Hybrid structure with suspension properties

Abstract

A hybrid structure having suspension properties, comprising: a core member having an outer surface; a reducible volume layer associated with the outer surface of the core member and having a reducible volume in at least some regions thereof; and a cover layer having an outer surface and an inner surface and connected to the core member via a reducible laminate by a connecting device. The reducible volume can be formed by air gaps spaced apart from one another, or by portions of such gaps and an elastic foam layer contained within the air gaps, or by an elastic foam layer sandwiched between the outer surface of the core member and the cover layer, forming a plurality of such regions without any spaces between them. The cover layer is made of a material and has a thickness such that, when a bending force is applied to the region covering the reducible volume, the region can deflect into the reducible volume while maintaining a thickness between the inner and outer surfaces of the cover layer in the region, and can return to its original state when the bending force is released, thereby providing suspension properties to the hybrid structure.

Description

Technical Field

[0001] Articles or products having suspension characteristics / properties for improving the comfortable softness of a user are well known. Such articles include a bicycle seat, an electric vehicle seat, a component of a chair, a sofa, and an automotive interior part that suspends or collapses when a force is applied thereto.

[0002] Conventionally, these articles are formed of different materials and often include a compressible elastomeric foam layer to provide suspension properties, are covered by an outer fabric layer, and are joined by an adhesive, or by heat treatment, or by sewing. One or more of the plurality of layers can absorb energy and reduce the impact on the user when the user applies a force to the article.

[0003] The materials used as layers of the above articles are often thermosetting and non-recyclable, continuously increasing environmental waste. Examples of such materials include polyurethane (PU), polyvinyl chloride (PVC), or ethylene-vinyl acetate (EVA).

[0004] CN107826186A relates to a bicycle seat cushion configured to be mounted on a tapered end of a bicycle seat to provide enhanced heat dissipation. The bicycle seat cushion includes a flexible cushion plate covered by a cloth layer, and the flexible plate has a plurality of protrusions that contact the surface of the bicycle seat and separate the flexible cushion plate from the bicycle seat. A ventilation gap is formed between all the protrusions to increase the heat dissipation area and accelerate the heat dissipation of the flexible cushion plate.

[0005] US2019 / 291802 relates to a motorcycle saddle, comprising a foam material layer and a surface layer arranged on the saddle, the surface layer being placed on top of and covering the foam material layer, and multiple spaced through-holes formed in the foam material layer. A biogel layer is formed on the underside of the foam material layer. Multiple biogel blocks are filled into each of the through-holes in the foam material layer. Each biogel block has a top end that contacts the underside of the surface layer and a bottom end that is integrally connected to the biogel layer. The biogel layer provides the rider with a comfortable riding experience and also achieves antibacterial effects. [Overview of the project] [Means for solving the problem]

[0006] According to one aspect of the subject matter of the present disclosure, a hybrid structure is provided which can be formed from or constitute part of the above-described type of article, the hybrid structure comprising a thin rigid coating layer connected to a thick rigid core member, and which provides the structure with suspension properties through a layer of decreaseable volume between them when a bending force is applied to the coating layer.

[0007] The hybrid structure may comprise a core member having an outer surface, a coating layer connected to the core member and having an outer and inner surface, and a layer of reduceable volume in at least several regions between the outer surface of the core member and the inner surface of the coating layer, wherein the combination of the material from which the coating layer is made, the thickness of the coating layer, and the dimensions of the reduceable volume causes, when a bending force is applied to the region of the coating layer covering the reduceable volume, the region to flex into the reduceable volume while maintaining the thickness of the coating layer in that region, and then return to its original state, thereby providing suspension properties similar to those of an elastic foam without using such foam as a coating layer.

[0008] Accordingly, in this description and claims, unless otherwise specifically indicated, the terms “force” or “flexion force” mean a force that provides suspension properties and is at least partially directed along the thickness direction of the coating layer and structure, i.e., a direction perpendicular to the outer surface of the coating layer; the term “rigidity” as used with respect to a component or material means being substantially rigider than an elastic foam so as to maintain its shape as generated and be incompressible under the above force (e.g., as in the coating layer) or substantially less compressible under the force (e.g., as in the core member); the term “thin” with respect to a coating layer means that the thickness of the layer is thin enough to allow it to flex as described above; the term “thick” with respect to a core member means that the thickness of the member is substantially greater than the thickness of the coating layer and thick enough to reliably hold the coating layer on it by a connecting device.

[0009] The coating layer is fixedly and flexibly connected to the core member, where in this description and the claims, “fixed” means that the connection is permanent, i.e., the coating layer cannot be easily detached from the core member, and “flexible” means that the connection allows the coating layer to bend as described above.

[0010] The volume-reducible layer can be formed by an air gap formed between spaced core members and a coating layer, for example by bumps on the outer surface of the core members and / or the inner surface of the coating layer, or by such gap and the elastic foam layer portion contained within the gap, or by an elastic layer without such gap sandwiched between the coating layer and the outer surface of the core members. If an elastic layer is used, whether or not there is an air gap, it is configured to be elastically compressed by that region of the coating layer in response to the bending force applied thereto.

[0011] The connection between the core member and the coating layer via a layer of reducible volume can be provided by a suspension-enabled connecting device comprising a plurality of connecting elements associated with the coating layer that engage with corresponding connecting elements of the core member, thereby allowing free movement inward of the core member, together with the corresponding connecting elements of the core member having this volume above, when the bending force is applied to the region of the coating layer associated with the connecting elements and having a reducible volume below.

[0012] The connecting device enabling the suspension can be a quick-connecting mating device. For example, the connecting element can be in the form of a lockable projection protruding from the inner surface of the coating layer, and the core member can be provided with a corresponding locking recess that receives the projection, for example by a snap-fitting device. Each lockable projection can be associated with a region of the coating layer having a reduced volume below it, and it can lock-engage with a region of the core member having this volume above it. The lockable projections can be located in several regions of the coating layer that are received by the corresponding locking recesses of the core member. This arrangement can be such as to allow each projection to move inward into the corresponding recess having a corresponding depth when the associated region of the coating layer flexes into the reduced volume disposed below it. In this case, the thickness of the core member must be thick enough to accommodate the locking recess having the aforementioned depth.

[0013] Therefore, in the described hybrid structure, the suspension properties achieved by the combination of parameters of the coating layer and the layer of reduceable volume on the core member are further enhanced by the connecting device that enables the suspension.

[0014] The parameters of the coating layer and the reduceable volume layer include the thickness and material of the coating layer and the thickness of the reduceable volume layer, and when this layer comprises regions of reduceable volume spaced apart from each other, the entire geometry of such regions is selected to allow the region of the coating layer covering the region of reduceable volume to flex into the region and return to its original state, like a film supported by adjacent, non-flexed regions of the coating layer, i.e., a region where no force is applied.

[0015] If the above-mentioned regions are in the form of air gaps between core members separated from each other by bumps on the outer surface of the core members or the inner surface of the coating layer, for example, the above parameters include the arrangement and dimensions of the gaps defined by the dimensions of the bumps and the spatial regions between them, which are selected to allow the region of the coating layer covering the spatial region to flex into the corresponding gap and return to its original state, like a membrane supported by adjacent, non-flexible regions of the coating layer. With respect to the parameters of the bumps and spatial regions, at least the majority of the spatial region between the bumps can essentially have a length exceeding the maximum dimension of the bumps along the outer surface of the core members. The bumps can have a height that is lower than, and at least greater than, the distance between them, and optionally higher than the thickness of the coating layer. The bumps can be arranged in a pattern that follows the distribution of suspension properties along the coating layer that needs to be achieved.

[0016] When a core member is formed on its outer surface with bumps, the coating may have a thickness that does not exceed the height of the bumps defining the depth of the gap. The core member may have a thickness that is at least greater than the thickness of the coating layer when measured through the bumps. The thickness of the core member can be essentially greater than the thickness of the coating layer.

[0017] When the coating layer is formed on its inner surface together with the bumps, the height of the bumps defines the height of the gap, and the coating layer can have a thickness thinner than the height of the bumps in the region between the bumps.

[0018] When a core member or coating layer is formed with bumps, the structure may further comprise an elastic layer formed with holes corresponding to the bumps and configured to be positioned between the coating layer and the core member such that the bumps protrude from the holes toward the coating layer, the coating layer resting on at least some of the bumps and allowing to flex toward or inward toward the elastic layer in the region corresponding to the gap in response to the application of force. In this case, if the elastic layer is in the form of a layer of reduceable volume that does not contain any gaps between the regions of its reduceable volume, the thickness of the elastic layer / part may exceed the thickness of the coating layer, or at least be less than its thickness.

[0019] When the elastic layer or elastic layer portion constitutes a layer with a volume that can be reduced, the connecting device that enables the above-mentioned suspension connects the covering layer to the core member both fixedly and flexibly via the elastic layer.

[0020] To reduce the weight of the structure, the core members can be more compact than the coating layers, i.e., have a lower bulk density, yet still be rigid enough to maintain the shape and connections of their connecting elements during use. In addition, the material of the core members can have higher compressibility than the material of the coating layers. In this case, if the outer surface of the core member is formed with the bumps, the bumps may be compressed when a bending force is applied to the coating layer in the area covering the bumps, and if the inner surface of the coating layer is formed with the bumps, the area of ​​the outer surface of the core member below the rear bump may be compressed by the bending force when a bending force is applied to the corresponding area of ​​the coating layer above the bumps.

[0021] The suspension-enabling connecting device can connect the coating layer to the core member via a layer of volume that can be reduced by a snap-fit ​​device, and may comprise a male portion that protrudes from the inner surface of the coating layer away from its outer surface and constitutes the aforementioned lockable projection, and a female portion within the core member that is open toward the coating layer and constitutes the aforementioned lockable recess and is configured to lockably receive the male portion / lockable element passing through the elastic layer.

