melts on the surface rather than being adhered thereto.
  • other impact resistance materials such as an elastomeric material, could be used to fill the spaces between the regions of closed-cell foam.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un matériau flexible, résistant au choc, lequel procédé comporte les étapes consistant à se procurer une feuille d'un matériau en mousse à cellules fermées (15) et à couper la feuille en au moins deux motifs en mosaïque (8, 9), de préférence au moyen d'un outil de coupe (10). Les motifs en mosaïque (8, 9) sont ensuite déplacés de façon différentielle l'un par rapport à l'autre de telle sorte que la surface de l'un des motifs en mosaïque (9) est proéminente par rapport à la surface des autres motifs en mosaïque (8). Une première couche flexible de matériau (19) est ensuite liée à la surface du motif en mosaïque (9) proéminente par rapport au reste. De préférence, un agencement en bloc (13) est situé dans l'outil de coupe (10) qui amène les motifs en mosaïque (8, 9) à se déplacer l'un par rapport à l'autre après que la feuille de matériau en mousse (15) a été coupée.
PCT/GB2007/003836 2006-10-11 2007-10-09 Procédé de fabrication d'un stratifié flexible, résistant au choc WO2008044007A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP20070824090 EP2084004B1 (fr) 2006-10-11 2007-10-09 Procédé de fabrication d'un stratifié flexible, résistant au choc
US12/294,869 US20100285299A1 (en) 2006-10-11 2007-10-09 Method of manufacturing a flexible, impact- resistant laminate

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB0620110A GB0620110D0 (en) 2006-10-11 2006-10-11 A flexible,impact-resistant laminate and a method of manufacturing same
GB0620110.7 2006-10-11
GB0621460.5 2006-10-27
GB0621460A GB0621460D0 (en) 2006-10-11 2006-10-27 A method of manufacturing a flexible, impact-reistaint laminate

Publications (1)

Publication Number Publication Date
WO2008044007A1 true WO2008044007A1 (fr) 2008-04-17

Family

ID=38924792

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2007/003836 WO2008044007A1 (fr) 2006-10-11 2007-10-09 Procédé de fabrication d'un stratifié flexible, résistant au choc

Country Status (1)

Country Link
WO (1) WO2008044007A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8931119B2 (en) 2009-08-11 2015-01-13 Adidas Ag Pad for a garment, padded garment and method of manufacturing same

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2304539A (en) * 1995-08-25 1997-03-26 Anthony Alan Richardson Body protectors
DE19640263A1 (de) * 1996-09-30 1998-04-02 Alveo Ag Polsterformkörper auf Basis eines Polyolefin-Schaumstoffes
WO2001003530A1 (fr) * 1999-07-13 2001-01-18 Stirling Moulded Composites Limited Materiau souple
WO2001003550A1 (fr) 1999-07-07 2001-01-18 Danny Morris Meuble
WO2002081202A1 (fr) * 2001-04-03 2002-10-17 Alan Percy Fowle Composites formables
US20050153107A1 (en) * 2004-01-12 2005-07-14 Tdk Corporation Substrate having functional layer pattern formed thereon and method of forming functional layer pattern
US20050287346A1 (en) * 2000-08-25 2005-12-29 Sekisui Chemical Co., Ltd. Expandable thermoplastic resin product, method for manufacture of expandable thermoplastic resin product and thermoplastic resin foam
WO2006036072A1 (fr) * 2004-09-27 2006-04-06 Body Armour (1995) Limited Stratifies resistant au choc

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2304539A (en) * 1995-08-25 1997-03-26 Anthony Alan Richardson Body protectors
DE19640263A1 (de) * 1996-09-30 1998-04-02 Alveo Ag Polsterformkörper auf Basis eines Polyolefin-Schaumstoffes
WO2001003550A1 (fr) 1999-07-07 2001-01-18 Danny Morris Meuble
WO2001003530A1 (fr) * 1999-07-13 2001-01-18 Stirling Moulded Composites Limited Materiau souple
US20050287346A1 (en) * 2000-08-25 2005-12-29 Sekisui Chemical Co., Ltd. Expandable thermoplastic resin product, method for manufacture of expandable thermoplastic resin product and thermoplastic resin foam
WO2002081202A1 (fr) * 2001-04-03 2002-10-17 Alan Percy Fowle Composites formables
US20050153107A1 (en) * 2004-01-12 2005-07-14 Tdk Corporation Substrate having functional layer pattern formed thereon and method of forming functional layer pattern
WO2006036072A1 (fr) * 2004-09-27 2006-04-06 Body Armour (1995) Limited Stratifies resistant au choc

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8931119B2 (en) 2009-08-11 2015-01-13 Adidas Ag Pad for a garment, padded garment and method of manufacturing same
US10548357B2 (en) 2009-08-11 2020-02-04 Adidas Ag Pad for a garment, padded garment and method of manufacturing same
US11717038B2 (en) 2009-08-11 2023-08-08 Adidas Ag Pad for a garment, padded garment and method of manufacturing same

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