Patent ID: 7972549

Claim:
A method for manufacturing a non-textile fabric comprising an interconnected array of first elements and second elements forming a flexible or bendable web, including the acts of: forming at least three of said first elements so that each has first inter-engaging surfaces enabling it to inter-engage with one of said second elements and so that each has further inter-engaging surfaces enabling each to inter-engage with at least one other of said second elements; and forming said one of said second elements such that it is in the form of a plate structure and is in intimate pivoting mechanical connection with said at least three first elements by molding said one of said second elements against substantially all of said first inter-engaging surfaces of each said at least three first elements; wherein said first elements are plate structures; wherein forming said first elements includes the act of solid phase forming said first elements by positioning a polymer pellet in a first mold cavity and forcing said polymer pellet in said first mold cavity to adapt the shape of said first mold cavity; and wherein forming said second element includes the act of solid phase forming said second element by positioning a polymer pellet in a second mold cavity and forcing said polymer pellet in said second mold cavity to adapt the shape of said second mold cavity and be operably connected with said first element.