US 2014/0154452 A1 · COMPOSITE CUSHIONING MATERIAL AND JIGLESS METHOD FOR MAKING THE SAME

Abstract

The present application discloses a method for fabricating a composite structure for use as a resilient cushion, including: (a) placing a sheet of first resilient material on a surface; (b) cutting the sheet of first resilient material by pressing a cutter on to the first resilient material to produce a cut sheet of first resilient material displaying a cutting pattern of discrete first resilient elements of defined widths and lengths, wherein at least one of the first resilient elements touches adjacent resilient elements along its side; and (c) mounting a first expanse of material on at least one of the first resilient elements of the cut sheet of first resilient material to form a first composite structure.

Claims26

Dependent claims

A method for fabricating a composite structure for use as a resilient cushion, comprising:

(a) placing a sheet of first resilient material on a surface;
(b) cutting the sheet of first resilient material by pressing a cutter on to the first resilient material to produce a cut sheet of first resilient material displaying a cutting pattern of discrete first resilient elements of defined widths and lengths, wherein at least one of the first resilient elements touches adjacent resilient elements along its side;
and
(c) mounting a first expanse of material on at least one of the first resilient elements of the cut sheet of first resilient material to form a first composite structure.

1 more element

A method for fabricating a multiple density resilient element composite structure for use as a resilient cushion, comprising:

(a) placing a sheet of third resilient material on a surface;
(b) cutting the sheet of third resilient material by pressing a cutter on to the third resilient material to produce a cut sheet of third resilient material displaying a cutting pattern of discrete third resilient elements of defined widths and lengths;
(c) placing a sheet of fourth resilient material on a surface;
(d) cutting the sheet of fourth resilient material by pressing a cutter on to the fourth resilient material to produce a cut sheet of fourth resilient material displaying a cutting pattern of discrete fourth resilient elements of defined widths and lengths, wherein the fourth resilient material is composed of material that has slower shape changing rate when exposed to heat, pressure or both than the third resilient material, or changes shape or dimension to a lesser extent when exposed to heat, pressure or both than the third resilient material;
(e) removing at least one third resilient element from the cut sheet of third resilient material and replacing it by inserting a fourth resilient element into the cut sheet of third resilient material to form a second composite resilient material;
(f) placing a sheet of the second composite resilient material on a surface;
(g) cutting the sheet of second composite resilient material by pressing a cutter on to the second composite resilient material to produce a cut sheet of second composite resilient material displaying a cutting pattern of discrete fifth resilient elements of defined widths and lengths, wherein at least one of the fifth resilient elements comprises a combination of the third resilient material and fourth resilient element;
and
(h) mounting a first expanse of material on at least one of the fifth resilient elements of the cut sheet of second composite resilient material to form a fifth composite structure comprising multiple density resilient element composite.

6 more elements

Dependencies are inferred from the claim text.

Composite cushioning material and jigless method for making the same

Life of this patent

Composite cushioning material and jigless method for making the same

Life of this patent

Abstract

Claims26