Composite structure with suspension performance

Abstract

The present application provides a composite structure having a suspension property. The composite structure includes a rigid core member having an outer surface, a rigid covering layer having an outer surface and an inner surface, and a plurality of bumps protruding at least along at least a part of the outer surface of the core member and the inner surface of the covering layer from at least one of the outer surface of the core member and the inner surface of the covering layer, with spaces between the bumps. The composite structure further includes a connecting device that fixedly connects the covering layer to the core member to form a plurality of gaps between the inner surface of the covering layer and the outer surface of the core member, the gaps being defined by the spaces. The covering layer is configured to bend inwardly into the gaps when a force is applied to the outer surface of the covering layer at regions corresponding to the gaps, and bend back when the force is removed, thereby providing a structure having the suspension property.

Description

Technical Field

[0001] The present invention relates to a composite structure, and more particularly to a composite structure having suspension performance. Background Art

[0002] Articles or products with suspension characteristics / properties to enhance the soft comfort of users are well known. The articles or products include bicycle seats, motor vehicle seats, seat assemblies, sofas, and automotive interior components that suspend or compress when a force is applied thereto.

[0003] Generally, the article is formed of different materials, which typically include an elastic foam layer that is compressible to provide suspension performance, and the article is covered by an outer fabric layer, either by an adhesive or by heat treatment or by saw joining. When a user applies a force to the article, one or more of the layers can absorb energy and reduce the impact on the user.

[0004] The materials used as layers in the above articles are typically thermosetting and non-recyclable, thus increasing the growing environmental waste. Examples of such materials include polyurethane (PU), polyvinyl chloride (PVC), or ethylene-vinyl acetate (EVA).

[0005] CN107826186A relates to a bicycle seat cushion configured to be mounted on a tapered end of a bicycle seat to increase heat dissipation. The bicycle seat cushion includes a flexible seat plate covered by a cloth layer, the flexible plate having a plurality of protrusions that contact the surface of the bicycle seat to isolate the flexible seat plate from the bicycle seat cushion. Ventilation gaps are formed between all the protrusions to increase the heat dissipation area, thereby accelerating the heat dissipation of the flexible buffer plate.

[0006] US2019291802 relates to a bicycle saddle that includes a layer of foam material disposed in the saddle and a surface layer disposed on and covering the surface of the foam material layer, with a plurality of spaced-apart through holes formed in the foam material layer. A bio-gel layer is formed on the lower surface of the foam material layer. A plurality of bio-gel blocks are respectively filled in the through holes of the foam material layer. Each bio-gel block has a top end that contacts the lower side of the surface layer and a bottom end that is integrally connected to the bio-gel layer. The bio-gel layer provides a comfortable riding experience for the rider and also achieves an antibacterial effect. Summary of the Invention

[0007] According to one aspect of the subject matter of the present disclosure, there is provided a composite structure which may be in the form of an article of the above type or form part of an article of the above type, the composite structure comprising a thin rigid cover layer connected to a thick rigid core member via a resilient volume layer therebetween so as to provide suspension performance for the structure when a bending force is applied to the cover layer.

[0008] The composite structure may include a core member having an outer surface, a cover layer connected to the core member and having an inner surface and an outer surface, and a resilient volume layer in at least a partial region between the outer surface of the core member and the inner surface of the cover layer, wherein the combination of the material forming the cover layer, the thickness of the cover layer, and the dimensions of the resilient volume is such that when a bending force is applied to a region of the cover layer above the resilient volume, the region bends into the resilient volume while maintaining the thickness of the cover layer at that region and then bends back, thereby providing suspension performance similar to that of an elastic foam without using a foam as the cover layer.

[0009] Accordingly, in this specification and the claims, unless otherwise specifically stated, the term "force" or "bending force" refers to a force that provides suspension performance at least partially along the thickness direction of the cover layer and the structure, i.e., perpendicular to the outer surface of the cover layer; the term "rigid" when used with respect to a component or material means that it is significantly more rigid than an elastic foam so that it can maintain the shape it was manufactured in and is either incompressible under the action of the above force (e.g., like the cover layer) or has a significantly lower compressibility than an elastic foam under the action of the force (e.g., like in the core member); the term "thin" with respect to the cover layer means that the thickness of the layer is small enough to allow it to have the flexibility as described above, and the term "thick" with respect to the core member means that the thickness of the member significantly exceeds the thickness of the cover layer and is sufficient to firmly hold the cover layer thereon by a connecting means.

[0010] The cover layer is fixedly and flexibly connected to the core member, wherein in this specification and the claims, the term "fixed" means that the connection is permanent, i.e., the cover layer cannot be easily disconnected from the core member, and the term "flexible" means that the connection allows the cover layer to bend as described above.

[0011] The resilient volume layer may be constituted by an air gap formed between the core member and the cover layer and spaced apart from each other, for example, by bumps on the outer surface of the core member and / or the inner surface of the cover layer; or may be partially constituted by such a gap and an elastic foam layer accommodated in the gap; or may be constituted by an elastic layer located between the cover layer and the outer surface of the core member without such a gap. When using an elastic layer, whether or not there is an air gap, it is configured to be elastically compressed by the region of the cover layer when a bending force is applied thereto.

[0012] The connection between the core member and the cover layer via the recoverable volume layer can be provided by a suspension - allowing connection device, which includes a plurality of connection elements associated with the cover layer. The plurality of connection elements engage lockingly with corresponding connection elements of the core member so that when a bending force is applied to the area of the cover layer associated with the connection elements, with the recoverable volume below the cover layer and the recoverable volume being above the corresponding connection elements of the core member, the connection elements can move freely along the inner direction of the core member.

[0013] The suspension - allowing connection device can be a quick - connection assembly device. For example, the connection elements can be in the form of lockable protrusions protruding from the inner surface of the cover layer, and the core member can include corresponding locking recesses for receiving the protrusions, for example, by snap - fit arrangement. Each lockable protrusion can be associated with an area of the cover layer having a recoverable volume thereunder, and it can engage lockingly with an area of the core member having the recoverable volume thereabove. The lockable protrusions can be located at several areas of the cover layer received in the corresponding locking recesses of the core member. When the relevant area of the cover layer is bent into the recoverable volume provided thereunder, the device can allow each protrusion to move inwards in the corresponding recess having a corresponding depth. In this case, the thickness of the core member should be large enough to accommodate the locking recesses having the above - mentioned depth.

[0014] Thus, in the described composite structure, the suspension performance achieved by the combination of the parameters of the cover layer and the recoverable volume layer above the core member is further facilitated by the suspension - allowing connection device.

[0015] The parameters of the cover layer and the recoverable volume layer include the thickness and material of the cover layer, the thickness of the recoverable volume layer, and the geometry of these areas when the layer includes recoverable volume regions separated from each other. These areas are selected such that the area of the cover layer covering the recoverable volume regions can be bent into and back from these regions, like a membrane supported by adjacent non - bent regions (i.e., regions where no force is applied) of the cover layer.

[0016] When the above-mentioned regions are in the form of air gaps separated from each other in the core member, for example, by bumps on the outer surface of the core member or the outer surface of the covering layer, the above-mentioned parameters include the distribution and size of the gaps defined by the size of the bumps and the intervening spaced regions, and these distributions and sizes are selected such that the regions of the covering layer covering the spaced regions can bend into the corresponding gaps and bend back, similar to a membrane supported by adjacent non-bending regions of the covering layer. Regarding the parameters of the bumps and the spaced regions, at least most of the spaced regions between the bumps can have a length substantially exceeding the maximum size of the bumps along the outer surface of the core member. The bumps can have a height less than the distance between them and at least not less than the thickness of the covering layer, and optionally greater than the thickness of the covering layer. The bumps can be arranged in a pattern according to the suspension performance distribution to be achieved along the covering layer.

[0017] When the core member is formed with bumps on its outer surface, the covering member can have a thickness not exceeding the height of the bumps defining the depth of the gap. The core member can have a thickness at least greater than that of the covering layer when measured through the bumps. The thickness of the core member can be substantially greater than that of the covering layer.

[0018] When the covering layer is formed with bumps on its inner surface, the height of the bumps defines the height of the gap, and the covering layer can have a thickness less than the height of the bumps in the regions between the bumps.

[0019] When the core member or the covering layer is formed with bumps, the structure can further include an elastic layer formed with holes corresponding to the bumps, and the elastic layer is configured to be located between the covering layer and the core member such that the bumps protrude from the holes towards the covering layer, and when a force is applied, the covering layer can be placed on at least a part of the bumps and bend towards the elastic layer or bend into the elastic layer at the regions corresponding to the gaps. In this case, and in the case where the resilient volume layer is an elastic layer having no any spacing between the resilient volume regions, the thickness of the elastic layer / elastic layer portion can exceed or at least not be less than the thickness of the covering layer.

[0020] When the elastic layer or the elastic layer portion constitutes the resilient volume layer, the above-mentioned suspension allows the connecting device to fixedly and flexibly connect the covering layer to the core member through the elastic layer.

[0021] To reduce the weight of the structure, the core member may be less dense than the cover layer, i.e., have a lower bulk density, but still be rigid enough to maintain its shape and connection to the connecting element in use. Additionally, the material of the core member may have a higher compressibility than the material of the cover layer. In this case, when bumps are formed on the outer surface of the core member, the bumps can be compressed when a bending force is applied at a region above the cover layer bumps, and when bumps are formed on the inner surface of the cover layer, the region below the bumps on the outer surface of the core member can be compressed when a bending force is applied at a corresponding region above the cover layer bumps.

[0022] The suspension allowing connection means can connect the cover layer to the core member via a resilient volume layer by means of a snap engagement means, and can include a protrusion protruding from the inner surface of the cover layer away from its outer surface and constituting the above-mentioned lockable protrusion, and a recess in the core member opening towards the cover layer and constituting the above-mentioned locking recess, the recess being configured to lockingly receive therein the protrusion / lockable element passing through the resilient layer.

