U.S. patent application number 11/558981 was filed with the patent office on 2007-05-17 for conformable pod for a manual implement.
This patent application is currently assigned to WILLAT ERGONOMIC TECHNOLOGIES, LLC. Invention is credited to Adrian Cordova, Gary D. Delgado, Robert C. Portillo, Boyd I. Willat.
Application Number | 20070110495 11/558981 |
Document ID | / |
Family ID | 39430452 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070110495 |
Kind Code |
A1 |
Willat; Boyd I. ; et
al. |
May 17, 2007 |
CONFORMABLE POD FOR A MANUAL IMPLEMENT
Abstract
A conformable pod and related method of production are provided,
wherein the pod defines a soft structure adapted for deformation in
response to minimal pressure applied manually, i.e., by contact
with some portion of the body, and for retaining a deformed
configuration substantially in the absence of continued application
of manual pressure. The pod includes a viscous and tacky gel
material encased within a closed chamber defined at least in part
by a relatively thin and easily deformed outer skin providing
minimal deformation resistance. In a preferred form, the encased
gel material is a coagulated or partially coagulated gel such as a
silicone-based gel material adapted for deformation in response to
minimal applied pressure, and for substantially pressureless
retention of the as-deformed shape, followed by relatively slow
return (at least two seconds or more) to an initial nondeformed
shape upon release of the pod.
Inventors: |
Willat; Boyd I.; (Los
Angeles, CA) ; Cordova; Adrian; (San Diego, CA)
; Portillo; Robert C.; (Carlsbad, CA) ; Delgado;
Gary D.; (New York, NY) |
Correspondence
Address: |
KELLY LOWRY & KELLEY, LLP
6320 CANOGA AVENUE
SUITE 1650
WOODLAND HILLS
CA
91367
US
|
Assignee: |
WILLAT ERGONOMIC TECHNOLOGIES,
LLC
9120 Oriole Way
Los Angeles
CA
90069
|
Family ID: |
39430452 |
Appl. No.: |
11/558981 |
Filed: |
November 13, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11158900 |
Jun 21, 2005 |
|
|
|
11558981 |
Nov 13, 2006 |
|
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Current U.S.
Class: |
401/6 |
Current CPC
Class: |
B25G 1/10 20130101 |
Class at
Publication: |
401/006 |
International
Class: |
A46B 5/02 20060101
A46B005/02 |
Claims
1. A conformable pod for mounting onto a user-contacted implement,
comprising: a viscous gel material encased within a substantially
closed chamber having a user-contacted front side defined at least
in part by a relatively thin and easily deformable outer skin, and
a rear-side substrate; and at least one fastener carried by said
rear-side substrate for mounting the pod onto a user-contacted
implement, said fastener being at least partially embedded within
the pod; said outer skin and said gel material being deformable to
a deformed shape in response to engagement with minimal applied
manual pressure, and for substantially pressureless retention of
said deformed shape.
2. The conformable pod of claim 1 further including a support strip
disposed generally at the rear side of the pod, said support strip
having a stiffness substantially greater than the stiffness of said
outer skin, said at least one fastener being carried by said
support strip.
3. The conformable pod of claim 2 wherein said support strip is
disposed within said chamber generally at an inboard side of said
rear-side substrate.
4. The conformable pod of claim 2 wherein said at least one
fastener is at least partially embedded within said support
strip.
5. The conformable pod of claim 1 wherein said rear-side substrate
has a stiffness substantially greater than the stiffness of said
outer skin, said at least one fastener being carried at least
partially embedded within said rear-side substrate.
6. The conformable pod of claim 1 wherein said at least one
fastener comprises a plurality of fasteners.
7. The conformable pod of claim 1 wherein said at least one
fastener comprises a bolt protruding rearwardly from said rear-side
substrate.
8. The conformable pod of claim 1 wherein said at least one
fastener comprises a magnet carried at the rear side of the
pod.
9. The conformable pod of claim 1 wherein said outer skin is shaped
to define said closed chamber having a plurality of elongated
raised ribs separated by intervening recessed troughs, and wherein
said troughs are spaced at least slightly from said rear-side
substrate.
10. The conformable pod of claim 1 wherein said gel material has a
memory for retaining said deformed shape for a predetermined time
delay period following release thereof, and for thereafter
returning relatively slowly following said time delay period
substantially to an initial nondeformed shape.
11. The conformable pod of claim 10 wherein said time delay period
is at least about two seconds, and wherein said gel material
thereafter returns over at least about four seconds substantially
to the initial nondeformed shape.
12. The conformable pod of claim 1 wherein said gel material
comprises an at least partially coagulated gel material.
13. A conformable pod for mounting onto a user-contacted implement,
comprising: a viscous gel material encased within a substantially
closed chamber having a user-contacted front side defined at least
in part by a relatively thin and easily deformable outer skin, and
a rear-side substrate, said outer skin being shaped to define said
closed chamber front side having a plurality of elongated raised
ribs separated by intervening recessed troughs, and wherein said
troughs are spaced at least slightly from said rear-side substrate,
said gel material extending in a continuum substantially throughout
said closed chamber; and at least one fastener carried at least in
part by said rear-side substrate and rearwardly exposed for
mounting the pod onto a user-contacted implement; said outer skin
and said gel material being deformable to a deformed shape in
response to engagement with minimal applied manual pressure, and
for substantially pressureless retention of said deformed
shape.
