Reusable Food Wrap and Bag

Abstract

A reusable flexible sheet is disclosed. The flexible sheet includes a central layer that can assume a manipulated shape. The central conformable layer is encased within a first sheet on one side, and a second sheet on the opposite side. The three layers move in unison. The outer first sheet and second sheet are generally impermeable to liquids and solids, and allow the flexible sheet to be cleaned and reused. In some cases, the flexible sheet material can be folded or formed into a storage bag. Various methods of making the reusable flexible sheet are also disclosed.

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.

Claims

1. A flexible sheet, comprising:

a central layer, a first sheet and a second sheet, wherein the central layer is disposed between the first sheet and the second sheet;

the central layer being more rigid than the first sheet, the central layer being more rigid than the second sheet;

the central layer being more plastically deformable than the first sheet, the central layer being more plastically deformable than the second sheet;

wherein the first sheet, the central layer and the second sheet are joined together so that they all deflect in unison.

2. The flexible sheet according to claim 1, wherein the central layer retains a manipulated configuration, and wherein the first sheet attains a first configuration that corresponds to the manipulated configuration of the central layer, and wherein second sheet attains a second configuration that corresponds to the manipulated configuration of the central layer.

3. The flexible sheet according to claim 1, wherein the central layer is made of a material that includes a metal.

4. The flexible sheet according to claim 1, wherein the first sheet is made of a material including a polymer, and wherein the second sheet is made of the same material as the first sheet.

5. The flexible sheet according to claim 1, wherein the first sheet is less permeable than the central layer.

6. The flexible sheet according to claim 1, wherein the flexible sheet may be returned to an original configuration after being plastically deformed.

7. A flexible sheet, comprising:

a central layer, a first sheet and a second sheet, wherein the central layer is disposed between the first sheet and the second sheet;

the central layer being made of a material that can retain its shape better than the first layer, the central layer also being capable of retaining its shape better than the second sheet;

the first sheet being less permeable than the central layer, the second sheet also being less permeable than the central layer;

wherein the first sheet and the second sheet encase the central layer and prevent foreign objects from contacting the central layer.

8. The flexible sheet according to claim 7, wherein the central layer is more plastically deformable than the first sheet, and wherein the central layer is more plastically deformable than the second sheet.

9. The flexible sheet according to claim 7, wherein the central layer is made of a material that includes a metal.

10. The flexible sheet according to claim 7, wherein the first sheet is made of a material including a polymer, and wherein the second sheet is made of the same material as the first sheet.

11. The flexible sheet according to claim 7, further comprising a first intermediate sheet disposed between the central layer and the first sheet, the first intermediate sheet being made of a material different than the central layer, and the first intermediate sheet being made of a material different than the first sheet.

12. The flexible sheet according to claim 11, further comprising a second intermediate sheet disposed between the central layer and the second sheet, the second intermediate sheet being made of a material different than the central layer, and the second intermediate sheet being made of a material different than the second sheet.

13. The flexible sheet according to claim 12, wherein the central layer is attached to the first sheet and wherein the central layer is attached to the second sheet, and wherein the first sheet, the central layer and the second sheet all move in unison with one another.

14. The flexible sheet according to claim 7, wherein the flexible sheet can be shaped into a self-standing structure.

15. A method of making a flexible sheet, comprising: wherein the central layer is more rigid than the first sheet and the central layer is more rigid than the second sheet; and wherein the central layer is more plastically deformable than the first sheet and the central layer is more plastically deformable than the second sheet.

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;

sealing a first perimeter of the first sheet with a second perimeter of the second sheet;

16. The method according to claim 15, wherein the step of sealing further includes placing a rubber cord around the first perimeter and the second perimeter.

17. The method according to claim 15, wherein the central layer, the first sheet and the second sheet are die cut into a predetermined shape prior to sealing the first perimeter of the first sheet with the second perimeter of the second sheet.

18. The method according to claim 15, wherein a cloth layer is placed between the first sheet and the central layer during the step of alignment.

19. The method according to claim 15, wherein the method includes inserting the first sheet, the second sheet and the central layer through a set of rollers to press the first sheet, the second sheet and the central layer together.

20. The method according to claim 15, wherein the central layer is smaller than the first sheet, wherein the central layer is smaller than the second sheet and wherein a perimeter of the central layer is disposed inwardly of the first perimeter and the second perimeter.

21. The method according to claim 15, wherein the central layer is a layer of glass cloth with metal wire woven through the glass cloth.