# US 2014/0154452 A1 · Composite cushioning material and jigless method for making the same

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- Number: US 2014/0154452 A1
- Document ID: US20140154452A1
- Status: Published application
- Kind: A1
- Application number: 13/901,034
- Filed: 2013-05-23
- Published: 2014-06-05
- Earliest claimed: 2010-11-24
- Assignees: Applied FT Composite Solutions Inc.
- Applicants: Applied FT Composite Solutions Inc.
- Inventors: Daniel Kim
- Web page: https://patentgrep.com/patent/US20140154452A1

## CPC

- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- A43B 13/187: {Resiliency achieved by the features of the material, e.g. foam, non liquid materials}
- A43B 17/14: made of sponge, rubber, or plastic materials
- B29D 35/128: {Moulds or apparatus therefor}
- B29D 35/148: {Moulds or apparatus therefor}
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- A41D 31/28: Shock absorbing
- Y10T 156/1043: Subsequent to assembly
- Y10T 156/1062: Prior to assembly
- Y10T 428/18: Longitudinally sectional layer of three or more sections
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- A41D: OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The method according to claim 1, further comprising:
holding the resilient elements in place on the surface without aid of a jig.

### Claim 3 (depends on 2)

The method according to claim 2, further comprising:
holding the resilient elements in place through vacuum applied from the surface.

### Claim 4 (depends on 2)

The method according to claim 2, further comprising:
holding the resilient elements in place through frictional contact between the resilient elements.

### Claim 5 (depends on 2)

The method according to claim 2, further comprising:
holding the resilient elements in place through frictional contact between the resilient elements and at least one perimetral edge.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the discrete resilient elements interlock with each other.

### Claim 7 (depends on 6)

The method according to claim 6, wherein the resilient elements are concave and convex shapes, wherein the concave shaped resilient elements interlock with the convex shaped resilient elements.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the discrete resilient element is shaped as a cylinder, cube, or trapezoid.

### Claim 9 (depends on 1)

The method according to claim 1, comprising applying heat, pressure or both sufficient to change shape of at least one of the resilient elements at or near the site of contact with a source of heat or pressure generation or both, without affecting shape of the shape-changed resilient element progressively away from the site of contact along the axis perpendicular to the source of heat or pressure, to provide spacing with respect to the shape-changed resilient element and an adjacent structure.

### Claim 10 (depends on 1)

The method according to claim 1, comprising applying heat, pressure or both sufficient to change shape of at least one of the resilient elements at or near the site of contact with a source of heat or pressure generation or both, to provide spacing with respect to the shape-changed resilient element and an adjacent structure.

### Claim at position 11

11-37. (canceled)

### Claim 38 (depends on 1)

The method according to claim 1, further comprising in step (b),
(i) cutting a sheet of second resilient material by pressing a cutter on to the second resilient material to produce a cut sheet of second resilient material displaying a cutting pattern of discrete second resilient elements of defined widths and lengths, and
(ii) exchanging at least one first resilient element in the cut sheet of first resilient material with at least one second resilient element from the cut sheet of the second resilient material to form a first composite resilient material, wherein the first expanse of material mounted on the first composite resilient material forms a third composite structure.

### Claim at position 13

39-40. (canceled)

### Claim 41 (depends on 38)

The method according to claim 38, wherein the second resilient elements are obtained comprising the steps of:
(i) placing a sheet of second resilient material on a surface, wherein the second resilient material has different physical properties from the first resilient material;
(ii) cutting the sheet of second resilient material to produce a cut sheet of second resilient material displaying a cutting pattern that matches at least in areas identified to be exchanged in the first cut resilient material; and
(iii) removing at least one second resilient element from the cut sheet of second resilient material.

### Claim at position 15

42-67. (canceled)

### Claim 68

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.

### Claim 69 (depends on 68)

The method according to claim 68, wherein the material that has slower shape changing rate when exposed to heat, pressure or both is denser material.

### Claim at position 18

70-98. (canceled)

### Claim 99

A composite material for use as a resilient cushion, comprising
(i) a first expanse of material; and
(ii) at least one resilient element having defined length and width and physical characteristics connected to the first expanse of material at one end of the length of the resilient elements to form the composite material.

### Claim 100 (depends on 99)

The composite material according to claim 99, comprising a plurality of resilient elements.

### Claim 101 (depends on 100)

The composite material according to claim 100, wherein at least some of the plurality of resilient elements are different from each other in physical characteristics.

### Claim at position 22

102-122. (canceled)

### Claim 123

A multiple density composite material for use as a resilient cushion, comprising
(i) a first expanse of material; and
(ii) at least one resilient element having defined first end and second end and a middle along the length of the resilient element, as well as defined width along the length of the resilient element, connected to the first expanse of material at the first end of the resilient element to form the composite material, wherein the first end of the resilient element connected to the first expanse of material has maximum diameter that is less than the maximum diameter of the middle of the resilient element.

### Claim 124 (depends on 123)

The composite material according to claim 123, wherein the maximum diameter of the first end is less than the maximum diameter of the middle of the resilient element by about 1 to 50%.

### Claim 125 (depends on 124)

The composite material according to claim 124, wherein the maximum diameter of the first end is less than the maximum diameter of the middle of the resilient element by about 10 to 40%.

### Claim at position 26

126-138. (canceled)