Patent Publication Number: US-2017349345-A1

Title: Reusable Food Wrap and Bag

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to McNicholas et al., U.S. Provisional Application No. 62/337,472, filed May 17, 2016, and titled Flexible Composite Material, the entirety of which is herein incorporated by reference. 
    
    
     BACKGROUND 
     The embodiments are generally directed to reusable food wraps and bags. 
     Generally, the use of aluminum foil and plastic wrap are known. However, both of these products are difficult, if not impossible, to reuse. They are both generally regarded as single use items. This is particularly true if cleanliness is required. For example, in the food service industry, where cross-contamination is a serious consideration, the reuse of aluminum foil would be impractical. Instead of trying to wash and sanitize a used sheet of aluminum foil for reuse, it would simply be discarded and a new sheet would be used. The same would be true of plastic wrap. It would be impractical to attempt to clean and reuse a piece of plastic wrap. 
     SUMMARY 
     In one aspect, a flexible sheet includes a central layer, a first sheet and a second sheet, where the central layer is disposed between the first sheet and the second sheet. The central layer is more rigid than the first sheet and the central layer is more rigid than the second sheet. The central layer is more plastically deformable than the first sheet and the central layer is more plastically deformable than the second sheet. The first sheet, the central layer and the second sheet are joined together so that they all deflect in unison. 
     In another aspect, a flexible sheet includes a central layer, a first sheet and a second sheet. The central layer is disposed between the first sheet and the second sheet. The central layer is made of a material that can retain its shape better than the first layer and the central layer is also capable of retaining its shape better than the second sheet. The first sheet is less permeable than the central layer and the second sheet is also less permeable than the central layer. The first sheet and the second sheet encase the central layer and prevent foreign objects from contacting the central layer. 
     In another aspect, a method of making a flexible sheet includes aligning a central layer between a first sheet and a second sheet, placing the central layer, the first sheet and the second sheet in a compression mold and sealing a first perimeter of the first sheet with a second perimeter of the second sheet. The central layer is more rigid than the first sheet and the central layer is more rigid than the second sheet. The central layer is more plastically deformable than the first sheet and the central layer is more plastically deformable than the second sheet. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
         FIG. 1  is an exploded schematic diagram of an embodiment of a flexible sheet; 
         FIG. 2  is an illustrative diagram demonstrating the concept of plastic deformation in bending; 
         FIG. 3  is an exploded an exploded schematic diagram of another embodiment of a flexible sheet; 
         FIG. 4  is a schematic diagram of an embodiment of an edge being finished; 
         FIG. 5  is schematic diagram of an embodiment of a flexible sheet in use; 
         FIG. 6  is a schematic diagram of an embodiment of a flexible sheet in another use; 
         FIG. 7  is a schematic diagram of an embodiment of a flexible sheet in another use; 
         FIG. 8  is a schematic diagram of an embodiment of a flexible sheet in a pre-assembled condition; 
         FIG. 9  is a schematic diagram of an embodiment of a flexible sheet assembled as a bag; 
         FIG. 10  is an isometric view of a schematic diagram of an embodiment of a bag in an open configuration; 
         FIG. 11  is a schematic diagram of an embodiment of a flexible sheet in a pre-assembled condition; 
         FIG. 12  is a schematic diagram of an embodiment of a flexible sheet assembled as a wide bag; 
         FIG. 13  is a schematic diagram of an embodiment of a bag in use; 
         FIG. 14  is a schematic diagram of an embodiment of a bag in use; 
         FIG. 15  is a schematic diagram of an embodiment of a step of forming a first sheet; 
         FIG. 16  is a schematic diagram of an embodiment of a step of compression molding multiple layers together; 
         FIG. 17  is a schematic diagram of an embodiment of a step of cutting a composite into discrete pieces; 
         FIG. 18  is a schematic diagram of an embodiment of a step of sealing a first sheet and a second sheet together; 
         FIG. 19  is a schematic diagram of an embodiment of a step of pressing several different layers together using a calendar; 
         FIG. 20  is a schematic diagram of an embodiment of a step of pressing a rubber sheet and a cloth sheet together using calendar; 
         FIG. 21  is a schematic diagram of an embodiment of a step of cutting discrete pieces of a composite sheet and also cutting discrete pieces of a metal sheet; 
         FIG. 22  is a schematic diagram of an embodiment of step of sealing two sheets together; 
         FIG. 23  is a schematic diagram of an embodiment of a step of making a metal and glass cloth; and 
         FIG. 24  is a schematic diagram of an embodiment of a step of pressing two outer sheets with a central metal and glass cloth using a calendar. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments of the present invention are directed to a flexible, conformable device that has the ability to retain a desired shape. Generally, the device can initially take the form of a flexible sheet. This flexible sheet can be manipulated by a user to attain any desired shape. In some cases, this flexible sheet can be manipulated in a manner similar to the way a sheet of aluminum foil may be manipulated. For example, the flexible sheet can be used to cover a bowl where those portions of the flexible sheet that overhang the opening of the bowl can be folded down around the sides of the bowl. As another example, the flexible sheet can be used to line a cookie sheet or other cooking container. As another example, the flexible sheet can be folded into a pocket or pouch to retain food for storage or cooking. 
