BACKGROUND

Articles or products having suspension characteristics/quality to improve softness comfort of users are well known. These include cycle seats, motor vehicle seats, chair components, sofas, and interior car parts that suspend or compress on application of force thereon.

Conventionally, the articles are formed of different materials, often including an elastic foam layer compressible to provide suspension quality thereto, covered by an external fabric layer, joined by means of adhesives or by heat treatment or by sawing. One or more of the multiple layers can absorb energy and reduce impact on the users when the users apply a force on the article.

Materials used as layers in the above articles are often thermoset and non-recyclable, adding to the ever-increasing environmental waste. Examples of these materials are Polyurethane (PU), Polyvinyl chloride (PVC), or Ethylene-vinyl acetate (EVA).

GENERAL DESCRIPTION

The presently disclosed subject matter is directed to a hybrid structure which can be in the form, or constitute a part, of an article of the above kind, which comprises a thin rigid covering layer fixedly connected to a thick rigid core member, optionally with an elastic layer therebetween, configured so as to provide a suspension quality to the structure, with at least the covering layer being rigid enough to be incompressible by a force under which the suspension quality is to be provided. Thus, in the present description and claims, and unless specifically indicated otherwise, the term ‘force’ or ‘flexing force’ means a force under which the suspension quality is to be provided, directed at least partially along the thickness direction of the structure, i.e. direction perpendicular to an exterior surface of the covering layer, and the term ‘rigid’ used with respect to a component or material means ‘so rigid as to maintain its shape as produced and be either incompressible under the above force (e.g. as the covering layer) or having a substantially lower compressibility under said force than an elastic foam (e.g. as in the core member)’; the term ‘thin’ with respect to the covering layer means that the thickness of this layer is so small as to allow it to be flexible as indicated above, and the term ‘thick’ with respect to the core member means that the thickness of this member substantially exceeds that of the covering layer and is thick enough to securely hold the covering layer thereon by means of a connection arrangement.. According to a first aspect of the presently disclosed subject matter, there is provided a hybrid structure comprising: a core member having an outer surface; a covering layer connected to the core member and having thickness between an internal surface configured to face the core member and an opposite external surface; a reduceable-volume layer disposed at least at a number of regions between the internal surface of the covering layer and the outer surface of the core member, the covering layer being configured so that, upon application of a flexing force at any of a plurality of areas of the covering layer corresponding to said number of regions, each such area of the covering layer flexes inwardly into the reduceable-volume layer while maintaining the thickness of the covering layer at said area and flexes back when the force is removed, thereby providing the structure with a suspension quality; and a connection arrangement connecting the core member and the covering layer to each other, said connection arrangement comprising an array of lockable portions associated with the internal surface of the covering layer and an array of corresponding locking portions in the core member, said locking portions being configured to lockingly engage at least partially the corresponding lockable portions, said locking portions of the core member being reinforced.

In the present description and claims, the term “reinforced’ with respect to an element means that this element is made of a material which is stronger, e.g. has a higher density, than the material which at least partially surrounds the reinforced element.

The core member can comprise at least a front side and a back side, said covering layer comprising at least a front covering layer part and at least a back covering layer part, said reinforced locking portions comprising front locking portion configured to lockingly engage corresponding lockable portions of the front covering layer part and back locking portions configured to lockingly engage corresponding back lockable portion of the back covering layer part.

The reinforced locking portions can be considered as constituting a part of a reinforced structure which can be continuous, i.e. having all portions thereof connected to each other, or rather can be discontinuous and have at least some of its portions that are not connected to any other reinforced portions. The reinforced structure can constitute a skeleton for the hybrid structure facilitating its strength and stability, when necessary. In some examples, the reinforced structure can be configured to be assembled with the core member after the core member and the reinforced structure have been fabricated. In other examples, the core member can be injected using over-molding technique on the reinforced structure.

The reinforced structure can comprise a mounting portion configured to facilitate mounting of the hybrid structure to an external body. The mounting portion can at least partially protrude from the core member so as to facilitate said mounting. For instance, the hybrid structure can be used for manufacturing a seat part and/or or a back rest part for a seat configured to be held by some frame, and the mounting portion of each such part can facilitate mounting thereof to the frame.

In some examples, the lockable portions can be at least partially formed integrally as a unitary body with the covering layer. In other examples, the lockable portions can be formed separately and later mounted to the covering layer.

At least some of the lockable portions can be formed at the areas of the covering layer having the reduceable volume thereunder and the corresponding locking portions are positioned so as to have this volume thereabove. In this case, at least some of the lockable portions or the corresponding locking portions can extend through the reduceable-volume layer so as to maintain the thickness of the reduceable-volume layer adjacent to those lockable portions, at least in absence of the flexing force and can have such longitudinal dimensions in a direction of the thickness of the covering layer, as to allow the lockable portion to be moved inwardly towards the locking portion when the associated area of the covering layer flexes into the reduceable volume disposed thereunder.

