In order to solve the problems of poor mechanical properties and incapable reuse for single cellular foam, this study proposed low-cost spring-like sandwich flexible foam composites (SFFCs) with a 3D resilient concave–convex structured fabric core (RCFC) and two gradient-structured styrene-ethylene/butene–styrene copolymer (SEBS)-g-maleic anhydride (MAH)-filled polyurethane (PU) foam faces through two-step foaming. RCFC plied with different sizes and distances constituted warp-knitted spacer fabrics (WKSF) sealed between two layers of low-melting polyester nonwovens through thermal bonding. The effects of SEBS-g-MAH content and volume content of RCFC cubes on compression and dynamic low-velocity impact properties were explored at different impact energy levels. At 3:4 (wt%) ratio of the upper-to-lower SEBS-g-MAH content faces and at 0.4 ratio of WKSF-to-PU volume ratio, the resultant SFFCs showed a compression stress of 68.4 kPa (40%) and absorbed up to 98% of impact energy under 16 J. After five cycles of impact, this sandwich foam composite maintained 98% absorption of impact energy, demonstrating excellent spring-like dynamic-impact-recovery property. Overall, this study provided a novel structure design for lower cost, higher-performance recycling cushion materials in industrial construction, transport packaging, and sports fields.

为了解决机械性能差和单孔泡沫无法重复使用的问题，本研究提出了一种低成本的弹簧状夹芯柔性泡沫复合材料（SFFC），该复合材料具有3D弹性凹凸结构织物芯（RCFC）和两个梯度结构苯乙烯-乙烯/丁烯-苯乙烯共聚物（SEBS）-g-马来酸酐（MAH）填充的聚氨酯（PU）泡沫面通过两步发泡。具有不同尺寸和距离的RCFC构成了经编织的间隔织物（WKSF），它们通过热粘合密封在两层低熔点聚酯无纺布之间。探讨了在不同冲击能级下SEBS-g-MAH含量和RCFC立方体体积含量对压缩和动态低速冲击性能的影响。SEBS-g-MAH含量上下比率为3：4（wt％）时为0。当WKSF与PU体积比为4时，所得的SFFC在16 J下显示出68.4 kPa（40％）的压缩应力，并吸收了高达98％的冲击能。此冲击泡沫经过5个循环后，保持了98 ％的冲击能量吸收，表现出出色的弹簧式动态冲击恢复特性。总体而言，这项研究为工业建筑，运输包装和运动领域中的低成本，高性能回收垫材料提供了新颖的结构设计。