     Flexible sheet  100  may be comprised of one or more layers. In some cases, layers having different properties may be combined to form flexible sheet  100 . In some embodiments, flexible sheet  100  may include layers that have similar characteristics and layers that have different characteristics. In some embodiments, flexible sheet  100  may include a central layer that is different than other layers. 
       FIG. 1  is an exploded schematic view of an embodiment of flexible sheet  100 . Flexible sheet  100  includes a central layer  102  and another layer. In the embodiment shown in  FIG. 1 , this other layer is shown as first sheet  104 . This embodiment also includes second sheet  106  disposed on the opposite side of central layer  102  from first sheet  104 . In other words, central layer  102  is disposed between, and “sandwiched” between, first sheet  104  and second sheet  106 . 
     In the embodiment shown in  FIG. 1 , central layer  102  may have characteristics or properties that differ from first sheet  104 . In some cases, these differences in characteristics or properties are caused by the central layer  102  being composed of materials that are different than the materials used to form first sheet  104 . In the embodiment shown in  FIG. 1 , central layer  102  is composed of a material that is predominantly metallic, while, in contrast, first sheet  104  is composed of a material that is predominantly non-metallic. 
     In addition to their different material compositions, central layer  102  may have a different configuration than first sheet  104 . For example, first sheet  104  may have a continuous configuration, while central layer  102  has a different kind of configuration. In some cases, central layer  102  may have a discontinuous configuration. 
     In some embodiments, central layer  102  may be formed of an arrangement of metallic elements. In some cases, one or more wires may be used. The wires may be disposed in a regular or irregular configuration. In some cases, the wires may be arranged as a mesh or net where a first set of wires are disposed at regular intervals, and a second set of wires, also disposed at regular intervals, intersects the first set. In some embodiments, the wires can be loosely woven so that a single wire extends above then below intersecting wires. In some cases, a single wire may be knitted to form a fabric-like layer. In any case, central layer  102  includes some arrangement of thin, easily plastically deformable metal elements that allow central layer  102  to assume and retain a desired shape. 
     Some embodiments can include a second sheet  106 . Second sheet  106  is disposed on the opposite side of central layer as first sheet  104 . In other words, central layer  102  is sandwiched between first sheet  104  on one side, and second sheet  106  on the other side. In some embodiments, second sheet  106  is less permeable to liquids and gases than central layer  102 . In some embodiments, central layer  102  is more plastically deformable than second layer  106 , and central layer  102  is better able to retain a manipulated shape better than second layer  106 . In some embodiments, second layer  106  may be made of a material similar to first layer  104 . In some cases, second layer  106  is made of the same material as first layer  104 . 