[0023] In fact, in the composite structure according to any embodiment, the cover layer and the core member providing the suspension performance for the structure are not made of elastic foam materials, which provides many advantages, including but not limited to the ability to easily perform maintenance of the cover layer, such as its cleaning and the ability to connect the cover layer to the core member by mechanical connection, thereby avoiding the need for using adhesives, sawing, etc. Additionally, in the case where the cover layer is rigid, it can be connected to the core member by a simple quick-connect assembly means, thus facilitating the simple and cost-effective assembly of the composite structure.

[0024] Another advantage of the above composite structure is that all or at least most of its components and connecting elements can be made of materials that can be recycled including heat treatment without separating the core member from the layer. This constitutes another aspect of the subject matter of the present disclosure, according to which the composite structure includes a plurality of components connected to each other only by mechanical means, such as in the above connection means, and the materials of the manufacturing components and connecting elements can be recycled including heat treatment without separation. For example, at least the materials of the core member and the cover layer can include the same basic thermoplastic substance or different basic thermoplastic substances that can be melted at the same recycling temperature, where the / each substance is optionally the only substance in the material that changes its material form at the temperature.

[0025] The above basic substances in the materials of the components of the composite structure can be recyclable thermoplastic polymers of the same polymer family, such as the polypropylene family, which have different material forms in different components of the composite structure. The components can exceed 90% of the weight of the entire composite structure, optionally exceed 93%, for example at least 95%. For example, the material of at least one thick component of the structure can be in the form of foamed particle foam, and the material of at least one or more other components including the connecting elements can be a dense continuous material, which has a significantly higher bulk density than the bulk density of the core member. For example, in a composite structure including a core member, a covering layer and the connecting means as described above, the core member has a maximum thickness made of foamed particle foam, and the covering layer and its connecting elements are made of a dense material having a higher bulk density than the bulk density of the core member. In this case, the core member can be formed into a desired shape by particle-foam molding, and the covering layer can be made by injection molding or compression molding, thermoforming, extrusion, vacuum forming or other techniques, enabling the covering layer and the connecting elements to maintain their manufactured shapes.

[0026] The elastic layer (if any) can have a weight, which can constitute a small part of the weight of the entire composite structure. Thus, even if the elastic layer is made of a material that cannot be melted at the above-mentioned recycling temperature, the elastic layer can be recycled together with the other components of the composite structure without separating from them.

[0027] It should be noted that in this application and the claims, "non-separating recycling" of the composite structure refers to conventional plastic recycling processes, which generally include grinding / crushing the entire composite structure into small pieces, heating them so that the fusible substances therein melt, and then using the mixture of the molten substances and the small pieces of non-fusible substances suspended therein for any suitable purpose.

[0028] In each of the above examples of the composite structure, it can have any combination of one or more of the following features:

[0029] The flexural modulus of the thermoplastic polymer is 110 - 1800 MPa;

[0030] The thickness of the covering layer is between 0.5 - 3.5 mm;

[0031] In all the above examples, the components of the above-mentioned connecting means, which are referred to as connecting pieces and connecting elements, or lockable protrusions and locking recesses, or protrusions and recesses, can be formed integrally with the covering layer and the core member, or can be manufactured separately and then assembled with one or both of the covering layer and the core member.

[0032] The following are exemplary embodiments that the composite structure according to the subject matter of the present disclosure can have:

[0033] 1. A composite structure, said composite structure comprising at least:

[0034] A core member having an outer surface;

[0035] A covering layer made of a thermoplastic polymer having a flexural modulus much greater than that of the core member, said covering layer having an outer surface and an inner surface, and at least said inner surface having the same shape as at least a part of the outer surface of the core member;

[0036] A plurality of bumps protruding from at least one of the outer surface of the core member and the inner surface of the covering layer, and having a space between the bumps, a plurality of gaps being formed between the inner surface of the covering layer and the spaced regions of the core member;

[0037] A quick-connect assembly device that connects the core member and the covering layer to each other;

[0038] The covering layer and the gaps are configured such that when a bending force is applied to the outer surface of the covering layer at a region corresponding to the gaps, the region bends inwardly into the gaps and bends back when the force is removed, thereby providing a structure having suspension properties similar to those of an elastic foam.

[0039] 2. The structure according to embodiment 1, wherein the flexural modulus of the thermoplastic polymer is 110 - 1800 MPa.

[0040] 3. The structure according to embodiment 1 or 2, wherein the thickness of the core member is greater than the thickness of the covering layer.

[0041] 4. The structure according to embodiment 3, wherein the thickness of the covering layer is between 0.5 - 3.5 mm.

[0042] 5. The structure according to any one of embodiments 1 to 4, wherein the quick-connect assembly device is in the form of a snap-fit device.

[0043] 6. The structure according to embodiment 5, wherein the quick-connect assembly device includes a plurality of recesses in the core member and a plurality of corresponding protrusions protruding from the covering layer and configured to be received in the recesses, thereby firmly connecting the core member to the covering layer.

[0044] 7. The structure according to embodiment 6, wherein the covering layer is formed as a single piece with the protrusions.

[0045] 8. The structure according to any one of the foregoing embodiments, wherein at least before assembling the structure, the covering layer comprises at least two separate covering layer components, wherein at least a part of the periphery of the first component and at least a part of the periphery of the second component are connected to each other and to the core component by a connecting member.

[0046] 9. The structure according to embodiment 8, wherein the connecting member is configured to facilitate the assembly of the core component and the covering layer and the coupling to one or more external components.

[0047] 10. The structure according to any one of embodiments 1 to 9, the structure further comprising an elastic layer, the elastic layer being formed with holes corresponding to the bumps, and the elastic layer being located between the covering layer and the core component such that the bumps protrude from the holes and, when the force is applied, the covering layer bends inwardly into the elastic layer within the gap, thereby compressing the elastic layer in the region thereof corresponding to the gap.

[0048] 11. The structure according to any one of embodiments 1 to 10, wherein at least most of the spaced regions between the bumps have a length substantially exceeding the thickness of the covering layer.

[0049] 12. The structure according to any one of embodiments 1 to 11, wherein the thickness of the covering layer is less than the height of the bumps.

[0050] 13. The structure according to any one of embodiments 1 to 12, wherein the maximum dimension along the outer surface of the bumps adjacent to the position where the covering layer is fixed to the core component is larger than the maximum dimension of the bumps spaced apart from the position.

[0051] 14. The structure according to any one of embodiments 1 to 13, wherein at least most of the bumps are uniformly arranged along at least most of the outer surface covered by the core component.

[0052] 15. A composite structure, the composite structure comprising at least:

[0053] A core component having an outer surface;

[0054] A covering layer made of a thermoplastic polymer having a bending modulus much larger than that of the core component, the covering layer having an outer surface and an inner surface, and at least the inner surface having the same shape as at least a part of the outer surface of the core component;

[0055] A quick-connect assembly device that connects the core component and the covering layer to each other; and

[0056] An elastic layer located between the covering layer and the core component;

[0057] The covering layer is configured such that when a bending force is applied at a region of the covering layer, the region bends inwardly into the elastic layer and bends back when the force is removed, thereby providing a structure with suspension properties such that the structure can behave like an elastic foam without using foam as the covering layer.

[0058] 16. The structure according to embodiment 15, wherein the elastic layer is made of an elastic foam material.

[0059] 17. The structure according to embodiments 15 - 16, wherein the bending modulus of the thermoplastic polymer is 110 - 1800 MPa.

[0060] 18. The structure according to embodiment 17, wherein the thickness of the covering layer is between 0.5 - 3.5 mm.

[0061] 19. The structure according to any one of embodiments 15 to 18, wherein the quick - connect fitting device is in the form of a snap - fit device.

[0062] 20. The structure according to embodiment 19, wherein the quick - connect fitting device includes a plurality of recesses in the core member and a corresponding plurality of protrusions protruding from the covering layer and configured to be received within the recesses, thereby firmly connecting the core member to the covering layer.

[0063] 21. The structure according to embodiment 20, wherein the covering layer is formed as a single piece with the protrusions.

[0064] 22. The structure according to any one of the foregoing embodiments, wherein the core member, the covering layer, and the elastic layer (if any) are made of materials that can be recycled without separation.

[0065] 23. The structure according to any one of the foregoing embodiments, wherein the materials for making the core member and the covering layer include the same basic substance and are different in material form.

[0066] 24. The structure according to embodiment 23 when directly or indirectly subordinate to any one of embodiments 10 and 15, wherein the material for making the elastic layer includes the same basic substance and is different in form from the materials of the core member and the covering layer.

[0067] 25. The structure according to any one of the foregoing embodiments, wherein when the bending force is applied, the covering layer maintains its thickness when bending.

[0068] 26. The structure according to any one of the foregoing embodiments, wherein the material for making the core member is foamed particle foam.

[0069] 27. The structure according to any one of the foregoing embodiments, wherein the bulk density of the covering layer is higher than the bulk density of the core member.

[0070] 28. The structure according to any of the foregoing embodiments, wherein the materials for making the core member and the covering layer include polypropylene.

[0071] 29. The structure according to embodiment 28, wherein the material (if any) for making the elastic layer includes polypropylene.

[0072] 30. The structure according to any one of the foregoing embodiments, wherein at least one surface of the core member and the covering layer has a curved shape.

[0073] 31. A composite structure, the composite structure comprising:

[0074] A core member having an outer surface;

[0075] A covering layer having an outer surface and an inner surface, and at least the inner surface has the same shape as at least a part of the outer surface of the core member,

[0076] A plurality of bumps protruding from at least one of the outer surface of the core member and the inner surface of the covering layer, with spaces between the bumps;

[0077] The covering layer is configured to be fixedly attached to the core member to form a plurality of gaps between the inner surface of the covering layer and the outer surface of the core member, and the gaps are defined by the spaces,

[0078] The covering layer and the gaps are configured such that when a force is applied to the outer surface of the covering layer at a region corresponding to the gaps, the region bends into the gaps and bends back when the force is removed.

