U.S. patent application number 13/420999 was filed with the patent office on 2015-11-26 for breathable gel.
This patent application is currently assigned to EDIZONE, LLC. The applicant listed for this patent is LaVon Lee Bennett, Tony M. Pearce, Russell B. Whatcott. Invention is credited to LaVon Lee Bennett, Tony M. Pearce, Russell B. Whatcott.
Application Number | 20150335166 13/420999 |
Document ID | / |
Family ID | 46877571 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150335166 |
Kind Code |
A9 |
Pearce; Tony M. ; et
al. |
November 26, 2015 |
BREATHABLE GEL
Abstract
Cushioning elements include a breathable material configured to
allow gases to pass through at least a portion thereof, and a
plurality of discrete segments of thermoplastic elastomeric gel
("gel") heat-fused or otherwise attached to the breathable
material. The gel comprises an elastomeric polymer and a
plasticizer, with a plasticizer-to-polymer ratio of from about 0.3
to about 50. The plurality of discrete segments defines at least
one breathable gap between adjacent discrete segments. Methods of
forming cushioning elements include forming a plurality of discrete
segments of gel, securing each segment to a breathable material,
and providing a gas path through the breathable material and
between adjacent segments. Another method includes providing molten
gel within a mold, providing at least a second portion of the gel
within a permeable material, and solidifying the gel to form
discrete segments of gel.
Inventors: |
Pearce; Tony M.; (Alpine,
UT) ; Whatcott; Russell B.; (Eagle Mountain, UT)
; Bennett; LaVon Lee; (Alpine, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pearce; Tony M.
Whatcott; Russell B.
Bennett; LaVon Lee |
Alpine
Eagle Mountain
Alpine |
UT
UT
UT |
US
US
US |
|
|
Assignee: |
EDIZONE, LLC
Alpine
UT
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20120244312 A1 |
September 27, 2012 |
|
|
Family ID: |
46877571 |
Appl. No.: |
13/420999 |
Filed: |
March 15, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12784247 |
May 20, 2010 |
8932692 |
|
|
13420999 |
|
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|
|
12287047 |
Oct 3, 2008 |
8434748 |
|
|
12784247 |
|
|
|
|
61465911 |
Mar 25, 2011 |
|
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|
61216787 |
May 21, 2009 |
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Current U.S.
Class: |
267/142 ; 156/65;
428/131; 428/136; 428/195.1; 428/196 |
Current CPC
Class: |
B29C 66/30326 20130101;
B29C 66/71 20130101; B29L 2031/751 20130101; Y10T 428/24802
20150115; D06N 2209/123 20130101; Y10T 428/24331 20150115; A47C
27/15 20130101; B29C 66/71 20130101; A47C 27/10 20130101; B29C
66/30325 20130101; B68G 5/00 20130101; D06N 2211/14 20130101; B29C
66/472 20130101; B32B 3/266 20130101; A47C 27/00 20130101; Y10T
428/24322 20150115; B29C 66/729 20130101; D06N 7/0092 20130101;
B32B 3/16 20130101; D06N 2203/042 20130101; B29K 2021/003 20130101;
D06N 3/106 20130101; B29L 2031/58 20130101; A47C 31/116 20130101;
B32B 3/22 20130101; B29C 66/73181 20130101; B29C 66/727 20130101;
B29C 66/7392 20130101; B29C 65/02 20130101; B29C 65/48 20130101;
Y10T 428/2481 20150115; B29L 2031/7138 20130101; D06N 2201/042
20130101; A47C 27/20 20130101; Y10T 428/24273 20150115; Y10T
428/24314 20150115 |
International
Class: |
B32B 3/16 20060101
B32B003/16; B68G 5/00 20060101 B68G005/00; B29C 65/02 20060101
B29C065/02 |
Claims
1. A cushioning element, comprising: a breathable material
configured to allow gases to pass through at least a portion
thereof; and a plurality of discrete segments of thermoplastic
elastomeric gel heat-fused to the breathable material, the
thermoplastic elastomeric gel comprising an elastomeric polymer and
a plasticizer; wherein a ratio of a weight of the plasticizer to a
weight of the elastomeric polymer is from about 0.3 to about 50;
and wherein the plurality of discrete segments defines at least one
breathable gap between adjacent discrete segments.
