Protective materials and methods for producing protective materials

Abstract

The present disclosure is directed to protective materials and methods for producing protective materials. The protective materials include a plurality of foam elements having a molded surface and a cut surface. The molded surfaces of the foam elements are attached to a fabric sheet such that the cut surfaces each define planes that are spaced from the fabric sheet when the fabric sheet is substantially planar. The protective materials are produced by using a mold to form the plurality of foam elements on one side of a foam sheet, attaching a fabric sheet to the top of the foam elements, and cutting the foam elements from the foam sheet.

What is claimed is: 
     
         1 . A method for producing a protective material including a plurality of foam elements attached to a fabric sheet, the method comprising: providing a mold having a surface and a plurality of cavities spaced along the surface; placing a sheet of foam material onto the surface of the mold so that the foam sheet covers the cavities; compressing the foam sheet against the surface of the mold, whereby portions of the foam material at least partially fill the cavities to form a plurality of molded foam elements on one side of the compressed foam sheet, each foam element having a molded surface with a top portion distal from the compressed foam sheet; removing the compressed foam sheet from the mold to expose the foam elements; attaching a first fabric sheet to the top portions of the molded surfaces; and cutting the plurality of foam elements from the compressed foam sheet to form the protective material. 
     
     
         2 . The method of  claim 1 , wherein after attaching the first fabric sheet to the top portions of the molded surfaces, the first fabric sheet is substantially planar when the compressed foam sheet is substantially planar, and the first fabric sheet is spaced from the compressed foam sheet. 
     
     
         3 . The method of  claim 2 , wherein after attaching the first fabric sheet to the top portions of the molded surfaces, the first fabric sheet is substantially parallel to the compressed foam sheet when the compressed foam sheet is substantially planar. 
     
     
         4 . The method of  claim 1 , wherein the step of cutting the foam elements from the foam sheet comprises: selecting a depth of the foam elements that is less than or equal to the depth of the foam elements after the foam elements have been formed in the cavities; and cutting the foam elements to the selected depth. 
     
     
         5 . The method of  claim 1 , wherein the step of providing a mold having a surface and a plurality of cavities spaced along the surface includes providing a mold having a first cavity with a shape that is different than a second cavity. 
     
     
         6 . The method of  claim 5 , wherein the step of compressing the foam sheet against the surface of the mold shape causes a first portion of the foam material to at least partially fill the first cavity to form a first molded foam element, and a second portion of the foam material to at least partially fill the second cavity to form a second foam element, wherein the first foam element has a different shape than the second foam element. 
     
     
         7 . The method of  claim 1 , wherein the step of compressing the foam sheet against the surface of the mold shape causes a first portion of the foam material to at least partially fill a first cavity to form a first foam element, wherein a cross-section of the first foam element defines a shape selected from the group consisting of a circle, an ellipse, an oval, a polygon, a heart, and a barbell. 
     
     
         8 . The method of  claim 1 , wherein the step of cutting the plurality of foam elements from the compressed foam sheet includes cutting a first foam element to form a cut surface defining a plane that is spaced from the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         9 . The method of  claim 8 , wherein after the step of cutting the first foam element to form a cut surface, the plane defined by the cut surface is substantially parallel to the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         10 . The method of  claim 1 , wherein the step of cutting the plurality of foam elements from the compressed foam sheet includes forming a cut surface on each of the foam elements, the method further comprising attaching a second fabric sheet to the cut surfaces of the foam elements so that the second fabric sheet is substantially planar when the first fabric sheet is substantially planar, and the second fabric sheet is spaced from the first fabric sheet. 
     
     
         11 . The method of  claim 10 , wherein after attaching the second fabric sheet to the cut surfaces of the foam elements, the second fabric sheet is substantially parallel to the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         12 . The method of  claim 1 , wherein the step of providing a mold having a surface and a plurality of cavities spaced along the surface includes providing a mold having plurality of cavities spaced along the surface of the mold to form a pattern, and wherein after cutting the plurality of foam elements from the compressed foam sheet, the plurality of foam elements form a pattern on the first fabric sheet corresponding to the pattern of the cavities. 
     
     
         13 . The method of  claim 11 , wherein the plurality of foam elements form a substantially homogenous pattern on the first fabric sheet. 
     
     
         14 . The method of  claim 11 , wherein the plurality of foam elements form a heterogeneous pattern on the first fabric sheet. 
     
     
         15 . A protective material, comprising: a first fabric sheet; and a plurality of molded foam elements, each foam element including a molded surface and a cut surface formed by cutting the molded foam element from a sheet of foam material, wherein for each foam element, a portion of the molded surface is attached to the fabric sheet, and the cut surface defines a plane that is spaced from the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         16 . The protective material of  claim 15 , wherein for each foam element, the cut surface defines a plane that is substantially parallel to the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         17 . The protective material of  claim 15 , wherein each foam element has a selected depth, and when the first fabric sheet is substantially planar, the first fabric sheet is spaced from the cut surface of each foam element by the depth of that foam element. 
     
     
         18 . The protective material of  claim 15 , wherein each foam element has a selected shape, and wherein the shape of a first foam element is different than the shape of a second foam element. 
     
     
         19 . The protective material of  claim 15 , wherein a cross-section of at least one foam element defines a shape selected from the group consisting of a circle, an ellipse, an oval, a polygon, and a barbell. 
     
     
         20 . The protective material of  claim 15 , further comprising a second fabric sheet attached to the cut surfaces of the plurality of foam elements. 
     
     
         21 . The protective material of  claim 20 , wherein the second fabric sheet is substantially planar and is spaced from the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         22 . The protective material of  claim 21 , wherein the second fabric sheet is substantially parallel to the first fabric sheet when the first fabric sheet is substantially planar. 
     
     
         23 . The protective material of  claim 15 , wherein the plurality of foam elements are spaced from one another along the first fabric sheet to form a pattern on the first fabric sheet. 
     
     
         24 . The protective material of  claim 23 , wherein the plurality of foam elements form a substantially homogenous pattern on the first fabric sheet. 
     
     
         25 . The protective material of  claim 23 , wherein the plurality of foam elements form a heterogeneous pattern on the first fabric sheet. 
     
     
         26 . A composite material, comprising: a foam sheet; a plurality of foam elements extending from a side of the foam sheet, each foam element including a molded surface with a top portion distal from the foam sheet; and a fabric sheet attached to the top portions of the molded surfaces. 
     
     
         27 . The composite material of  claim 26 , wherein the fabric sheet is spaced from the foam sheet. 
     
     
         28 . The composite material of  claim 27 , wherein the fabric sheet is substantially planar when the foam sheet is substantially planar. 
     
     
         29 . The composite material of  claim 28 , wherein the fabric sheet is substantially parallel to the foam sheet.