       FIG. 2  is an illustrative diagram demonstrating the concept of plastic deformation in bending. Referring to  FIG. 2 , table top  202  includes an edge  204 . A wire hanger  206  is placed on table top  202  with first end  208  hanging over edge  204 . At rest, and prior to any deflection, the first end  208  of wire hanger  206  is in first position  210 . As a vertically downward load is applied to first end  208 , and assuming the other end of wire hanger  206  is secured, first end  208  will bend and deflect downwards. 
     Eventually, first end  208  will reach second position  212 . In this example, second position  212  is the elastic limit of wire hanger  206 . That means that, at this point, if the vertical load is removed, then first end  208  will return to its original position, first position  210 . Because  212  is the elastic limit, zone  214  represents the elastic deformation zone, where no permanent changes are made to wire hanger  206 , and first end  208  will always return to first position  210  after the load has been removed. 
     Returning to the second position  212 , if the vertical load is increased at this point, then first end  208  begins to plastically deform. Plastic deformation in bending is the condition where a material will no longer return to its original position, but rather, remain deformed and bent. In some cases, there might be some spring back, but generally, the material will retain its deformed shape. 
     As the load is continuously applied, first end  208  eventually reaches third position  218 , which is substantially vertically downward. At this point, the range of motion is limited by the edge  204  of table top  202 . The third position  218  and the second position  212  define a zone of plastic deformation. When first end  208  of wire hanger  206  is deflected and bent into this plastic deformation zone  216 , the first end  208  will generally retain its shape. 
     A wire hanger  206  was used to demonstrate the concepts of elastic deformation and plastic deformation because of its size and because most people have observed a bent wire hanger. Most metallic materials behave according to these deformation principles. In one embodiment, a component of central layer  102  (see  FIG. 1 ) may be wire  220  shown in  FIG. 2 . In some embodiments, wire  220  is made of a material that includes a metal, and wire  220  behaves in a manner similar to wire hanger  206 . Wire  220  has an elastic zone  222 , and bending wire  220  past this elastic zone  222 , causes wire  220  to enter plastic deformation zone  224 . When wire  220  is bent into the plastic deformation zone  224 , wire  220  will generally retain that bent shape. 
     This greatly simplified example, where wire  220  is bent in a single direction and around edge  204 , is merely used to demonstrate the principles of elastic and plastic deformation in bending. Referring to  FIGS. 1 and 2 , it should be appreciated that wire  220  may be bent multiple times along its length and may also be bent in complex shapes. Similarly, if central layer  102  is comprised of a mesh or grid of wires, central layer  102  can be manipulated into highly complex shapes. After use, central layer  102  can be manipulated and returned to a generally flat configuration for cleaning or storage. The ability of the components (wire  220 ) of central layer  102  to plastically deform, in turn, allows central layer  102  itself to plastically deform and attain any desired shape. 
     Some embodiments can include optional provisions to protect the outer sheets from the central layer. In some cases, when the central layer is composed of a wire array or grid, individual wires may damage or puncture one of the outer sheets. To prevent this, some embodiments include optional provisions to protect the outer sheets. In some cases, these provisions can include a puncture resistant device. 
     Referring to  FIG. 3 , which shows an exploded schematic diagram of an alternative embodiment of a flexible sheet  300 , various layers of this embodiment can be observed. In this embodiment, flexible sheet  300  includes a central layer  302  and another layer. In the embodiment shown in  FIG. 3 , this other layer is shown as first sheet  304 . This embodiment also includes second sheet  306  disposed on the opposite side of central layer  302  as first sheet  304 . In other words, central layer  302  is disposed between and “sandwiched” between first sheet  304  and second sheet  306 . 
     In contrast to the previous embodiment shown in  FIG. 1 , this embodiment shown in  FIG. 3 , includes additional layers. This embodiment includes first intermediate layer  308  and second intermediate layer  310 . As shown in  FIG. 3 , first intermediate layer  308  is disposed between central layer  302  and first sheet  304 . Likewise, second intermediate layer  310  is disposed between central layer  302  and second sheet  306 . As previously noted, these intermediate layers, first intermediate layer  308  and second intermediate layer  310 , are optional and may be omitted. 
