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US 2012/0070606 A1Published application
Composite matrix and gel padding and method of manufacturing
OwnerRichard B. Villatainventor
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Abstract
Composite and laminated composite padding materials or cushions formed from an elastic foam matrix structurally supporting and encapsulated gel elements are disclosed. Methods of manufacturing such composite and laminated composite padding materials or cushions are also disclosed.
Claims23
An elastic composite cushion, comprising:
- an array of viscous gel elements;
- an elastic matrix encapsulating the array of viscous gel elements;
- and
- wherein upon compression of the elastic composite cushion, the gel elements flatten until adjacent neighboring gel elements restrict further flattening.
1 more element
A layer of padding, comprising:
- an elastic matrix including an array of regularly spaced voids formed within the elastic matrix;
- and
- one or more of the voids comprises a viscous gel.
A method of forming a polyurethane pad, comprising:
- providing a mold for receiving polyurethane foam fluid having preselected dimensions of length, width and thickness, the mold having a bottom surface and an array of structural elements extending from the bottom surface;
- providing a polymerizable polyurethane foam fluid;
- providing a soft polyurethane gel;
- disposing the polymerizable polyurethane foam fluid over the mold;
- polymerizing the polymerizable polyurethane foam fluid;
- removing the mold from the polymerized polyurethane foam fluid to obtain polyurethane foam having voids corresponding to the array of structural elements extending from the bottom surface of the mold;
- selectively injecting the soft polyurethane gel into the voids;
- and
- sealing the selectively injected soft polyurethane gel within the voids thereby forming the polyurethane pad.
6 more elements
A composite cushion, comprising:
- an elastic matrix having an array of voids formed between webbing within the matrix;
- a regularly spaced subset of the array of voids filled with a soft viscous gel, each gel-filled void forming a gel element surrounded by webbing from the elastic matrix;
- remaining voids filled with an ambient pressure, compressible gas, thereby forming regularly interspersed gaseous voids;
- a membrane encapsulating the elastic matrix, the gel elements and the gaseous to form the composite cushion;
- and
- the composite cushion structured and arranged such that when compressed the gel elements flatten thereby compressing the surrounding matrix webbing and adjacent gaseous voids to absorb compressive forces.
3 more elements
Dependencies are inferred from the claim text.