[0079] 32. The composite structure according to embodiment 31, wherein the core member and the covering layer are configured to be fixedly connected to each other by a quick-connection assembly device such as snap-fitting.

[0080] 33. A composite structure, the composite structure comprising:

[0081] A core member having an outer surface;

[0082] A covering layer having an outer surface and an inner surface, and at least the inner surface has the same shape as at least a part of the outer surface of the core member;

[0083] A plurality of bumps protruding from at least one of the outer surface of the core member and the inner surface of the covering layer, with spaces between the bumps, forming a plurality of gaps between the inner surface of the covering layer and the outer surface of the core member;

[0084] A quick-connect assembly device that connects a core member and a cover layer to each other;

[0085] The cover layer and the gap are configured such that when a bending force is applied to the outer surface of the cover layer at a region corresponding to the gap, the region bends inwardly into the gap and bends back when the force is removed, thereby providing a structure having suspension performance similar to that of elastic foam.

[0086] 34. The composite structure according to embodiment 31, 32, or 33, wherein the length of at least most of the spaced regions between the bumps substantially exceeds the maximum dimension of the bumps along the outer surface of the core member.

[0087] 35. The composite structure according to any one of embodiments 31 to 34, wherein the height of the bumps is less than the distance between the bumps and is at least not less than the thickness of the cover layer, preferably greater than the thickness of the cover layer.

[0088] 36. The composite structure according to any one of embodiments 31 to 35, wherein the cover layer has a thickness not exceeding the height of the bumps.

[0089] 37. The composite structure according to any one of embodiments 32 to 36, wherein the quick-connect assembly device configured to fixedly connect the cover layer to the core member includes a convex portion and a concave portion. The convex portion projects from the inner surface of the cover layer away from its outer surface, the concave portion opens towards the cover layer in the core member, and the concave portion is configured to lockingly receive the convex portion.

[0090] 38. The composite structure according to embodiment 37, wherein the convex portion is formed integrally with the cover layer.

[0091] 39. The composite structure according to embodiment 36, 37, or 38, wherein the convex portion is located at several of the spaced regions of the cover layer covering the spaced regions, and the concave portion is located in the corresponding spaced regions.

[0092] 40. The composite structure according to any one of embodiments 30 to 39, the composite structure further comprising an elastic layer formed with holes corresponding to the bumps, and the elastic layer is configured to be located between the cover layer and the core member such that the bumps project from the holes, and when the force is applied, the cover layer bends towards the elastic layer or bends into the elastic layer at its region corresponding to the gap.

[0093] 41. The composite structure according to any one of embodiments 30 to 40, wherein the core member, the cover layer, and the elastic layer (if any) are made of materials that can be recycled without separation.

[0094] 42. A composite structure having suspension performance, the composite structure comprising:

[0095] A core member having an outer surface;

[0096] A covering layer having an outer surface and an inner surface, at least the inner surface of the covering layer having the same shape as at least a portion of the outer surface of the core member, the covering layer being configured to be fixedly attached to the core member;

[0097] An elastic layer, optionally made of a foam material, and located between the covering layer and the core member;

[0098] The covering layer is configured such that when a force is applied at a region of the covering layer, the region bends into the elastic layer and bends back when the force is removed to provide suspension performance.

[0099] 43. The composite structure according to embodiment 42, wherein the core member and the covering layer are configured to be fixedly connected to each other via the elastic layer by a quick-connection assembly device such as snap-fitting.

[0100] 44. A composite structure, the composite structure comprising:

[0101] A core member having an outer surface;

[0102] A covering layer having an outer surface and an inner surface, and at least the inner surface having the same shape as at least a portion of the outer surface of the core member;

[0103] A quick-connection assembly device that connects the core member and the covering layer to each other; and

[0104] An elastic layer located between the covering layer and the core member;

[0105] The covering layer is configured such that when a bending force is applied at a region of the covering layer, the region bends inward into the elastic layer and bends back when the force is removed, thereby providing a structure with suspension performance, such that the structure can behave like an elastic foam when not using foam as the covering layer.

[0106] 45. The composite structure according to any one of embodiments 42, 43, and 44, wherein the thickness of the covering layer does not exceed the thickness of the elastic layer.

[0107] 46. The composite structure according to any one of embodiments 42 to 45, wherein the thickness of the core member is greater than the thickness of the covering layer.

[0108] 47. The composite structure according to any one of embodiments 42 to 46, wherein the core member is made of a material having a bulk density lower than the bulk density of the covering layer.

[0109] 48. The composite structure according to any one of embodiments 43 to 47, wherein the quick-connect assembly device configured to fixedly connect the cover layer to the core member via an elastic layer includes a convex portion protruding from the inner surface of the cover layer away from its outer surface and a concave portion formed in the core member and opening towards the cover layer.

[0110] 49. The composite structure according to embodiment 48, wherein the convex portion is integrally formed with the cover layer.

[0111] 50. The composite structure according to embodiment 47, 48 or 49, wherein the convex portion is located at several of the regions of the cover layer, and the concave portion is formed at corresponding positions on the outer surface of the core member.

[0112] 51. The composite structure according to any one of embodiments 41 to 50, wherein the core member, the cover layer and the elastic layer are made of materials that can be recycled without separation.

[0113] 52. A composite structure comprising a core member, a recoverable volume layer and a cover layer, the core member having an outer surface and a shape defined by the intended use of the composite structure, the recoverable volume layer being associated with the outer surface of the core member and having recoverable volume at least in a plurality of its regions, the cover layer being fixedly connected to the core member, wherein the combination of the material forming the cover layer, the thickness of the cover layer, and the dimensions of the recoverable volume is such that when a bending force is applied to the region of the cover layer covering the recoverable volume, the region bends into the recoverable volume while maintaining the thickness of the cover layer at the region, and then bends back, thereby providing a suspension performance similar to that of elastic foam without using foam as the cover layer.

[0114] 53. The composite structure according to embodiment 52, wherein the recoverable volume layer is constituted by one of the following:

[0115] Air gaps formed in the core member and spaced apart from each other, and optionally, elastic foam layer portions accommodated in the air gaps; or

[0116] An elastic layer provided under the cover layer.

[0117] 54. The composite structure according to embodiment 52 or 53, further comprising a quick-connect assembly device including a plurality of lockable protrusions protruding from the inner surface of the cover layer and corresponding plurality of locking depressions in the core member, each locking depression being configured to lockingly receive a corresponding lockable protrusion therein.

[0118] 55. The composite structure according to embodiment 54, wherein each lockable protrusion is formed at an area of the covering layer that has a recoverable volume thereunder, and a corresponding locking recess is formed to have the recoverable volume thereabove.

[0119] 56. The composite structure according to embodiment 54 or 55, wherein the longitudinal dimensions of the lockable protrusion and the locking recess are such that when a relevant area of the covering layer is bent into the recoverable volume disposed thereunder, it allows the lockable protrusion to move inwardly into the locking recess.

[0120] 57. The composite structure according to embodiment 54, 55 or 56, wherein the lockable protrusion is formed integrally with the covering layer.

[0121] 58. The composite structure according to any one of embodiments 54 to 57, wherein the lockable protrusions are located at a plurality of said areas of the covering layer, and locking recesses are formed at corresponding positions on the outer surface of the core member.

[0122] 59. The composite structure according to any one of embodiments 31 to 58, wherein the materials for making the core member and the covering layer include the same base substance and are different in material form and / or physical properties, and if the structure includes an elastic layer located between the covering layer and the core member, the elastic layer is also made of a material including the base substance.

[0123] 60. The composite structure according to embodiment 59, wherein the material is a thermoplastic polymer material.

[0124] 61. The composite structure according to embodiment 60, wherein the material of the core member is in the form of a foamed particle foam.

[0125] 62. The composite structure according to embodiment 61, wherein the covering layer has a higher bulk density than the bulk density of the core member.

[0126] 63. The composite structure according to any one of embodiments 59 to 62, wherein the base substance is polypropylene.

[0127] 63. A composite structure comprising a core member and a covering member, the covering member being fixedly connected to the core member so as to be bendable into or towards the core member. Optionally, the composite structure further includes an elastic layer located under at least some areas of the covering layer between the core member and the covering layer, wherein the materials for making the core member, the covering layer and the elastic layer (if any) include the same base substance and are different in form so as to be able to recycle the structure without separating the covering layer and the elastic layer (if any) from the core member.

[0128] 64. The composite structure according to embodiment 63, wherein the material is a thermoplastic polymer material.

[0129] 65. The composite structure according to embodiment 64, wherein the material of the core member is in the form of foamed particulate foam.

[0130] 66. The composite structure according to embodiment 64 or 65, wherein the material of the covering layer is a dense continuous material, and the density of the dense continuous material is significantly higher than the density of the dense continuous material of the core member.

[0131] 67. The composite structure according to any one of embodiments 31 to 66, wherein the material of the covering layer has a flexural modulus significantly greater than that of the material of the core member.

[0132] 68. The composite structure according to embodiment 67, wherein the flexural modulus of the material of the covering layer is in the range of 110 - 1800 MPa.

[0133] 69. The composite structure according to any one of embodiments 31 to 68, wherein the thickness of the covering layer is in the range of 0.5 - 3.5 mm.

[0134] 70. The composite structure according to any one of the foregoing embodiments, wherein at least the outer surface of the core member has a curved shape and the covering layer has a corresponding curved shape to conform to the curvature of the core member.

[0135] 71. The composite structure according to any one of the foregoing embodiments, wherein the covering layer is made of a material that is incompressible under the force.