     In some embodiments, these intermediate layers may be used to help protect first sheet  304  and second sheet  306  from central layer  302 . In some cases, the intermediate layers may be made of a material that resists puncture or damage caused by central layer  302 . In some embodiments, the intermediate layers may include a cloth or fabric material in its composition. The cloth or fabric material may be woven, knitted or some other arrangement of cord, thread and/or fibers. Regardless of the composition, the intermediate layers are preferably durable and puncture resistant. 
     The intermediate layers are also selected or formed in such a way that they do not interfere with the general operation of the flexible sheet. In other words, the intermediate layers allow manipulation of central layer  302  into any desired shape and generally avoid interfering with the deformation of central layer  302 . In some cases, first intermediate layer  308  may be formed of a material similar to second intermediate layer  310 . However, in other cases, first intermediate layer  308  may be formed of a material that is different from second intermediate layer  310 . In some cases, it may be desirable to select a material for the intermediate layers that is readily bond compatible with first sheet  304  and second sheet  306 . 
     Another optional feature is shown in the embodiment disclosed in  FIG. 3 . In some embodiments, flexible sheet  300  may include a finished edge. In some cases, the entire periphery of flexible sheet  300  includes a finished edge, while in other embodiments, only a portion of the outer periphery of flexible sheet  300  includes a finished edge. 
     In some cases, the finished edge can be provided by additional processing of the outer periphery of flexible sheet  300 . For example, additional heat sealing, additional pressure, the infusion of chemicals or other processes that help to ensure adequate bonding between the various layers and that help to prevent delamination. Some embodiments also include a bonding margin near the outer periphery where central layer  302  is not present. In other words, first sheet  304  and second sheet  306  may extend beyond the outer periphery of central layer  302  to provide an outer zone where central layer  302  is missing, and only other sheets or layers are present. 
     In other embodiments, the outer periphery is finished with an additional component. This edge finishing is optional, and not all embodiments include a finished edge with an additional component. In some embodiments, a feature similar to binding or flat piping may be provided on an outer peripheral edge. In traditional sewing arts, binding is generally attached by sewing or stitching. While the edge treatment may be attached using those traditional methods, the edge treatment may also be attached with other techniques as well. 
     Referring to  FIG. 4 , which shows a schematic diagram of an embodiment of an edge being finished, edge treatment  402  is being attached to flexible sheet  400 . In the embodiment shown in  FIG. 4 , a bonding margin is provided and the central layer is not visible on the edge  420  of flexible sheet  400 . Since the central layer is not visible, edge  420  is comprised of first edge  422  (of first sheet  404 ) and second edge  424  (of second sheet  406 ). In this embodiment, first edge  422  contacts second edge  424  to form the edge  420  of flexible sheet  400 . 
     In the embodiment shown in  FIG. 4 , edge treatment  402  is in the process of being attached to flexible sheet  400 . Edge treatment includes an attached portion  408 , and a detached portion  410 . The detached portion is currently separated from flexible sheet  400  for purposes of illustration. 
     Observing detached portion  410 , details of edge treatment  402  are visible. Edge treatment  402  includes a first overlapping portion  412  and a second overlapping portion  414 . Disposed between these portions is a sidewall portion  416 . In the embodiment shown in  FIG. 4 , sidewall portion  416  is configured to confront and be disposed over edge  420  of flexible sheet  400 . First overlapping portion  412  is configured to wrap over and confront the upper portion of first sheet  404 . Similarly, second overlapping portion  414  is configured to wrap over and confront second sheet  406 . In the embodiment shown in  FIG. 4 , edge treatment  402  may resemble a C-channel in appearance. However, different configurations and shapes of edge treatments may also be used. 
     Edge treatment  402  may be attached in any suitable way. In some embodiments, an adhesive may be used. In other embodiments, edge treatment  402  is made of a material that has been selected to be mold or bond compatible with flexible sheet  400  so that heat or pressure may be used to attach the two materials together. In some embodiments, edge treatment may be over-molded onto flexible sheet  400 . 