The connection arrangement is a suspension-allowing connection arrangement and can be a quick fitting connection arrangement. For example, the lockable portions can comprise lockable protrusions and the locking portions comprise locking recesses, each configured to irreversibly receive therein at least partially the corresponding lockable protrusion. Each of the locking portions can further comprise a reinforced support member and each of the lockable protrusions can comprise a pairing member, which can also be reinforced and which extends into the support member and is configured for restricted axial displacement within the support member in a direction in which the locking portions receive the lockable portions. The lockable portions can each be formed unitarily with the pairing member or can have lockable elements formed unitarily with the covering layer each fixedly engaging the pairing member.

The thickness of the covering layer can be so small as to allow it to function as a membrane at said areas, which flex into the reduceable-volume layer when said flexing force is applied thereon. The reduceable volume layer can have a thickness exceeding that of the covering layer at least at said areas, and it can be constituted either by a plurality of air gaps formed between the outer surface of the core member and the internal surface of the covering layer, the gaps being spaced from each other, e.g., by bumps on the outer surface of the core member and/or on the internal surface of the covering layer; or by such gaps in combination with an elastic layer portions accommodated therein; or by an elastic layer disposed between the covering layer and the outer surface of the core member which is free of the above air gaps. When the elastic layer is used, with or without the air gaps, it is configured to be elastically compressed by said areas of the covering layer upon the application of said flexing force thereon.

The elastic layer can be in the form of an elastic foam layer or the like.

In all the examples described above, materials from which all or at least most of the components of the hybrid structure are made, can be such as to allow their recycling including thermal processing thereof, under the same conditions and thus without separation. In particular, the materials of at least the core member, the covering layer and at least a part of the connection arrangement can be meltable at the same or about the same recycling temperature. For example, these materials can comprise the same basic thermoplastic substance or different basic thermoplastic substances that are meltable at the same recycling temperature, and each can be the only substance within the corresponding materials that changes its form at said temperature.

For example, the above basic substances can be thermoplastic polymers of the same family of the polymers. Among currently available thermoplastic polymer substances, thermoplastic polypropylene is one example of a substance that can be used as a basic substance for the above described materials.

In components of the hybrid structure made of the materials having the same or similar basic substance, such as e.g. thermoplastic polypropylene, these materials have different material form and/or different physical characteristics. Such components can have a total weight which constitutes more than 90%, optionally, more than 93%, e.g. at least 95%, of the weight of the entire hybrid structure. For example, when these components are the core member, the covering structure and at least a part of the connection arrangement, the core member can have a rigid body made of an expanded particle foam, and the covering layer and the connection arrangement comprising its reinforced portions/structure/members can be injection-molded rigid bodies having a bulk density higher than that of the core member, where the connection arrangement can have the same or higher density than that of the covering layer.

The elastic layer, if any, can have weight, which can constitute a minor fraction of the weight of the entire hybrid structure, so even if it is made of a material not meltable at the above recycling temperature, it can be recycled together with the other components of the hybrid structure without separation therefrom.

It should be mentioned that in the present application and claims, ‘recycling without separation’ with respect to a hybrid structure, means a conventional plastic recycling process generally including grinding/crushing the entire hybrid structure into small pieces/bits, heating them to allow meltable substance/s therein to melt and subsequently using the mixture of the melted substance with bits of non-meltable substances suspended therein for any suitable purpose.

In all the examples described above, the core member can comprise receiving elements configured to lockingly receive connectors associated with add-on elements to be connected to the hybrid structure, and the covering layer and the elastic layer, if any, can comprise holes aligned with the receiving elements and configured to provide access thereto for the connectors.

In all the examples described above, the hybrid structure can be as described and shown in International Patent Application PCT/IL2021/051225, the contents of which are incorporated herein by reference, with the addition of the specific connection arrangement of the hybrid structure described above.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

FIG. 1A is a cross-sectional perspective view of a portion of hybrid structure in accordance with one example of the subject matter of the present application.

FIG. IB is an exploded perspective view of the hybrid structure illustrated in FIG. 1A. FIG. 1C is a cross-sectional perspective view of the same portion of the hybrid structure as that of FIG. 1A, showing the structure in operation.

FIG. 2A shows a cross-sectional perspective view of a hybrid structure according to a further example of the subject matter of the present application, the structure being similar to that of FIG. 1A, but with a core member having bumps, and without an elastic layer, and with a covering layer being shown as transparent for illustration purposes.

FIG. 2B shows is a cross-sectional perspective view of a hybrid structure according to another example of the subject matter of the present application, the structure being similar to that of FIG. 2A, but comprising elastic layer portions accommodated in gaps between the bumps.

FIG. 3A is a perspective view of a two-sided hybrid structure according to another example of the subject matter of the present application.

FIG. 3B is an exploded perspective view of a two-sided hybrid structure according to further example of the subject matter of the present application, with a continuous two-sided reinforced structure.

FIG. 4A is a perspective view of a two-sided hybrid structure according to another example of the subject matter of the present application, having add-on receiving portions at one side of its core member, shown with an add-on attached thereto for illustration purposes.

