Formed felt device and method of making the same

Abstract

A bumper for protecting a contact point of a surface from engagement with an object and a method of fabricating the same are provided. The bumper includes a shell having first and second ends, an outer surface, and an inner surface defining a passageway through the shell between the first and second ends. A resilient material is positioned in the passageway and extends between the first end and the second end of the shell.

1 . A bumper for protecting a contact point of a surface from engagement with an object, comprising: 
 a shell having first and second ends, an outer surface, and an inner surface defining a passageway through the shell between the first and second ends; and    a resilient material positioned in the passageway and extending between the first end and the second end of the shell.    
   
   
       2 . The bumper of  claim 1  wherein the passageway intersects the first end of the shell at a first opening and wherein the passageway intersects the second end of the shell at a second opening.  
   
   
       3 . The bumper of  claim 2  wherein the first opening and the second opening have diameters and wherein the diameter of the first opening is less than the diameter of the second opening.  
   
   
       4 . The bumper of  claim 2  wherein the inner surface of the shell includes a first generally conical portion extending from the first opening in the first end of the shell.  
   
   
       5 . The bumper of  claim 4  wherein the inner surface of the shell includes a second generally conical portion extending from the second opening in the second end of the shell.  
   
   
       6 . The bumper of  claim 1  further comprising a ring projecting radially from the outer surface of the shell at a location adjacent to the second end.  
   
   
       7 . The bumper of  claim 1  wherein the inner surface of the shell is defined by first and second sidewalls and first and second end walls.  
   
   
       8 . The bumper of  claim 7  wherein the first and second sidewalls intersect the first end of the shell and diverge from each other.  
   
   
       9 . The bumper of  claim 8  wherein the first and second end walls intersect the first end of the shell and diverge from each other.  
   
   
       10 . A bumper for protecting a contact point of a surface from engagement with an object, comprising: 
 a shell having: 
 a first end having an opening therein;  
 a second end having an opening therein;  
 an inner surface defining a passageway that interconnects the opening in  
 the first end of the shell and the opening in the second end of the shell; and  
 an outer surface;  
   a resilient material positioned in the passageway and extending between the first end and the second end of the shell.    
   
   
       11 . The bumper of  claim 10  wherein the first opening and the second opening have diameters and wherein the diameter of the first opening is less than the diameter of the second opening.  
   
   
       12 . The bumper of  claim 11  wherein the inner surface of the shell includes a first generally conical portion extending from the first opening in the first end of the shell.  
   
   
       13 . The bumper of  claim 12  wherein the inner surface of the shell includes a second generally conical portion extending from the second opening in the second end of the shell.  
   
   
       14 . The bumper of  claim 10  further comprising a ring projecting radially from the outer surface of the shell at a location adjacent to the second end.  
   
   
       15 . The bumper of  claim 10  wherein the inner surface of the shell is defined by first and second sidewalls and first and second end walls.  
   
   
       16 . The bumper of  claim 15  wherein the first and second sidewalls intersect the first end of the shell and diverge from each other.  
   
   
       17 . The bumper of  claim 16  wherein the first and second end walls intersect the first end of the shell and diverge from each other.  
   
   
       18 . A method of fabricating a bumper that protects a contact point of a surface from engagement with an object, comprising the steps of: 
 providing a quantity of pliable felt having a predetermined configuration and an outer surface; and    applying a predetermined stimulus to a first portion of the felt so as to form a rigid outer shell from the felt, the outer shell having first and second ends, an outer surface, and an inner surface defining a center in the outer shell;    wherein a second portion of the felt within the center of outer shell remains pliable.    
   
   
       19 . The method of  claim 18  wherein the felt is formed from a plurality of fibers and wherein the step of applying the predetermined stimulus includes the additional step of increasing the density of the fibers of the first portion of the felt.  
   
   
       20 . The method of  claim 18  wherein the step of applying the predetermined stimulus includes the additional step of heating an outer portion of the quantity of felt.  
   
   
       21 . The method of  claim 20  wherein the outer portion of the quantity of felt is heated to a temperature greater than 275 degrees Fahrenheit.  
   
   
       22 . The method of  claim 21  wherein the outer portion of the quantity of felt is heated to a temperature in the range of 325 degrees Fahrenheit to 450 degrees Fahrenheit.  
   
   
       23 . The method of  claim 22  wherein the step of applying the predetermined stimulus includes the additional step of decreasing the temperature of the quantity of felt to a predetermined value after the step of heating an outer portion of the quantity of felt.  
   
   
       24 . The method of  claim 23  wherein the temperature of the quantity of felt is decreased to a temperature of less than 200 degrees Fahrenheit.