     As discussed above, the nature of flexible sheet  400  allows a user to manipulate flexible sheet  400  into any desired shape or configuration. Once flexible sheet  400  has been manipulated into the desired shape, flexible sheet  400  will generally retain that shape, against the forces of gravity, until it is manipulated again by the user. The following are various examples of shapes and configurations that flexible sheet  400  can achieve. 
       FIG. 5  shows an embodiment of flexible sheet  400  used as a flat baking or serving sheet. In this embodiment, flexible sheet  400  is flattened out and a large, flat central surface  430  is provided. In this configuration, products, such as cookies  432 , may be placed onto central surface  430 . Because of the materials used to construct preferred embodiments of flexible sheet  400 , the cookies  432  can be baked on flexible sheet  400 . In some embodiments, edge treatment  402  may include a lip that rises above the upper surface of central surface  430 . This lip can be used to retain fluids and to prevent products from sliding off central surface  430  during movement. And after baking, flexible sheet  400  can be used as a try to serve cookies  432 . 
       FIG. 6  shows an embodiment of flexible sheet  400  being used as a wrap. In this embodiment, flexible sheet  400  includes a central flat surface  440 , disposed under product  442 . In this embodiment, side portions  444  of flexible sheet  400  can be used to envelop and surround product  442 . The embodiment shown in  FIG. 6  is an intermediate embodiment, and side portions  444  can be used to cover the upper portion of product  442 , thereby completely surrounding product  442 . In the embodiment shown in  FIG. 6 , product  442  is sandwich, however, flexible sheet  400  may be used to wrap any suitably sized product. 
       FIG. 7  shows an embodiment of flexible sheet  400  being used as a cover. In this embodiment, flexible sheet  400  includes a central cover surface  450  covering a bowl  452 . In this embodiment, side portions  454  of flexible sheet  400  can be used to engage the sides of bowl  452 . Because of the properties of flexible sheet  400 , side portions  454  will generally retain their shape until further manipulated by a user. In some embodiments, the materials selected for flexible sheet  400  can provide a seal between central cover surface  450  and bowl  452 . In some cases, this seal can be nearly impermeable. 
     In the embodiments discussed above, flexible sheet  400  preferably includes at least one layer of material that is capable of plasticly deforming. This ability allows flexible sheet  400  to assume any desired configuration or shape, and retain that configuration or shape until it is manipulated again. Because of this, flexible sheet  400  is malleable and may be reconfigured any number of times. After a particular use, flexible sheet  400  may be reconfigured to a flat condition, similar to the configuration shown in  FIG. 5  for cleaning or storage. For example, in the embodiments shown in  FIGS. 6-7 , after use, the flexible sheet may be flattened back to its original condition. 
     Some embodiments may be pre-configured in some way. In some cases, a flexible sheet may be configured to retain material or configured in way so that portions of the flexible sheet define an interior void. In some embodiments, flexible sheet may include a fold, a seem or some kind of joint so that a flat flexible sheet can attain a different kind of configuration. In one embodiment, a flexible sheet has been pre-configured as a bag or a pouch. 
     Referring to  FIGS. 8 and 9 , flexible sheet  800  includes a rear side portion  802  and a front side portion  804 . A fold line  806  may be disposed between rear side portion  802  and front side portion  804 . In some embodiments, a border  808  may be applied to the outer periphery of flexible sheet  800 . Some embodiments may omit border  808 . 
     Flexible sheet  800  may be pre-configured as a bag or pouch by folding the front side portion  804  towards rear side portion  802  along fold line  806 . In this embodiment, fold line  806  can serve as a bottom of the pre-configured bag. Once front side portion  804  confronts rear side portion  802 , the left bottom border  810  associates with left front border  814 , and likewise, right bottom border  812  associates with right front border  816 . 
     In some embodiments, left bottom border  810  is permanently joined to left front border  814  forming left sealed border  902 . And right bottom border  812  is permanently joined to right front border  816  forming right sealed border  904 . This configuration is generally shown in  FIG. 9 . Fold line  806  forms bottom of bag  900 . In some embodiments, a border may be optionally applied to fold line  806 . 