14. The conformable pod of claim 13 wherein said at least one
fastener is at least partially embedded within the pod.
15. The conformable pod of claim 14 further including a support
strip disposed generally at the rear side of the pod, said support
strip having a stiffness substantially greater than the stiffness
of said outer skin, said at least one fastener being carried by
said support strip.
16. The conformable pod of claim 14 wherein said rear-side
substrate has a stiffness substantially greater than the stiffness
of said outer skin, said at least one fastener being carried at
least partially embedded within said rear-side substrate.
17. The conformable pod of claim 13 wherein said at least one
fastener comprises a bolt protruding rearwardly from said rear-side
substrate.
18. The conformable pod of claim 13 wherein said at least one
fastener comprises a magnet carried at the rear side of the
pod.
19. The conformable pod of claim 13 wherein said gel material has a
memory for retaining said deformed shape for a predetermined time
delay period following release thereof, and for thereafter
returning relatively slowly following said time delay period
substantially to an initial nondeformed shape.
20. The conformable pod of claim 19 wherein said time delay period
is at least about two seconds, and wherein said gel material
thereafter returns over at least about four seconds substantially
to the initial nondeformed shape.
21. The conformable pod of claim 13 wherein said gel material
comprises an at least partially coagulated gel material.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to improvements in user
contact surfaces and related shape-conforming or biomorphic pods
and grips for use with manually grasped implements and the like,
such as a cooking vessel, hair brush, paint brush, sports racquet
or bat, scissors or other hand tool, musical instrument, or
virtually any other type of manually grasped device having a handle
or related structure for manual grasping or engagement as by means
of the hand or fingertips, or alternatively for contact and/or
manipulation by a portion of the human body.
[0002] More specifically, this invention relates to an improved
bioconforming or biomorphic pod for mounting onto an appropriate
implement surface, and a related method of pod production, wherein
the conformable pod incorporates a viscous and tacky gel material
adapted for custom-fit shape deformation in response to a minimal
applied inertia or pressure, and for substantially pressureless
retention of the deformed shape until the pod is released by the
user. When released, the pod exhibits a memory characteristic for
subsequent relatively slow return to an initial nondeformed
shape.
[0003] Manual implements generally incorporate a handle or related
structure having a size and shape for appropriate manual grasping
and manipulation of the implement during normal intended use. In
one common form, the handle structure comprises an elongated rigid
element having one end securely connected to the implement, such as
a cooking pot or pan, a hair brush, a tool head, etc. In another
common form, the manual implement is normally grasped directly
about the body thereof, such as in the case of writing and other
marking instruments, baseball and softball bats, etc. Other manual
implements are adapted for fingertip manipulation and thereby
include one or more keypads for fingertip depression, e.g.,
keyboards, musical instruments such as a clarinet, saxophone,
trumpet and the like. Still other manual implements incorporate
handle-like structures of alternative or complex shapes, such as
circular structures adapted for finger or fingertip insertion to
manipulation the implement, e.g., scissors and shears, and the
like. In this regard, a variety of improved grips and the like have
been developed in recent years for use with such manual implements,
primarily to provide a relatively soft and resilient grip structure
for enhanced user comfort and/or improved control of the manual
implement during normal use thereof.
[0004] In the past, grip structures for relatively large manual
implements such as sports equipment, hand tools, cookware, and hair
brushes and the like have generally been limited to relatively soft
and resilient rubber or rubber-like elastomer sleeves or
sleeve-like wraps mounted onto the implement handle. While such
grip structures beneficially provide a degree of cushioning for
improved user comfort, the relative deformation of such grip
structures during normal use is inherently limited. In particular,
such cushioned grip structures are generally incapable of
significant shape deformation, and thus have generally not provided
a high degree of shape deformation needed to assume a customized
ergonomical shape conforming closely to the anatomical contours of
an individual user's hand and/or fingers. Such customized ergonomic
shape is beneficially conducive to substantially optimized user
comfort with substantially minimized user fatigue, by providing
anatomical pressure relief while enhancing manual dexterity and
improving manual control of the related device or implement.
[0005] In relatively small manual implements such as writing
instruments and the like, cushioned grip structures have been
similarly provided in the form of resilient elastomer sleeves and
the like. In some designs, an outer resilient sleeve encloses an
internal cavity which is filled with a flowable substance such as a
deformable putty or relatively viscous liquid adapted to displace
and thereby achieve substantial shape deformation when the grip
structure is manually grasped. With such deformable grip
structures, the outer resilient sleeve can exhibit a relatively
high stiffness in comparison with the deformable putty or flowable
substance contained within the internal cavity, whereby a
significant minimum applied pressure for grip deformation is
defined by the structure of the outer sleeve and not by the
flowable material contained within said outer sleeve. In this
regard, the structural thickness and thus the stiffness of the
outer sleeve is often increased with a view toward preventing or
minimizing inadvertent sleeve puncture and resultant undesirable
escape of the flowable material from the internal cavity. Increased
sleeve stiffness is, of course, contrary to a desire to provide a
significantly reduced and substantially minimized pressure
threshold for initiating deformation of the deformable grip.