[0136] 72. The composite structure according to any one of the foregoing embodiments, wherein the core member is rigid.

[0137] 73. The composite structure according to any one of embodiments 31 to 72, wherein the covering layer includes at least two separate covering layer components, and at least a portion of the periphery of the first component and at least a portion of the periphery of the second component are connected to each other and to the core member by a connecting member.

[0138] 74. The composite structure according to embodiment 73, wherein the connecting element has a protrusion, and the core member has a recess configured to securely receive the protrusion of the connecting element. BRIEF DESCRIPTION OF THE DRAWINGS

[0139] To better understand the subject matter disclosed herein and to illustrate how it may be implemented in practice, embodiments will now be described by way of non - limiting example only with reference to the accompanying drawings, in which:

[0140] Figure 1AIs a perspective view of the structure of an example according to the subject matter of the present application.

[0141] Figure 1B Is the same as Figure 1A The same structural view, with its overlay shown as transparent for illustration purposes.

[0142] Figure 1C Is Figure 1A An exploded view of the structure shown.

[0143] Figure 1D Is the same as Figure 1A The same structural view, showing the structure in use.

[0144] Figure 2 Is the same as Figure 1B The same structural view, showing the dimensions of the bumps and the spacer regions.

[0145] Figure 3 Is a perspective view of the structure of another example according to the subject matter of the present application, where at least some of the bumps may have different shapes and sizes from other bumps.

[0146] Figures 4A - 4D A view showing the structure of another example according to the subject matter of the present application, which corresponds to Figures 1A - 1D The structure and includes an additional elastic layer.

[0147] Figure 5A Is a perspective view of a part of an article according to another example of the subject matter of the present application.

[0148] Figure 5B Is Figure 5A Another perspective view of the part of the article in

[0149] Figure 6A Is a perspective view of the structure of yet another example according to the subject matter of the present application.

[0150] Figure 6B Is Figure 6A The view of the structure shown, with its overlay shown as transparent for illustration purposes.

[0151] Figure 6C Is Figure 6B An exploded view of the structure shown.

[0152] Figure 6D Is Figure 6A The view shown, which shows the structure in use.

[0153] Figure 7 Schematically shows an example of the connection between the overlay and the core member, which can be used in the structure according to the subject matter of the present application.

[0154] Figure 8 Another example of the connection between the covering layer and the core member is schematically shown, which can be used in the structure according to the subject matter of the present application.

[0155] Figure 9A and Figure 9B A cross-sectional view of a structure according to another example of the subject matter of the present application in different states is shown.

[0156] Figure 10A and Figure 10B A cross-sectional view of a structure according to another example of the subject matter of the present application in different states is shown.

[0157] Figure 11A and Figure 11B A cross-sectional view of a structure according to another example of the subject matter of the present application in different states is shown.

[0158] Figure 12 An example of a covering layer that can be used in any structure according to the subject matter of the present application is shown, where the covering layer is shown in its bottom perspective view.

[0159] Figure 13A and Figure 13B A cross-sectional view of a structure according to another example of the subject matter of the present application in different states is shown.

[0160] Figure 14A and Figure 14B A cross-sectional view of a structure according to another example of the subject matter of the present application is shown, and the structure is Figure 13A and Figure 13B the structure shown in combination with additional connecting means.

[0161] Figure 15 A cross-sectional view of a structure according to another example of the subject matter of the present application is shown.

[0162] Figure 16 A cross-sectional view of a structure according to another example of the subject matter of the present application is shown, and the structure is Figure 15 the structure shown in combination with additional connecting means. Detailed Description

[0163] Figures 1A - 1D A composite structure having suspension performance according to an example of the first aspect of the subject matter of the present application is shown. The composite structure shown in these figures constitutes an exemplary part of an article 100 to be incorporated into a product to provide a soft feeling to the user. The product can be, for example, a bicycle seat, a motor vehicle seat, a chair assembly, a sofa, an interior component of a vehicle, or any such part or assembly that requires an outer layer to provide a soft feeling.

[0164] The composite structure / article 100 includes a core member 110 and a covering layer 120. The core member 110 has an outer surface 112 facing the direction of the covering layer 120. The core member 110 is rigid and has a plurality of bumps 115 that project from the outer surface 112 in the direction of the covering layer and are spaced apart from each other by an intervening region 116 between any two adjacent bumps 115.

[0165] According to the illustrated embodiment, the bumps are integrally formed with the core member 110. However, in another embodiment (not shown), the bumps 115 can be manufactured separately and then assembled with the core member 110. In the latter case, the bumps 115 can be formed of the same or different material as the core member 110. For example, the material for the bumps 115 can include the same basic substances as the core member 110 but have different forms and / or different physical properties.

[0166] The covering layer 120 has an inner surface 122 facing the direction of the core member 110 and an outer surface 124 facing the exterior of the article 100, and the covering layer 120 can have a predetermined shape that is the same as the shape of the outer surface 112 of the core member 110. The covering layer is manufactured in this shape, i.e., as can be clearly seen from Figure 1C the covering layer already has the said shape before the core member 110 and the covering layer 120 are assembled. Although in the present embodiment, the entire covering layer has the same shape as the outer surface of the core member, in another embodiment (not shown), only the inner surface of the covering layer can have this shape.

[0167] The covering layer 120 is configured to be fixedly attached to the core member 110 by any suitable means, some examples of which will be described in detail below. As Figure 1A and Figure 1B shown, when attached to the core member 110, the covering layer 120 covers the outer surface 112 of the core member 110 such that the inner surface 122 of the covering layer 120 is placed on the bumps 115. As further seen in Figure 1A and Figure 1B when the inner surface 122 is placed on the bumps 115, a plurality of gaps G are formed at positions between the covering layer 120 and the core member 110 where the inner surface 122 does not contact the bumps 115. In other words, the gaps G are formed at positions corresponding to the intervening region 116 and are defined by the intervening region 116. According to the said embodiment, the gaps G are filled with air. According to another embodiment, as will be described in detail later below, the gaps G can include an elastic material.

[0168] As Figure 1DAs shown, the overlay 120 and the gap G are constructed such that the overlay is made of such a material and has such a thickness, and the gap G has such dimensions that when a bending force F is applied to the outer surface 124 of the overlay 120 at the region above the gap G, the overlay 120 bends slightly inward into the gap G. When the force F is removed, the overlay 120 bends back to its normal shape. Thus, suspension characteristics are achieved, and the overlay 120 provides the article with a soft feel like that of an elastic foam. In other words, as Figure 1D shown, the overlay and the gap are constructed such that when a force F is applied to the overlay, the regions of the overlay 120 associated with the gap G all behave membranously, and the membranousness shown is held in place by the adjacent regions of the overlay supported by the bumps, and the outer surface 124 and the inner surface 122 of the overlay 120 bend inward into the gap G at these regions. Thus, when a force F is applied to the outer surface 124 of the overlay 120 and the overlay 120 bends into the gap G, the volume of the gap decreases.

[0169] Additionally, the bumps 115 can be constructed to be compressible under the action of the above-described force to further enhance the suspension of the overlay at the regions where it covers the bumps and thus increase the soft feel of the article. In another embodiment, the bumps 115 can be constructed to be rigid. The compressibility / rigidity of the bumps 115 can be selected according to the utility of the end product into which the article is to be incorporated.

[0170] For example, the bending modulus of the overlay can be significantly higher than that of the core member, for example, between 110 and 1800 MPa, and its thickness can be between 0.5 - 3.5 mm. The core member can have any thickness determined by the function of the structure in the article, which is significantly greater than the thickness of the overlay in any case, and the material from which the core member can be made can have a bending modulus lower than that of the overlay, thereby further enhancing the suspension of the overlay at the regions where it covers the bumps.

[0171] The materials from which the core member 110 and the overlay 120 can be made are described at the end of this specification.

[0172] In addition to the material of the cover layer 120, the thickness of the cover layer 120, the length of the spacer region 116, the maximum dimension of the bumps 115 along the outer surface 112, the height of the bumps 115, and the correlations therebetween should be such that the cover layer 120 can bend into the gap G and affect the suspension characteristics of the article. For example, at least 30% of the area of the inner surface 122 of the cover layer 120 should correspond to the spacer region 116, i.e., should not contact the bumps 115, so that there is air below it to be able to bend inward into the air, thereby reducing its volume when a force is applied. Thus, the cover layer 120 can only bend when a force is applied during installation, so that there is a recoverable volume below it, such as the gap G in this example, and if the cover layer 120 is placed on a rigid, incompressible surface, the cover layer 120 will not be able to bend.

[0173] As Figure 2 shown, the length of at least most of the spacer region 116, or in other words, the distance between most adjacent pairs of bumps 115 (referred to herein as DS) is at least not shorter than the maximum dimension of each of most of the bumps 115 along the outer surface 112 (referred to herein as DB), and preferably longer than the maximum dimension of each of most of the bumps 115 along the outer surface 112. In addition, the length DS of the spacer region 116 is greater than the height H of the bumps 115 perpendicular to the outer surface 112. In addition, the thickness T of the cover layer 120 is less than the length DS of the spacer region 116 and does not exceed the height H of the bumps.

[0174] At least most of the bumps 115 can be arranged on most of the outer surface 112 in a uniform manner. In addition, at least most of the bumps 115 can have the same maximum dimension along the outer surface 112. In Figure 2 the embodiment shown, all of the bumps in the shown portion of the article 100 have the same shape and size. According to another embodiment, for example, as Figure 3 shown, the maximum dimension DB of at least some of the bumps 115 along the outer surface is longer than the maximum dimension DB of at least some other bumps 115. For example, the bumps 115 adjacent to the position where the cover layer 120 can be fixed to the core member 110 (in this case, the periphery 113 of the article or a part thereof) can have a maximum dimension DB along the outer surface 112 that is longer than the maximum dimension DB of the bumps 115 separated from said position. An option for the latter embodiment can be that the article or a part thereof has a single continuous protrusion extending along its periphery.

