US 8,784,982 B2 · Cushioning elements comprising elastomeric material and methods of forming same

Abstract

Cushioning elements include a porous foam comprising a series of interconnected cell walls and an elastomeric material formed over at least a portion of the interconnected cell walls. The porous foam is configured to allow gases to pass through at least a portion thereof. Methods of forming cushioning elements may include coating interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material, solidifying at least a portion of the elastomeric material, and providing a gas path through the elastomeric material. Other methods include pressing sheets of foam together at a pinch point, disposing a liquid between the foam over the pinch point, coating the foam with the liquid, and separating the sheets beyond the pinch point. Some methods include consolidating a plurality of portions of porous foam into a continuous cushioning material.

Claims23

Dependent claims

A cushioning element, comprising:

a breathable porous foam comprising a series of interconnected cell walls and defining an open pore network;
and
an elastomeric material formed over at least a portion of the interconnected cell walls, the elastomeric material comprising an elastomeric polymer and a plasticizer, wherein the elastomeric polymer comprises an A-B-A triblock copolymer, and wherein a ratio of a weight of the plasticizer to a weight of the elastomeric polymer is from about 0.1 to about 50;
wherein the breathable porous foam has a portion uncoated with the elastomeric material;
and
wherein the coated breathable porous foam allows gases to pass through at least a portion of the open pore network adjacent the elastomeric material, and wherein the elastomeric material further comprises a material selected from the group consisting of a gelatinous elastomer, a thermoplastic elastomer, rubber, a synthetic elastomer, and combinations thereof.

3 more elements

A method of forming a cushioning element, comprising:

coating a portion of interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material, the coated interconnected cell walls forming an open pore network that allows gases to flow therethrough, wherein coating interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material comprises:
disposing the liquid comprising an elastomeric material within pores defined by the interconnected cell walls, wherein the elastomeric material comprises an elastomeric polymer and a plasticizer, wherein the elastomeric polymer comprises an A-B-A triblock copolymer, wherein the elastomeric material further comprises a material selected from the group consisting of a gelatinous elastomer, a thermoplastic elastomer, rubber, a synthetic elastomer, and combinations thereof, and wherein a ratio of a weight of the plasticizer to a weight of the elastomeric polymer is from about 0.1 to about 50;
removing a portion of the liquid comprising the elastomeric material from the pores;
leaving a portion of the breathable porous foam uncoated with the elastomeric material;
solidifying at least a portion of the elastomeric material;
and
providing a gas path through the elastomeric material, the elastomeric material adjacent the open pore network of the breathable porous foam.

4 more elements

Dependencies are inferred from the claim text.

Cushioning elements comprising elastomeric material and methods of forming same

Life of this patent

Cushioning elements comprising elastomeric material and methods of forming same

Life of this patent

Abstract

Claims23