Method of making a self-inflating structure
OwnerRobert K. Vicinoinventor
Life of this patent
Estimating the term…
Abstract
A self-inflating structure consists essentially of a block of open-cell, resiliently compressible, foam material which has been shaped to a desired form and covered with an airtight envelope having a sealable aperture. The structure can be pressed to expel any air or other fluid out of the foam material and any internal void through the aperture. The structure is kept pressed or the aperture is sealed in order to keep it in its collapsed state. Upon release of the pressing form or the opening of the aperture, the block of foam bounces back to its original state sucking in ambient air and restoring the structure to its full size. The method for shaping the foam block includes extruding, machining, and carving with patterned sets of blades or burning wires.
Claims26
A process for making a self-inflating copy of a three-dimensional structure which comprises:
- selecting at least one block of open-cell, resiliently compressible foam material;
- shaping at least one portion of said block into an image of said structure;
- making an envelope having at least one opening with at least one pliable sheet of material around said block;
- collapsing said envelope and block by removing fluid held therein;
- and
- constraining said envelope and block into a collapsed state;
- wherein said step of making said envelope comprises:
- selecting a first of said pliable sheet and at least one additional sheet;
- forming said first pliable sheet into a soft and pliable cradle shaped and dimensioned to intimately contact a surface area of the shaped portion of said block;
- placing said block between said first and said at least one additional sheet;
- and
- bonding peripheral areas of said first sheet to said at least one additional sheet around said block.
A process for making a self-inflating structure which comprises:
- shaping at least one block of open-cell, resiliently compressible foam material;
- making an envelope having at least one opening with at least one pliable sheet of airtight material around said block including readying a first of said pliable sheet and a second sheet made of airtight material, forming said first sheet into a first cradle shaped and dimensioned to intimately contact a surface portion of said block;
- positioning said surface portion into said first cradle and covering uncontacted surface portions of said block with said second sheet;
- and
- bonding peripheral areas of said first sheet to said second sheet around said block;
- and
- pressing said envelope and block to expel fluid contained therein through said opening;
- wherein the step of shaping said at least one block comprises:
- forming a slab of a first resiliently compressible, open-cell foam material having a first pore count;
- covering a surface portion of said slab with a layer of a second resiliently compressible, open-cell foam material having a higher pore count than said first foam material.
A process for making a self-inflating copy of a three-dimensional structure which comprises:
- selecting at least one block of open-cell, resiliently compressible foam material;
- shaping at least one portion of said block into an image of said structure;
- making an envelope having at least one opening with at least one pliable sheet of material around said block;
- collapsing said envelope and block by removing fluid held therein;
- wherein said step of making said envelope comprises:
- selecting a first of said pliable sheet and a second at least one additional sheet;
- forming said first pliable sheet into a soft and pliable cradle shaped and dimensioned to intimately contact a surface area of the shaped portion of said block;
- placing said block between said first and said at least one additional sheet;
- bonding peripheral areas of said first sheet to said at least one additional sheet around said block;
- and
- wherein said step of placing comprises:
- positioning said surface area of the shaped portion into said cradle;
- and
- covering surface portions of said block, uncontacted by said first pliable sheet, with a rigid sheet.
Dependencies are inferred from the claim text.