FIG. 4B is an exploded perspective view of the structure illustrated in FIG. 4A.

DETAILED DESCRIPTION OF EMBODIMENTS

FIGS. 1A-1C illustrate a hybrid structure having a suspension quality, in accordance with one example of a first aspect of the subject matter of the present application. The hybrid structure shown in these Figures constitutes an exemplary portion of an article 100 to be incorporated into a product to provide a feeling of softness to a user. The product can, for example, be a cycle seat, motor vehicle seat, chair component, sofa, interior car parts, or any such part or component that requires the outer layer to provide a feeling of softness.

The hybrid structure/article 100 includes a core member 110, a covering layer 120, and a reduceable-volume layer 130, which in the illustrated embodiment is an elastic foam layer 130 sandwiched between the core member and the covering layer. The core member 110 has an outer surface 112 facing in the direction of the covering layer 120. The covering layer 120 has an internal surface 122 facing in the direction of the core member 110 and an external surface 124 facing towards the exterior of the article 100. The covering layer 120 is fixedly attached to the core member 110 via the elastic layer 130, by a suspension-allowing connection arrangement generally designated as 125. The core member 110 and the covering layer 120 are rigid, and the elastic layer 130 is elastic enough to take the shape that of the outer surface 112 of the core member 110 and the internal surface of the covering layer upon assembly of the structure.

The covering layer 120 and the elastic layer 130 are made of such materials and have such thicknesses that, when a flexing force F is applied at an area of the external surface 124 of the covering layer 120 along a thickness direction T of the structure, this area of the covering layer 120 flexes inwardly into the elastic layer 130. Thus, the suspension characteristics are achieved and the covering layer 120 provides a feeling of softness to the article like that of elastic foam. In other words, the covering layer 120 and the elastic layer 130 are configured so that each area of the covering layer 120 to which the force F is applied behaves like a membrane held in place by adjacent areas of the covering layer 120 where the force is not applied, with both the external surface 124 as well as the internal surface 122 of the covering layer 120 at these areas flexing inwardly into the elastic layer 130, as shown in FIG. 1C. Thus, when the force F is applied at a plurality of areas at the external surface 124 of the covering layer 120, and the covering layer 120 flexes into the elastic layer 130 at such areas, the volume of the elastic layer 130 under these areas is reduced. The covering layer 120 is capable of flexing upon application of force only when mounted so as to have reduceable volume underneath. In the absence of the reduceable volume, the covering layer 120 is not flexible, i.e., the volume of the covering layer 120 is not compressible itself upon the application of the flexing force, and when the covering layer 120 flexes, both the internal surface 122 and the external surface 124 of the covering layer flex equally thereby maintaining the thickness of the covering layer 120 at the area of flexing.

In general, the connection arrangement by means of which the covering layer is fixedly connected to the core member, can include an array of lockable portions associated with the internal surface of the covering layer and an array of corresponding r locking portions associated with the core member and at least indirectly lockingly engaging the lockable portions via the elastic layer. The locking portions are reinforced relative to adjacent areas of the core member, i.e. the reinforced locking portions have a greater holding strength than that of areas of the core member adjacent thereto. The lockable portions can also be at least partially reinforced. The connection arrangement can be a quick fitting connection arrangement, in which a locking engagement can be provided, at least indirectly, between the lockable portions and the locking portions by a quick pushing action on the covering layer. The lockable portions can comprise lockable elements that can be formed as a unitary body with the covering layer and pairing members, which can also be reinforced, and the reinforced locking portions can be formed separately and positioned in the core member or can be integrally formed with the core member. The pairing members can each have an engaging portion, which can fixedly engage the lockable elements, optionally with a corresponding hole in the elastic layer, by the quick pushing action on the covering layer, thereby providing quick connection between the lockable portion and the locking portion.

In the illustrated embodiment, the lockable portions are designated as 126, their lockable elements are designated as 126A and their reinforced pairing members are designated as 116, the reinforced locking portions are designated as 114 and the elastic layer 130 includes holes 132 corresponding to the lockable portions 126 and the locking portions 114 allowing the lockable portions 126 and the locking portions 114 to lockingly engage each other therethrough.

In general, each of the locking portions can include a support member and each of the pairing members can have, in addition to the engaging portion fixedly engaging the lockable element, optionally within the corresponding hole of the elastic layer, a restricted portion positioned within the support member so as to allow restricted displacement of the pairing member in the thickness direction T of the structure when the flexing force is applied to the corresponding area of the covering layer.

In the present example, each of the locking portions 114 includes a support member 115 having a first restricting surface 115A and a second restricting surface 115B spaced by a spacing SI from the first restricting surface 115A. Each of the lockable portions 126 includes a lockable cup 126A and the corresponding elongated pairing member 116 having an engaging portion 116A tightly received in the lockable cup 126A within a corresponding hole in the elastic layer and a restricted portion 116B positioned within the spacing SI such that the restricted portion 116B is displaceable, upon the displacement of the pairing member 116, in the direction towards the covering layer 120 while remaining restricted within the spacing SI..