     Some embodiments can include a releasable closure feature. In some cases, the releasable closure feature can include a flap. In the embodiment shown in  FIGS. 8 and 9 , flap  906  is formed as an extension of rear side portion  802 . Generally, flap  906  extends beyond front side portion  804 . The upper edge  908  of front side portion  804  is generally not attached to rear side portion  802  to define an opening  912  to interior void  910 . Flap  906  may be used to releasably close opening  912 . Because bag  900  is generally made of flexible sheet material, flap  906  may plastically deform and remain bent over opening  912  until flap  906  is manipulated into a different position. 
     In some embodiments, one or more bevels  914  may be provided. These bevels may help to prevent separation or delamination of the flexible sheet material, or these bevels may be provided for aesthetic reasons. If bevels are provided, corresponding cut outs may be provided prior to assembly as shown in  FIG. 8 . 
       FIG. 10  is an isometric view of an embodiment of bag  900 . As shown in  FIG. 10 , bag  900  includes opening  912 , which is formed when upper edge  908  is spaced from an upper portion of rear side portion  802 . The upper portion being proximate to flap  906 . Opening  912  provides access to interior void  910 . As shown in  FIG. 10 , this interior void  910  can taper as the interior void  910  approaches fold line  806 . 
     The bag, made of flexible sheet material, may be formed in any desired size or proportion. In addition to the embodiment shown in  FIGS. 8 and 9 , a bag with different proportions, a wide bag  1200  may be constructed as shown in  FIGS. 11 and 12 .  FIG. 11 , which is analogous to  FIG. 9 , shows wide bag  1200  in a pre-assembly condition. In some embodiments, this is the appearance of wide bag  1200  after cutting. In some cases, a flexible sheet material may be die cut to this shape and size. This is also true of  FIG. 9 . Wide bag  1200  may be assembled in a manner similar to bag  900  above. 
     Wide bag  1200  may include different proportions than bag  900 . For example, wide bag  1200  may include left sealed border  1202  and right sealed border  1204 . Wide bag  1200  may also include bottom fold line  1206  and opening  1208 . Opening  1208  may provide access to interior void  1210 . Finally, wide bag  1200  may include flap  1212  that provides a releasable closure mechanism. In the embodiment shown in  FIGS. 11 and 12 , wide bag  1200  includes a width dimension, defined as a distance between left sealed border  1202  and right sealed border  1204 , that is generally greater than a height of wide bag  1200 . The height being defined as a distance between bottom fold line  1206  and opening  1208 . 
       FIGS. 13 and 14  shows an embodiment of bag  1300  in use. In the embodiment shown in  FIG. 13 , bag  1300  is in an open configuration, with opening  1312  providing access to interior void  1310 . In this embodiment, bag  1300  is being filled with fruit, namely cherries  1350 . Obviously, bag  1300  can be used to hold any food product or other item of suitable size and dimension. After bag  1300  has been filled, flap  1306  may be manipulated to close bag  1300 . In some embodiments, flap  1306  may be folded over to cover opening  1312 . In other embodiments, flap  1306  may be folded with additional portions of bag  1300  to provide a second fold, as shown in  FIG. 14 . After bag  1300  has been closed, bag  1300  may be opened by manipulating flap  1306  away from opening  1312 . 
     The flexible sheets as discussed herein may be plastically deformable and may hold their shape even when they have been separated from a container or food item. In particular, the flexible sheets may be designed to be self-standing structures capable of supporting their own weight and not losing their shape or collapsing under the force of gravity. In some cases, these provisions are achieved by the use of central layers that may retain their shape, such as a central metal mesh layer. This allows the flexible sheets to be arranged into bowl-like shapes as well as bags or other shapes that can retain their shape even when not supported by, or otherwise disposed against, another object (like a bowl or other container). In other words, the flexible sheets can be formed into free standing structures that do not rely on other rigid structures to maintain their shape. 
     Embodiments can include provisions for manufacturing a flexible sheet. Such provisions may include processes for manufacturing one or more layers of a flexible sheet, assembling two or more layers and/or finishing an assembly of layers to form the flexible sheet. 
