Thermoformed Composite Hockey Pad Shell

The patent applies composite materials by combining a rigid outer shell layer with a foam core layer. The rigid layer provides impact protection while the foam core provides shock absorption and reduces overall weight. This composite structure resolves the contradiction by integrating two materials with complementary properties - the rigid material for strength and the foam for weight reduction and shock absorption.

The patent applies local quality by creating a multi-layer structure where different regions of the outer shell have different properties. The outer surface maintains rigidity for protection, while the internal foam core provides cushioning and weight reduction. This allows the shell to have both hard protective qualities where needed and softer, lighter qualities in other regions.

The patent applies segmentation by dividing the outer shell into distinct functional layers: a rigid outer layer and a foam core layer. Each layer can be manufactured separately using optimized processes for that material type, then assembled together. This segmentation allows each layer to be produced with appropriate manufacturing techniques without requiring a completely new complex manufacturing system.

The patent uses composite materials construction where the rigid shell and foam core are assembled together. This approach allows leveraging existing manufacturing capabilities for both rigid plastics and foam materials, combining them through joining techniques rather than requiring entirely new manufacturing processes.