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US 7,173,070 B2Granted
Foam cushion and method of making and using the same
AssigneePhat Cushion LLC
InventorAdam J. Koffler
Life of this patent
Estimating the term…
Abstract
The present invention provides a foam cushion, a method of making the foam cushion, and a method of using the foam cushion. The foam cushion is formed from: (a) at least one of rubber and a resin; (b) a blowing agent; (c) a polymeric adhesion modifier; (d) a decomposition accelerating agent, and (e) a cross-linking agent.
Claims23
A method for manufacturing a foam cushion, the method comprising the steps of:
- (a) contacting with mixing and heating natural rubber, ethylene-vinyl acetate (EVA) copolymer, azodicarbonamide, an anhydride grafted polymeric adhesion modifier, and a combination of zinc oxide and stearic acid to form a first mixture;
- (b) contacting with mixing and heating the first mixture with dicumyl peroxide to form a second mixture;
- (c) dividing the second mixture into lumps;
- (d) heating further with mixing the separated lumps of the second mixture;
- (e) thinning a lump of the second mixture to form a sheet;
- (f) cooling the sheet;
- (g) stacking a plurality of the sheets in a press mold such that between 0% and 50% of the interior perimeter of the press mold remains exposed;
- (h) pressing the plurality of sheets in the press mold to form a cooked stack;
- and
- (i) slicing the cooked stack to provide the foam cushion.
7 more elements
A method for manufacturing a foam cushion, the method comprising the steps of:
- (a) contacting with mixing natural rubber, ethylene-vinyl acetate (EVA) copolymer, azodicarbonamide, an anhydride grafted polymeric adhesion modifier, and a combination of zinc oxide and stearic acid for about 8 minutes to about 20 minutes at about 110° C. to about 130° C. to form a first mixture;
- (b) contacting with mixing the first mixture with dicumyl peroxide for about 1 minute to about 5 minutes at about 110° C. to about 130° C. to form a second mixture;
- (c) dividing the second mixture into lumps;
- (d) heating further with mixing the separated lumps of the second mixture at about 100° C. to about 120° C.
- (e) thinning a lump of the second mixture to form a sheet of a thickness ranging from about 0.1 mm to about 50 mm;
- (f) cooling the sheet to below about 80° C.;
- (g) stacking a plurality of the sheets in a press mold such that between 0% and 50% of the interior perimeter of the press mold remains exposed;
- (h) pressing the plurality of the sheets in the press mold for about 28 minutes to about 35 minutes at about 160° C. to about 175° C. to form a cooked stack;
- and
- (i) slicing the cooked stack into sliced pieces having a thickness of about 1 mm to about 20 mm to provide the foam cushion.
7 more elements
Dependencies are inferred from the claim text.