In order to connect the covering layer 120 to the core member 110, each lockable cup 126A is aligned with the corresponding pairing member 116, and when the lockable cup 126A engages with the engaging portion 116A of the pairing member 116 and the corresponding portion of the covering layer 120 is pushed further, the engaging portion 116A displaces in the direction of the pushing force until the restricted portion 116B abuts the second restricting surface 115B of the support member 115. A further push on the covering layer 120 causes the lockable cup 126A to tightly dress onto the engaging portion 116A thereby locking the lockable cup 126A to the pairing member 116. Upon removal of the pushing force, by virtue of the suspension quality of the covering layer 120, the pairing member 116 moves together with the corresponding lockable cup 126A away from the second restricting surface 115B, thereby leaving a spacing S2 between the restricted portion 116B of the pairing member 116 and the second restricting surface 115B. When the flexing force F is applied onto the covering layer 120 at an area corresponding to the lockable portion 126, the spacing S2 allows the pairing member 116 to displace into the locking portion 114 thereby maintaining the suspension quality of the covering layer 120 at the areas corresponding to the connection between the covering layer 120 and the core member 110.

Further, as can be seen in FIG. 1A, the longitudinal dimensions of the lockable portions 126 including those of the engaging portions 116A of the pairing members 116 with the lockable cups 126A dressed thereon within the elastic layer 130, are such as to maintain a spacing S3 between the internal surface 122 of the covering layer 120 and the outer surface 112 of the core member 110 at portions of the elastic layer 130 adjacent to the lockable portions 126 when the flexing force is not applied. The spacing S3 allows the areas of the covering layer 120 corresponding to the lockable portions 126 to flex inwardly into the elastic layer 130 upon the application of the flexing force F.

In another embodiment (not shown), lockable portions of the covering layer can include lockable reinforced or non-reinforced protrusions protruding from the internal surface of the covering layer, and the locking portions can include reinforced locking recesses in the core member, each configured to irreversibly receive therein the corresponding lockable protrusion, while maintaining all other features of the connection arrangement as described above according to the illustrated embodiment. This arrangement is similar to that in a hybrid structure shown in the corresponding figures of International Patent Application PCT/IL2021/051225, incorporated herein by reference, with the addition of reinforcement to its recesses as described above.

In the illustrated example, the lockable cups 126A of the lockable portions 126 are formed integrally as a unitary body with the covering layer 120. In another embodiment (not shown), the entire lockable portions 126 can be separately formed and mounted to the covering layer 120. In some examples, the locking portions and the lockable portions can have dimensions in a direction along the outer surface, so as to allow the covering layer to slightly move relative to the core member in the tangential direction, when respective flexing and tangential forces are at least indirectly applied to areas of the covering layer, resulting in an added dimension to the suspension characteristics of the covering layer, and thus, an improved feeling of softness to the article.

FIG. 2A illustrates a hybrid structure constituting a portion of another article 100 having the same connection arrangement as described above with respect to the article illustrated in Figs. 1A to 1C, the difference between them being only in that the reduceable-volume layer 130 being constituted by air gaps G formed in the core member 110. The air gaps G are formed between bumps 117 formed on the outer surface 112 of the core member 110. The bumps 117 protrude from the outer surface 112 in the direction of the covering layer 120 and spaced from each other by spacing regions 118 between any two adjacent bumps 117. This hybrid structure can be the same as shown in the corresponding figures of International Patent Application PCT/IL2021/051225, incorporated herein by reference, with the addition of reinforcement to its recesses as described above.

According to the illustrated embodiment, the bumps 117 are unitarily formed with the core member 110. However, in another embodiment (not shown), the bumps 117 can be separately manufactured, and then assembled together with the core member 110. In the latter case, the bumps 117 can be formed of the same or different material as that of the core member 110, e.g. the material used in the bumps 117 can comprise the same basic substance as that of the core member 110 but be in a different form and/or have different physical characteristics.

The covering layer 120, when attached to the core member 110, covers the outer surface 112 of the core member 110 such that, as seen in FIG. 2A, the internal surface 122 of the covering layer 120 rests on the bumps 117, and the plurality of gaps G are formed between the covering layer 120 and the core member 110 at locations where the internal surface 122 does not contact the bumps 117. In other words, the gaps G are formed at locations corresponding to the spacing regions 118 and are defined by the spacing regions 118. According to the illustrated embodiment, the gaps G are filled with air. According to another embodiment, the gaps G can comprise an elastic material, as described in detail later herein below with reference to FIG. 2B. The covering layer 120 and the gaps G are so configured, i.e. the covering layer 120 is made of such material and has such a thickness, and gaps G have such dimensions that, when a flexing force F is applied at the external surface 124 of the covering layer 120 at areas above the gaps G, the covering layer 120 slightly flexes inwardly into the gaps G, and when the force F is removed, it flexes back to its normal shape. Thus, the suspension characteristics are achieved and the covering layer 120 provides a feeling of softness to the article like that of an elastic foam. In other words, the covering layer 120 and the gaps G are configured so that areas of the covering layer 120 associated with the gaps G each behave like a membrane, when the force F is applied thereto, held in place by adjacent areas of the covering layer 120 supported by the bumps 117, with both the external surface 124 as well as the internal surface 122 of the covering layer 120 at these areas flexing inwardly into the gaps G and maintaining a thickness and volume of the covering layer 120. Thus, when the force F is applied at the external surface 124 of the covering layer 120, and the covering layer 120 flexes into the gaps G, the volume of the gaps G is reduced.