Moreover, such grip structures having a flowable material encased
within a resilient outer sleeve are difficult to manufacture and
assemble.
[0006] Exemplary grip structures having a flowable material encased
within an outer resilient sleeve or the like are shown and
described in U.S. Pat. Nos. 5,000,599 and 6,647,582 and 6,725,505;
U.S. Publication Nos. US2003/0123917; US2003/0051316; US
2004/0233169; and US 2004/0248063; and in copending U.S. Ser. Nos.
09/484,127, filed Jan. 15, 2000 and Ser. No. 10/678,148, filed Oct.
2, 2003.
[0007] There exists, therefore, a need for further improvements in
and to deformable pods and grips of the type used with manual
implements and the like, particularly wherein a pod or grip
structure can be initially deformed to a customized ergonomic shape
upon application of an extremely light and substantially minimal
pressure, and thereafter retain the deformed shape in substantial
conformance with the unique anatomical contours of a specific user,
substantially without requiring further or continued application of
pressure, followed by relatively slow return upon release of the
pod or grip structure substantially to its initial non-deformed
shape. The present invention fulfills these needs and provides
further related advantages.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention, a conformable or
biomorphic pod and related method of production are provided,
wherein the pod defines a soft structure adapted for mounting onto
a user-contacted surface of a manual implement or the like, and for
shape deformation in response to minimal pressure applied thereto,
i.e., by contact with some portion of the body including but not
limited to the fingers, fingertips, and hands, and for retaining a
deformed configuration substantially in the absence of continued
application of manual pressure. The pod includes a viscous and
tacky gel material encased or contained within a closed chamber or
cavity defined at least in part by a relatively thin and easily
deformed outer skin providing minimal deformation resistance to pod
deformation and shape conformance to a substantially customized
ergonomic shape conforming with the anatomical contours of the
individual user. In a preferred form, the encased gel material is a
coagulated or partially coagulated gel such as a silicone-based gel
material adapted for deformation in response to minimal applied
manual pressure, and for substantially pressureless retention of
the as-deformed shape, followed by shape retention for a time delay
period following user release (at least about two seconds or more)
before relatively slow return (at least about four seconds or more)
to an initial nondeformed shape.
[0009] A fastener element such as a pressure sensitive adhesive
film is carried by the pod for stick-on attachment to a selected
surface of a manual implement or the like. In one alternative form,
the fastener element may comprise an elongated rim or rib carried
by the pod and shaped for assembly as by clamped retention or the
like between opposed structures forming the manual implement or the
like.
[0010] In the preferred form, the gel material comprises a
coagulated or partially coagulated or catalized gel or equivalent
colloidal material such as a silicone-based gel material adapted
for deformation in response to minimal applied pressure. This gel
material can be relatively tacky or sticky and thereby adheres to
the chamber-defining interior surfaces provided by the overlying
pod skin. In one form, the highly deformable pod skin cooperates
with a rear-side substrate which may comprise a thicker, less
deformable material, to define the gel-containing chamber or
cavity. The fastener element may be formed on or as part of, or
otherwise connected to the substrate.
[0011] In use, when the conformable pod is mounted onto a manual
implement or the like at a position for user contact during normal
implement use, the outer skin is exposed for shape deformation in
response to a relatively light or minimal applied manual or tactile
pressure or the like. Such shape deformation of the outer skin is
accompanied by a corresponding or conforming displacement of the
gel material contained within the pod cavity, wherein this gel
material tends to retain the deformed shape upon continued contact
by the user but without requiring any significant continued
application of manual or tactile pressure or the like. Thereafter,
following user release of the pod, the gel material exhibits a
memory characteristic causing the pod to initially retain the
deformed shape following user release for a time delay period of at
least about two seconds, and then return relatively slowly over a
period of at least about four seconds to its initial nondeformed
shape.
[0012] The conformable pod may be constructed by initially forming
the outer skin as by injection, tumble, compression, or blow
molding, or the like. The pod skin, in an inverted orientation,
defines an open-sided chamber which is then substantially filled
with the gel material, followed by closing and sealing the pod
chamber with the substrate.
[0013] In one preferred form and method, the skin may incorporate a
textured pattern and/or multiple folds in a corrugated
configuration at one or more locations or zones for further
reducing the requisite tactile force or the like required to deform
the pod skin thereby displacing the contained gel material within
the enclosed chamber. In this construction, the patterned or folded
skin accommodates close control over the timing and/or direction of
skin and resultant overall pod displacement. In a modified form,
the patterned or folded skin zone or zones may each include a
region of reduced or variable skin wall thickness. In each
configuration, following user release, the gel material encased by
the skin returns slowly to an initial, substantially nondeformed
shape.
