Abstract: Disclosed is a flexible, odor-absorbing web for use under casts or other devices used in prolonged close contact with the human body. The web comprises a sheet-like matrix comprising an open-celled or closed-celled foam, or cellulosic fibers in a binder, filled with activated carbon particles. On the surface of the matrix designed for contact with the skin is a hydrophobic fiber layer, preferably needle-punched into the carbon-containing matrix. The opposite surface of the matrix may include a hydrophilic fiber layer.

Abstract: A material is formed by needling a layer of hydrophobic fibers into one face of a layer of closed-cell, foamed, thermoformable plastic, and needling a layer of hydrophilic fibers into the opposite face so that the hydrophobic fibers and the hydrophilic fibers overlap within the foam. The material may be thermoformed to produce articles having a surface shape conforming to the contours of a region of the human body such as resilient supportive innersoles, soft casts or splints, and impact-absorbing pads. Such articles, in addition to their usual function, wick perspiration and moisture away from the skin.

Abstract: A laminate is formed by needling a layer of hydrophobic fibers through a middle odor-absorbing layer into a bottom layer of closed-cell foamed thermoplastic. The laminate may be thermoformed to produce articles having a surface shape conforming to the contours of a region of the human body such as resilient supportive innersoles, soft casts or splints, and impact-absorbing pads. Such articles, in addition to their usual function, absorb odors significantly and wick perspiration away from the skin. Innersoles made from the laminates resist delamination and disintegration even when used in athletic footwear.

Abstract: A hollow shaped article is formed from a preformed sheet of foamed thermoplastic material wherein a joint is formed along the length of two abutting edges of the preformed sheet at the sheet's surfaces but inwardly of the surfaces the abutting edges are left unbonded. The process for forming the articles is characterized by flexing the preformed sheet into the desired general shape, placing it into a two-part mold, and then heating it in two heating steps.