In addition, the bumps 117 can be configured to be compressible to impart further compressibility and thus increased feeling of softness to the article. It is to be understood herein that the core member 110 and/or bumps 117 of the core member 110 have a compressibility higher than that of the covering layer 120, but still lower than that an elastic foam generally has. The compressibility /rigidity of the bumps 117 can be selected based on the utility of the final product in which the article is to be incorporated.

The thickness of the covering layer 120, the length of spacing regions 118, the maximal dimension of the bumps 117 along the outer surface 112, and the height of the bumps 117, and correlations therebetween should be such as to allow the covering layer 120 to flex into the gaps G and effect the suspension characteristics of the article. For example, at least 30% of the area of the internal surface 122 of the covering layer 120 should correspond to the spacing regions 118, i.e., should be free of contact with bumps 117, thereby sitting on air to be able to flex inwardly into the air and thus reduce its volume, upon application of force. Thus, the covering layer 120 is capable of flexing upon application of force only when mounted so as to have reduce able volume underneath, such as the gaps G in the present example and it would not be able to flex if placed over a rigid, incompressible surface.

In another embodiment not illustrated in the present application but the same as shown in the corresponding figures of International Patent Application PCT/IL2021/051225, incorporated herein by reference, with the addition of reinforcement to its recesses as described above., the covering layer can have bumps protruding therefrom and configured to rest on the outer surface of the core member when the covering layer is connected to the core member. The bumps of the covering layer can be in the alternative to or in addition to the bumps of the core member and are configured to serve the same purpose as that of the bumps of the core member. The description about the structure, dimensions, positioning of the bumps of the core member applies to the bumps of the covering layer as well and has not been repeated herein for the sake of conciseness. Also, the covering layer functions in the same manner with the bumps formed on the covering layer as that with the bumps formed on the core member. The core member is formed of such a material and is configured to be compressed when a force is applied at areas corresponding to the bumps (of the core member as well as of the covering layer). For instance, when the flexing force is applied on the covering layer on areas corresponding to the bumps of the covering layer, the bumps compress the core member thereunder.

In case when the core member and the covering layer both have bumps, the covering layer is placed over the core member such the bumps of the two do not coincide. In other words, the bumps of the core member and the covering are received at the locations corresponding to spacing regions between such bumps of the other component and the connections arrangement is disposed at regions between such bumps as well.

According to another embodiment, for example as illustrated in FIG. 2B, the hybrid structure 100 (illustrated in FIG. 2 A) has an additional elastic foam layer 130 with its portions accommodated within the gaps G. The elastic layer portions constitute the reduceable volume underneath the covering layer 120 and imparts the suspension quality to the structure. This hybrid structure can be the same as shown in the corresponding figures of International Patent Application PCT/IL2021/051225, incorporated herein by reference, with the addition of reinforcement to its recesses as described above.

The covering layer 120 along with the entire structure 100 shown in FIG. 2B have all the features and characteristics of the structure shown in FIG. 2 A and the only difference being that the reduceable volume layer is partially constituted by the elastic layer 130 instead of the air. The elastic layer 130 has holes 132 corresponding in shape and dimensions to the bumps 117 such that the bumps 117 protrude from the outer surface 112 of the core member 110 towards the internal surface 122 of the covering layer 120 through the holes 132. The thickness of the elastic layer 130 does not exceed or at least does not essentially exceed the height of the bumps 117 so that the elastic layer 130 allows the covering layer 120 to rest on the bumps 117 at least when the covering layer 120 is flexed towards the core member 110.

The elastic layer 130 fills in at least a part of the volume defined by gaps G, constituting a reduceable volume therewith, configured such that when the force F is applied on the external surface 124 of the covering layer 120 at areas thereof above the portions of the elastic layer 130 disposed in the gaps, or in other words the portions where the covering layer 120 does not rest on the bumps 117, the covering layer 120 flexes inwardly towards or into the elastic layer 130 depending on the thickness of the elastic layer 130. Thus, the suspension characteristics can be adjusted and the covering layer 120 and the elastic layer 130 together provide a desired feeling of softness to the article like that of elastic foam.

In the embodiment with bumps formed on the covering layer, in addition or alternative to the bumps of the core member, an elastic foam layer can fill in at least some of the spacing regions between the bumps of the covering layer.