[0022] In any embodiment of the hybrid structure, the fact that the covering layer and core members are not made of elastic foam material, due to the suspension properties provided to the structure, offers several advantages, including, but not limited to, the ability to easily maintain the covering layer, such as cleaning, and the ability to connect the covering layer to the core members by mechanical connections, thereby avoiding the need to use adhesives, stitching, etc. Furthermore, the rigidity of the covering layer allows it to be connected to the core members by simple quick-connect fitting devices, facilitating the simple and cost-effective assembly of the hybrid structure.

[0023] A further advantage of the hybrid structure described above is that all or at least most of its components and connecting elements can be made from materials that allow for their recycling, including heat treatment, without separating the core member and the layers. This constitutes another aspect of the subject matter of the present disclosure in which the hybrid structure comprises multiple components connected to each other solely by mechanical means, such as the connecting device described above, and the materials from which the components and connecting elements are made can allow for their recycling, including heat treatment, without separation. For example, at least the core member and the coating layer material can be made from the same thermoplastic base material or different thermoplastic base materials that can melt at the same recycling temperature, wherein each base material is optionally the only substance in the material that melts at that temperature.

[0024] The basic material in the components of the hybrid structure described above can be a thermoplastic polymer of the same polymer group, such as polypropylene, which has different material forms in different components of the hybrid structure. Such components can have a total weight that constitutes more than 90%, optionally more than 93%, or at least 95%, of the total weight of the hybrid structure. For example, the material of at least one of the thickest components of the structure can be in the form of an expanded particle foam, and the material of at least one other component, including connecting elements, can be a compressed continuous material having a much higher bulk density than the core member. For example, in a hybrid structure having a core member, a coating layer, and a connecting device as described above, the core member having the maximum thickness can be made of an expanded particle foam, and the coating layer and its connecting elements are made of a compressed material having a higher bulk density than the core member. In this case, the core member can be formed by particle foam molding into the desired shape, and the coating layer can be manufactured by injection molding or compression molding, thermoforming, extrusion, vacuum forming, or other techniques, allowing the coating layer and connecting elements to be maintained in their as-generated shape.

[0025] If present, the elastic layer can have a weight that constitutes a small portion of the overall weight of the hybrid structure, and therefore, even if it is made of a material that cannot be melted at temperatures above the recycling temperature, it can be recycled together with the other components of the hybrid structure without being separated from it.

[0026] In this application and claims, “recycling without separation” with respect to hybrid structures should be noted as generally meaning conventional plastic recycling processes, which include grinding / crushing the entire hybrid structure into smaller parts / pieces, heating them to melt the molten material therein, and then using a mixture of the molten material and any non-molten material suspended therein for any preferred purpose.

[0027] In all of the above examples, the components of the connecting device referred to above as the connecting elements and the connecting member, or the locking projections and the locking recesses, or the male part and the female part, can be formed as a single body with the coating layer and the core member, or can be manufactured separately and then assembled together with one or both of the coating layer and the core member. <0> <0>