       FIGS. 15-18  illustrate schematic views of steps in a process for manufacturing a flexible sheet, according to one embodiment. In a first step, shown in  FIG. 15 , an input material  1502  may be run through part of a calendar (e.g., first roller  1510  and second roller  1512 ) to form a sheet-like layer  1504  comprised of the input material. In this exemplary embodiment, input material  1502  may be gum rubber and sheet-like layer  1504  may be sheet rubber. However, in other embodiments, other input materials can be used to form various kinds of sheet layers. Exemplary materials that could be used for form sheet rubber may comprise, but are not limited to materials including: silicone, acrylonitrile butadiene rubber (NBR), natural rubber poly-isoprene (NR), ethylene propylene diene monomer (M-class) (EPDM), as well as other kinds of materials. In some embodiments, a silicone sheet may be formed that is sufficiently pliable compared to other materials used in the flexible sheet. 
     In a second step, shown in  FIG. 16 , two sheet-like layers that have been assembled as in a previous step (e.g., a sheet rubber layer) may be compression molded (using compression molding system  1600 ) with additional layers to form a composite. In some embodiments, two sheets (i.e., first sheet  1602  and second sheet  1604 ) may be arranged as the outermost layers with one or more internal or central layers. In some cases, the central layers could comprise one or more cloth layers. In other cases, the central layers could comprise one or more metal layers. In still other cases, the central layers could comprise a combination of cloth and metal layers. In a first example shown in  FIG. 16 , a five-ply composite may be formed by compression molding a first cloth layer  1610 , a metal layer  1612  (or metal mesh layer) and a second cloth layer  1614  between first sheet  1602  and second sheet  1604 . In some embodiments, metal layer  1612  could comprise a stainless-steel mesh. 
     Alternatively, in a second example shown in  FIG. 16 , the internal layers could comprise a single cloth layer  1620  along with metal layer  1622 . In yet another example shown in  FIG. 16 , the internal layers could comprise only a metal layer  1630 . Thus, it may be appreciated that a composite may be a three-ply, four-ply or five-ply composite. In still other embodiments, a composite could comprise more than 5 plies. 
     It may be appreciated that multiple plies of material can be compression molded to form a composite structure using any known methods, processes, machines and/or systems for compression molding. 
     In a third step, depicted in  FIG. 17 , discrete pieces  1702  of the composite  1704  (formed during the previous step of compression molding—and comprised of rubber sheets with one or more central layers between them) may be cut. In some embodiments, die cutting can be used to remove pieces  1702 . Alternatively, in other embodiments, other methods of cutting could be used including laser cutting, water jet cutting or other methods. In different embodiments, the shape of a cut piece could vary. Exemplary shapes may include circles, triangles, rectangles, pentagons, hexagons, regular shapes as well as irregular shapes. In the embodiment shown in  FIG. 17 , the discrete pieces  1702  are die cut into hexagonal shapes. 
     In a fourth step, depicted in  FIG. 18 , a discrete piece  1802  of a composite can be finished by applying a sealing element around the edges. In some embodiments, a rubber cord  1804  can be laid around the perimeter  1806  of discrete piece  1802 . Using compression mold  1800 , rubber cord  1804  can be pressed with discrete piece  1802  to seal the perimeter. 
     It may be appreciated that the rubber cord can be bonded directly against the edges of one or more sheets. In addition, in some embodiments, an overlapping portion of a rubber cord or other finished component could overlap a bonding margin adjacent the edges (i.e., perimeters) of one or more sheets. Thus, attaching two or more layers at their perimeters (or peripheries) may comprise attaching them at their edges and/or attaching them along a bonding margin that extends inwardly from their perimeters. 