A hybrid structure according to the presently disclosed subject matter, can be two-sided and its structure described above can constitute a front part of a complex hybrid structure whose back and/or sides can include respective back/side portions of the core member, back/side portions of the covering layer and back/side elements of the connection arrangement. The structure can have suspension quality on both sides or only at its front, in which case its back connection arrangement can be different from or the same as its front connection arrangement.

FIG. 3A illustrates a hybrid structure constituting a portion of an article 200 having a suspension quality at both sides thereof, according to a further example of the subject matter of the present application. The portion shown in these Figures represents an exemplary small section of the article 200 to be incorporated into a product to provide a feeling of softness to a user. The product can be a cycle seat, motor vehicle seat, chair component, sofa, interior car parts, or any such part or component that requires the outer layer to provide a feeling of softness.

The article/hybrid structure 200 has two sides, each incorporating at least some features of article 100 as detailed above with reference to FIGs. 1 A to 2B, specifically the ones related to the core member, the covering layer, and the elastic layer. More particularly, the hybrid structure/article 200 includes a core member 210 having two sides, 210A and 210B, each having an outer surface 212, each side being associated with a covering layer 220 having an internal surface 222 and an external surface 224, and a reduceable-volume layer 230, which in the illustrated embodiment is an elastic foam layer 230.

The covering layer 220 and the elastic layer 230 are configured to include all the suspension quality and characteristics of the covering layer 120 and the elastic layer 130 as described above. The covering layer 220 and the elastic layer 230 are configured so that the covering layer 220 flexes inwardly into the elastic layer 230 when a flexing force F is applied on the external surface 224 of the covering layer 220. Thus, the suspension characteristics are achieved and the covering layer 220 provides a feeling of softness to the article like that of elastic foam. In other words, the covering layer 220 and the elastic layer 230 are configured so that an area of the covering layer 220 to which the force F is applied behaves like a membrane held in place by adjacent areas of the covering layer 220 where the force is not applied, with both the external surface 224 as well as the internal surface 222 of the covering layer 220 at these areas flexing inwardly into the elastic layer 230. Thus, when the force F is applied at the external surface 224 of the covering layer 220, and the covering layer 220 flexes into the elastic layer 230, the volume of the elastic layer 230 under said areas is reduced. The covering layer 120 is capable of flexing upon application of force only when mounted so as to have reduceable volume underneath. In the absence of the reduceable volume, the covering layer 220 is not flexible, i.e., the volume of the covering layer 220 is not compressible itself, and when the covering layer 220 flexes, both the internal surface 222 and the external surface 224 of the covering layer flex equally thereby maintaining a thickness of the covering layer 220 at the area of flexing.

The hybrid structure 200 further includes a connection arrangement having two sides each corresponding to the connection arrangement of the hybrid structure 100 described above with reference to Figs. 1A to 1C and connecting the covering layer 220 to one of the sides 210A and 210B of the core member 210. Each side of the connection arrangement includes an array of lockable portions 226 associated with the internal surface 222 of the covering layer 220 and an array of corresponding locking portions 214 associated with the core member 210 and lockingly engaging the lockable portions 226 through the elastic layer. Each of the locking portions 214 is reinforced relative to areas of the core member 210 adjacent thereto. At least a part of the lockable portions 226 of the covering layer 220 can also be reinforced. The reinforced locking portions 214 have a greater holding strength than that of the areas of the core member 210 adjacent thereto. In the illustrated example, the reinforced locking portions 214 are formed separately and positioned in the core member 210. In some embodiments (not shown), the reinforced locking portions 214 can be integrally formed with the core member 210.

The elastic layer 230 includes holes 232 corresponding to the lockable portions 226 and the locking portions 214 configured to allow the lockable portions 226 and the locking portions 214 to lockingly engage each other therethrough.

The locking portions 214 including their support members 215 have the same structure as that of locking portions 114 with their support members 115 described above.

The lockable portions 226 also have the same structure as that of the lockable portions 126 described above including lockable cups 226A formed unitarily with the covering layer, and reinforced elongated pairing members 216.

FIG. 3B illustrates a hybrid structure constituting a portion of an article 200 having a suspension quality at both sides thereof, according to a further example of the subject matter of the present application. The hybrid structure 200 of Fig. 3B is identical to the hybrid structure 200 of Fig. 3 A with the only difference being in that the locking portions 214 and more particularly their support members 215 are connected to each other by a common base portion 241 all forming a part of a continuous two-sided reinforced structure 240.

In the illustrated example, the core member 210 includes a front side 210’ and a back side 210”, each side being associated with respective front and back covering layers 220’ and 220” and front and back elastic layers 230’ and 230’ ’

The base portion 241 of the reinforced structure 240 constitutes a bridge between the locking portions 214 associated with the outer surface 212 of the core member 210 at two sides thereof, connecting them together, thereby facilitating manufacturing of the hybrid structure with the reinforced portions in its core member. The reinforced structure 240 can thus act as a skeleton for the hybrid structure 200 providing it with the ability to bear heavier loads thereupon and providing a strong connection between the core member 210 and the covering layer 220 without affecting the suspension quality of the hybrid structure.