[0028] <0> The following are exemplary embodiments that a hybrid structure according to the subject matter of the present disclosure may have. <0> Embodiment 1. A hybrid structure comprising at least <0> a core member having an outer surface, <0> a coating layer made of a thermoplastic polymer having a flexural modulus substantially higher than that of the core member, the coating layer having an outer surface and an inner surface and being formed with at least an inner surface having substantially the same shape as at least a portion of the outer surface of the core member, <0> a plurality of bumps protruding at least partially along at least one of the outer surface of the core member and the inner surface of the coating layer, the plurality of bumps defining a plurality of gaps between the inner surface of the coating layer and the space region of the core member, <0> and a quick-connect fitting device for connecting the core member and the coating layer to each other. <0> A hybrid structure, wherein the coating layer and the gaps are configured such that upon application of a flexural force on the outer surface of the coating layer in the region corresponding to the gaps, the region deflects inwardly into the gaps and returns to its original state when the force is removed, thereby providing a structure having suspension properties such as an elastic foam. <0> Embodiment 2. The structure according to Embodiment 1, wherein the flexural modulus of the thermoplastic polymer is from 110 to 1800 MPa. <0> Embodiment 3. The structure according to Embodiment 1 or 2, wherein the core member has a thickness greater than the thickness of the coating member. <0> Embodiment 4. The structure according to Embodiment 3, wherein the thickness of the coating layer is from 0.5 to 3.5 mm. <0> Embodiment 5. The structure according to any one of Embodiments 1 to 4, wherein the quick-connect fitting device is in the form of a snap-fit device. <0> Embodiment 6. The structure according to Embodiment 5, wherein the quick-connect mating device comprises a plurality of female portions within a core member and a plurality of corresponding male portions that protrude from the coating layer and are received within the female portions, thereby ensuring that the core member is securely connected to the coating layer. Embodiment 7. The structure according to Embodiment 6, wherein the coating layer is formed as a single unit with the male portion. Embodiment 8. The structure according to any one of claims 1 to 11, wherein the coating layer comprises at least two separate coating layer components, at least before the assembly of the structure, wherein at least a portion of the outer periphery of the first portion and at least a portion of the outer periphery of the second portion are connected to each other and to the core member by connecting members. Embodiment 9. The structure according to Embodiment 8, wherein the connecting member is configured to facilitate the joining of one or more external elements by the assembly of the core member and the covering layer. Embodiment 10. The structure according to any one of Embodiments 1 to 9, further comprising an elastic layer formed with holes corresponding to bumps and positioned between the coating layer and the core member such that the bumps protrude from the holes, wherein the coating layer flexes inward into the elastic layer in the gap in response to the application of the force, thereby compressing the elastic layer in the region corresponding to the gap. Embodiment 11. The structure according to any one of Embodiments 1 to 10, wherein at least a large portion of the spatial region between the bumps has a length that is essentially greater than the thickness of the coating layer. Embodiment 12. The structure according to any one of Embodiments 1 to 11, wherein the thickness of the coating layer is thinner than the height of the bump. Embodiment 13. The structure according to any one of Embodiments 1 to 12, wherein a bump adjacent to the location where the coating layer is fixed to the core member has a maximum dimension along the outer surface that is longer than the maximum dimension of the bump further away from that location. Embodiment 14. The structure according to any one of embodiments 1 to 13, wherein at least a large portion of the bumps are uniformly arranged along at least a large portion of the outer surface covered by the core member. Embodiment 15. A hybrid structure comprising at least, A core member having an outer surface, A coating layer made of a thermoplastic polymer having a flexural modulus substantially higher than that of the core member, having an outer surface and an inner surface, and being produced together with at least the inner surface having the same shape as at least a portion of the outer surface of the core member, A quick-connection fitting device for connecting the core member and the coating layer to each other, It comprises an elastic layer between the coating layer and the core member, A hybrid structure in which the coating layer is configured such that, in response to the application of a bending force in the region of the coating layer, this region flexes inward into the elastic layer, and returns to its original state when the force is removed, thereby providing the structure with suspension properties and enabling the structure to behave like an elastic foam without using such foam as a coating layer. Embodiment 16. The structure according to Embodiment 15, wherein the elastic layer is made of an elastic foam material. Embodiment 17. The structure according to Embodiment 15 or 16, wherein the flexural modulus of the thermoplastic polymer is 110 to 1800 MPa. Embodiment 18. The structure according to Embodiment 17, wherein the thickness of the coating layer is 0.5 to 3.5 mm. Embodiment 19. The structure according to any one of Embodiments 15 to 18, wherein the quick connection mating device is in the form of a snap-fastening mating device. Embodiment 20. The structure according to Embodiment 19, wherein the quick-connect mating device comprises a plurality of female portions within a core member and a plurality of corresponding male portions that protrude from the coating layer and are received within the female portions, thereby ensuring that the core member is securely connected to the coating layer. Embodiment 21. The structure according to Embodiment 20, wherein the coating layer is formed as a single unit with the male portion. Embodiment 22. The structure according to any one of Embodiments 1 to 21, wherein the core member, the coating layer, and the elastic layer, if any, are made of a material that allows for recycling without separation. Embodiment 23. A structure according to any one of Embodiments 1 to 22, wherein the material from which the core member and the coating layer are made contains the same basic substance but the material form is different. Embodiment 24. The structure according to Embodiment 23, which is directly or indirectly dependent on Embodiment 10 or 15, wherein the elastic layer contains the same basic material as the core member and the coating layer, but differs from them in material form. Embodiment 25. The structure according to any one of Embodiments 1 to 24, wherein the coating layer maintains its thickness when it bends in response to the application of the bending force. Embodiment 26. The structure according to any one of Embodiments 1 to 25, wherein the material from which the core member is made is an expanded particle foam. Embodiment 27. The structure according to any one of Embodiments 1 to 26, wherein the coating layer has a bulk density higher than that of the core member. Embodiment 28. A structure according to any one of Embodiments 1 to 27, wherein the material from which the core member and the coating layer are made includes polypropylene. Embodiment 29. The structure according to Embodiment 28, wherein the material from which the elastic layer is made, if any, includes polypropylene. Embodiment 30. The structure according to any one of Embodiments 1 to 29, wherein at least one of the core member and the coating layer has a curved shape on at least one of its surfaces. Embodiment 31. A hybrid structure, A core member having an outer surface, A coating layer having an outer surface and an inner surface, and formed together with at least the inner surface having the same shape as at least a portion of the outer surface of the core member, A plurality of bumps projecting from at least one of the outer surface of the core member and the inner surface of the coating layer, along at least a portion thereof, with spacing between the plurality of bumps, The coating layer is fixedly attached to the core member and configured to create multiple gaps between the inner surface of the coating layer and the outer surface of the core member, and the gaps are defined by the intervals between them. A hybrid structure in which the coating layer and the gap are configured such that, in response to the application of force to the outer surface of the coating layer in the region corresponding to the gap, the region flexes inward into the gap, and returns to its original state when the force is removed. Embodiment 32. The hybrid 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 fitting device, such as a snap fitting. Embodiment 33. A hybrid structure, A core member having an outer surface, A coating layer having an outer surface and an inner surface, and formed together with at least the inner surface having the same shape as at least a portion of the outer surface of the core member, A plurality of bumps projecting from at least one of the outer surface of the core member and the inner surface of the coating layer, along at least a portion thereof, with spacing between the plurality of bumps defining a plurality of gaps between the inner surface of the coating layer and the outer surface of the core member, It comprises a quick-connection fitting device for connecting the core member and the coating layer to each other, A hybrid structure in which a coating layer and a gap are configured such that, in response to the application of a bending force on the outer surface of the coating layer in the region corresponding to the gap, the region flexes inward into the gap, and returns to its original state when the force is removed, thereby providing a structure having suspension properties similar to those of an elastic foam. Embodiment 34. A hybrid structure according to any one of Embodiments 31, 32, or 33, wherein at least a large portion of the space between bumps essentially has a length exceeding the maximum dimension of the bumps along the outer surface of the core member. Embodiment 35. A hybrid structure according to any one of Embodiments 31 to 34, wherein the bumps are lower than the distance between them and optionally have a height greater than or equal to at least the thickness of the coating layer. Embodiment 36. A hybrid structure according to any one of Embodiments 31 to 35, wherein the coating layer has a thickness less than or equal to the height of the bump. Embodiment 37. A hybrid structure according to any one of embodiments 32 to 36, wherein a quick-connect mating device configured to fixally connect the coating layer to a core member comprises a male portion protruding from the inner surface of the coating layer away from its outer surface, and a female portion in the core member that is open toward the coating layer and configured to lock in and receive the male portion therein. Embodiment 38. The hybrid structure according to Embodiment 37, wherein the male portion is formed as a single unit with the covering member. Embodiment 39. A hybrid structure according to any one of Embodiments 36, 37, or 38, wherein the male portion is located in some of the regions of a covering layer that covers a spatial region, and the female portion is located within the corresponding spatial region. Embodiment 40. A hybrid structure according to any one of embodiments 30 to 39, further comprising an elastic layer formed with holes corresponding to bumps and configured to be positioned between the coating layer and the core member such that the bumps protrude from the holes, thereby allowing the coating layer to flex inward toward or into the elastic layer in the region corresponding to the gap in response to the application of the force. Embodiment 41. A hybrid structure according to any one of Embodiments 30 to 40, wherein the core member, the coating layer, and the elastic layer, if any, are made of a material that allows for recycling without separation. Embodiment 42. A hybrid structure having suspension properties, A core member having an outer surface, A coating layer having an outer surface and an inner surface, wherein the coating layer is produced together with at least an inner surface having the same shape as at least a portion of the outer surface of the core member, and is configured to be fixedly attached to the core member, It comprises an elastic layer between the coating layer and the core member, which is optionally made of foamed material, A hybrid structure in which the coating layer is configured to provide a suspension property such that, in response to the application of force in a region of the coating layer, this region flexes inward into the elastic layer and returns to its original state when the force is removed. Embodiment 43. The hybrid structure according to Embodiment 42, wherein the core member and the covering layer are configured to be fixedly connected to each other via an elastic layer by a quick connection fitting device, such as a snap fitting. Embodiment 44. A hybrid structure, A core member having an outer surface, A coating layer having an outer surface and an inner surface, and formed together with at least the inner surface having the same shape as at least a portion of the outer surface of the core member, A quick-connection fitting device for connecting the core member and the coating layer to each other, It comprises an elastic layer between the coating layer and the core member, A hybrid structure in which the coating layer is configured such that, in response to the application of a bending force in the region of the coating layer, this region flexes inward into the elastic layer, and returns to its original state when the force is removed, thereby providing the structure with suspension properties and enabling the structure to behave like an elastic foam without using such foam as a coating layer. Embodiment 45. The hybrid structure according to any one of Embodiments 42, 43, and 44, wherein the coating layer has a thickness not exceeding the thickness of the elastic layer. Embodiment 46. A hybrid structure according to any one of Embodiments 42 to 45, wherein the core member has a thickness greater than the thickness of the coating layer. Embodiment 47. A hybrid 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 that of the coating layer. Embodiment 48. A hybrid structure according to any one of embodiments 43 to 47, wherein a quick-connect fitting device configured to fixally connect a coating layer to a core member via an elastic layer comprises a male portion that protrudes from the inner surface of the coating layer away from its outer surface and a female portion formed within the core member and opening toward the coating layer. Embodiment 49. The hybrid structure according to Embodiment 48, wherein the male portion is formed as a single unit with the covering member. Embodiment 50. A hybrid structure according to any one of Embodiments 47, 48, or 49, wherein the male portion is located in some of the areas of the coating layer and the female portion is formed in corresponding locations on the outer surface of the core member. Embodiment 51. A hybrid structure according to any one of Embodiments 41 to 50, wherein the core member, coating layer, and elastic layer are made of materials that allow for recycling without separation. Embodiment 52. A hybrid structure comprising: a core member having an outer surface and shape determined by the intended use of the hybrid structure; a layer of reduceable volume associated with the outer surface of the core member and having a reduceable volume in at least some of its regions; and a covering layer fixedly connected to the core member, wherein the combination of the material from which the covering layer is made, the thickness of the covering layer, and the dimensions of the reduceable volume causes, when a bending force is applied to a region of the covering layer covering the reduceable volume, the region to flex into the reduceable volume while maintaining the thickness of the covering layer in that region, and then return to its original state, thereby providing suspension properties similar to those of an elastic foam without using such foam as a covering layer. Embodiment 53. A layer of volume that can be reduced, - Air gaps formed within the core member and spaced apart from each other, optionally, elastic foam layer portions housed within the gaps, or - A hybrid structure according to embodiment 52, comprising one of the elastic layers disposed beneath the coating layer. Embodiment 54. The hybrid structure according to Embodiment 52 or 53, further comprising a rapid connection mating device including a plurality of lockable projections protruding from the inner surface of the coating layer and a plurality of corresponding locking recesses in a core member, each configured to lockably receive a corresponding lockable projection therein. Embodiment 55. The hybrid structure according to claim 54, wherein each lockable projection is formed in a region of the coating layer having a volume that can be reduced downward, and a corresponding locking recess is formed so as to have this volume above it. Embodiment 56. The hybrid structure according to Embodiment 54 or 55, wherein the lockable projection and lockable recess have longitudinal dimensions such that the former moves inward into the latter when the associated region of the coating layer flexes into a reductionable volume disposed beneath it. Embodiment 57. A hybrid structure according to any one of Embodiments 54, 55, or 56, wherein a lockable projection is formed as a single unit with the covering member. Embodiment 58. A hybrid structure according to any one of embodiments 54 to 57, wherein lockable projections are located in some of the areas of the coating layer, and lockable recesses are formed in corresponding locations on the outer surface of the core member. Embodiment 59. A hybrid structure according to any one of Embodiments 31 to 58, wherein the materials from which the core member and the coating layer are made contain the same basic substance, but the morphology and / or physical properties of the materials differ, and if the structure includes an elastic layer between the coating layer and the core member, the elastic layer is also made of a material containing the basic substance. Embodiment 60. The hybrid structure according to Embodiment 59, wherein the material is a thermoplastic polymer material. Embodiment 61. The hybrid structure according to Embodiment 60, wherein the material of the core member is in the form of an expanded particle foam. Embodiment 62. The hybrid structure according to Embodiment 61, wherein the coating layer has a higher bulk density than the core member. Embodiment 63. The hybrid structure according to any one of Embodiments 59 to 62, wherein the base material is polypropylene. Embodiment 63. A hybrid structure comprising a core member, a covering member fixedly connected thereto so as to be able to flex into or toward the core member, and optionally, an elastic layer between them below at least a portion of the covering layer, wherein the material from which the core member, the covering layer, and the elastic layer, if any, are made comprises the same basic material but differs in shape, enabling the structure to be recycled without separating the covering layer and the elastic layer, if any, from the core member. Embodiment 64. The hybrid structure according to Embodiment 63, wherein the material is a thermoplastic polymer material. Embodiment 65. The hybrid structure according to Embodiment 64, wherein the material of the core member is in the form of an expanded particle foam. Embodiment 66. The hybrid structure according to Embodiment 64 or 65, wherein the material of the coating layer is a compressed continuous material having a density substantially higher than that of the core member. Embodiment 67. The hybrid structure according to any one of Embodiments 31 to 66, wherein the material from which the coating layer is made has a substantially higher flexural modulus than the flexural modulus of the core member material. Embodiment 68. The hybrid structure according to Embodiment 67, wherein the flexural modulus of the material from which the coating layer is made is 110 to 1800 MPa. Embodiment 69. A hybrid structure according to any one of Embodiments 31 to 68, wherein the thickness of the coating layer is 0.5 to 3.5 mm. Embodiment 70. A hybrid structure according to any one of Embodiments 1 to 69, wherein at least the outer surface of the core member has a curved shape, and the coating layer has a corresponding curved shape that conforms to the curvature of the core member. Embodiment 71. A hybrid structure according to any one of Embodiments 1 to 70, wherein the coating layer is made of a material that is incompressible under the force. Embodiment 72. A hybrid structure according to any one of Embodiments 1 to 71, wherein the core member is rigid. Embodiment 73. A hybrid structure according to any one of embodiments 31 to 72, wherein the coating layer is composed of at least two separate coating layer components, and at least a portion of the outer circumference of the first portion and at least a portion of the outer circumference of the second portion are connected to each other and to the core member by a connecting member. Embodiment 74. The hybrid structure according to Embodiment 73, wherein the connecting element has a male portion, and the core member has a female portion configured to reliably receive the male portion of the connecting element therein. [Brief explanation of the drawing]