[0175] Figures 4A - 4D shows a composite structure forming part of another article 100, said another article 100 having the same as described above with respect to Figures 1A to 3the same components and features as described for the article shown, and an additional elastic layer 130. The elastic layer 130 is located between the core member 110 and the cover layer 120 and includes holes 132 corresponding in shape and size to the bumps 115 such that the bumps 115 project through the holes 132 from the outer surface 112 of the core member 110 towards the inner surface 122 of the cover layer 120. The thickness of the elastic layer does not exceed or is at least substantially no more than the height H of the bumps 115 such that the elastic layer 130 enables the cover layer 120 to be placed on the bumps 115 at least when the cover layer is bent towards the core member. The elastic layer 130 fills at least a part of the volume defined by the gap G and constitutes its recoverable volume, the gap G being configured such that when a force F is applied to the outer surface 124 of the cover layer 120 at a region above the part of the elastic layer 130 disposed in the gap (or in other words, at the part where the cover layer 120 is not placed on the bumps 115), the cover layer 120 bends towards the elastic layer 130 or inwards into the elastic layer 130 according to the thickness of the elastic layer 130 (as Figure 4D shown). Thereby, the suspension characteristics can be adjusted, and the cover layer 120 and the elastic layer 130 together provide the article with a desired softness such as that of an elastic foam.

[0176] It should be noted here that, as Figure 4C shown, the elastic layer 130 does not need to be manufactured in a shape corresponding to the outer surface 112 of the core member 110. For example, as Figure 4C shown, the layer 130 can be planar compared to the outer surface 112 of the core member 110 and can adapt to the shapes of the core member and the cover layer during article assembly due to its elasticity. The materials from which the elastic layer 130 can be made are described at the end of this specification.

[0177] In Figures 4A to 4D the embodiment, the thickness of the elastic layer 130 is equal to the height H of the bumps 115 such that the inner surface 122 of the cover layer 120 is placed on the bumps 115 together with the elastic layer 130. In this case, when a force F is applied to the outer surface 124 of the cover layer 120 at a position corresponding to the gap between the bumps, the cover layer 120 bends inwards into the elastic layer 130. When the thickness of the elastic layer 130 is less than the height H of the bumps 115 such that the inner surface 122 of the cover layer 120 is only placed on the bumps 115, when a force F is applied to the outer surface 124 of the cover layer 120 at a region corresponding to the gap between the bumps, the cover layer 120 will bend inwards towards the elastic layer 130 between the bumps.

[0178] Figures 5A - 5B shows a composite structure which forms part of an article 1 having the same components and features as in the article 100 described above with reference to Figures 1A - 3 but having a cover layer including two parts. More specifically, asFigures 1A - 3 As described above, article 1 includes the core member 110, bumps 115, and cover layer 120 as described above, but the cover layer 120 includes two separate cover layer components 120A and 120B that are connected to each other at corresponding peripheries and to the core member 110. In other embodiments, the cover layer 120 can be molded into a single component, or any number of components, depending on the nature, size, structure, and / or utility of the final product incorporating the article. Figures 1A to 3 Components 120A and 120B can be connected to each other and to the core member by any suitable means. In the examples shown in

[0179] and Figure 5A and Figure 5B shown below, by connection member 70 as described in further detail below with reference to Figure 7 In addition, in the examples shown in Figure 5A and Figure 5B the cover layer 120 includes a skirt 125 that extends at least from some portions of the periphery of the cover layer 120 toward the core member 110, thereby increasing the rigidity of the article at its periphery. The skirt can also cover the core member or at least some portions thereof including the gap G from the side.

[0180] Figures 6A - 6D A composite structure forming a part of article 200 having suspension properties according to another example of the subject matter of the present application is shown, the views of which respectively correspond to the views of article 100 shown in Figures 1A - 1D These portions shown in the figures represent exemplary small portions of article 200 to be incorporated into a product to provide a soft feel to the user. The product can be a bicycle seat, a motor vehicle seat, a chair assembly, a sofa, an interior vehicle component, or any such part or assembly that requires an outer layer to provide a soft feel.

[0181] Article 200 includes a core member 210, a cover layer 220, and an elastic layer 230. The core member 210 includes an outer surface 212 facing the exterior of the article. The cover layer 220 has the same characteristics as the cover layer 120 of article 100 and has an inner surface 222 and an opposite outer surface 224. The inner surface 222 of the cover layer 220 has a predetermined shape, i.e., is manufactured in that shape, such that the cover layer 220 has that shape at least before being assembled with the core member 210.

[0182] The cover layer 220 is configured to be fixedly attached to the core member 210 via the elastic layer by any suitable means, some examples of which will be described in detail below. The elastic layer 230 is located between the core member 210 and the cover layer 220 such that the elastic layer is clamped between the outer surface 212 of the core member 210 and the inner surface 222 of the cover layer 220 during assembly. As Figure 6CAs shown, the elastic layer 230 does not need to have a shape corresponding to the outer surface 212 of the core member 210 before the assembly of the article. Thus, in the present example, as Figure 6C shown, the elastic layer 230 is planar compared to the outer surface 212 of the core member 210, and when the article is assembled, the elastic layer 230 elastically deforms to the shape of the outer surface 212 of the core member 210.

[0183] The cover layer 220 and the elastic layer are configured such that when a force F is applied to the outer surface 224 of the cover layer 220, the cover layer bends inwardly into the elastic layer 230. Thus, a suspension property is achieved, and the cover layer 220 provides a soft feeling similar to that of an elastic foam to the article. In other words, the cover layer and the elastic layer are configured such that the region of the cover layer 120 to which the force F is applied behaves as a membrane with the non-force-applied adjacent regions of the cover layer remaining in place, and the outer surface 124 and the inner surface 122 of the cover layer 120 at these regions bend inwardly into the elastic layer, as Figure 6D shown. Thus, when a force F is applied at the outer surface 124 of the cover layer 120 and the cover layer 120 bends into the gap G, the volume below the region of the elastic layer decreases. Thus, the cover layer 220 can only bend when a force is applied during installation, so that there is a recoverable volume below it.

[0184] The materials for fabricating the core member 210, the cover layer 220, and the elastic layer 230 are described at the end of this specification.

[0185] In the articles 1, 100, and 200 described above and any other articles according to different aspects of the subject matter of the present disclosure, the core member and the cover layer can be mechanically connected to each other in various ways, and some examples are given below. It should be understood here that when the connecting means are described below with reference only to the article 1 for simplicity, these connecting means are applicable to any article according to the subject matter of the present disclosure.

[0186] According to a specific embodiment of the subject matter of the present disclosure, Figure 7 a composite structure forming part of the article 1 is shown, wherein, Figure 7An enlarged view of the connection between a part of the periphery of the first member 120A showing the covering layer 120, a part of the periphery of the second member 120B of the covering layer 120, and the core member 110 is shown. As shown in the enlarged view, the peripheries of the first and second members of the covering layer are bent to form corresponding flanges 126. The connecting member 70 includes two lips 71, each lip 71 being configured to engage and grip the corresponding flange 126. The lips 71 extend towards the wide bottom 720 of the connecting member 70. The wide bottom 720 is configured to be inserted into a corresponding groove 114 formed in the core member 110. The wide bottom 720 and the portion extending from the lips 71 form a narrower neck 730 to prevent the bottom 720 from being pulled out of the groove 114. The engagement of the flange 126, the lips 71, the bottom 720, and the groove 114 fixes the two members 120A and 120B of the covering layer to the core member 110. A recess 740 is formed between the extensions of the lips 71 and extends into the bottom 720. The recess 740 is configured to accommodate therein an external component to be connected to the article or the final product. The external component can be a decorative component such as a metal plate 1000, or can be a protrusion of an external connector such as a zipper, thereby enabling the article to be connected to any external product. The connecting member 70 can be made of the same material as the core member or the covering layer of the article 1.

[0187] Figure 8 An exploded view showing a part of the seat incorporating the article 1 is shown. Figure 8 A part of the periphery 111 of the core member 110 is shown, which includes a plurality of protrusions 81 of the quick-connect fitting device. Figure 8 A part of the periphery 121 of the covering layer 120 is also shown, which includes a plurality of recesses 82 corresponding to the protrusions 81 of the quick-connect fitting device. During the assembly of the article, the covering layer 120 is mounted on the core member 110, and the protrusions 81 and the recesses 82 are mechanically connected to each other by a quick-fit engagement (such as a snap connection), thereby firmly connecting the core member 110 to the covering layer 120. In some examples, the covering layer can include protrusions and the core member can include recesses.

[0188] The above-mentioned snap connection device is arranged in one or more parts of the peripheries of the core member and the covering layer. However, it should be understood that the connection device can also be arranged along the entire periphery.

[0189] At least some snap - fit connection devices may be arranged at regions of the cover layer and the core member remote from the periphery and including their central regions. The snap - fit connection devices may include connection elements such as locking recesses, which constitute recesses of the connection device formed in one of the core member and the cover layer, and corresponding connection elements such as lockable protrusions, which constitute protrusions of the connection device and protrude from the other of the core member and the cover layer towards the recess. For example, the protrusion may be integrally mounted on the cover layer or formed integrally with the cover layer, and the recess may be integrally formed in the core member or formed integrally with the core member.

[0190] In any of the above examples, the cover layer may be connected to the core member by suspension allowing the connection device. The device may include recesses and protrusions of the above - described type, which may have such a construction and dimensions that the protrusion can move within the recess in the thickness direction of the structure and, optionally, also in the tangential direction perpendicular to the thickness direction. This may enable the cover layer to bend in the thickness direction as described above and also, when corresponding bending forces and tangential forces are applied at least indirectly to the region of the cover layer associated with the protrusion, enable the cover layer to move slightly relative to the core member in the tangential direction, resulting in an increase in size due to the suspension characteristics of the cover layer, thereby improving the softness of the article. This will be described below with reference to Figures 9A - 11B Examples of connection devices in articles having the same components and features as articles 1, 100, and 200 described above will be described. Thus, in these examples, only the features of the articles required to describe the structure and operation of the connection devices will be described.

