U.S. patent application number 09/286949 was filed with the patent office on 2002-05-23 for elastomer film laminated cushion.
Invention is credited to YATES, PAUL M..
Application Number | 20020061384 09/286949 |
Document ID | / |
Family ID | 23100836 |
Filed Date | 2002-05-23 |
United States Patent
Application |
20020061384 |
Kind Code |
A1 |
YATES, PAUL M. |
May 23, 2002 |
ELASTOMER FILM LAMINATED CUSHION
Abstract
An elastomer film laminated cushion includes an elastomer having
the physical properties of flexibility and compressibilities in the
range of flexibilities and compressibilities of stable elastomer
block polymer gels. A film is provided for encapsulating the
elastomer with the film having physical properties of flexibility
to enable uninhibited flexure compression of the elastomer by a
user. A compatibilizing layer is provided for laminating the film
to an exterior of the elastomer. The compatibilizing layer also has
physical properties of flexibility to enable uninhibited flexure
and compression of the elastomer by the user.
Inventors: |
YATES, PAUL M.; (LACANADA,
CA) |
Correspondence
Address: |
WALTER A HACKLER
2372 S E BRISTOL
SUITE B
NEWPORT BEACH
CA
92660
|
Family ID: |
23100836 |
Appl. No.: |
09/286949 |
Filed: |
April 8, 1999 |
Current U.S.
Class: |
428/76 ;
428/68 |
Current CPC
Class: |
Y10T 428/31855 20150401;
Y10T 428/239 20150115; Y10T 428/23 20150115; B32B 25/08 20130101;
Y10T 428/31938 20150401; Y10T 428/31504 20150401 |
Class at
Publication: |
428/76 ;
428/68 |
International
Class: |
B32B 003/02 |
Claims
What is claimed is:
1. An elastomer film laminated cushion comprising: an elastomer
having the physical properties of flexibility and compressibility
in the range of flexibilities and compressibilities of stable
elastomeric block polymer gels; film means for encapsulating said
elastomer, said film means having physical properties of
flexibility to enable uninhibited flexure and compression of said
elastomer by a user; and compatibilizing layer means for laminating
said film means to an exterior of said elastomer, said
compatibilizing layer means having physical properties of
flexibility to enable uninhibited flexure and compression of said
elastomer by the user.
2. The cushion according to claim 1 wherein said film means is
formed from a urethane resin, said elastomer is formed from an
elastomer resin and said compatibilizing layer means comprises a
mixture of urethane resin and elastomer resin.
3. The cushion according to claim 1 wherein said film means is
formed from a urethane resin, said elastomer is formed from an
elastomer resin and said compatibilizing layer means comprises a
mixture of urethane resin and elastomer resin.
4. The cushion according to claim 2 wherein said mixture comprises
about 25 percent urethane resin and about 75 percent elastomer
resin.
5. The cushion according to claim 4 wherein said film means has a
thickness of between about 1 mil and about 5 mils.
6. The cushion according to claim 5 wherein said compatibilizing
layer means has a thickness of between about 10 mils and about 15
mils.
7. The cushion according to claim 6 wherein said elastomer is a
stable elastomeric block polymer gel-oil composition.
8. The cushion according to claim 7 wherein said film means is
sealed around a cushion exterior to prevent oil leakage from the
gel-oil composition.
9. An elastomer film laminated cushion comprising: an elastomer
having the physical properties of flexibility and compressibility
in the range of flexibilities and compressibilities of stable
elastomer block polymer gels; film means disposed around said
elastomer, said film means having physical properties of
flexibility to enable uninhibited flexure and compression of said
elastomer by a user; and compatibilizing means for enabling heat
laminating said elastomer to said film means at temperatures up to
about 400.degree. F. without shriveling and bubbling said film
means, said compatibilizing means having physical properties of
flexibility to enable uninhibited flexure and compression of said
elastomer by the user.
10. The cushion according to claim 9 wherein said film means is
formed from a urethane resin, said elastomer is formed from an
elastomer resin and said compatibilizing means comprises a mixture
of urethane resin and elastomer resin.
11. The cushion according to claim 9 wherein said film means is
formed from a urethane resin, said elastomer is formed from an
elastomer resin and said compatibilizing layer means comprises a
mixture of urethane resin and elastomer resin.
12. The cushion according to claim 10 wherein said mixture
comprises about 25 percent urethane resin and about 75 percent
elastomer resin.
13. The cushion according to claim 12 wherein said film means has a
thickness of between about 1 mil and about 5 mils.
14. The cushion according to claim 13 wherein said compatibilizing
means comprises a layer having a thickness of between about 10 mils
and about 15 mils.
15. The cushion according to claim 14 wherein said elastomer is a
stable elastomeric block polymer gel-oil composition.
16. The cushion according to claim 15 wherein said film means is
sealed around a cushion exterior to prevent oil leakage from the
gel-oil composition.
