System and method of in-place functionalization of 3D regions and arrays thereof, in VLAP cushions, as integrated VLAP pressure sensing cushions

A method for functionalizing, into a compressible pressure varying electrical conductance device, a portion of a compressible nonwoven material (CNM) cushion, comprising:

• forming within a three-dimensional (3D) target region of the CNM cushion a columnar distribution of a non-solidified conductive polymer, extending along a column axis normal to a front surface and a back surface of the CNM cushion, the column having a first end and a second end spaced a height, in a direction toward the front surface, from the first end, the forming comprising injecting into at least a portion of the 3D target region a liquid carrying conductive polymer in suspension;
• and
• converting the columnar distribution of non-solidified conductive polymer into a columnar compressible pressure varying electrical conductance structure extending from the column first end to the column second end by drying or curing of the columnar distribution of the non-solidified polymer so as to at least partially cover nonwoven fibers of the CNM with a thin film of solidified conductive polymer so as to produce a functionalized area of the CNM which comprises a columnar structure that changes conductivity as empty spaces in the CNM are collapsed or expanded so as to increase or decrease connection points between portions of the solidified conductive polymer.