[0014] In one alternative preferred form, the deformable outer skin
of the conformable pod can be shaped to define a plurality of
elongated ribs formed generally in parallel relation and spaced
apart by intervening troughs or valley of substantial depth. This
deformable outer skin cooperates with a rear-side pod substrate
which may comprises a thicker and/or less deformable material to
define a closed chamber cavity that is filled or substantially
filled with the gel material. In one form, one or more fasteners
such as mounting bolts are anchored as by co-molding within the
rear-side pod substrate and protrude rearwardly therefrom for quick
and easy connection with an article or implement such as a chair
structure, e.g., a chair seat or chair seatback. In use, a person
sitting in the chair contacts the distal surfaces of the elongated
ribs, resulting in displacement of the gel material within and
between the pod ribs.
[0015] In one further alternative configuration, modified fasteners
such as mechanical fasteners can be connected to a relatively stiff
support strip formed from a suitable material and inserted as by
co-molding within the pod generally at an inboard side of the
rear-side pod substrate, with a portion of the fasteners protruding
from or otherwise externally exposed at the rear side of the pod
for mounting onto the selected article or implement. Alternative
fasteners, e.g., magnet-type fasteners can be carried at the rear
side of the pod for mounting onto the selected article or
implement. Alternative fastening methods can also be used, such as
co-molding of the selected article or implement directly to the
rear side of the pod.
[0016] Other features and advantages of the present invention will
become more apparent from the following detailed description, taken
in conjunction with the accompanying drawings which illustrate, by
way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings illustrate the invention. In such
drawings:
[0018] sFIG. 1 is a perspective view illustrating a conformable pod
for use with a manual implement or the like, constructed in
accordance with the present invention;
[0019] FIG. 2 is an enlarged fragmented longitudinal sectional view
taken generally on the line 2-2 of FIG. 1;
[0020] FIG. 3 is an enlarged and fragmented sectional view
illustrating an initial process step for constructing the pod of
FIGS. 1 and 2;
[0021] FIG. 4 is an enlarged and fragmented sectional view showing
a subsequent process step for constructing the pod;
[0022] FIG. 5 is a enlarged and fragmented sectional view depicting
a further process step for constructing the pod;
[0023] FIG. 6 is an enlarged and fragmented sectional view showing
the conformable pod installed onto a user-contacted surface of a
manual implement or the like;
[0024] FIG. 7 is an enlarged and fragmented sectional view similar
to FIG. 6, but illustrating pod deformation in response to a manual
force or the like applied thereto;
[0025] FIG. 8 is a fragmented perspective view of a plurality of
conformable pods constructed in accordance with the present
invention, and connected end-to-end to define an elongated tape or
the like adapted for installation onto a manual implement or the
like;
[0026] FIG. 9 is an enlarged and fragmented sectional view similar
to FIG. 6, but depicting one alternative preferred form of the
invention;
[0027] FIG. 10 is an enlarged and fragmented sectional view similar
to FIGS. 6 and 9, but showing another alternative preferred form of
the invention;
[0028] FIG. 11 is an enlarged and fragmented sectional view similar
to FIGS. 6, 9 and 1 0, but illustrating a further alternative
preferred form of the invention;
[0029] FIG. 12 is a side elevation view of a pair of scissors
incorporating a conformable pod constructed in accordance with
another alternative preferred form of the invention;
[0030] FIG. 13 is an enlarged perspective view, show in partial
section, of the conformable pod for use in the scissors depicted in
FIG. 12;
[0031] FIG. 14 is an exploded perspective view showing installation
of the pod of FIG. 13 onto a pair of scissors;
[0032] FIG. 15 is an exploded perspective view similar to FIG. 14,
but showing an alternative mounting arrangement for installing the
conformable pod onto a pair of scissors or the like;
[0033] FIG. 16 is a front perspective view of a chair including a
plurality of conformable pods mounted thereon;
[0034] FIG. 17 is an exploded perspective view of a portion of the
chair shown in FIG. 16, and illustrating the multiple conformable
pods in exploded relation with a chair structure defining a chair
seat and seatback;
[0035] FIG. 18 is a rear perspective view of one of the conformable
pods shown in FIGS. 16 and 17;
[0036] FIG. 19 is an enlarged fragmented sectional view taken
generally on the line 19-19 of FIG. 18;
[0037] FIG. 20 is an enlarged and partially exploded perspective
view showing one preferred fastener for use in the conformable pod
of FIGS. 16-19;
[0038] FIG. 21 is a perspective view of the fastener shown in FIG.
20; and
[0039] FIG. 22 is an enlarged fragmented sectional view
illustrating connection of the conformable pod of FIGS. 16-19 with
the chair structure.
DETAILED DESCRIPTION OF THE PREFERRED EMOBIDMENTS
[0040] As shown in the exemplary drawings, an improved conformable
or biomorphic pod referred to generally in FIGS. 1-7 by the
reference numeral 10 is provided for use with a manually grasped
implement 12 (FIGS. 6-7) or the like. The conformable pod 10 is
designed for placement onto a user-contacted surface of the
implement 12 where the pod flexibly and resiliently changes shape
in response to a relatively small or lightweight applied pressure
such as a manual or tactile fingertip pressure or other bodily
contact during normal use of the implement 12, so that the pod 10
deformably absorbs energy while conforming geometrically to the
unique and customized anatomical contours and particular grasping
technique of an individual user. The improved pod 10 of the present
invention further is designed to retain the deformed shape upon
continuity of manual grasping or bodily contact, but without
requiring further application of manual pressure or the like
thereto, in combination with memory characteristics for subsequent
relatively slow return to an initial nondeformed shape upon manual
pressure release. As a result, the conformable pod 10 of the
present invention provides anatomical pressure relief resulting in
enhanced user comfort and reduced user fatigue otherwise
attributable, e.g., to repetitive motion or constant muscular
exertion in the act of grasping the pod in the course of implement
manipulation. Such anatomical pressure relief is beneficially
accompanied by improved user dexterity and control of the implement
12.