[0029] Embodiments are described herein, only as non-limiting examples, with reference to the accompanying drawings, in order to better understand the subject matter disclosed herein and to illustrate how it can actually be carried out. [Figure 1A] This is a perspective view of a structure according to one embodiment of the subject matter of this application. [Figure 1B] This is the same figure of the same structure as Figure 1A, with the coating layer transparently shown for illustrative purposes. [Figure 1C] Figure 1A is an exploded view of the structure exemplified by this example. [Figure 1D] This is the same diagram of the same structure as Figure 1A, showing the structure in operation. [Figure 2] This is a diagram of the same structure as Figure 1B, showing the dimensions of the bump and spatial area. [Figure 3] This is a perspective view of a structure according to another embodiment of the subject matter of this application, in which at least some of the bumps may have different shapes and dimensions from the other bumps. [Figure 4A] Figures of structures according to further embodiments of the subject matter of this application, corresponding to the structures in Figures 1A to 1D, respectively, are shown, each having an additional elastic layer. [Figure 4B] Figures of structures according to further embodiments of the subject matter of this application, corresponding to the structures in Figures 1A to 1D, respectively, are shown, each having an additional elastic layer. [Figure 4C] Figures of structures according to further embodiments of the subject matter of this application, corresponding to the structures in Figures 1A to 1D, respectively, are shown, each having an additional elastic layer. [Figure 4D] Figures of structures according to further embodiments of the subject matter of this application, corresponding to the structures in Figures 1A to 1D, respectively, are shown, each having an additional elastic layer. [Figure 5A] This is a perspective view of a portion of an article according to a further embodiment of the subject matter of this application. [Figure 5B] Another perspective view of a portion of the article in Figure 5A, with its coating layer transparently shown for illustrative purposes. [Figure 6A] This is a perspective view of a structure according to a further embodiment of the subject matter of this application. [Figure 6B] This is a diagram of the structure illustrated in Figure 6A, in which the coating layer is transparently shown for illustrative purposes. [Figure 6C] Figure 6B is an exploded view of the structure exemplified by the example shown. [Figure 6D] Figure 6A illustrates a structure in operation. [Figure 7]A schematic example of a connection between a coating layer and a core member that can be used in a structure according to the subject matter of this application is provided below. [Figure 8] Another embodiment of the connection between the coating layer and the core member that can be used in the structure according to the subject matter of this application is schematically illustrated. [Figure 9A] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 9B] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 10A] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 10B] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 11A] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 11B] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 12] An example of a coating layer that can be used in any structure according to the subject matter of this application is shown in the bottom perspective view of the coating layer. [Figure 13A] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 13B] Cross-sectional views of structures according to further embodiments of the subject matter of this application, in different states, are provided as examples. [Figure 14A] A cross-sectional view of a structure according to a further embodiment of the subject matter of this application is shown, which is the structure illustrated in Figures 13A and 13B, having additional connecting means. [Figure 14B] A cross-sectional view of a structure according to a further embodiment of the subject matter of this application is shown, which is the structure illustrated in Figures 13A and 13B, having additional connecting means. [Figure 15] A cross-sectional view of a structure according to a further embodiment of the subject matter of this application is provided as an example. [Figure 16] A cross-sectional view of a structure according to a further embodiment of the subject matter of this application is shown, which is the structure illustrated in Figure 15 and has additional connecting means. [Modes for carrying out the invention]

[0030] Figures 1A to 1D illustrate a suspension-type hybrid structure according to an embodiment of a first aspect of the subject matter of this application. The hybrid structures shown in these drawings constitute an exemplary part of an article 100 incorporated into a product to provide a soft feel to the user. The product could be, for example, a bicycle seat, a seat for an electric vehicle, a chair component, a sofa, an automotive interior component, or any such component or part that requires an outer layer to provide a soft feel.

[0031] The hybrid structure / article 100 includes a core member 110 and a coating layer 120. The core member 110 has an outer surface 112 facing the coating layer 120. The core member 110 is rigid and also has a plurality of bumps 115 that project from the outer surface 112 toward the coating layer and are spaced apart from each other by a spatial region 116 between any two adjacent bumps 115.

[0032] According to the illustrated embodiment, the bump is formed integrally with the core member 110. However, in another embodiment (not shown), the bump 115 may be manufactured separately and then assembled together with the core member 110. In the latter case, the bump 115 may be formed of the same or different material as the core member 110. For example, the material used for the bump 115 may contain the same base material as the base material of the core member, but may be in a different form and / or have different physical properties.

[0033] The coating layer 120 has an inner surface 122 facing the direction of the core member 110 and an outer surface 124 facing the outside of the article 100, and also has a predetermined shape which can be the same as the shape of the outer surface 112 of the core member 110. As can be seen best in Figure 1C, the coating layer is produced in this shape, i.e., it has this shape before the core member 110 and the coating layer 120 are assembled. In this embodiment, the entire coating layer has the same shape as the outer surface of the core member, but in another embodiment (not shown), only the inner surface of the coating layer may have such a shape.

[0034] The coating layer 120 is configured to be fixedly attached to the core member 110 by any preferred means, several embodiments thereof are described in detail below this specification. When the coating layer 120 is attached to the core member 110, it covers the outer surface 112 of the core member 110 such that the inner surface 122 of the coating layer 120 rests on the bump 115, as seen in Figures 1A and 1B. As further seen in Figures 1A and 1B, when the inner surface 122 rests on the bump 115, a plurality of gaps G are formed between the coating layer 120 and the core member 110 in places where the inner surface 122 does not contact the bump 115. In other words, the gaps G are formed in places corresponding to and defined by the spatial region 116. According to the exemplary embodiment, the gaps G are filled with air. According to another embodiment, the gaps G may be made of an elastic material, as will be described in detail below this specification.

[0035] The coating layer 120 and the gap G are configured such that, as best seen in Figure 1D, when a bending force F is applied to the outer surface 124 of the coating layer 120 in the region above the gap G, the coating layer 120 flexes slightly inward into the gap G, and returns to its original shape when the force F is removed. Thus, suspension properties are achieved, and the coating layer 120 provides the article with a soft feel similar to that of an elastic foam. In other words, the coating layer and the gap are configured such that, as shown in Figure 1D, each region of the coating layer 120 associated with the gap G behaves like a film when a force F is applied, is held in place by adjacent regions of the coating layer supported by bumps, and both the outer surface 124 and inner surface 122 of the coating layer 120 in these regions flex inward into the gap G. Therefore, when a force F is applied to the outer surface 124 of the coating layer 120, and the coating layer 120 bends into the gap G, the volume of the gap is reduced.

[0036] In addition, the bump 115 can be configured to be compressible when subjected to an upward force, thereby providing further suspension to the covering layer in the area overlapping the bump and thus enhancing the softness of the article. In another embodiment, the bump 115 can be configured to be rigid. The compressibility / rigidity of the bump 115 can be selected based on the practicality of the final product into which the article is incorporated.

[0037] For example, the coating layer may have a substantially higher flexural modulus than that of the core member, for example, 110 to 1800 MPa, and may have a thickness of 0.5 to 3.5 mm. The core member may have any thickness determined by the function of the structure within the article, substantially thicker than the thickness of the coating layer in any case, and the material that can be manufactured may have a lower flexural modulus than that of the coating layer, but may have a higher compressibility than that of the coating layer, thereby further improving the suspension of the coating layer in the region overlapping the bump.

[0038] The materials that can be used to fabricate the core member 110 and the coating layer 120 are listed at the end of this description.

[0039] Apart from the material of the coating layer 120, the thickness of the coating layer 120, and the length of the space region 116, the maximum dimensions of the bumps 115 along the outer surface 112, the height of the bumps 115, and their correlations must enable the coating layer 120 to flex into the gap G and to produce suspension characteristics for the article. For example, at least 30% of the area of ​​the inner surface 122 of the coating layer 120 must correspond to the space region 116, i.e., not in contact with the bumps 115, and thereby be able to float in the air so as to flex inward into the air, and thus be able to reduce its volume in response to the application of force. Thus, the coating layer 120 can flex in response to the application of force only when it is mounted to have a reduceable volume such as the gap G in this embodiment, and cannot flex when placed on a rigid, incompressible surface.

[0040] As shown in Figure 2, the length of at least the majority of the spatial region 116, or in other words, the distance between most pairs of adjacent bumps 115, hereafter referred to as DS, is at least not shorter than, preferably longer than, the maximum dimension of each of the majority of bumps 115 along the outer surface 112, hereafter referred to as DB. Also, the length DS of the spatial region 116 is longer than the height H of the bumps 115 perpendicular to the outer surface 112. Furthermore, the thickness T of the coating layer 120 is thinner than the length DS of the spatial region 116 and does not exceed the height H of the bumps.

[0041] At least most of the bumps 115 can be arranged uniformly on most of the outer surface 112. Also, at least most of the bumps 115 can have the same maximum dimension along the outer surface 112. In the embodiment illustrated in Figure 2, all bumps on the illustrated portion of article 100 have the same shape and dimensions. According to another embodiment, as illustrated, for example, in Figure 3, at least some of the bumps 115 have a maximum dimension DB along the outer surface 12 that is longer than the maximum dimension DB of at least some of the other bumps 115. For example, a bump 115 adjacent to a location where the coating layer 120 can be fixed to the core member 110, here being the outer perimeter 113 of the article or a portion thereof, can have a maximum dimension DB along the outer surface 112 that is longer than the maximum dimension DB of a bump 115 that is further away from that location. One option of the latter embodiment is that the article or a portion thereof has a single continuous projection extending along its outer perimeter.

