Formable protector
View Patent ↗A sandwich construction including a core having inner and outer surfaces and comprising a sheet material oriented extending between the inner and outer core surfaces in a configuration providing resistance to crushing in a direction between the inner and outer surfaces. The formable protector further includes an outer facing layer of a sheet material adhered to the outer surface of the core layer; and an inner facing layer adhered to the core inner surface and being sufficiently deformable to conform to a sharp edge of a protected object when the protector is bent therearound, and being substantially more compressible or stretchable than the outer facing layer. The core has sufficient resistance to crushing and the outer facing layer is sufficiently durable for causing the core to partially crush when the protector is bent around the sharp edge while partially retaining crushing resistance for protecting the sharp edge against impact.
1. A sandwich construction, comprising:
a core having inner and outer surfaces and comprising a sheet material oriented extending between the inner and outer core surfaces in a configuration providing resistance to crushing in a direction between the inner and outer surfaces, wherein the core sheet material is a honeycomb structure;
an outer facing layer of a sheet material adhered to the outer surface of the core layer, wherein the sheet material of the outer facing layer comprises paper sheet; and
an inner facing layer adhered to the core inner surface and being sufficiently deformable to conform to a sharp edge of a protected object when the sandwich construction is bent therearound, and being substantially more compressible or stretchable than the outer facing layer, wherein the inner facing layer is compressible and stretchable in the plane of the inner facing layer such that the inner facing layer does not tear when the formable protector is bent around the sharp edge;
wherein the core has sufficient resistance to crushing and the outer facing layer is sufficiently durable for causing the core to partially crush when the sandwich construction is bent around the sharp edge while partially retaining crushing resistance for protecting the sharp edge against impact.
2. The sandwich construction of claim 1 , wherein the inner facing layer is substantially less stiff than the outer facing layer in compression or extension.
3. The sandwich construction of claim 1 , wherein the core sheet material is configured in a two-dimensional pattern normal to the inner and outer surfaces.
4. The sandwich construction of claim 1 , wherein the sheet material of the core comprises paper sheet.
5. The sandwich construction of claim 1 , wherein the outer facing layer includes a printable-clay coated paper.
6. The sandwich construction of claim 1 , wherein the inner facing layer is sufficiently deformable for conforming to the core crushed about the sharp edge to at least half the core depth without tearing.
7. The sandwich construction of claim 1 , wherein the inner facing layer is sufficiently deformable for conforming to the core without tearing when the core is completely crushed about the sharp edge.
8. The sandwich construction of claim 1 , wherein the inner facing layer is at least one of sufficiently compressible or sufficiently stretchable for conforming to the core without tearing when the core is at least partially crushed about the sharp edge.
9. The sandwich construction of claim 1 , wherein the inner and outer facing layers are substantially continuous.
10. The sandwich construction of claim 1 , wherein the inner facing layer includes wadded paper.
11. The sandwich construction of claim 1 , wherein the inner facing layer includes a foam layer.
12. The sandwich construction of claim 1 , wherein the sandwich construction includes a formable protector.
13. A formable protector, comprising:
a honeycomb core having inner and outer surfaces and comprising a sheet material oriented extending between the inner and outer core surfaces in a configuration providing resistance to crushing in a direction between the inner and outer surfaces, wherein the resistance to crushing is between about 50 psi and about 90 psi;
an outer facing layer of a substantially unstretchable paper sheet material adhered to the outer surface of the core layer; and
an inner facing layer adhered to the core inner surface and being sufficiently stretchable to conform to a sharp edge of a protected object when the formable protector is bent therearound, wherein the inner facing layer comprises either a polymer fiber material or a wadded paper material, such that the inner facing layer is compressible and stretchable in the plane of the inner facing layer;
wherein the core has sufficient resistance to crushing and the outer facing layer is sufficiently durable for causing the core to partially crush when the formable protector is bent around the sharp edge while partially retaining crushing resistance for protecting the sharp edge against impact.
14. The formable protector according to claim 13 , wherein the inner and outer facing layers are substantially continuous.
15. The formable protector according to claim 13 , wherein the inner facing layer includes a foam layer.
16. The formable protector of claim 13 , wherein the inner facing layer is sufficiently deformable for conforming to the core crushed about the sharp edge to at least half the core depth without tearing.
17. The formable protector of claim 13 , wherein the inner facing layer is sufficiently deformable for conforming to the core without tearing when the core is completely crushed about the sharp edge.
18. The formable protector of claim 13 , wherein the inner facing layer is substantially more compressible and stretchable than the outer facing layer.