[0041] The conformable pod 10 of the present invention may be used
with a wide range of implements and devices designed or intended
for contacting the human skin, particularly such as manually
grasped implements including but not limited to items such as a
cooking vessel, hair brush, paint brush, scissors, sports racquet
or bat, hand tool, musical instrument, or virtually any other type
of manually grasped device having a handle or related structure for
manual grasping or engagement as by means of the hand or
fingertips. In this regard, it will be understood that use herein
of the term manual implement will include devices that are grasped,
held, manipulated, or otherwise contacted by some portion of a
user's body in the course of normal operation and/or use. The
conformable pod 10 may be constructed in a wide range of different
sizes and shapes, or combination of multiple pods assembled for
mounting as a group, onto the handle structure or fingertip keypad
structure or other selected user-contacted surface of the related
manual implement or the like. In this regard, the pod 10 may be
sized and shaped for mounting onto a flat surface, a curvilinear
surface, or other geometric surfaces. In addition, the pod 10 may
be construction in a cylindrical, sleeve-shaped configuration sized
for slide-fit onto an implement handle or the like.
[0042] In accordance with a primary aspect of the invention, the
conformable pod 10 incorporates a viscous and tacky gel or
equivalent colloidal material 14 adapted for resilient deformation
when subjected to manual or other bodily pressure. This gel
material 14 is contained within a substantially closed chamber 16
defined at least in part by an outer skin 18 formed from a
material, and having a thickness selected for minimal deformation
resistance to applied lightweight manual or tactile pressure.
Accordingly, the easily deformable skin 18 does not provide
significant resistance to pod deformation, thereby enabling the
encased gel material 14 to deform in response to minimal applied
pressure.
[0043] Once deformed, the gel material 14 exhibits sufficient shape
memory capacity for relatively slow return to its initial
nondeformed shape following a time delay of at least about two
seconds after release of the applied pressure. Accordingly, after
deformation, the gel material retains its deformed shape upon
continued user contact, but in a pressureless manner substantially
without requiring further input of manual force or pressure to
retain the pod 10 in the deformed shape. Following the post-release
time delay, the gel material returns slowly over a period of at
least about four seconds or more substantially to the initial
nondeformed shape. In addition, in the event of inadvertent or
accidental puncture of the outer skin 18, the gel material 14
exhibits sufficient material integrity to prevent leakage outflow
of the gel material from the pod interior.
[0044] As viewed in one preferred form in FIGS. 1 and 2, the
conformable pod 10 generally comprises an underlying substrate 20
of generally planar configuration, and which may be relatively
thick, stiff, and/or resistant to easy deformation in comparison
with the outer skin 18. This substrate 20 is formed in a selected
size and shape, such as the illustrative generally rectangular
shape. A peripheral margin of the substrate layer 20 is joined as
by suitable bonding with a peripheral lower edge 22 of an
upstanding perimeter side wall 24 formed as a portion of the
overlying skin 18. This upstanding side wall 24 extends upwardly
from the substrate 20 and is joined at its upper end to a face wall
26. The assembled skin 18 (defined by the perimeter side wall 24
and the face wall 26) and substrate 20 cooperatively define the
enclosed cavity or chamber 16 filled with the deformable gel
material 14. A fastener element 28 such as a film of pressure
sensitive adhesive of the like is carried at the underside of the
substrate 20 for quick and easy affixation of the assembled pod 10
onto a selected implement 12 (FIGS. 6-7). FIG. 2 illustrates a
peel-off liner 30 of paper-based material or the like for exposing
the fastener film 28 immediately prior to mounting of the
conformable pod 10 onto the selected implement.
[0045] While the illustrative drawings show the conformable pod 10
to have a generally rectangular shape, persons skilled in the art
will understand that numerous alternative pad configurations such
as circular, oval, toroidal, cylindrical or sleeve-shaped, etc.,
may used. Moreover, persons skilled in the art will recognize and
appreciate that other types of fastener elements may be employed,
such as Velcro-type fastener components, ribs or rims protruding
from the substrate 20, and the like.
[0046] FIGS. 3-5 illustrate one preferred process for forming the
conformable pod 10 of the present invention. As viewed in FIG. 3,
the overlying skin 18 may be formed as by an injection molding
process or the like wherein flowable skin-forming material is
injected under pressure as illustrated by arrow 32 into a mold
cavity 34 defined between a pair of separable upper and lower male
and female mold dies 36 and 38. In such molding step, the skin 18
is formed to have a selected overall size and shape, in combination
with a selected, relatively thin wall thickness chosen for easy
deformation with little and virtually no resistance in response to
applied manual pressure. In one preferred form of the invention,
the skin material comprises a thermoplastic resin such as a
silicone-based or polyurethane elastomer having soft structure
(preferred durometer of less than about 40-50 Shore A hardness),
and preferably a thin wall thickness of the order of about 0.030
inch. As viewed in FIG. 3, the thus-molded skin 18 may include an
integrally molded sprue 40 which is cut therefrom prior to
subsequent process steps. Alternative production processes such as
tumble, compression, and blow molding will be apparent to persons
skilled in the art.