[0042] Figures 4A to 4D illustrate a hybrid structure that constitutes part of another article 100, having the same components and features as described above with respect to the articles illustrated in Figures 1A to 3, as well as an additional elastic layer 130. The elastic layer 130 is located between the core member 110 and the coating layer 120 such that a bump 115 protrudes through a hole 132 from the outer surface 112 of the core member 110 toward the inner surface 122 of the coating layer 120, and includes a hole 132 corresponding to the shape and dimensions of the bump 115. The thickness of the elastic layer does not exceed, or at least essentially exceed, the height H of the bump 115, so as to allow the elastic layer 130 to rest the coating layer 120 on the bump 115 when the coating layer flexes toward the core member. The elastic layer 130 fills at least a portion of the volume defined by the gap G, thereby constituting a decrementable volume, and is configured such that, when a force F is applied to the outer surface 124 of the coating layer 120 in the area above the portion of the elastic layer 130 that is placed in the gap, or in other words, to the portion of the coating layer 120 that is not resting on the bump 115, the coating layer 120 flexes inward toward or into the elastic layer 130 (as shown in Figure 4D), depending on the thickness of the elastic layer 130. Thus, the suspension characteristics can be adjusted, and together the coating layer 120 and the elastic layer 130 provide the article with a desired softness, such as the softness of an elastic foam.

[0043] In this specification, as best seen in Figure 4C, the elastic layer 130 does not need to be manufactured in a shape corresponding to the shape of the outer surface 112 of the core member 110. For example, as seen in Figure 4C, since the layer 130 is elastic, its shape can conform to the shapes of the core member and the coating layer depending on the assembly of the article, and therefore it can be planar compared to the outer surface 112 of the core member 110. Materials that can be used to fabricate the elastic layer 130 are listed at the end of this description.

[0044] In the embodiments shown in Figures 4A to 4D, the thickness of the elastic layer 130 is equal to the height H of the bump 115, such that the inner surface 122 of the coating layer 120 rests together with the bump 115 and the elastic layer 130. In such a case, the coating layer 120 flexes inward into the elastic layer 130 in response to a force F applied to the outer surface 124 of the coating layer 120 at a location corresponding to the gap between the bumps. If the thickness of the elastic layer 130 is thinner than the height H of the bump 115, such that the inner surface 122 of the coating layer 120 rests only with the bump 115, the coating layer 120 flexes inward towards the elastic layer 130 between the bumps in response to a force F applied to the outer surface 124 of the coating layer 120 in a region corresponding to the gap between the bumps.

[0045] Figures 5A to 5B illustrate a hybrid structure that constitutes a portion of Article 1 having the same components and features as Article 100 described above with reference to Figures 1A to 3, but having a coating layer comprising two parts. More specifically, Article 1 includes the core member 110, bump 115, and coating layer 120 described above with reference to Figures 1A to 3, but the coating layer 120 comprises two separate coating layer parts 120A and 120B, which are connected to each other and to the core member 110 on their respective outer circumferences. In other embodiments, the coating layer 120 can be molded as a single part or as any number of parts, depending on the shape, size, structure, and / or equipment of the final product into which the article is incorporated.

[0046] Parts 120A and 120B can be connected to each other and to the core member by any preferred means. In the embodiments illustrated in Figures 5A and 5B, this is done by a connecting member 700, as will be described in more detail below with reference to Figure 7. Furthermore, in the embodiments of Figures 5A and 5B, the coating layer 120 includes a skirt 125 that extends toward the core member 110 from at least some portion of the outer periphery of the coating layer 120, thereby improving the rigidity of the article on its outer periphery. The skirt can also cover the core member from the sides, or at least some portion thereof including the gap G.

[0047] Figures 6A to 6D illustrate a hybrid structure constituting a portion of an article 200 having suspension properties according to a further embodiment of the subject matter of this application, in a view corresponding to the views of article 100 shown in Figures 1A to 1D, respectively. The portions shown in these drawings represent exemplary small sections of article 200 incorporated into a product to provide a soft feel to the user. This product may be a bicycle seat, a seat for an electric vehicle, a chair component, a sofa, an automotive interior component, or any such component or part that requires an outer layer to provide a soft feel.

[0048] Article 200 includes a core member 210, a coating layer 220, and an elastic layer 230. The core member 210 includes an outer surface 212 facing the outside of the article. The coating layer 220 has the same characteristics as the coating layer 120 of article 100 and also has an inner surface 222 and an opposing outer surface 224. The inner surface 222 of the coating layer 220 has a predetermined shape, that is, it is manufactured in this shape and therefore has this shape at least before the coating layer 220 is assembled with the core member 210.

[0049] The coating layer 220 is configured to be fixedly attached to the core member 210 via an elastic layer by any preferred means, several embodiments thereof are described in detail below. The elastic layer 230 is positioned between the core member 210 and the coating layer 220 such that when assembled, the elastic layer is sandwiched between the outer surface 212 of the core member 210 and the inner surface 222 of the coating layer 220. As is best seen in Figure 6C, the elastic layer 230 does not need to be produced in a shape corresponding to the shape of the outer surface 212 of the core member 210 before the article is assembled. Thus, in this embodiment, as seen in Figure 6C, the elastic layer 230 is planar compared to the outer surface 212 of the core member 210 and, being elastic, takes on the shape of the outer surface 212 of the core member 210 as the article is assembled.

[0050] The coating layer 220 and the elastic layer are configured such that when a force F is applied to the outer surface 224 of the coating layer 220, the coating layer 220 flexes inward into the elastic layer 230. Thus, suspension characteristics are achieved, and the coating layer 220 provides the article with a soft feel similar to the soft feel of an elastic foam. In other words, as shown in Figure 6D, the coating layer and the elastic layer are configured such that the region of the coating layer 120 to which force F is applied behaves like a film held in place by the adjacent region of the coating layer to which no force is applied, and the outer surface 124 of these regions and the inner surface 122 of the coating layer 120 flex inward into the elastic layer. Thus, when a force F is applied to the outer surface 124 of the coating layer 120 and the coating layer 120 flexes into the gap G, the volume of the elastic layer below that region is reduced. Thus, the coating layer 220 can only flex in response to applied force when it is mounted such that it has a volume that can be reduced below it.

[0051] The materials that can be used to fabricate the core member 210, the coating layer 220, and the elastic layer 230 are listed at the end of this description.

[0052] In Articles 1, 100, and 200 described above, and in any other Articles according to different embodiments of the subject matter of this disclosure, the core members and coatings can be mechanically connected to one another by means, some embodiments of which are presented below. For the sake of brevity, in this specification the connecting means are described below with reference only to Article 1, but it should be understood that they apply to any Article according to the subject matter of this disclosure.

[0053] Figure 7 illustrates a hybrid structure comprising a portion of Article 1, with a pop-out showing an enlarged view of the connection between a portion of the outer periphery of a first portion 120A of the coating layer 120, a portion of the outer periphery of a second portion 120B of the coating layer 120, and a core member 110, by a connecting member 700 according to one particular embodiment of the subject matter of this disclosure. As shown in the enlarged view, the outer periphery of the first portion and the second portion of the coating layer are bent to form their respective flanges 126. The connecting member 700 includes two lip portions 710, each configured to engage with and grip their respective flanges 126. The lip portions 710 extend toward a wide bottom portion 720 of the connecting member 700. The wide bottom portion 720 is configured to be inserted into a corresponding groove 114 formed in the core member 110. The wide bottom portion 720 and the extensions from the lip portions 710 form a narrower neck portion 730 that prevents the bottom portion 720 from being pulled out of the groove 114. The engagement of the flange 126, lip portion 710, bottom portion 720, and groove 114 secures the two coating layer components 120A and 120B to the core member 110. The recess 740 is formed between the extensions of the lip portion 710 and extends into the bottom portion 720. The recess 740 is configured to receive an external component to be connected to an article or final product. The external component may be a decorative component such as a metal plate 1000, or a male component of an external connector such as a zipper, thereby enabling the article to be connected to any external product. The connecting member 700 may be made of the same material as the core member or the coating layer material of article 1.

[0054] Figure 8 illustrates an exploded view of a portion of a sheet incorporating Article 1. Figure 8 shows a portion of the outer circumference 111 of a core member 110 having a plurality of male portions 810 of a quick-connect mating device. Figure 8 further shows a portion of the outer circumference 121 of a covering layer 120 having a plurality of female portions 820 corresponding to the male portions 810 of the quick-connect mating device. During the assembly of the article, the covering layer 120 is mounted on the core member 110, and the male portions 810 and female portions 820 are mechanically connected to each other by quick-connecting engagements such as snap-fit ​​connections, thereby securely connecting the core member 110 to the covering layer 120. In some embodiments, the covering layer may have male portions, and the core member may have female portions.

[0055] While the snap-fitting connection means described above are positioned on the outer circumference of the core member and on one or more portions of the coating layer, it should be understood that the connection means can also be positioned along the entire outer circumference.

[0056] At least some of the snap-fitting connection means can be positioned in a region of the coating layer and core member away from the outer periphery, including its central region. The snap-fitting connection means may include, for example, a connection element such as a locking recess that constitutes the female portion of the connection means formed in one of the core member and the coating layer, and a corresponding connection element such as a lockable projection that constitutes the male portion of the connected means that protrudes from the other of the core member and the coating layer toward the female portion. For example, the male portion may be integrally attached to the coating layer or constitute a single unit with the coating layer, and the female portion may be integrally formed within the core member or constitute a single unit with the core member.