[0191] Figure 9A and 9B A cross - sectional view of a composite structure is shown, which constitutes a part of an article 300 having all the components and features of article 100 described above with reference to Figures 1A - 3 and also having a snap - fit connection device.

[0192] More specifically, article 300 has a core member 310 and a cover layer 320, both of which are Figures 1A - 3The corresponding cover layer and core member of the article 100 shown have the same basic structure, are made of the same material (described at the end of this specification), and operate in the same manner. The core member 310 has an outer surface 312 facing the direction of the cover layer 320. The core member 310 has a plurality of bumps 315 that protrude from the outer surface 312 in the direction of the cover layer 320 and are spaced apart from each other by an interval region 316 between any two adjacent bumps 315, such that when the cover layer is placed on the core member, a plurality of voids G are formed between the interval region and the associated region above the interval region of the cover layer. The cover layer 320 has an inner surface 322 facing the direction of the core member 310 and an outer surface 324 facing the outside of the article 300.

[0193] The engaging connection device of the article 300 includes a plurality of recesses 318 and a plurality of protrusions 328. The plurality of recesses 318 extend inward from the outer surface of the core member 310 into the core member 310 at some of the interval regions 316. The plurality of protrusions 328 protrude from the inner surface of the cover layer at the regions of the cover separation regions of the cover layer, and the plurality of protrusions 328 are configured to be lockingly received in the respective recesses 318. In other words, each pair of protrusions and recesses is associated with a gap G.

[0194] Each recess has a wide bottom 318A, a narrow top 318B, and a shoulder 318C connecting the wide bottom 318A and the narrow top 318B. Each protrusion 328 has at least two lobes 328A and 328B at its end away from the inner surface 322. The protrusion 328 is flexible and its lobes are configured to press towards each other when passing through the narrow top 318B of the recess 318 and return to their original positions when entering its wide bottom 318A, whereby each protrusion is held within the recess 318 and locked at the shoulder 318C to prevent the protrusion 328 from being pulled out of the recess 318 and to fixedly attach the cover layer 320 to the core member 310.

[0195] As Figure 9A shown, when attached to the core member 310, the cover layer 320 covers the outer surface 312 of the core member 310 such that the inner surface 322 of the cover layer 320 is placed on the bumps 315 and the protrusions 328 are locked within the recesses 318.

[0196] As in Figure 9A and Figure 9BAs further seen in, the dimensions and configuration of the recess and the protrusion are such that when the leaf portions 328A and 328B are locked at the shoulder 318C in the normal state of the corresponding regions of the cover layer 320, a space S1 is left between the bottom surface 318D of the recess 318 and the distal end of the protrusion 328, thereby allowing the protrusion 328 to move towards the bottom surface 318D of the recess 318 while remaining locked in the recess 318 when the corresponding region of the cover layer 320 is bent into the associated gap G under the action of a bending force, thus reducing the space S1 to S2, as Figure 9B shown. Further, as Figure 9A and 9B shown, the dimensions and configuration of the recess and the protrusion are such that when inserted into the recess 318, the protrusion 328 is spaced apart from the side wall of the recess 318 by a distance D, thereby allowing the protrusion to move relative to the recess in the tangential direction when a tangential force is applied at least indirectly to the cover layer at or adjacent to the above-mentioned region. Thus, while the cover layer 320 is firmly attached to the core member, it can bend inwardly towards the core member 310 together with the protrusion at the region associated with the protrusion, and when a tangential force is applied at least indirectly to these regions, the cover layer 320 moves slightly relative to the core member in the tangential direction.

[0197] Figure 10A and 10B show a composite structure forming part of the article 300, which article 300 has all the components and features described above with respect to the structure shown in Figures 4A - 4D , and a snap-fit connection structure identical to the snap-fit connection device described above with respect to Figure 9A and Figure 9B , and the snap-fit connection structure additionally includes holes in the elastic layer that can use the connection means.

[0198] Thus, Figure 10A and Figure 10B the structure shown includes a core member 310, a cover layer 320, and an elastic layer 330 disposed therebetween such that the elastic layer 330 fills at least a portion of the recoverable volume defined by the gap G' between the core member 310 and the cover layer 320, and the core member 310, the cover layer 320, and the elastic layer 330 can have the same basic configuration, be made of the same materials (described at the end of this specification), and operate in the same manner as the corresponding cover layer, core member, and elastic layer of the article 100 shown in Figures 4A to 4D .

[0199] The elastic layer 330 includes a plurality of first holes 332 corresponding in shape and size to the bumps 315 such that when the article is assembled, the bumps 315 project through the corresponding holes 332 from the outer surface 312 of the core member 310, enabling the cover layer 320 to be placed on at least some of the bumps 315. The elastic layer 330 further includes a plurality of second holes 334 which are respectively provided at positions corresponding to the positions of the concave portions 318 of the core member 310 and the convex portions 328 of the cover layer 320 in association with a part of the clearance G'. The plurality of second holes 334 enable the convex portions 328, particularly their wide bottoms, to pass therethrough into the concave portions 318, to be locked in the corresponding concave portions 318 when the article is assembled, and the convex portions 328 have the ability to move within a range S1 - S2 in the thickness direction and within a distance D in the tangential direction. Accordingly, the cover layer 320 is fixedly attached to the core member 310 via the elastic layer clamped therebetween, and at the same time, when a bending force and a tangential force are applied to the cover layer, it functions as described above with reference to Figure 9A and 9B as described.

[0200] Figure 11A and 11B FIG. shows a cross-sectional view of a composite structure which forms a part of an article 400 having all the components and features of the article 200 described above with reference to Figures 6A - 6D and having the same snap-fit connection means as those described with reference to Figure 10A and Figure 10B described above.

[0201] More specifically, the article 400 includes a core member 410, a cover layer 420, and an elastic layer 430, and the core member 410, the cover layer 420, and the elastic layer 430 can all have the same basic structure as the respective cover layer, core member, and elastic layer of the article 200 shown in Figures 6A to 6D be made of the same material (described at the end of this specification), and operate in the same manner.

[0202] The core member 410 includes an outer surface 412 facing the outside of the article. The cover layer 420 has an inner surface 422 and an opposite outer surface 424. The elastic layer 430 is located between the core member 410 and the cover layer 420 such that when the article is assembled, the elastic layer 430 is placed on the outer surface 412 of the core member 410, and the inner surface 422 of the cover layer 420 is placed on the elastic layer 430.

[0203] The snap - fit connection device includes a plurality of recesses 418 on the outer surface of the core member 410 and a corresponding plurality of protrusions 428 protruding from the inner surface 422 of the cover layer 420 towards the core member 410. Each recess 418 includes a wide bottom 418A, a narrow top 418B, and a shoulder 418C connecting the wide bottom 418A and the narrow top 418B. Each protrusion 428 includes at least two lobes 428A and 428B at its end remote from the inner surface 422. The lobes 428A and 428B are configured to be held within the recess 418 and locked at the shoulder 418C to prevent the protrusion 428 from being withdrawn from the recess 418, whereby the cover layer 420 is fixedly attached to the core member 410.

[0204] The elastic layer 430 includes a plurality of holes 434 disposed at positions corresponding to the positions of the recesses 418 and the protrusions 428. Each hole 434 allows the protrusion 428 to pass through during assembly of the article so that the protrusion is received within the corresponding recess and locked therein, and the protrusion has the ability to move within a range of S1 - S2 in the thickness direction and within a distance D in the tangential direction. Thus, the cover layer 420 is fixedly attached to the core member 410 by the elastic layer sandwiched therebetween, and at the same time, in the case where bending force and tangential force are applied to the cover layer as described above with reference to Figure 9A and 9B it functions.

[0205] In Figure 10A 、 10B and the articles shown in 11A, 11B, where the elastic layer includes holes through which the protrusions enter the corresponding recesses, these holes may have a cross - section corresponding to the cross - section of the narrow top of the protrusion, and these holes can elastically radially extend during serving as a passage.

[0206] While in Figures 9A - 11B a snap - fit connection device is shown such that only two engaging elements can be seen in each protrusion (since these figures are cross - sectional views), and the protrusion can include any desired number of engaging elements. Figure 12 Shows an example of a protrusion 528 having a cross - sectional view as shown in Figures 9A - 11B wherein the cover layer 520 is the same as the cover layers 320 and 420 shown in Figures 9A - 11B . Figure 12 A selected area of the cover layer 520 is shown in a perspective bottom view. The protrusions 528 are integrally formed with the cover layer 520 and are at least evenly distributed along the Figure 12 shown area, and are configured to be received within corresponding recesses formed in any of the core members of Figures 9A - 11B . In the example, each protrusion 528 is annular and includes six engaging elements, each engaging element constituting a sector of a cylinder and having a shape in accordance with Figures 9A - 11BThe leaf portions 328A, 328B of the corresponding convex portion 328 of the snap - fitting connection device shown in the figure and the leaf portions 428A, 428B of the convex portion 428 radially protrude in the same manner.

[0207] Although all the illustrated examples of forming bumps on the outer surface of the core member have been described above, where the covering layer is configured to bend when a bending force is applied, it should be understood here that in all these examples, the core member and / or the bumps can also be compressible. More specifically, in all such examples, the bumps protrude from the core member, and the core member, the bumps, or both of them can have a higher compressibility than the covering layer, such that when a bending force is applied to the covering layer at the region covering such bumps on the covering layer, the bumps are compressed, thus facilitating the suspension characteristics of the composite structure, especially in the region corresponding to the bumps.

