Patent ID: 7927447
Filing Date: 2011-04-19
Classification: B29C,B32B,Y10T

Abstract:
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, 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.