2. The cushioning element of claim 1, wherein the plurality of
discrete segments comprises a plurality of segments each having a
generally square cross section.
3. The cushioning element of claim 1, wherein the plurality of
discrete segments comprises a plurality of continuous segments.
4. The cushioning element of claim 1, wherein at least one discrete
segment of the plurality defines at least one internal gap within
the segment.
5. The cushioning element of claim 4, wherein the at least one
internal gap has an aspect ratio of from about 1 to about 20.
6. The cushioning element of claim 4, wherein the at least one
discrete segment of the plurality comprises a thermoplastic
elastomeric gel material disposed between adjacent internal
gaps.
7. The cushioning element of claim 1, wherein a portion of each of
the discrete segments permeates the breathable material.
8. The cushioning element of claim 1, wherein each segment of the
plurality has a thickness of less than about 25.4 mm (about 1.0
in).
9. The cushioning element of claim 8, wherein each segment of the
plurality has a thickness of less than about 12.7 mm (0.50 in).
10. The cushioning element of claim 1, wherein the plurality of
discrete segments defines a generally planar surface, broken by the
at least one breathable gap between adjacent discrete segments.
11. The cushioning element of claim 1, wherein the cushioning
element is free of a continuous impermeable barrier.
12. The cushioning element of claim 1, wherein the elastomeric
polymer comprises an A-B-A triblock copolymer.
13. A method of forming a cushioning element, comprising: forming a
plurality of discrete segments of thermoplastic elastomeric gel,
the thermoplastic elastomeric gel comprising an elastomeric polymer
and a plasticizer, wherein a ratio of a weight of the plasticizer
to a weight of the elastomeric polymer is from about 0.3 to about
50; securing each discrete segment of thermoplastic elastomeric gel
to a breathable material configured to allow gases to pass through
at least a portion thereof; and providing a gas path through the
breathable material and between adjacent discrete segments of
thermoplastic elastomeric gel.
14. The method of claim 13, further comprising permeating the
breathable material with at least a portion of each of the discrete
segments of thermoplastic elastomeric gel.
15. The method of claim 14, wherein permeating the breathable
material with at least a portion of each of the discrete segments
of thermoplastic elastomeric gel comprises applying pressure to the
thermoplastic elastomeric gel.
16. The method of claim 14, wherein permeating the breathable
material with at least a portion of each of the discrete segments
of thermoplastic elastomeric gel comprises permeating a fabric with
at least a portion of the discrete segments of thermoplastic
elastomeric gel.
17. The method of claim 13, wherein forming a plurality of discrete
segments of thermoplastic elastomeric gel comprises: providing
molten thermoplastic elastomeric gel within a mold; and solidifying
the molten thermoplastic elastomeric gel.
18. The method of claim 17, further comprising moving at least one
of the mold and the breathable material such that the mold is
adjacent a portion of the breathable material substantially free of
the thermoplastic elastomeric gel.
19. The method of claim 13, further comprising securing at least a
portion of the breathable material to another cushioning
element.
20. The method of claim 13, wherein forming the plurality of
discrete segments of thermoplastic elastomeric gel comprises
continuously forming the plurality of discrete segments of
thermoplastic elastomeric gel on a roll of the breathable
material.
21. The method of claim 13, wherein forming a plurality of discrete
segments of thermoplastic elastomeric gel comprises selecting the
elastomeric polymer to comprise an A-B-A triblock copolymer.
22. The method of claim 13, further comprising quilting at least a
portion of the breathable material to a cover.