[0208] Optionally, or additionally, when the core member has a higher compressibility than the covering layer, the covering layer can be formed with bumps that protrude from the covering layer towards the core member and are configured to compress the core member when a bending force is applied to the covering layer at the region covering such bumps on the covering layer, thus facilitating the suspension characteristics of the composite structure, especially at the region corresponding to the bumps.

[0209] Figure 13A and 13B A cross - sectional view of a composite structure forming part of an article 500 is shown. The article 500 has all the components and features of the article 100 described above with reference to the figure, the only difference being that in the article 500, the bumps protrude from the covering layer instead of from the core member as in the article 100.

[0210] More specifically, the article 500 has a core member 510 and a covering layer 520, both of which are Figures 1A to 3The corresponding cover layer and core member of the article 100 shown have the same basic structure, are made of the same material (described at the end of this specification), and operate in the same manner. The core member 510 has an outer surface 512 facing the direction of the cover layer 520. The cover layer 520 has a plurality of bumps 525 protruding from the inner surface 522 along the direction of the core member 510, and is spaced apart from each other by an interval region 526 between any two adjacent bumps 525, such that when the cover layer 520 is connected to the core member 510, the bumps 525 are placed on the outer surface 512 of the core member 510, forming a plurality of voids G between the relevant regions below the interval region and the separated region of the outer surface 512. The height of the bumps 525 defines the height of the gap, and the cover layer 520 has a thickness less than the height of the bumps 525 in the region between the bumps 525. According to the illustrated embodiment, the bumps are integrally formed with the cover layer 520. However, in another embodiment (not shown), the bumps can be manufactured separately and then assembled with the cover layer.

[0211] Similarly, as described above regarding the cover layer 120 and the gap G of the article 100, the cover layer 520 and the gap G of the article 500 are constructed such that the cover layer 520 is made of such a material and has such a thickness, and the gap G has such dimensions that when a bending force F is applied to the outer surface 524 of the cover layer 520 at the region above the gap G, as Figure 13B shown, the cover layer 520 bends slightly inward into the gap G, and when the force F is removed, the cover layer 520 bends back to its normal shape.

[0212] In addition to the above bending, the core member 510 has higher compressibility than the cover layer, and when a bending force F is applied to the outer surface 524 of the cover layer 520 at the region corresponding to the bumps 525, the region of the outer surface 512 of the core member 510 located below the bumps 525 is compressed, as Figure 13B shown, and returns to its original shape when the force is removed.

[0213] Although the bumps 525 are formed on the cover layer 520 rather than on the core member (as in the case of the article 100), the descriptions regarding the structure, dimensions, and positioning of the bumps according to different examples of the article 100 also apply to the bumps 525 and are not repeated here for the sake of brevity. In addition, in a manner similar to the description of the cover layer 120, while bending, the cover layer 520 maintains its thickness at the region where the bending force F is applied, and the inner surface and the outer surface of the cover layer 520 bend uniformly into the gap G

[0214] Thus, in the article 500, the suspension performance and the soft feeling are achieved by the bending of the covering layer and the compression of the core member in the area under the bumps. It should be understood here that the compressibility of the core member is higher than that of the covering layer, but still less than that of a normal elastic foam. More specifically, if a force is applied over a large area thereof, the core member is compressed significantly less, and the compressibility of the core member is located in the area under the bumps. The dimensions of the bumps and the spaced areas in the direction along the outer surface of the core member affect the compressibility of the core member. For example, the narrower the bumps, the higher the compressibility of the core member in the area under these bumps, and the farther the bumps are from each other, the higher the compressibility of the core member in the area under these bumps.

[0215] Figure 14A and 14B shows a cross-sectional view of a composite structure forming part of an article 600, which article 600 has all the components and features of the article 500 described above with reference to Figures 13A - 13B and also has snap-fit connection means.

[0216] More specifically, the article 600 has a core member 610 and a covering layer 620, both of which have the same basic construction as the corresponding covering layer and core member of the Figure 13A and 13B shown article 500, are made of the same materials (described at the end of this specification), and operate in the same manner. The core member 610 has an outer surface 612 in the direction towards the covering layer 620. The covering layer 620 has a plurality of bumps 625 that project from the inner surface 622 in the direction of the core member 610 and are spaced apart from each other by spaced areas 626 between any two adjacent bumps 625, such that when the covering layer is connected to the core member, the bumps 625 are placed on the outer surface 612 of the core member 610, and a plurality of voids G are formed between the spaced areas and the relevant areas of the core member located below the spaced areas.

[0217] The snap-fit connection means of the article 600 is the same in structure and operation as the snap-fit connection means of the Figure 9A and 9B described article 300. More specifically, the snap-fit connection means of the article 600 includes a plurality of recesses 618 and a plurality of protrusions 628, wherein the plurality of recesses 618 extend from its outer surface into the core member 610 in the area of the core member under part of the spaced areas 626, the plurality of protrusions 628 project from the inner surface 622 of the covering layer 620 in the areas corresponding to the spaced areas, and are configured to be lockingly received in the respective recesses 618. In other words, each pair of protrusions and recesses is associated with a gap G.

[0218] The engaging connection device of article 600 is a suspension-permitting connection device identical to that of article 300. For example, the sizes and configurations of recess 618 and protrusion 628 are such that when the cover layer is connected to the core member, in addition to the suspension provided by bending the cover layer at regions corresponding to the spacer regions and compressing the core member at regions corresponding to the bumps as described above with reference to article 500, when a bending force F is applied to the outer surface 624 of cover layer 620 at the region corresponding to protrusion 628, protrusion 628 moves within recess 618 as described above with reference to article 300, thereby providing suspension at the region corresponding to the connection device. Thus, while cover layer 620 is firmly attached to the core member, it bends inwardly toward core member 610 together with the protrusion at the region related to the protrusion, and when a tangential force is applied to these regions at least indirectly, cover layer 620 moves slightly in the tangential direction relative to the core member in the same manner as described above with reference to article 300.

[0219] Figure 15 A cross-sectional view of a composite structure forming part of an article 700 is shown, the article 700 having all of the components and features of article 500 described above Figure 13A and 13B and further having a plurality of bumps protruding from the core member.

[0220] More specifically, article 700 has a core member 710 and a cover layer 720, both having the same Figure 13A and 13BThe corresponding cover layer and core member of the article 500 shown have the same basic structure, are made of the same material (described at the end of this specification), and operate in the same manner. The core member 710 has an outer surface 712 facing the direction of the cover layer 720. The cover layer 720 has an inner surface 722 facing the core member 710 and has a plurality of bumps 725 that project in the direction of the core member 710 and are spaced apart from each other by an intervening region 726 between any two adjacent bumps 725. The core member 710 has a plurality of bumps 715 that project from the outer surface 712 of the core member 710 in the direction of the cover layer 720 and are spaced apart from each other by an intervening region 716 between any two adjacent bumps 715. In the example shown, the bumps 715 and 725 have dimensions in the direction extending from the core member to the cover layer such that when the cover layer 720 is connected to the core member 710, the inner surface 722 of the cover layer 720 is placed on the bumps 715 projecting from the core member 710, and the bumps 725 projecting from the cover layer 720 are placed on the outer surface 712 of the core member 710, and a plurality of gaps G are formed between the intervening region 726 and the associated region of the outer surface 712 of the core member 710 located below the intervening region 726 and between the intervening region 716 and the associated region of the inner surface 722 of the cover layer 720 located above the intervening region 716.

[0221] In some embodiments (not shown), the dimensions of the bumps 715 and 725 may be such that the cover layer 720 is placed on the bumps 715 and holds the space between the bumps 725 and the core member 710, or the bumps 725 are placed on the core member 710 and hold the space between the cover layer 720 and the bumps 715.

[0222] The bumps 715 and the bumps 725 may be uniformly or non-uniformly distributed in any pattern along the respective surfaces of the core member and the cover layer, or distributed in a pattern similar to that described above for the article 100, and such that none of the bumps 71 coincide with any of the bumps 725. In other words, each of the bumps 715 and 725 is arranged on the respective surfaces of the core member and the cover layer to be aligned with the intervening region between another bump.

[0223] Similarly as described above for the cover layer 520 and the gap G of the article 500, the cover layer 720 and the gap G of the article 700 are constructed such that the cover layer 720 is made of such a material and has such a thickness, and the gap G has such dimensions that when a bending force F is applied to the outer surface 724 of the cover layer 720 at a region above the gap G, the cover layer 720 bends slightly inward into the gap G, and when the force F is removed, the cover layer 720 bends back to its normal shape.

[0224] In addition to the above bending, the core member 710 has higher compressibility than the cover layer, and when a bending force F is applied to the region corresponding to the bump 725 on the outer surface 724 of the cover layer 720, the region of the outer surface 712 of the core member 710 located below the bump 725 is compressed and returns to its original shape when the force is removed.

[0225] In addition, the bump 715 protruding from the core member 710 is compressible, such that when a bending force F is applied to the outer surface 724 of the cover layer 720 at the region corresponding to the bump 715, the bump 715 is elastically compressed by the force.

[0226] Accordingly, in the article 700, suspension performance and a soft feel are achieved by bending of the cover layer, compression of the core member at the region below the bump 725, and compression of the bump 715. It should be understood here that the compressibility of the core member and / or the bump 715 is higher than that of the cover layer, but still less than the compressibility typically possessed by an elastic foam.

[0227] It should be understood here that the descriptions regarding the structure, dimensions, and positioning of the bumps according to different examples of the article 100 also apply to the bumps 715 and 725, and are not repeated here for the sake of brevity. In addition, in a manner similar to the description of the cover layer 120, while bending, the cover layer 720 maintains its thickness in the region where the bending force F is applied, and the inner and outer surfaces of the cover layer 720 are uniformly bent into the gap G.