     It may be appreciated that in other embodiments, one or more steps of the preceding method could vary. For example, in another embodiment that utilizes only a single internal layer, a sheet of metal (e.g., metal mesh) could be inserted between adjacent rubber sheets using a calendaring process. One exemplary process is depicted in  FIG. 19 . In this case, a first sheet  1902  and a second sheet  1904  (e.g., first and second rubber sheets) are created simultaneously with a first set of rollers  1910  and a second set of rollers  1912 , respectively. These sheets are then fed into a third set of rollers  1914  along with an intermediate metal layer  1916  (which may be a sheet of a metal mesh). In this case, the calendaring process creates a three-ply composite that may then be die-cut and finished in a similar manner to the steps described above and shown in  FIGS. 17 and 18 . 
       FIGS. 20-22  illustrate schematic views of steps in a process for manufacturing a flexible sheet, according to an embodiment. In a first step, shown in  FIG. 20 , a rubber sheet  2002  and a cloth layer  2004  may be fed into a set of rollers  2006  to form a 2-ply composite  2008  of rubber and cloth. In a second step, shown in  FIG. 21 , pieces of this two-ply composite  2008  can be die-cut. Additionally, pieces of a metal sheet  2102  (continuous or mesh) can be die cut in similar shapes having a smaller offset size. 
     In a third step, shown in  FIG. 22 , two die-cut pieces of the two-ply composite (rubber and cloth) may be compression molded together with an internal die-cut piece of metal. Specifically, as seen in  FIG. 22 , a metal piece  2202  may be arranged between a first composite piece  2204  (of rubber and cloth) and a second composite piece  2206  (of rubber and cloth). Each composite piece may be oriented so that the rubber layers are outwardly facing and the cloth layers are facing inwardly towards the metal piece  2202 . 
     When arranged within compression mold  2200 , the smaller metal piece  2202  is centered so that the two composite layers contact one another directly along bonding margins associated with their perimeters. This allows the perimeters (i.e., a first perimeter of the first composite piece and a second perimeter of the second composite piece) and the associated bonding margins of these composite pieces to bond to one another during the compression process. 
     Other embodiments may include provisions for incorporating a composite layer comprised of metal wire interwoven within a fiberglass cloth. For example,  FIG. 23  depicts an exemplary process for manufacturing a fiberglass and metal composite layer. This may be accomplished by weaving a metal wire into a fiberglass cloth  2302 . In some cases, the metal wire may run in both the warp and weft of the fiberglass cloth. This method may form a cloth comprised of a wire and fiberglass grid. This composite structure provides a fiberglass cloth that is able to bend and hold a form. 
     Next, as seen in  FIG. 24 , the metal and glass cloth  2402  may be pressed between opposing rubber layers (i.e., rubber sheet  2404  and rubber sheet  2406 ) using rollers  2408  in a calendaring process. This three-ply composite (comprised of two outer rubber layers and an internal layer of metal and glass cloth) may then be die-cut and finished with a rubber cord as described above and shown in  FIGS. 17 and 18 . 
     It may be appreciated that in some embodiments one or more adhesives could be used to bond various layers together. For example, in some embodiments, an adhesive could be used between two or more layers that are compression molded together. In still other embodiments, an adhesive could be used between layers prior to passing the layers through rollers of a calendar. Of course, in other embodiments, adhesives may be omitted and bonding may primarily occur through the application of pressure and heat. 
     Although some embodiments may use preformed sheets to form the outer layers of a flexible sheet (e.g., preformed silicone sheets), other embodiments could use other methods of applying rubber or other materials onto one or more central layers to form a flexible sheet. For example, in another embodiment one or more outer layers of a flexible sheet could be formed by spraying a coating of polymer rubber onto a central layer (e.g., a metal mesh layer, cloth layer or metal and fiberglass layer). Alternatively, in some embodiments, the flexible sheet may be formed by dipping or immersing a central layer into a liquid material. In some cases, the central layer may be dipped multiple times into the same liquid material, or dipped into multiple different liquid materials. After or during the dipping process, the liquid material may be cured, fused or bonded to the central layer. The liquid material is selected so that after curing, the desired material used for the outer layers is attached to the central layer. 
     While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Also, any feature of any embodiment may be combined with prior art features or elements to derive inventive subject matter. Therefore, it will be understood that any of the features shown and/or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.