[0047] The upper male mold die 36 is then separated from the lower
female die 38 having the molded skin 18 supported therein. In this
configuration, the molded skin 18 is supported in an inverted
orientation for facilitated pour-in reception of the gel material
14, as illustrated by arrow 42 in FIG. 4. The molded skin 18 is
substantially filled with the gel material, which preferably
comprises a coagulated or partially coagulated or catalized gel
such as a highly viscous and tacky silicone or polyurethane gel
material wherein the molecules are believed to be attached but not
firmly held thereby permitting relative movement in response to
applied manual pressure. Importantly, the tacky or sticky character
of the gel material causes the gel to adhere or stick intimately
with the inboard or underside surface of the inverted molded skin
18, but substantially without fusing or conjoining of the gel
material 14 with the skin 18. With a molded skin 18 formed from a
suitable silicon-based film material, it is believed that a
molecular attraction between the skin 18 and the gel material 14,
short of molecular bonding, effectively resists sliding
displacement between the skin 18 and the gel 14 for enhanced pod
displacement during use.
[0048] Exemplary gel materials include Silgel 612, available from
Wacker Chemical Corporation, Adrian, Mich., and ER 8015 GE TSE3053,
both available from GE Silicones, Wilton, Mass. Importantly, such
gel materials exhibit a memory characteristic whereby the material
deformably responds to relatively lightweight or minimal applied
pressure, but thereafter, following a time delay of at least about
two seconds after user release, the gel material returns relatively
slowly (over a period of at least five seconds or more) to its
initial nondeformed shape. The gel material has a preferred
penetration range of about 100-1,000 cm/sec., and preferably a
precured viscosity range of about 500 cP (centepoids) to about
1,500 cP.
[0049] FIG. 5 shows a subsequent process step wherein the substrate
20 is formed as by pouring (as illustrated by arrow 44) a selected
elastomer such as a silicone-based or polyurethane material over
the gel material 14, to cooperatively form the enclosed chamber 16
having the gel material sealingly encased therein. For this step, a
containment die 46 may be assembled with the lower mold die 38 to
retain the thus-poured liquid substrate-forming resin until it
cures sufficiently in adhered, substantially sealed engagement with
the peripheral edge 22 of the skin 18. Then, the thus-assembled
cushioned pad 10 can be removed from the mold die 38 and suitably
assembled with the fastener element 28, as previously described
(FIG. 2). A shallow textured pattern 48 (FIG. 1) may be defined on
the outboard surface of the face wall 26 to facilitate pod removal
from the mold die 38, if desired.
[0050] FIG. 6 shows the conformable pod 10 of the present invention
installed onto a selected manual implement 12, with the pod face
wall 26 defined by the thin outer skin 18 presented outwardly for
appropriate manual or fingertip contact or the like during use of
the implement. FIG. 7 shows deformable response to an applied force
such as a manual or tactile force depicted by arrow 50, namely,
downward deformation of the thin outer skin 18 with minimal
resistance for transferring the applied manual force to the gel
material 14 contained within the enclosed chamber. As the gel
material 14 deforms, the molecules thereof shift about within the
chamber 18, and adhere to the inboard surfaces of the skin and
substrate 18 and 20, while absorbing the applied energy. At the
same time, the outwardly presented geometry of the skin 18
deformably conforms to the anatomical shape of the person's hand or
fingertips or the like in contact with therewith. The result is a
highly comfortable, substantially custom-fitted interface between
the person's hand or fingertips and the manual implement, thereby
reducing friction, irritation, and user fatigue particularly such
as fatigue and/or injury associated with and/or attributable to
repetitive motion and/or continuity of applied manual force over an
extended period of time.
[0051] In accordance with one important aspect of the invention,
the gel material 14 retains the deformed shape in a substantially
pressureless manner, i.e., substantially without requiring the user
to exert a deformation force for the purpose of holding and
retaining the pod 10 in the desired custom-fitted geometry.
Instead, the user can operate and/or manipulate the implement 12 in
a secure, stable, and comfortable manner, without requiring
continued exertion of additional forces to hold the pod 10 in the
desired deformed shape. The gel material 14 maintains the deformed
shape for at least a short delay period following release of the
applied pressure therefrom. That is, the gel material 14 tends to
retain the deformed shape for at least about two seconds or more,
following release of the applied pressure, and thereafter returns
slowly over a period of about four seconds or more to the initial
nondeformed shape.
[0052] FIG. 8 shows one alternative form of the invention, wherein
a plurality of individually formed conformable pods 10 as
previously shown and described herein may be assembled as by means
of a common substrate 20 to form an enlarged or elongated
deformable grip or the like for mounting onto a selected manual
implement or the like. Such enlarged or elongated deformable grip
may be defined by interconnecting a single row of multiple pods 10
formed end-to-end as shown to defined an elongated tape-like
structure adapted for wrapped installation, e.g., about the handle
of a manual implement, such as wrapping about the handle of a golf
club, baseball or softball bat, or tennis racquet or the like.