In the illustrated example, the reinforced structure 240 is configured to be assembled with the core member 210 after both the reinforced structure 240 and the core member 210 have been (separately) fabricated. The reinforced structure 240 can be detachably assembled with the core member 210 via corresponding regions 260 formed in the core member 210. In other embodiments (not shown), the core member 210 can be over- molded over the reinforced structure 240. As can be seen in FIG. 3B, the base portion 241 of the reinforced structure 240 extends along a plane perpendicular to the thickness direction and it includes a mounting portion 242 that protrudes from the core member 210 when the reinforced structure 240 is assembled with the core member 210. The mounting portion 242 can be configured to facilitate mounting of the hybrid structure to an external body.

The reinforced locking portions 214 include front locking portions 214’ protruding from the base portion 241 towards the front side 210’ of the core member 210 and lockingly engaging corresponding lockable portions 226’ of the front covering layer 220’, and back locking portions 214” protruding from the base portion 241 in the direction away from the front side 210’ of the core member 210 and lockingly engaging corresponding lockable portions 226” of the back covering layer part 220’. In the illustrated embodiment, the front locking portions 214’ and the back locking portions 214” are spaced from the base portion 241 to different distances, the former protruding therefrom to a greater extent so as to reach corresponding apertures 213 in the outer surface of the front side 210’ of the core member 210.

The locking portions 214’ and 214” both can have the same construction as described above with reference to Figs. 1A to 2B. In other embodiments (not shown), the front locking portions 214’ and the back locking portions 214” can have different constructions some or all of which can differ from those described above with reference to Figs. 1A to 2B.

Whilst in the illustrated example, the hybrid structure 200 has two sides having suspension quality, each having the locking portions, it is to be understood herein that the hybrid structure can also have just one side with suspension quality, and corresponding locking portions.

It is to be understood herein that although the hybrid structure 100 described with reference to FIGS. 1A to 1C and 2A to 2B have been illustrated as having one side with suspension quality, the hybrid structure 100 can, in some embodiments not shown, have two sides with suspension quality and corresponding locking portions, elastic layer, and covering layer in a similar manner as described above with reference to hybrid structure 200.

FIGS. 4A and 4B illustrate hybrid structures each constituting a portion of an article 300 having a suspension quality, according to a further example of the subject matter of the present application. The portion shown in these Figures represents an exemplary small section of the article 300 to be incorporated into a product to provide a feeling of softness to a user. The product can be a cycle seat, motor vehicle seat, chair component, sofa, interior car parts, or any such part or component that requires the outer layer to provide a feeling of softness.

The article/hybrid structures 300 of Figs. 4A and 4B incorporate at least some features of article 100 as detailed above with reference to FIGS. 1A to 2B and those of the article 200 as detailed above with reference to respective FIG. 3 A and 3B, specifically the ones related to the core member, the covering layer, the elastic layer, and the connection arrangement. In particular, the hybrid structures 300 each include a core member 310 having an outer surface 312, a covering layer 320 having an internal surface 322 and an external surface 324, a reduceable -volume layer 330, which in the illustrated embodiment is an elastic layer 330, corresponding to the core member, covering layer, and elastic layer of the article/hybrid structure 300. The covering layer 320 and the elastic layer 330 are configured to include all the suspension quality and characteristics of the covering layers 120, 220 and the elastic layers 130, 230 as described above.

The hybrid structures 300 of Figs. 4A and 4B each further includes a connection arrangement having the same features as the connection arrangement of the hybrid structures 100 and 200, connecting the core member 310 and the covering layer 320 to each other. In particular, the connection arrangement includes an array of lockable portions 326 associated with the internal surface 322 of the covering layer 320 and an array of corresponding locking portions 314 associated with the core member 310 and lockingly engaging the lockable portions 326. The locking portions 314 and the lockable portions 326 have the same structure and are operable in the same manner as those of the hybrid structures 100 and 200 described above. The locking portions 314 and pairing members 316 of the hybrid structure 300 shown in Fig. 4B are reinforced and constitute a part of a reinforced structure 340 having a base portion 341, corresponding to and having same construction as the reinforced structure 240 of the hybrid structure 200, with its base portion 241, as shown in Fig. 3B.

The hybrid structure 300 of each of Figs. 4A and 4B can be considered as being identical to the hybrid structure 200 of the respective Figs. 3A and 3B, with the only difference being in that the hybrid structure 300 of each of Figs. 4A and 4B is configured for being used with an add-on 1000 attachable thereto at its front side 300A.

For this purpose, the core member 310 of each of the hybrid structures 300 of Figs. 4A and 4B, comprises an array of receiving elements 350 formed in the core member 310 and being accessible through a front outer surface 312 of the core member 310 via the covering layer 320 and the elastic layer 330. The receiving elements 350 are configured to receive connectors 1010 associated with the add-on element 1000. The add-on element 1000 can be any element to be connected as an additional element to the hybrid structure based on the purpose and usage of a product manufactured from the hybrid structure. In the illustrated example, the add-on element is a cushion for a seat comprising the hybrid structure 300.