[0057] In any of the embodiments described above, the coating layer can be connected to the core member by a connecting device that enables suspension. This device may comprise female and male parts of the types described above, which may have configurations and dimensions that allow the movement of the latter part within the former part in the thickness direction of the structure, optionally, and also in the tangential direction perpendicular to the thickness direction. This allows the coating layer to flex in the thickness direction as described above, and also to move slightly tangentially with respect to the core member, each flexing and bringing a new dimension to the suspension characteristics of the coating layer when a tangential force is applied at least indirectly to the area of ​​the coating layer associated with the male part, resulting in an improved softness to the article. Hereinafter, embodiments of such connecting devices for articles having the same components and features as articles 1, 100, and 200 described above will be described with reference to Figures 9A to 11B. Therefore, in these embodiments, only the features of the article necessary for describing the structure and operation of the connecting device will be described.

[0058] Figures 9A and 9B illustrate cross-sectional views of a hybrid structure that constitutes a part of article 300, having all the components and features of article 100 described above with reference to Figures 1A to 3, and additionally having snap-fitting connection means.

[0059] More specifically, article 300 comprises a core member 310 and a coating layer 320, both having the same basic configuration as the respective coating layer and core member of article 100 shown in Figures 1A to 3, being made of the same material (described at the end of this description), and operating in the same manner. The core member 310 has an outer surface 312 facing the coating layer 320. The core member 310 has a plurality of bumps 315 projecting from the outer surface 312 toward the coating layer 320, spaced apart by a spatial region 316 between any two adjacent bumps 315, so that when the coating layer is placed on the core member, a plurality of gaps G are formed between the spatial region and the associated region of the coating layer covering the spatial region. The coating layer 320 has an inner surface 322 facing the core member 310 and an outer surface 324 facing toward the outside of article 300.

[0060] The snap-fitting connection means of article 300 comprises a plurality of female portions 318 extending inward from their outer surface into the core member 310 in some of the spatial regions 316, and a plurality of male portions 328 protruding from the inner surface of the coating layer in the region overlapping these spatial regions and configured to be receptively received by each female portion 318. In other words, each pair of male and female portions is associated with one of the gaps G.

[0061] Each female mold portion has a wide bottom portion 318A, a narrow top portion 318B, and a shoulder portion 318C that joins the wide portion 318A and the narrow portion 318B. Each male mold portion 328 has at least two leaf portions 328A and 328B at its distal end from the inner surface 322. The male mold portions 328 are flexible, and their leaf portions are pressed toward each other as they pass through the narrow top portion 318B of the female mold portion 318 and return to their original positions when they enter the wide bottom portion 318A, thereby holding each male mold portion within the female mold portion 318 and locking at the shoulder portion 318C, preventing the female mold portion 318 from being pulled out of the male mold portion 328, and fixing the coating layer 320 to the core member 310.

[0062] When the coating layer 320 is attached to the core member 310, as shown in Figure 9A, the inner surface 322 of the coating layer 320 rests on the bump 315 and covers the outer surface 312 of the core member 310 such that the male portion 328 is locked inside the female portion 318.

[0063] As can be seen further in Figures 9A and 9B, the dimensions and configuration of the female and male portions are such that when the leaf portions 328A and 328B are locked at the shoulder portion 318C in the normal state of the corresponding region of the coating layer 320, a space S1 remains between the bottom surface 318D of the female portion 318 and the distal end of the male portion 328, thereby allowing the male portion 328 to move toward the bottom surface 318D of the female portion 318 while keeping the female portion 318 locked, when the corresponding region of the coating layer 320 flexes into the associated gap G under the application of a bending force thereto, thereby reducing the space S1 to S2, as shown in Figure 9B. Furthermore, as can be seen in Figures 9A and 9B, the dimensions and configuration of the female and male parts are such that when the male part 328 is inserted into the female part 318, it is spaced apart by a distance D from the side wall of the female part 318, thereby allowing the male part to move tangentially with respect to the female part when a tangential force is applied, at least indirectly, to the upper region or the adjacent coating layer. Thus, the coating layer 320 is securely attached to the core member, and in the region associated with the male part, it is possible for it to flex inward toward the core member 310 together with the male part, and to move slightly tangentially with respect to the core member when a tangential force is applied, at least indirectly, to these regions.

[0064] Figures 10A and 10B illustrate a hybrid structure which is a portion of article 300 having all the components and features described above with respect to the structure shown in Figures 4A to 4D, and which is the same as the snap-fit ​​connection means described above with respect to Figures 9A and 9B, and additionally comprises a hole in an elastic layer that enables the use of the connection means.

[0065] Therefore, the structures shown in Figures 10A and 10B comprise a core member 310, a coating layer 320, and an elastic layer 330 disposed between them such that the elastic layer 330 fills at least a portion of the reductionable volume defined by the gap G' between the core member 310 and the coating layer 320, all of which can have the same basic configuration as the respective coating layer, core member, and elastic layer of article 100 shown in Figures 4A to 4D, be made of the same material (described at the end of this description), and operate in the same manner.

[0066] The elastic layer 330 includes a first plurality of holes 332 whose shape and dimensions correspond to the bumps 315, so that when the article is assembled, the bumps 315 protrude from the outer surface 312 of the core member 310 through the corresponding holes 332, and the coating layer 320 rests on at least some of the bumps 315. The elastic layer 330 further includes a second plurality of holes 334 provided at positions corresponding to the positions of the female portion 318 and male portion 328 of the core member 310 and the coating layer 320 associated with some of the gaps G'. The second plurality of holes 334 allow the male portion 328 and in particular their wide bottom portions to enter the female portion 318 through the holes and engage with the corresponding female portion 318 by the ability to move in the thickness direction within the range S1 to S2 and in the tangential direction within the distance D. Therefore, the coating layer 320 is fixedly attached to the core member 310 via an elastic layer sandwiched between the coating layer and the core member, functioning as described above with reference to Figures 9A and 9B, while subject to bending and tangential forces applied to the coating layer.

[0067] Figures 11A and 11B illustrate cross-sectional views of a hybrid structure that constitutes a part of article 400, having all the components and features of article 200 described above with reference to Figures 6A to 6D, and also having the same snap-fitting connection means as described above with reference to Figures 10A and 10B.

[0068] More specifically, article 400 includes a core member 410, a coating layer 420, and an elastic layer 430, all of which may have the same basic configuration and may be made of the same materials (described at the end of this description) as the respective coating layers, core members, and elastic layers of article 200 illustrated in Figures 6A to 6D, and may operate in the same manner.

[0069] The core member 410 includes an outer surface 412 facing the outside of the article. The coating layer 420 has an inner surface 422 and an opposing outer surface 424. The elastic layer 430 is positioned between the core member 410 and the coating layer 420 such that when the article is assembled, the elastic layer 430 rests on the outer surface 412 of the core member 410 and the inner surface 422 of the coating layer 420 rests on the elastic layer 430.

[0070] The snap-fitting connection means comprises a plurality of female portions 418 on the outer surface of the core member 410, each including a wide bottom portion 418A, a narrow top portion 418B, and a shoulder portion 418C that joins the wide portion 418A and the narrow portion 418B; and a plurality of corresponding male portions 428 that project from the inner surface 422 of the coating layer 420 toward the core member 410, each including at least two leaf portions 428A and 428B at its distal end toward the inner surface 422. The leaf portions 428A and 428B are held within the female portions 418 and locked at the shoulder portions 418C to prevent the male portions 428 from being pulled out of the female portions 418, thereby configuring the coating layer 420 to be fixedly attached to the core member 410.

[0071] The elastic layer 430 includes a plurality of holes 434 provided at positions corresponding to the positions of the female portion 418 and the male portion 428. Each hole 434 allows the male portion to be received and locked within the corresponding female portion by the ability of the wide bottom portion 418A of the male portion 428 to move through the hole in the thickness direction within the range S1'~S2' and in the tangential direction within the distance D' when the article is assembled. Thus, the coating layer 420 is fixedly attached to the core member 410 via the elastic layer sandwiched between the coating layer and the core member, functioning as described above with reference to Figures 9A and 9B, under the application of bending and tangential forces to the coating layer.

[0072] In articles illustrated in Figures 10A, 10B, and 11A, 11B, in which an elastic layer is provided with a male portion into which a corresponding female portion enters, these holes may have a cross-section corresponding to the cross-section of the narrow top portion of the male portion, and the holes are radially elastically expandable during such passage.

[0073] In Figures 9A to 11B, the snap-fitting connection means are shown with only two snap-fitting elements visible in each male portion (as these drawings are cross-sectional), but each male portion can have any desired number of snap-fitting elements. Figure 12 illustrates one embodiment of a male portion 528 having the cross-section shown in Figures 9A to 11B, and the coating layer 520 may be identical to the coating layers 320 and 420 shown in Figures 9A to 11B. Figure 12 shows a bottom perspective view of one selected region of the coating layer 520. The male portion 528 is formed integrally with the coating layer 520 and is uniformly distributed along at least the region shown in Figure 12, and is configured to be received in a corresponding female portion formed in one of the core members of Figures 9A to 11B. In this embodiment, each male portion 520 is of annular type and comprises six snap-fit ​​elements, each of which constitutes a sector of the cylinder and has a leaf portion projecting radially from it in the same manner as the leaf portions 328A, 328B and 428A, 428B of each male portion 328, 428 of the snap-fit ​​connection means shown in Figures 9A to 11B.

[0074] In all exemplary embodiments in which bumps are formed on the outer surface of the core member, as described herein, the coating layer is configured to flex in response to the application of a bending force; however, it should be understood that in all such embodiments, the core member and / or bumps may also be compressible. More specifically, in all embodiments in which bumps protrude from the core member, the core member, the bump, or both may have a higher compressibility than the coating layer, so that when a bending force is applied to the coating layer in the region covering such bumps, the bumps are compressed, thereby improving the suspension characteristics of the hybrid structure, particularly in the region corresponding to the bumps.