17. A method for producing an elastomeric film laminated cushion
comprising the steps of: providing thermosetting elastomer resin;
providing a urethane film; applying to the film a compatibilizing
layer onto the film, said compatibilizing layer comprising a
mixture of urethane resin and additional elastomer resin; heating
the elastomer resin to form a gel; and laminating the gel to said
compatibilizing layer at a temperature of up to about 400.degree.
F., said gel forming an elastomeric body having the physical
properties of flexibility and compressibility in the range of
flexibilities and compressibilities of stable elastomeric block
polymer gels.
18. The method according to claim 16 further comprising the steps
of sealing the film means together around the gel in order to
encapsulate the gel.
Description
[0001] The present invention generally relates to cushions and is
more particularly directed to a cushion utilizing an elastomeric
gel.
[0002] Cushions heretofore available have been made from a great
number of materials such as foams and gels. In particular, stable
elastomeric block polymer gels such as those described in U.S. Pat.
No. 3,676,387 have been utilized which are polymer-oil
combinations. Elastomeric block polymers have been combined with
oils in order to control the flexibility and compressibilities of
the gels. For example, when an elastomer block polymer, such as
described in the hereinabove referenced U.S. Pat. No. 3,676,387, is
combined with a non-aromatic paraffinic oil low volatility, an
extremely highly elastic material can be obtained. This gel is
thermoplastic/thermosetting and is capable of being melted upon
heating for casting in the formation of molded or other articles at
room temperature.
[0003] Unfortunately, these gels, after formation, tend to exude
oil over long periods of time. Accordingly, in order to utilize
these gels in an acceptable cushion, they must be encapsulated or
covered with a material to prevent seepage of oil therefrom, which
can cause staining to any support used for the cushion or provide
an uncomfortable oily-like surface if in direct contact with a
user.
[0004] Accordingly, such gels have been bonded to fabrics and films
in order to encapsulate the gels. The bonding or lamination of the
gel is typically done at high temperatures, for example, about
400.degree. F., and when used with very thin-films, such heated
contact can cause shriveling, or bubbling of the film, which
results in an unattractive finished product. The use of very thin
films is very important in the overall suitability of the cushion
in order to prevent restriction of the flexibility and
compressibility of the elastomer gel.
[0005] That is, uninhibited elastomer gel properties of flexibility
and compressibility are desired in the final product. Heretofore,
films utilized to encapsulate the elastomer gels require sufficient
thickness to prevent the hereinabove noted stretching and bubbling
of the film upon formation of the cushion. Unfortunately, such
thick films inhibit the flexural and compressible characteristics
of the gel which reduces the flexural and compressibility
characteristics of the completed cushion.
[0006] The present invention is directed to an elastomer film
laminated cushion which maintains the properties of the elastomer
gel utilized, while at the same time providing a barrier for oil
seepage from the elastomer gel into the environment.
SUMMARY OF THE INVENTION
[0007] An elastomer film laminated cushion in accordance with the
present invention generally includes an elastomer having the
physical properties of flexibility and compressibility in the range
of flexibilities and compressibilities of stable elastomer block
polymer gels. The film provides a means for encapsulating the
elastomer with the film having the physical properties of
flexibility to enable uninhibited flexure and compression of the
elastomer by a user.
[0008] Importantly, a compatibilizing layer provides a means for
laminating the film to an exterior of the elastomer. More
particularly, the compatibilizing means enables the heat lamination
of the elastomer to the film at temperatures up to about
400.degree. F. without shriveling and/or bubbling of the film.
Also, the compatibilizing layer means has physical properties of
flexibility to enable uninhibited flexure and compression of the
elastomer by a user.
[0009] The physical properties of both the film and the
compatibilizing layer are important in order to enable the cushion
to provide desirable flexibility and compressibility of the
elastomer, while at the same time preventing any oil leakage from
the cushion.
[0010] More particularly, when the film is formed from a urethane
resin and the elastomer is formed from elastomer resin, the
compatibilizing layer means comprises a mixture of the urethane
resin and the elastomer resin or a compatible elastomer resin.
[0011] In order to provide desired physical properties of the film
and the compatibilizing layer, the film should have a thickness of
between about 1 mil and about 5 mils and the compatibilizing layer
should have a thickness of between about 10 mils and about 15 mils.
With these thicknesses, the flexibility and compressibility
properties of the gel are uninhibited and thus the physical
properties of the resulting cushion are substantially the same as
those of the elastomer.
[0012] Still more particularly, the compatibilizing layer mixture
may comprise about 25 percent urethane resin and about 75 percent
elastomer resin.
[0013] A method in accordance with the present invention for
producing an elastomer film laminated cushion generally includes
the steps of providing a thermosetting elastomer resin and a
urethane film.
[0014] A compatibilizing layer is applied on to the film with the
compatibilizing layer comprising a mixture of urethane resin and
additional elastomer resin.