Alternatively, such tape-like structure may be constructed with
multiple rows of interconnected pods 10 to form a wider structure
adapted for wrapped or other suitable mounting onto a manual
implement or the like.
[0053] Additional alternative preferred forms of the invention are
depicted in FIGS. 9-11, wherein a modified conformable pod is
constructed generally as shown and described previously herein, but
wherein the overlying skin is modified for further enhanced
flexibility, i.e., further reduced resistance to deformation in
response to a relatively small or lightweight applied pressure.
FIG. 9 shows a modified face wall 126 of the conformable pod to
incorporate an array of shallow corrugations 60 designed to
decrease resistance to deformation in response to an applied force
as illustrated by arrow 62. FIG. 10 shows a modified side wall 124
to incorporate an array of shallow corrugations 64 designed to
decrease resistance to deformation in response to an applied manual
force as illustrated by arrow 66. FIG. 11 depicts a variation of
FIG. 10, wherein corrugations 164 formed in a modified side wall
224 are associated with a variable wall thickness, i.e., the
thickness of the side wall 224 is relatively thicker and thus
relatively stiffer near the point of attachment with the substrate
20, whereas the thickness of the side wall 224 progressively
decreases and thus becomes thinner and more flexible in a direction
toward the associated face wall 226. With this construction, the
overall resistance of the skin layer to an applied force as
illustrated by arrow 68 is reduced. Alternative skin configurations
may be employed wherein a relatively thick skin layer may
incorporate an array or arrays of shallow grooves in virtually any
pattern (as by molding or scoring) to accommodate enhanced
flexibility in response to an applied force.
[0054] FIGS. 12-16 depict a further alternative preferred form of
the invention including one or more modified conformable pods 110,
wherein components corresponding structurally and/or functionally
with those previously shown and described herein are identified by
common reference numerals increased by 100. As shown, the modified
pods 110 are constructed in a substantially ring-shaped or closed
loop geometry for mounting onto a manual implement or the like such
as the illustrative pair of scissors 70. In this regard, FIG. 12
shows a pair of pods 110 mounted on the scissors 70 for lining the
inner diameter margins of closed loop openings 72 and 74 provided
in a pair of scissors handles 76 and 78 for finger grasping and
manipulation of a pair of scissors blades 80 and 82. The
conformable pods 110 lining these openings 72, 74 thus provide soft
deformable structures for used contact during normal scissors
usage.
[0055] FIG. 13 shows the conformable pod 110 comprising a closed
loop or ring-shaped outer skin 118 having a generally circular
cross sectional shape to define an enclosed chamber 116 filled
substantially with a flowable material such as a gel or gel-like
material 114 preferably exhibiting the deformation and memory
characteristics described previously herein with respect to FIGS.
1-11. The outer skin 118 is joined to a substrate rim or rib 120
shown protruding generally radially outwardly from the
circumference or outer periphery of the ring-shaped skin 118. This
substrate 120 may be constructed from the same material as the skin
118, but with increased thickness, or from an alternative stiffer
and/or harder material to provide a sturdy structure adapted for
quick and easy mounting of the pod 110 onto the associated scissors
handles 76 or 78.
[0056] FIG. 14 shows the scissors handle 78 to be constructed from
a pair of initially split-apart handle segments 78a and 78b adapted
for assembly as by snap-fit and adhesive mounting in face-to-face
relation with the protruding substrate rim 120 securely clamped
therebetween. FIG. 15 shows a variation in this mounting
arrangement wherein a snap ring 84 is additionally provided for
seating and locking the substrate rim 120 securely between the
interfitting handle segments 78a and 78b. In either assembly
technique, the deformable pod 110 defined by the gel material 114
contained within the hollow skin ring 118 is positioned at the
inner periphery, or inner diametric edge, of the associated handle
opening 72, 74 wherein it is contacted by the user and compliantly
deforms as previously described herein to provide the desired
customized ergonomic shape. The peripheral rim 120 thus also
functions as a fastener element for use in mounting the pod 110
onto the selected implement, it being understood that the
ring-shaped pod 110 can be installed onto other types of implements
conducive to a closed loop pod geometry.
[0057] FIGS. 16-22 illustrate another alternative preferred form of
the invention including one or more modified conformable pods 310
and 310', wherein components corresponding structurally and/or
functionally with those previously shown and described herein are
identified by common reference numerals increased by 200. As shown
best in FIGS. 16 and 17, the modified pods 310 and 310' are
provided for mounting onto the support structure of a selected
article or implement such as a chair 300. Three of the modified
pods 310 are shown mounted onto a front or user-contacted side of a
support structure 312 such as chair seatback, whereas the modified
pod 310' comprises a single and larger conformable pod shown
mounted onto the top or user-contacted side of a support structure
312' such as a chair seat.