[0075] Alternatively, or in addition, if the core member has a higher compressibility than the coating layer, the coating layer can be formed with bumps protruding from there toward the core member, and can be configured to compress the latter when a bending force is applied to the coating layer in the region covering the bumps, thereby improving the suspension characteristics of the hybrid structure, particularly in the region corresponding to the bumps.

[0076] Figures 13A and 13B illustrate cross-sectional views of a hybrid structure that constitutes a part of article 500, all having the components and features of article 100 described above with reference to Figures 1A to 3, the only difference being that in article 500, the bumps protrude from the coating layer instead of being core members as in article 100.

[0077] More specifically, article 500 comprises a core member 510 and a coating layer 520, both having the same basic configuration as the respective coating layer and core member of article 100 shown in Figures 1A to 3, being made of the same material (described at the end of this description), and operating in the same manner. The core member 510 has an outer surface 512 facing the direction of the coating layer 520. The coating layer 520 has a plurality of bumps 525 that project from an inner surface 522 in the direction of the core member 510 and are spaced apart from each other by a spatial region 526 between any two adjacent bumps 525, so that when the coating layer 520 is connected to the core member 510 by the bumps 525 that rest on the outer surface 512 of the core member 510, a plurality of gaps G are formed between the spatial region and the associated region of the outer surface 512 below the spatial region. The height of the bump 525 defines the height of the gap, and the coating layer 520 has a thickness less than the height of the bump 525 in the region between the bumps 525. According to the illustrated embodiment, the bumps are formed integrally with the coating layer 520. However, in another embodiment (not shown), the bumps may be manufactured separately and then assembled together with the coating layer.

[0078] Similarly, as described above with respect to the coating layer 120 and gap G of article 100, the coating layer 520 and gap G of article 500 are configured such that, when a bending force F is applied to the outer surface 524 of the coating layer 520 in the region above the gap G, the coating layer 520 bends slightly inward into the gap G, and returns to its original state when the force F is removed.

[0079] In addition to the deflection described above, the core member 510 has higher compressibility than the coating layer. As shown in Figure 13B, when a bending force F is applied to the outer surface 524 of the coating layer 520 in the region corresponding to the bump 525, the region of the outer surface 512 of the core member 510 below the bump 525 is compressed, and returns to its original state when the force is removed.

[0080] Although the bump 525 is formed in the coating layer 520 instead of a core member (as in Article 100), the descriptions of the structure, dimensions, and location of the bumps in the different embodiments of Article 100 also apply to the bump 525 and are not repeated herein for the sake of brevity. Also, in a manner similar to that described for the coating layer 120, the coating layer 520 maintains its thickness in the region to which the bending force F is applied while it is flexing, and the inner and outer surfaces of the coating layer 520 flex equally into the gap G.

[0081] Therefore, in Article 500, the suspension properties and softness are achieved by the deflection of the coating layer and by the compression of the core members in the areas beneath the bumps. It should be understood herein that the core members have higher compressibility than the coating layer, but still lower than the compressibility generally possessed by elastic foams. More specifically, the core members can have very low compressibility when force is applied over a large area, and the compressibility of the core members is localized in the areas beneath the bumps. The dimensions of the bumps and the space areas affect the compressibility of the core members in the direction along the outer surface of the core members. For example, the narrower the bumps, the higher the compressibility of the core members in the areas beneath such bumps; similarly, the further apart the bumps are from each other, the higher the compressibility of the core members in the areas beneath such bumps.

[0082] Figures 14A and 14B illustrate cross-sectional views of a hybrid structure that constitutes a part of article 600, having all the components and features of article 500 described above, with reference to Figures 13A to 13B, and additionally having snap-fitting connection means.

[0083] More specifically, article 600 comprises a core member 610 and a coating layer 620, both having the same basic configuration as the respective coating layer and core member of article 500 shown in Figures 13A and 13B, being made of the same material (described at the end of this description), and operating in the same manner. The core member 610 has an outer surface 612 facing the coating layer 620. The coating layer 620 has a plurality of bumps 625 projecting from an inner surface 622 toward the core member 610 and spaced apart from each other by a spatial region 626 between any two adjacent bumps 625, so that when the coating layer is connected to the core member, the bumps 625 rest on the outer surface 612 of the core member 610, and a plurality of gaps G are formed between the spatial region and the associated region of the core member below the spatial region.

[0084] The snap-fitting connector of article 600 has the same structure and operation as the snap-fitting connector of article 300 described above with reference to Figures 9A and 9B. More specifically, the snap-fitting connector of article 600 comprises a plurality of female portions 618 extending inward from their outer surface into the core member 610 in areas of the core member below some of the spatial regions 626, and a plurality of male portions 628 protruding from the inner surface 622 of the coating layer 620 in areas corresponding to the spatial regions and configured to be receptively received by each female portion 618. In other words, each pair of male and female portions is associated with one of the gaps G.

[0085] The snap-fit ​​connection means of article 600 is a connection means that enables suspension, and is of the same type as the snap-fit ​​connection means of article 300. For example, the dimensions and configuration of the female portion 618 and the male portion 628 are such that, depending on the connection between the coating layer and the core member, when a bending force F is applied to the outer surface 624 of the coating layer 620 in the region corresponding to the male portion 628, the male portion 628 moves within the female portion 618 as described above with reference to article 300, thereby providing suspension in the region corresponding to the connection means, in addition to the suspension provided by the deflection of the coating layer in the region corresponding to the space region and the compression of the core member in the region corresponding to the bump, as described above with reference to article 500. Therefore, while securely attached to the core member in the same manner as described above with reference to article 300, the coating layer 620 is allowed to flex inward toward the core member 610 together with the male portion in the region associated with the male portion, and to move slightly tangentially with respect to the core member when a tangential force is applied at least indirectly to these regions.

[0086] Figure 15 illustrates a cross-sectional view of a hybrid structure that constitutes a portion of article 700, having all the components and features of article 500 described above, with reference to Figures 13A and 13B, and additionally having several bumps protruding from the core member.

[0087] More specifically, article 700 comprises a core member 710 and a coating layer 720, both having the same basic configuration as the respective coating layer and core member of article 500 shown in Figures 13A and 13B, being made of the same material (described at the end of this description), and operating in the same manner. The core member 710 has an outer surface 712 facing the coating layer 720. The coating layer 720 has an inner surface 722, which faces the core member 710 and has a plurality of bumps 725 projecting from there toward the core member 710 and spaced apart from each other by a spatial region 726 between any two adjacent bumps 725. The core member 710 has a plurality of bumps 715, which project from the outer surface 712 of the core member 710 toward the coating layer 720 and spaced apart from each other by a spatial region 716 between any two adjacent bumps 715. In the exemplary embodiment, the bumps 715 and 725 have dimensions in a direction extending from the core member to the coating layer such that when the coating layer 720 is connected to the core member 710, the inner surface 722 of the coating layer 720 rests on the bump 715 protruding from the core member 710, and the bump 725 protruding from the coating layer 720 rests on the outer surface 712 of the core member 710, and a plurality of gaps G are formed between the space region 726 and the associated region of the outer surface 712 of the core member 710 below the space region 726, and between the space region 716 and the associated region of the inner surface 722 of the coating layer 720 covering the space region 716.

[0088] In some embodiments (not shown), the dimensions of the bumps 715 and 725 can be such that the coating layer 720 rests on the bump 715 and a space remains between the bump 725 and the core member 710, or that the bump 725 rests on the core member 710 and a space remains between the coating layer 720 and the bump 715.

[0089] The bumps 715 and 725 can be distributed along the corresponding surfaces of the core member and the coating layer in any pattern, uniformly or non-uniformly, or as described above with respect to article 100, and such that none of the bumps 715 coincide with the bump 725. In other words, each of the bumps 715 and 725 is positioned on the corresponding surfaces of the core member and the coating layer to align with the spatial area between the other bump.

[0090] Similarly, with respect to the coating layer 520 and gap G of article 500, the coating layer 720 and gap G of article 700 are configured such that, when a bending force F is applied to the outer surface 724 of the coating layer 720 in the region above the gap G, the coating layer 720 bends slightly inward into the gap G, and returns to its original state when the force F is removed.

[0091] In addition to the deflection described above, the core member 710 has higher compressibility than the coating layer. When a bending force F is applied to the outer surface 724 of the coating layer 720 in the region corresponding to the bump 725, the outer surface 712 region of the core member 710 below the bump 725 is compressed, and returns to its original state when the force is removed.

[0092] Furthermore, the bumps 715 protruding from the core member 710 are compressible in such a manner that when a bending force F is applied to the outer surface 724 of the coating layer 720 in the region corresponding to the bumps 715, the bumps 715 are elastically compressed by that force.

[0093] Therefore, in article 700, the suspension properties and softness are achieved by the deflection of the coating layer, by the compression of the core member in the region below the bump 725, and by the compression of the bump 715. It should be understood herein that the core member and / or bump 715 have higher compressibility than the coating layer, but still lower than the compressibility generally possessed by elastic foams.

[0094] In this specification, the descriptions of the structure, dimensions, and location of the bumps in different embodiments of Article 100 also apply to bumps 715 and 725, and should be understood that for the sake of brevity, these descriptions are not repeated herein. Also, in a manner similar to that described for coating layer 120, coating layer 720 maintains its thickness in the region where the bending force F is applied while flexing, and the inner and outer surfaces of coating layer 720 flex equally into the gap G.

[0095] Figure 16 illustrates a cross-sectional view of a hybrid structure that constitutes a portion of article 800, having all the components and features of article 700 described above, with reference to Figure 15, and additionally having snap-fitting connection means.

