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US 2014/0004322 A1Published application
Resilient pad composite and process for making same without a die
AssigneeApplied FT Composite Solutions Inc.
InventorDaniel Kim
Life of this patent
Estimating the term…
Abstract
The present application describes making a resilient pad composite.
Claims23
A method of making a composite structure for use as resilient cushion comprising:
- (a) providing on a surface at least one sheet of resilient material of defined thickness having opposing sides;
- (b) applying an adhesive to either or both sides of the sheet of resilient material;
- (c) providing a first cutter having a surface and a plurality of cutting elements extending from the surface in a predetermined pattern;
- (d) pressing the first cutter into the sheet of resilient material, thereby forming a cut sheet of resilient material comprising a plurality of resilient elements having defined height and width;
- (e) withdrawing the cutter from the cut sheet of resilient material;
- (f) providing at least one sheet of reinforcing material having a defined thickness;
- (g) pressing a second cutter into the sheet of reinforcing material, thereby forming a cut sheet of reinforcing material comprising a plurality of reinforcing elements and a lattice of reinforcing material;
- (h) withdrawing the cutter from the cut sheet of reinforcing material;
- (i) separating the lattice of reinforcing material from the reinforcing elements, whereby the lattice of reinforcing material is left with a plurality of holes through the reinforcing material where the reinforcing elements used to be;
- (j) placing the cut sheet of resilient material adjacent to the lattice of reinforcing material, and aligning the cut sheet of resilient material so that the plurality of resilient elements are positioned adjacent to the plurality of holes in the lattice of reinforcing material;
- (k) pushing the resilient elements out of the cut sheet of resilient material, whereby the plurality of resilient elements are pushed into the plurality of holes in the lattice of reinforcing material, thereby forming a resilient material assembly comprising the plurality of resilient elements at least partially surrounded by at least one lattice of reinforcing material;
- (l) placing the resilient material assembly next to a heat platen, if heat-activated adhesive material is applied to a side of the resilient material;
- (m) placing a first sheet of fabric or mesh substrate onto either side of the resilient material assembly, wherein steps (l) and (m) are optionally reversible in order;
- and
- (n) pressing the first sheet of fabric or mesh substrate or the resilient assembly with the heat platen to activate the adhesive on the plurality of resilient elements, whereby the first sheet of fabric or mesh substrate adheres to the plurality of resilient elements thereby forming a first composite structure.
12 more elements
18-26. (canceled)
A composite pad structure comprising a substrate bonded to a plurality of discrete, spaced-apart, resilient elements engaged to at least one reinforcing structure, wherein there is no space between the reinforcing structure and the substrate.
28-45. (canceled)
A method of making a composite structure for use as resilient cushion comprising:
- (a) providing on a surface at least one sheet of resilient material of defined thickness having opposing sides;
- (b) applying an adhesive to either or both sides of the sheet of resilient material;
- (c) providing a first cutter having a surface and a plurality of cutting elements extending from the surface in a predetermined pattern;
- (d) pressing the first cutter into the sheet of resilient material, thereby forming a cut sheet of resilient material comprising a plurality of resilient elements having defined height and width;
- (e) withdrawing the cutter from the cut sheet of resilient material;
- (f) providing at least one sheet of first reinforcing material having a defined thickness;
- (g) pressing a second cutter into the sheet of first reinforcing material, thereby forming a cut sheet of reinforcing material comprising a plurality of reinforcing elements and a first lattice of reinforcing material;
- (h) withdrawing the cutter from the cut sheet of reinforcing material;
- (i) providing at least one sheet of second reinforcing material having a defined thickness;
- (j) pressing a third cutter into the sheet of second reinforcing material, thereby forming a cut sheet of reinforcing material comprising a plurality of reinforcing elements and a second lattice of reinforcing material;
- (k) withdrawing the cutter from the cut sheet of reinforcing material;
- (l) separating the first lattice of reinforcing material from the reinforcing elements, whereby the first lattice of reinforcing material is left with a plurality of holes through the reinforcing material where the reinforcing elements used to be;
- (m) placing the cut sheet of resilient material adjacent to the first lattice of reinforcing material, and aligning the cut sheet of resilient material so that the plurality of resilient elements are positioned adjacent to the plurality of holes in the first lattice of reinforcing material;
- (n) pushing the resilient elements out of the cut sheet of resilient material, whereby the plurality of resilient elements are pushed into the plurality of holes in the first lattice of reinforcing material, thereby forming a first resilient material assembly comprising the plurality of resilient elements at least partially surrounded by at least one lattice of reinforcing material;
- (o) placing the first resilient material assembly next to a heat platen, if heat-activated adhesive material is applied to a side of the resilient material;
- (p) placing a first sheet of fabric or mesh substrate onto either side of the resilient material assembly, wherein steps (o) and (p) are optionally reversible in order;
- and
- (q) pressing the first fabric or mesh sheet substrate or the resilient material assembly with the heat platen to activate the adhesive on the plurality of resilient elements, whereby the first fabric or mesh sheet substrate adheres to the plurality of resilient elements thereby forming a first composite structure;
- (r) separating the first lattice of reinforcing material from the first composite structure;
- and
- (s) replacing the first lattice of reinforcing material with the second lattice of reinforcing material to engage at least one resilient element, thereby forming the first composite structure comprising the second lattice of reinforcing material.
18 more elements
48-74. (canceled)
Dependencies are inferred from the claim text.