23. A method of forming a cushioning element, comprising: disposing
a permeable material adjacent a mold; providing at least a first
portion of a molten thermoplastic elastomeric gel within the mold,
the thermoplastic elastomeric gel comprising an elastomeric polymer
and a plasticizer, wherein a ratio of a weight of the plasticizer
to a weight of the elastomeric polymer is from about 0.3 to about
50; providing at least a second portion of the molten thermoplastic
elastomeric gel within the permeable material; solidifying the
molten thermoplastic elastomeric gel to form discrete segments of
thermoplastic elastomeric gel; and separating the mold from at
least a portion of the permeable material.
24. The method of claim 23, wherein disposing the permeable
material adjacent the mold and separating the mold from at least a
portion of the permeable material each comprises translating the
permeable material adjacent a rotating drum.
25. The method of claim 24, further comprising unwinding the
permeable material from a first roll and winding the permeable
material having discrete segments of thermoplastic elastomeric gel
to form a second roll.
26. A cushioning element, comprising: a breathable material
configured to allow gases to pass through at least a portion
thereof; and a plurality of discrete segments of thermoplastic
elastomeric gel attached to the breathable material, the plurality
of discrete segments heat-fused to the breathable material; wherein
the plurality of discrete segments and the breathable material
together define at least a portion of at least one void, wherein
the thermoplastic elastomeric gel comprises an elastomeric polymer
and a plasticizer, and wherein a ratio of a weight of the
plasticizer to a weight of the elastomeric polymer is from about
0.3 to about 50.
27. The cushioning element of claim 28, wherein the breathable
material comprises a material selected from the group consisting of
a woven fabric, a knit fabric, a mesh fabric, a spacer fabric, a
fabric laminated to a vapor-transmissible film, and a porous foam
having an open-pore network.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/465,911, filed Mar. 25, 2011, and
entitled "Breathable Gel for Cushioning and/or Temperature
Management," the disclosure of which is incorporated herein by
reference in its entirety.
FIELD
[0002] Embodiments of the disclosure relate generally to cushioning
elements comprising a gel component, to products including such
cushioning elements, and to methods of making and using such
cushioning elements.
BACKGROUND
[0003] Cushioning materials have a variety of uses, such as for
mattresses, seating surfaces, shoe inserts, packaging, medical
devices, etc. Cushioning materials may be formulated and/or
configured to reduce peak pressure on a cushioned body, which may
increase comfort for humans or animals, and may protect objects
from damage. Cushioning materials may be formed of materials that
deflect or deform under load, such as polyethylene or polyurethane
foams (e.g., convoluted foam), vinyl, rubber, springs, natural or
synthetic fibers, fluid-filled flexible containers, etc. Different
cushioning materials may have different responses to a given
pressure, and some materials may be well suited to different
applications. Cushioning materials may be used in combination with
one another to achieve selected properties.
[0004] For example, cushioning materials may include a foam layer
topped with a layer of thermoset elastomeric gel, such as a
polyurethane gel or a silicone gel. Because polyurethane gels and
silicone gels are generally structurally weak and/or sticky,
cushioning materials may include film covering such gels, such as a
thin thermoplastic polyurethane film. The film may reinforce the
strength of the gel, and may prevent other materials from sticking
to the gel, since the film generally adheres to the gel but is not
itself sticky.
[0005] Gels may be used for cushioning and/or temperature
management. Gels may provide cushioning because the gels may
hydrostatically flow to the shape of a cushioned object and may
tend to relieve pressure peaks and/or reduce stresses from shear.
Gels may have high thermal mass and/or thermal conductivity, and
may therefore be used for heating (such as in hot packs for sore
muscles), cooling (such as in cold packs for sprains or for a
feeling of coolness when lying on a mattress), or maintaining a
given temperature (such as in a mattress being used in a too-warm
or too-cool room). For example, gel may be fused to the top of a
mattress core, and a film may cover the gel. As another example,
gels may be used as the top layer of a foam wheelchair cushion.