[0228] Figure 16 A cross-sectional view of a composite structure forming part of an article 800 is shown, the article 800 having all of the components and features of the article 700 described above with reference to Figure 15 and further having snap-fit connection means.

[0229] More specifically, the article 800 has a core member 810 and a cover layer 820, both of which have the same basic construction as the corresponding cover layer and core member of the Figure 15 article 700 shown, are made of the same material (described at the end of this specification), and operate in the same manner. The core member 810 has an outer surface 812 facing the direction of the cover layer 820, and has a plurality of bumps 815 that protrude from the core member 810 and are spaced apart from each other by a spacer region 816. The cover layer 820 has an inner surface facing the direction of the core member 810, and has a plurality of bumps 825 that protrude from the core member 810 and are spaced apart from each other by a spacer region 826. When the cover layer is connected to the core member, the bumps 825 are placed on the outer surface 812 of the core member 810, and the inner surface of the cover layer is placed on the bumps 815.

[0230] The snap - fit connection device of the article 800 is identical in structure and operation to the snap - fit connection device of the article 300 with reference to the above Figure 9A and 9B The snap - fit connection device of the article 800 includes a plurality of recesses 818 and a plurality of protrusions 828. More specifically, the plurality of recesses 818 extend inward from the outer surface of the core member into the core member 810 at regions corresponding to some of the spaced - apart regions 816, and the plurality of protrusions 828 project from the inner surface 822 of the cover layer 820 at regions corresponding to some of the spaced - apart regions 826 and are configured to be lockingly received in the respective recesses 818.

[0231] The snap - fit connection device of the article 800 is a suspension - allowing connection device identical to the snap - fit connection devices of the articles 300 and 600. For example, the sizes and configurations of the recesses 818 and the protrusions 828 are such that when the cover layer is connected to the core member, when a bending force F is applied to the outer surface 824 of the cover layer 820 at a region corresponding to the protrusion 828, the protrusion 828 moves within the recess 818 as described above with reference to the article 300, thereby providing suspension at the region corresponding to the connection device. In addition to the suspension provided by bending the cover layer at regions that do not correspond to either the bump 815 or the bump 825, suspension is also provided by compressing the core member at a region corresponding to the bump 825 and by compressing the bump 815 as described above with reference to the article 700.

[0232] Although the above - mentioned articles 500, 600, 700, and 800 do not have an elastic layer portion in the respective spaced - apart regions, it should be understood here that any and / or all of these articles may further include an elastic layer portion located in the respective spaced - apart regions or an elastic layer disposed between the core member and the cover layer. The elastic layer (if any) has holes corresponding to the bumps and the connection device. The structure and operation of such an elastic layer or elastic layer portion may be the same as any of the above - mentioned elastic layers or elastic layer portions.

[0233] In all of the above examples, the protrusions and the recesses may be uniformly distributed relative to the inner surface of the cover layer and the outer surface of the core member, respectively. Alternatively, they may be arranged in a predetermined order. For example, more such connecting members are provided at positions near the periphery, or the center, or any other desired region of the article. Additionally, when one or both of the inner surface of the cover layer and the outer surface of the core member have bumps, the connecting members of the protrusions and the recesses may be arranged such that there are a plurality of such bumps between every two connecting members.

[0234] An article according to any aspect of the subject matter of the present disclosure may have the above - mentioned as Figures 9A - 12The snap - fit connection device shown in the figure or any other snap - fit connection device has other configurations and proportions. For example, the convex and concave portions may have a cross - sectional shape different from circular, for example, it may be oval, polygonal, etc. In addition, a quick mechanical connection similar to or different from the above snap - fit can be used with lockable protrusions configured to be received and locked in corresponding locking grooves in any suitable manner.

[0235] In all of the above examples, it is possible that the convex and concave portions of the connection device are formed integrally with the cover layer and the core member, respectively, because they are both rigid, i.e., configured to maintain their manufactured shape. Thus, an article having such a connection device according to any aspect of the subject matter of the present disclosure does not require any additional means for directly or via an elastic layer connecting its cover layer to the core member. Optionally, one or both of the convex and concave portions of the connection device used in an article according to the subject matter of the present disclosure can be manufactured separately and then assembled with one or both of the cover layer and the core member.

[0236] In the composite structures of all of the above embodiments, all components can be made of materials that can be recycled, including heat treatment, without separation between the components. For example, the materials of at least the core member and the cover layer with its connecting elements may include the same basic thermoplastic substance or different basic thermoplastic substances, which can be melted at the same recycling temperature, where the / each basic substance is optionally the only substance in the material that melts at that temperature. Since these materials can account for more than 90% of the total weight of the composite structure, optionally more than 93%, for example at least 95%, the structure can be recycled without separation even if the remaining materials in the structure are not meltable at the above temperature.

[0237] The above - mentioned basic substances in the materials of the core member and the cover layer can be thermoplastic polymers of the same polymer family, such as the polypropylene family, which may have different material forms at least in the core member and the cover layer, such that the core member and the cover layer have the physical properties required for their intended functions in the structure.

[0238] For example, a core layer that needs to be the thickest component in the structure can have a lower bulk density than the covering layer, which must be very thin in order to bend under the action of bending forces as described in the above embodiments, but the covering layer is still rigid to maintain its shape and the shape of its connecting elements. In particular, the core member can be made of foamed particle foam, and the covering layer with connecting elements can be made of a more compact material suitable for injection molding and the like. In this case, the core member can be formed into the desired shape by particle-foam molding, and the covering layer can be made by injection molding or compression molding, thermoforming, extrusion, vacuum forming or other techniques to allow the covering layer and the connecting elements to maintain their fabricated shapes.

[0239] The elastic layer (if any) can have a weight that can constitute a small part, such as 5% or less, of the weight of the entire composite structure. Thus, even if the elastic layer is made of a material that is not meltable at the above-mentioned recycling temperature, the elastic layer can be recycled together with the other components of the composite structure without separating them.

[0240] In a specific example, where the thermoplastic polymer substance is polypropylene, when it is used to produce the foamed particle foam core member or the elastic foam layer (if any), such a core member and such an elastic layer can each have a bulk density of 0.03 - 0.12 kg / l; when it is used to manufacture the covering layer with connecting elements, such a covering layer can have a density of 0.85 - 0.95 kg / l, more specifically, 0.91 kg / l.

[0241] The following are examples of all the above materials based on polypropylene, which can be used in the various composite structures described above:

[0242]

[0243] Although in all examples of the above composite structures, their components are connected to each other by means that do not contain any adhesives, if necessary, an adhesive can be used between the covering layer and the core member or between one or both of the covering layer and the core member and the elastic layer (if any), for example, if such an adhesive is made of a material containing the same basic substance as the other components of the article, such as polypropylene.

Claims

1. A composite structure with suspension performance, characterized in that, The composite structure comprises: a rigid core member having an outer surface; a recoverable volume layer associated with the outer surface of the core member and having recoverable volume in at least a plurality of its regions; a rigid cover layer having an outer surface and an inner surface and fixedly connected to the core member through connecting means, wherein a combination of the material forming the cover layer, the thickness of the cover layer, and the dimensions of the recoverable volume is such that when a bending force is applied to a region of the cover layer located above the recoverable volume, the region bends into the recoverable volume while maintaining the thickness of the cover layer at the region and then bends back, thereby providing suspension performance similar to that of elastic foam without using foam as the cover layer; wherein the compressibility of the core member is higher than that of the cover layer, and the flexural modulus of the core member is lower than that of the cover layer.

2. The composite structure according to claim 1, wherein The connecting means comprises a plurality of connecting elements associated with at least some of the regions of the cover layer, and in the case where the regions are associated with the connecting elements, when the bending force is applied at the regions of the cover layer, the connecting means firmly engages the corresponding connecting elements of the core member while freely moving within the core member in the thickness direction of the core member.

3. The composite structure according to claim 2, wherein The connecting elements are in the form of lockable protrusions projecting from the cover layer towards the core member and lockingly received in corresponding locking recesses in the core member.

4. The composite structure according to claim 3, wherein The lockable protrusions are at least partially integrally formed with the cover layer.

5. The composite structure according to any one of claims 1 to 4, characterized in that At least the core member and the cover layer are made of materials comprising the same basic substance in different forms, the basic substance being meltable at a melting temperature.

6. The composite structure according to any one of claims 1 to 4, characterized in that At least the core member and the cover layer are made of materials comprising different basic substances that are meltable at the same melting temperature.

7. The composite structure according to claim 5, characterized in that, The materials in the composite structure constitute at least 90% of the total weight of the structure.

8. The composite structure according to claim 5, characterized in that, The basic substance is a thermoplastic polymer.

9. The composite structure according to claim 8, characterized in that, The material of the core member is in the form of foamed particulate foam.

10. The composite structure according to claim 1, wherein The cover layer is made of a dense continuous material and has a bulk density much greater than that of the core member.

11. The composite structure according to claim 10, wherein, The cover layer is an injection-molded body.

12. The composite structure according to claim 8, wherein The basic substance is polypropylene.

13. The composite structure according to claim 1, wherein, The connecting means comprises a plurality of recesses in the core member and a corresponding plurality of protrusions projecting from the cover layer and configured to be received within the recesses, thereby firmly connecting the core member to the cover layer.

14. The composite structure according to claim 1, wherein The connecting means is a quick-connecting means.

15. The composite structure according to claim 14, wherein The quick-connecting means is a snap-fit means.

16. The composite structure according to claim 13, wherein The protrusions are at least partially integrally formed with the cover layer.

17. The composite structure according to claim 5, characterized in that, Each of the basic substances is the only substance in the corresponding material that melts at the temperature.

18. The composite structure according to claim 6, characterized in that, Each of the basic substances is the only substance in the corresponding material that melts at the temperature.

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