[0015] The elastomer resin is heated to form a gel and thereafter
laminated to the compatibilizing layer at temperatures of up to
about 400.degree.. A gel forms an elastomeric body having physical
properties of flexibility and compressibilities in the range of
flexibilities and compressibilities of stable elastomer block
polymer gels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention may be more clearly understood with
reference to the following detailed description in conjunction with
the appended drawings, of which:
[0017] FIG. 1 is a perspective view of a typical cushion made in
accordance with the present invention;
[0018] FIG. 2 is a cross sectional view of the cushion shown in
FIG. 1 taken along the line 2-2 showing a cross section of an
elastomer encapsulated by a film with a compatibilizing layer
therebetween; and
[0019] FIG. 3 is a representation of the method of producing the
cushion in accordance with the present invention.
DETAILED DESCRIPTION
[0020] With reference to FIG. 1 there is shown an elastomer film
laminated cushion 10 in accordance with the present invention,
which, as is more particularly shown in FIG. 2, includes an
elastomer 12 and a film 14 which provides a means for encapsulating
the elastomer 12. As hereinabove noted, encapsulation of the
elastomer 12 is important for providing a barrier to plasticizing
oil which may be utilized in the elastomer.
[0021] The elastomer 12 may be of any suitable type such as, for
example, a stable isomeric block polymer gel similar to the gel
described in U.S. Pat. No. 3,676,387. This patent is incorporated
herewith in its entirety for the purpose of describing a suitable
type of gel for incorporation into the present invention.
[0022] Generally, the gels are of polymer-oil combinations.
Specifically, the elastomer 12 has the physical properties of
flexibility and compressibility in the range of flexibilities and
compressibilities of the stable elastomer block polymer gels such
as set forth in U.S. Pat. No. 3,676,387.
[0023] With reference to FIGS. 2 and 3, the transparent film 14 may
be of urethane, or polyurethane film, which encapsulates the
elastomer 12. The film 14 thickness as hereinabove noted is
preferably between about 1 mil and about 5 mils in order to
encapsulate the elastomer 12 and have a resiliency which enables
uninhibited flexibility and compression of the elastomer 12 by a
user's wrist (not shown).
[0024] That is, the film 14 has physical properties of flexibility,
because of its thickness, to enable uninhibited flexure and
compression of the elastomer 12 by the user. A film 14 thickness
beyond this range has not been found to be effective in maintaining
the gel-like property of the elastomer 12 while providing
encapsulation of the elastomer 12.
[0025] Importantly, a compatibilizing layer 16 provides a means for
laminating the film 14 to an exterior 18 of the elastomer 12 at
temperatures up to about 400.degree. F. without shriveling and/or
bubbling of the film 14 during the process.
[0026] In order to maintain the flexibility and compressibility
properties of the elastomer 12, the compatibilizing layer 16 must
have physical properties of flexibility to enable such uninhibited
flexure and compression of the elastomer by the user. The
flexibility properties of both the film 14 and the compatibilizing
layer 16 are effected when the film 14 is made from a urethane film
having a thickness of between about 1 mil and about 5 mils.
[0027] The compatibilizing layer is a mixture of urethane resin and
elastomer resin, preferably about 25 percent urethane resin and
about 75 percent elastomer resin. The urethane and elastomer resins
are heated to a lower temperature than about 400.degree. F. and
applied to the film 14 in a conventional manner.
[0028] Thereafter, as is illustrated in FIG. 3, the elastomer 12 is
applied to the compatibilizing layer 16 and the film 14 is sealed
to an underside 20 of the elastomer 12 as illustrated by the arrows
22 in FIG. 3.
[0029] The basic process of forming the cushion 10 may be through
the process set forth in U.S. Pat. No. 5,679,193 entitled, METHOD
OF MANUFACTURING A GEL CUSHION; U.S. Pat. No. 5,756,184 entitled,
GEL CUSHION; and in U.S. patent application Ser. No. 08/856,775
filed May 15, 1997, entitled, CUSHION MANUFACTURING METHOD. Both of
these referenced patents and the application are incorporated
herewith in their entirety by this reference thereto, for
illustrating the manner in which the gel cushion in accordance with
the present invention may be manufactured.
[0030] An additional compatibilizing layer 26 may be applied to an
underside 28 of the cushion 10 for the purpose of obtaining a gripy
bottom for the cushion 10. Since the layer, which is also formed
from a mixture of urethane resin and elastomer resin, is rubbery,
somewhat like the gel 12, it provides a non-slip bottom texture
similar to neoprene products on the market. If the film 14 is not
sealed to the bottom 20 of the elastomer, the layer 26, because of
its urethane content, provides a barrier to prevent the leakage of
oil from the elastomer 12 onto a supporting surface, not shown.
[0031] Although there has been hereinabove described an elastomer
film laminated cushion in accordance with the present invention,
for the purpose of illustrating the manner in which the invention
may be used to advantage, it will be appreciated that the invention
is not limited thereto. Accordingly, any and all modifications,
variations or equivalent arrangements which may occur to those
skilled in the art, should be considered to be within the scope of
the invention as defined in the appended claims.
* * * * *