[0006] A conventional gel layer, with or without a plastic film,
may be a barrier to gases (e.g., air, vapors, or other gases). This
barrier may cause difficulties such as discomfort, such as when
body heat and/or perspiration accumulate between the user's body
and the gel layer. Even when a breathable material (such as a foam
cover or batting fiber) is disposed between a cushioned object and
the gel, gases can only travel laterally through the breathable
material. Since gases cannot penetrate the plastic film or the gel,
the plastic film or the gel inhibits the flow of the gases away
from the cushioned object. When the weight of the cushioned object
compresses the breathable material, the lateral gas flow paths may
become more constricted. Thus, it would be beneficial to provide a
cushioning material that alleviates some of these concerns.
BRIEF SUMMARY
[0007] In some embodiments, the present disclosure includes a
cushioning element comprising a breathable material configured to
allow gases to pass through at least a portion thereof, and a
plurality of discrete segments of thermoplastic elastomeric gel
heat-fused to the breathable material. The thermoplastic
elastomeric gel comprises an elastomeric polymer and a plasticizer.
A ratio of a weight of the plasticizer to a weight of the
elastomeric polymer is from about 0.3 to about 50. The plurality of
discrete segments defines at least one breathable gap between
adjacent discrete segments.
[0008] A method of forming a cushioning element comprises forming a
plurality of discrete segments of thermoplastic elastomeric gel,
securing each discrete segment of thermoplastic elastomeric gel to
a breathable material configured to allow gases to pass through at
least a portion thereof, and providing a gas path through the
breathable material and between adjacent discrete segments of
thermoplastic elastomeric gel. The thermoplastic elastomeric gel
comprises an elastomeric polymer and a plasticizer. A ratio of a
weight of the plasticizer to a weight of the elastomeric polymer is
from about 0.3 to about 50.
[0009] Another method of forming a cushioning element comprises
disposing a permeable material adjacent a mold, providing at least
a first portion of a molten thermoplastic elastomeric gel within
the mold, providing at least a second portion of the molten
thermoplastic elastomeric gel within the permeable material,
solidifying the molten thermoplastic elastomeric gel to form
discrete segments of thermoplastic elastomeric gel, and separating
the mold from at least a portion of the permeable material. The
thermoplastic elastomeric gel comprises an elastomeric polymer and
a plasticizer. A ratio of a weight of the plasticizer to a weight
of the elastomeric polymer is from about 0.3 to about 50.
[0010] Another cushioning element comprises a breathable material
configured to allow gases to pass through at least a portion
thereof and a plurality of discrete segments of thermoplastic
elastomeric gel attached to the breathable material. The plurality
of discrete segments is heat-fused to the breathable material. The
plurality of discrete segments and the breathable material together
define at least a portion of at least one void. The thermoplastic
elastomeric gel comprises an elastomeric polymer and a plasticizer,
and a ratio of a weight of the plasticizer to a weight of the
elastomeric polymer is from about 0.3 to about 50.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] While the specification concludes with claims particularly
pointing out and distinctly claiming that which are regarded as
embodiments of the present disclosure, various features and
advantages may be more readily ascertained from the following
description of example embodiments of the disclosure provided with
reference to the accompanying drawings, in which:
[0012] FIG. 1A is a simplified top view of a cushioning element,
showing generally square gel segments, a breathable material, and a
breathable gap among the segments of gel;
[0013] FIG. 1B is a simplified cross-sectional view of the
cushioning element of FIG. 1A;
[0014] FIG. 2A is a simplified perspective view of another
cushioning element, showing generally continuous rows or strips of
gel, a breathable material, and breathable gaps between the
TOWS;
[0015] FIG. 2B is a simplified cross-sectional view of the
cushioning element shown in FIG. 2A;
[0016] FIG. 3A is a simplified perspective view of another
cushioning element, showing gel segments with gaps between adjacent
segments and within each segment;
[0017] FIG. 3B is a simplified perspective view of a gel segment of
the cushioning element of FIG. 3A;
[0018] FIG. 3C is an additional simplified perspective view of the
cushioning element of FIG. 3A;
[0019] FIG. 3D is a simplified bottom view of the cushioning
element of FIG. 3A; and
[0020] FIG. 4 is a simplified drawing of a part of a mold that may
be used to make the gel segments shown in FIGS. 3A through 3D.