[0058] More particularly, each of the seatback pods 310 comprises a
plurality of elongated raised ribs 86 extending generally in
parallel and spaced-apart relation, and separated by intervening
recessed troughs or valleys 87. These seatback pods 310 are each
shown mounted onto the chair seatback 312 with the ribs 86 and
troughs 87 oriented to extend generally transversely or
horizontally across the chair seatback. Three of the seatback pods
312 are shown mounted onto the seatback 312 in vertically spaced
relation to each other. Persons skilled in the art will appreciate,
however, that each seatback pod 310 can be constructed with any
convenient number of elongated ribs 86 with intervening recessed
troughs 87. In this regard, the seat pod 310' has a similar
construction and is shown in the illustrative drawings with a
larger number of elongated raised ribs 86 with intervening recessed
troughs or valleys extending generally transversely across the
chair seat 312'.
[0059] FIGS. 18-21 depict further construction details for one of
the seatback pods 310, but it will be understood that the seat pod
310' has a similar construction. More specifically, the
illustrative seatback pod 310 includes an outer skin 318
constructed from a relatively thin and easily deformed material (as
previously shown and described herein with respect to FIGS. 1-15)
to incorporate a desired front-side or user-contacted side shape,
namely, the elongated raised ribs 86 separated by the intervening
recessed troughs 87. This outer skin 318 defines a front side of an
internal chamber or cavity 316 (FIG. 19) that is filled or
substantially filled with the viscous gel material 314, again as
previously shown and described herein. A rear side of this chamber
or cavity 316 is closed as by means of a rear-side substrate
320.
[0060] In accordance with one primary aspect of the embodiment
shown in FIGS. 16-21, modified fasteners 328 such as mounting bolts
88 are anchored within the conformable pod 310 and protrude
rearwardly from the rear-side substrate 320 for quick and easy
mounting of the pod 310 onto a selected article or implement such
as the chair seatback 312 or the like. FIG. 18 shows these mounting
bolts 88 protruding rearwardly from the rear-side substrate 320 in
a predetermined array or pattern for quick and easy slide-fit
reception rearwardly through pre-formed bolt holes 89 (FIG. 17)
formed in the chair seatback 312. A similar array of bolt holes 89
is also formed in the chair seat 312' for appropriate mounting of
the seat pod 310'. Suitable nuts such as wing nuts 90 or the like
(FIG. 22) are provided for removably mounting the bolts 88 onto the
structure, i.e., onto the chair seatback 312.
[0061] Each of the mounting bolts 88 has a head portion 91 securely
anchored to the associated conformable pod. As viewed best in one
preferred form in FIGS. 20-21, the bolt head portion 91 may
comprise a threaded nut 92 captured within a disk-shaped head
housing 93 formed from a suitable plastic material, with one end of
a threaded bolt shank 94 captured within said nut 92. With this
construction, the threaded bolt shank 94 protrudes outwardly from
one side of the disk-shaped head housing (FIG. 21). This mounting
bolt unit 88 is adapted for secure anchored installation of the
head portion 91 as by co-molding within a relatively stiff support
strip or plate 95 (FIG. 19) disposed at a rear side of the pod. As
shown, this support strip 95 may be co-molded within the pod,
generally at an inboard side of the rear-side substrate 320 to
provide a stiff and stable base for the mounting bolts 88. In one
preferred form, the support strip 95 comprises a layer of thicker
and less deformable material in comparison with the outer skin 318,
suitable for co-molded embedment of the bolt head portions 91
therein. Alternatively, the support strip 95 may be formed from a
rigid material, such as metal or plastic. As a further alternative,
the support strip 95 may incorporate and comprise the rear-side
substrate 320 of the conformable pod.
[0062] In use, when the conformable pods 310 or 310' are mounted
onto the appropriate article or implement such as the illustrative
chair seatback 312 or chair seat 312', the user contacts the raised
or distal end portions of the elongated ribs 86 resulting in
deformation of the gel material 314 contained therein. As shown
best in FIGS. 19, the recessed troughs or valleys 87 separating the
raised ribs 86 are at least slightly spaced from the rear-side
substrate 320 and/or the support strip 95 so that the
cavity-filling gel material 314 is present in a continuum
communicating within the closed chamber 316 between adjacent ribs
86. Thus, the gel material 314 responds to user-applied pressure to
conformably and deformably respond so that the ribs 86 collectively
compress to assume a custom anatomical configuration. When the
user-applied pressure is released, the gel material 314 will slowly
substantially to its original non-deformed shape, thereby returning
the pod substantially to its original rib and trough
configuration.
[0063] In further alternative form, different types of mechanical
fasteners may be employed, such as magnet fasteners carried by the
conformable pod at the rear side thereof for quick and easy
attachment to the structure of a selected article or implement. A
magnet can be carried at a rear side of the pod for attachment to a
suitable structure which may include a mating magnet of opposite
polarity. Or, in some configurations, the rear-side substrate of
the conformable pod may be designed for direct attachment as by
co-molding directly onto the structure of the selected article or
substrate.
[0064] A variety of further modifications and improvements in and
to the improved conformable pod of the present invention will be
apparent to those persons skilled in the art. Accordingly, no
limitation on the invention is intended by way of the foregoing
description and accompanying drawings, except as set forth in the
appended claims.
* * * * *