In the illustrated embodiment, each of the receiving elements 350 is a recess formed in the core member 310 extending inwardly into the core member 310 from the outer surface thereof and configured to lockingly receive therein the connector 1010 extending from the add-on element 1000. The covering layer 320 and the elastic layer 330 are formed with holes 327 and 337, respectively, corresponding to and aligned with the corresponding recesses 350 and configured to provide access thereto for the connectors 1010. The recesses 350 are configured to snap fittingly receive the connectors 1010 to establish a permanent connection therebetween. In some embodiments (not shown), the receiving elements can be configured to detachably receive the connectors.

Although the hybrid structures 300 of Figs. 4A and 4B have been illustrated as corresponding to the hybrid structures 200 shown in FIGS. 3 A and 3B, it is to be understood that the hybrid structure 300 can correspond to the hybrid structure 100 shown in any of the FIGS. 1A to 1C or 2A and 2B having features corresponding to all or some of those of the hybrid structure 100.

Furthermore, the hybrid structures 200 and 300 have been illustrated having the reduceable layer constituted by the elastic foam layer, it is to be understood that these structures can have the reduceable volume layer constituted by any combination of bumps, gaps and elastic foam layer portions as described above.

In all of the above examples of the hybrid structure, almost all components thereof can be made of materials allowing their recycling including thermal processing thereof, without separation. In particular, the materials of at least the core members 110, 210, 310, the covering layers 120, 220, 320, the connection arrangement including the lockable portions 126, 226, 326, with their reinforced pairing members 116, 216, 316, and the reinforced structures 240, 340 (in the hybrid structures 200 and 300) with their reinforced base portions 241, 341 and locking portions 114, 214, 314, can all be made of materials meltable at the same recycling temperature. For example, they can comprise the same basic substance or different basic substances that are meltable at the same recycling temperature and said/each basic substance is the only substance within said materials that changes its form at said temperature. Since these materials can constitute more than 90%, optionally, more than 93%, e.g. at least 95%, of the weight of the entire hybrid structure, the structure can be recycled without separation even if the remaining materials in the structure are not meltable at the above temperature.

The basic substances can be recyclable thermoplastic polymers which can differ in the material form between the core member and the covering layer and components of the connection arrangement. For example, the core layer which is the thickest component in the structure can have a bulk density lower than of the covering layer which must be very thin for flexing under the flexing force as described in the above examples but still rigid to maintain its shape and the shape of its connection elements.

One example of a hybrid structure of this kind can be such structure where the basic substances in the materials of at least the core member, covering layer and the connection arrangement are of the same family of recyclable thermoplastic polymers, e.g. such as polypropylene. In this case, the material of the core member can be in the form in an expanded particle foam and the materials of the covering layer and the reinforced components of the connection arrangement can each have a compact form having a bulk density higher than that of the core member. In the latter example, the core member can be formed by particle-foam injection molding into a desired shape based on, and to dictate the shape of, the final product to be manufactured from the article; and the covering layer and the connection arrangement can be made by injection molding or compression molding, thermoforming, extrusion, vacuum forming, or other technologies, allowing the covering layer and the elements of the connection arrangement to maintain their shape as produced.

As mentioned above, the material/s of the covering layer and elements of the connection arrangement can have greater bulk density than the material of the core member. In some examples, the material of the reinforced components of the connection arrangement can have greater bulk density than that of the covering layer.

In one specific example where the thermoplastic polymer substance is polypropylene, when it is used to produce the expanded-particle-foam core member, such core member can have a bulk density of 25 - 250 gram/litre, more particularly, 30-120 gram/litre; when it used to produce the covering layer, such covering layer can have a density of 800-1000 gram/litre, more particularly, about 900 gram/litre; when it is used to produce the reinforced portions/structure of the core member and, optionally, the pairing members, they can have a density of 900-1500 gram/litre. If the hybrid structure comprises an elastic foam layer whose basic substance is also polypropylene, such elastic layer can have a bulk density of 25-150gram/litre, more particularly, 30-120 gram/litre.

The elastic foam layer, if any, can have weight, which can constitute a minor fraction of the weight of the entire hybrid structure, e.g. 5% or less, so even if it is made of a material not meltable at the above recycling temperature, it can be recycled together with the other components of the hybrid structure without separation therefrom. The following are examples of the above materials all being polypropylene -based, which can be used in each of the hybrid structures described above:

Examples described above allow a core member, a covering layer, and optionally, an elastic layer and/or a reinforced portions/structure, all to be connected to each other by means which are free of any adhesives. Yet, if desired, an adhesive can be used between the covering layer and the core member or between one or both of these and the elastic layer, if any, or between the core member and the reinforced structure/reinforced pairing members, for example if such adhesive is made of a material comprising the same basic substance as, but differing in its material form and physical characteristics from, those of the other components of the hybrid structure. One example of such basic material can be polypropylene.