DETAILED DESCRIPTION
[0021] As used herein, the term "cushioning element" means and
includes any deformable device intended for use in cushioning one
body relative to another. As a non-limiting example, cushioning
elements include materials intended for use in cushioning the body
of a person relative to another object that might otherwise abut
against the body of the person, such as a seat cushion.
[0022] As used herein, the term "breathable" means configured to
allow gases (e.g., air and vapors, such as water vapor) to pass
through. A breathable material may be a fabric, a foam, or another
material having gas passageways.
[0023] As used herein, the term "elastomeric polymer" means and
includes a polymer capable of recovering its original size and
shape after deformation. In other words, an elastomeric polymer is
a polymer having elastic properties. Elastomeric polymers may also
be referred to as "elastomers" in the art. Elastomeric polymers
include, without limitation, homopolymers (polymers having a single
chemical unit repeated) and copolymers (polymers having two or more
chemical units).
[0024] As used herein, the term "elastomeric block copolymer" means
and includes an elastomeric polymer having groups or blocks of
homopolymers linked together, such as A-B diblock copolymers and
A-B-A triblock copolymers. A-B diblock copolymers have two distinct
blocks of homopolymers. A-B-A triblock copolymers have two blocks
of a single homopolymer (A) each linked to a single block of a
different homopolymer (B).
[0025] As used herein, the term "plasticizer" means and includes a
substance added to another material (e.g., an elastomeric polymer)
to increase a workability of the material. For example, a
plasticizer may increase the flexibility or softness of the
material. Plasticizers include hydrocarbon fluids, such as mineral
oils. Hydrocarbon plasticizers may be aromatic or aliphatic.
[0026] As used herein, the term "TPE gel" means and includes a
thermoplastic elastomeric gel having an elastomeric polymer (e.g.,
a homopolymer or a copolymer) and a plasticizer. TPE Gels are
thermoplastic (i.e., melting when heated and solidifying when
cooled) and elastic (i.e., capable of recovering size and shape
after deformation). TPE gels may be referred to in the art as
"thermoplastic gels," "thermoplastic elastomeric gels," "elastomer
gels," "gelatinous elastomers," or simply "gels."
[0027] The illustrations presented herein are not actual views of
any particular material or device, but are merely idealized
representations employed to describe embodiments of the present
disclosure. Elements common between figures may retain the same
numerical designation.
[0028] Cushioning elements having breathable gaps or voids are
disclosed herein. Such gaps or voids may allow gas flow through
and/or around portions of the cushioning elements. The cushioning
elements may be free of a continuous barrier impermeable to gases.
The cushioning elements may have temperature management features.
The cushioning elements may include discrete TPE gel segments that
have a generally coplanar or otherwise cooperatively shaped top
surface and have spaces between and/or within the gel segments.
[0029] FIGS. 1A through 3D show cushioning elements 10, 20, and 30,
each having a plurality of discrete gel segments 12. Surfaces of
the gel segments 12 define at least one breathable gap 14. The
breathable gap 14 may be configured to allow gases, such as air,
water vapor, etc., to pass between adjacent gel segments 12.
[0030] Gel segments 12 may be formed of TPE gel. TPE Gels are
described in, for example, U.S. Pat. No. 5,749,111, issued May 12,
1998, and entitled "Gelatinous Cushions with Buckling Columns;"
U.S. Pat. No. 6,026,527, issued Feb. 22, 2000, and entitled
"Gelatinous Cushions with Buckling Columns;" U.S. Pat. No.
5,994,450, issued Nov. 30, 1999, and entitled "Gelatinous Elastomer
and Methods of Making and Using the Same and Articles Made
Therefrom;" and U.S. Pat. No. 6,797,765, issued Sep. 28, 2004, and
entitled "Gelatinous Elastomer;" the disclosures of each of which
are incorporated herein in their entirety by this reference.