[0096] More specifically, article 800 comprises a core member 810 and a coating layer 820, both having the same basic configuration as the respective coating layer and core member of article 700 shown in Figure 15, being made of the same material (described at the end of this description), and operating in the same manner. The core member 810 has an outer surface 812 facing the coating layer 820, and a plurality of bumps 815 protruding therefrom and spaced apart by a spatial region 816. The coating layer 820 has an inner surface facing the core member 810, and a plurality of bumps 825 protruding therefrom and spaced apart by a spatial region 826. When the coating layer is connected to the core member, the bumps 825 rest on the outer surface 812 of the core member 810, and the inner surface of the coating layer rests on the bumps 815.

[0097] The snap-fitting connection means of article 800 has the same structure and operation as the snap-fitting connection means of article 300 described above with reference to Figures 9A and 9B. More specifically, the snap-fitting connection means of article 800 comprises a plurality of female portions 818 extending inward from their outer surface into the core member 810 in areas of the core member corresponding to some of the spatial regions 816, and a plurality of male portions 828 protruding from the inner surface 822 of the coating layer 820 in areas corresponding to some of the spatial regions 826, and configured to be receptively received by each female portion 818.

[0098] The snap-fit ​​connection means of article 800 is a connection means that enables suspension, and is of the same form as the snap-fit ​​connection means of articles 300 and 600. For example, the dimensions and configuration of the female portion 818 and the male portion 828 are such that, depending on the connection between the coating layer and the core member, when a bending force F is applied to the outer surface 824 of the coating layer 820 in the region corresponding to the male portion 828, the male portion 828 moves within the female portion 818 as described above with reference to article 300, thereby providing suspension in the region corresponding to the connection means, in addition to the suspension provided by the deflection of the coating layer in the region not corresponding to the bump 815 or bump 825, by the compression of the core member in the region corresponding to the bump 825, and by the compression of the bump 815, as described above with reference to article 700.

[0099] Articles 500, 600, 700, and 800 were described above without elastic layer portions disposed in corresponding spatial regions; however, it should be understood that any and / or all of these articles may further comprise elastic layer portions positioned in corresponding spatial regions, or elastic layers disposed between the core member and the coating layer, having holes corresponding to bumps and, if any, connecting means. Such elastic layers or elastic layer portions may be the same in structure and operation as any of the elastic layers / parts described above.

[0100] In all of the above embodiments, the pairs of male and female parts can be distributed uniformly with respect to the inner surface of the coating layer and the outer surface of the core member, respectively. Alternatively, these pairs can be arranged in a predetermined order, for example, with more pairs placed near the outer periphery, or in the center of the article, or in any other desired area. In addition, if one or both of the inner surface of the coating layer and the outer surface of the core member have bumps, the pairs of male and female parts can be arranged such that there are multiple such bumps between each pair of pairs.

[0101] Articles according to any aspect of the subject matter of this disclosure may have snap-fitting connections as illustrated in Figures 9A to 12 above, or any other snap-fitting connections, i.e., they may have other configurations and sizes. For example, the male and female portions may have cross-sectional shapes other than circular, such as elliptical, polygonal, etc. Furthermore, rapid mechanical connections similar to or other than the snap-fitting described above may be used in any preferred manner, together with lockable projections configured to be received and locked in corresponding locking grooves.

[0102] In all of the above embodiments, the male and female portions of the connecting means are formed as a single unit with the coating layer and the core member, respectively, which is possible because both are rigid, i.e., configured to maintain their shape. As a result, an article having such a connecting means according to any aspect of the subject matter of this disclosure does not require any additional means for connecting its coating layer to the core member directly or via an elastic layer. Alternatively, one or both of the male and female portions of the connecting device used in an article according to the subject matter of this disclosure may be manufactured separately and then assembled together with one or both of the coating layer and the core member.

[0103] In all of the above embodiments of the hybrid structure, all of its components can be made of materials that allow for their recycling, including heat treatment, without separation between components. For example, the material of at least the core member and the coating layer having its connecting elements can be made of the same thermoplastic base material or different thermoplastic base materials that are meltable at the same recycling temperature, wherein each base material is optionally the only substance in the material that melts at that temperature. Since these materials can constitute more than 90%, optionally more than 93%, for example at least 95%, of the total weight of the hybrid structure, the structure can be recycled without separation even if the residual material in the structure is not meltable at the above temperature.

[0104] The basic materials in the core members and coating layers described above can have different material forms, at least in the core members and coating layers, that enable them to have the physical properties required for their intended functions in the structure. For example, they can be thermoplastic polymers of the same polymer group, such as polypropylene.

[0105] For example, the core layer, which needs to be the thickest component in the structure, can have a lower bulk density than the coating layer, and the coating layer must be very thin to flex under bending forces, as described in the above embodiment, but still rigid to maintain its shape and the shape of its connecting elements. In particular, the core member can be made of expanded particle foam, and the coating layer with its connecting elements can be made of a more compressible material suitable for injection molding, etc. In this case, the core member can be formed by particle foam molding to the desired shape, and the coating layer can be made by injection molding or compression molding, thermoforming, extrusion, vacuum forming, or other techniques, making it possible to maintain the coating layer and connecting elements in their as-generated shape.

[0106] If present, the elastic layer can have a weight that constitutes a small portion of the overall weight of the hybrid structure, for example, less than 5%, so that even if it is made of a material that cannot be melted at temperatures above the recycling temperature, it can be recycled together with the other components of the hybrid structure without being separated from it.

[0107] In one particular embodiment, when the thermoplastic polymer material is polypropylene, when used to produce an expanded particle foam core member or, if any, an elastic foam layer, such core member and such elastic layer may each have a bulk density of 0.03 to 0.12 kg / liter, and when used to produce a coating layer having connecting elements, such coating layer may have a density of 0.85 to 0.95 kg / liter, more specifically 0.91 kg / liter.

[0108] The following are examples of the above materials, all of which are polypropylene-based and can be used in each of the hybrid structures described above.

[0109] [Table 1]

[0110] In all embodiments of the hybrid structures described above, the components are connected to each other by means that do not involve any adhesives; however, if such adhesive is made of the same basic material as the material of the other components of the article, for example, a material containing polypropylene, then, if desired, an adhesive may be used between the coating layer and the core member, or between one or both of these and the elastic layer, if any.

Claims

1. A hybrid structure having suspension properties, A core member having an outer surface, A layer of reduceable volume associated with the outer surface of the core member in at least some of its regions, A coating layer connected to the core member and having an outer surface and an inner surface, having a region covering the reductionable volume, each of which, when a bending force is applied to that region, can flex into the reductionable volume while maintaining the thickness of the coating layer in that region, and can return to its original state when the bending force is released, thereby providing the suspension properties to the hybrid structure, A connecting device that connects the inner surface of the coating layer to the core member via the layer of the decrementable volume, Equipped with, The connecting device comprises a plurality of connecting elements that are associated with the coating layer and securely engage with the corresponding connecting elements of the core member, A hybrid structure in which at least some of the connecting elements are formed in the region of the coating layer having the reductionable volume below them, and the corresponding connecting elements have this volume above them.

2. The hybrid structure according to claim 1, wherein the connecting element is in the form of a lockable projection that protrudes from the coating layer toward the core member and is receptively received in a corresponding locking recess of the core member.

3. The hybrid structure according to claim 1, wherein when the associated region of the coating layer flexes into the reductionable volume disposed beneath it, each connecting element associated with the region having the reductionable volume below it moves freely inward toward the core member.

4. The hybrid structure according to any one of claims 1 to 3, wherein the core member is made from a material in the form of an expanded particle foam.

5. The hybrid structure according to any one of claims 1 to 4, wherein the coating layer is made from a compressed continuous material having a density substantially higher than that of the core member.

6. The hybrid structure according to claim 5, wherein the coating layer is in the form of an injection-molded body.

7. The core member has a first compressibility and a first flexural modulus, The coating layer has a second compressibility lower than the first compressibility and a second flexural modulus higher than the first flexural modulus. A hybrid structure according to any one of claims 1 to 6.

8. The hybrid structure according to any one of claims 1 to 7, wherein the connection device is a rapid connection device.

9. The hybrid structure according to claim 8, wherein the rapid connection device is a snap-fit ​​device.

10. A hybrid structure having suspension properties, A core member having an outer surface and a first compressibility and a first flexural modulus, A layer of reduceable volume associated with the outer surface of the core member in at least some of its regions, A coating layer connected to the core member and having an outer surface and an inner surface, wherein the coating layer has a second compressibility lower than the first compressibility and a second flexural modulus higher than the first flexural modulus, and the coating layer has regions covering the reduceable volume, each of which, when a bending force is applied, can flex into the reduceable volume while maintaining the thickness of the coating layer in the region, and can return to its original state when the bending force is released, thereby providing the suspension properties to the hybrid structure. A hybrid structure equipped with these features.

11. The hybrid structure according to claim 10, further comprising a connecting device that connects the inner surface of the coating layer to the core member via the layer of the decrementable volume.

12. The hybrid structure according to claim 11, wherein the connecting device comprises a plurality of connecting elements that are associated with the coating layer and reliably engage with the corresponding connecting elements of the core member.

13. The hybrid structure according to claim 12, wherein the connecting element is in the form of a lockable projection that protrudes from the coating layer toward the core member and is receptively received in a corresponding locking recess of the core member.

14. The hybrid structure according to claim 12 or 13, wherein at least some of the connecting elements are formed in the region of the coating layer having the reductionable volume below them, and the corresponding connecting elements have this volume above them.

15. The hybrid structure according to claim 14, wherein when the associated region of the coating layer flexes into the reductionable volume disposed beneath it, each connecting element associated with the region having the reductionable volume below it moves freely inward toward the core member.

16. The hybrid structure according to any one of claims 10 to 15, wherein the core member is made from a material in the form of an expanded particle foam.

17. The hybrid structure according to any one of claims 10 to 16, wherein the coating layer is made from a compressed continuous material having a density substantially higher than that of the core member.

18. The hybrid structure according to claim 17, wherein the coating layer is in the form of an injection-molded body.

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