[0031] TPE gels may comprise A-B-A triblock copolymers such as
styrene ethylene propylene styrene (SEPS), styrene ethylene
butylene styrene (SEBS), and styrene ethylene ethylene propylene
styrene (SEEPS). For example, A-B-A triblock copolymers are
currently commercially available from Kuraray America, Inc., of
Houston, Tex., under the trade name SEPTON.RTM. 2002, and from
Kraton Polymers, LLC, of Houston, Tex., under the trade names
KRATON.RTM. G1643M and KRATON.RTM. MD6945M. In these examples, the
"A" blocks are styrene. The "B" block may be rubber (e.g.,
butadiene, isoprene. etc.) or hydrogenated rubber (e.g.,
ethylene/propylene or ethylene/butylene or
ethylene/ethylene/propylene) that may be plasticized with mineral
oil or other hydrocarbon fluids. TPE gels may comprise elastomeric
polymers other than styrene-based copolymers, such as elastomeric
polymers that are thermoplastic in nature or that can be solvated
by plasticizers.
[0032] TPE gels may comprise one or more plasticizers, such as
hydrocarbon fluids. For example, TPE gels may comprise
aromatic-free food-grade white paraffinic mineral oils, such as
those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade
names BLANDOL.RTM. and CARNATION.RTM..
[0033] In some embodiments, TPE gels may have
plasticizer-to-polymer ratios from about 0.3-to-1 to about 50-to-1
by weight. For example, TPE gels may have plasticizer-to-polymer
ratios from about 2-to-1 to about 30-to-1 by weight, or even from
about 5-to-1 to about 15-to-1 by weight. In further embodiments,
TPE gels may have plasticizer-to-polymer ratios of about 8-to-1 by
weight.
[0034] TPE gels may also include antioxidants. Antioxidants may
reduce the effects of thermal degradation during processing or may
improve long-term stability. Antioxidants include, for example,
pentaerythritol
tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate),
commercially available as IRGANOX.RTM. 1010, from BASF Corp., of
Iselin, N.J. or as EVERNOX.RTM.-10, from Everspring Chemical, of
Taichung, Taiwan;
octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,
commercially available as IRGANOX.RTM. 1076, from BASF Corp. or as
EVERNOX.RTM. 76, from Everspring Chemical; and
tris(2,4-di-tert-butylphenyl)phosphite, commercially available as
IRGAFOS.RTM. 168, from BASF Corp or as EVERFOS.RTM. 168, from
Everspring Chemical. One or more antioxidants may be combined in a
single TPE gel formulation. The use of antioxidants in mixtures of
plasticizers and polymers is described in columns 25-26 of U.S.
Pat. No. 5,994,450, previously incorporated by reference. TPE gel
formulations may comprise up to about 5 wt % antioxidants. For
instance, a TPE gel may comprise about 0.10 wt % to about 1.0%
antioxidants.
[0035] TPE gels may be formulated to be used without an impermeable
barrier (e.g., a plastic sheet). For example, TPE gels may be
formulated to be strong enough to not break under normal use, even
without the reinforcement that a plastic sheet provides to
conventional cushioning materials. Furthermore, TPE gels that have
lower stickiness than conventional gel cushioning materials may not
require a barrier to cover sticky surfaces of gel structures. The
lack of an impermeable barrier may allow gases to travel more
freely through the cushioning element 10, 20, via breathable gaps
14. Freely circulating gases may provide relief from moisture,
corrosive gases, perspiration, body heat, etc. Not only does the
elimination of impermeable barriers aid in allowing breathability,
it may also reduce materials and manufacturing costs.
[0036] Gel segments 12 may include a TPE gel that returns to its
original shape after deformation, and that may be elastically
stretched to many times its original size. Gel segments 12 may be
rubbery in feel, but may deform to the shape of an object applying
a deforming pressure better than conventional rubber materials, and
may have a durometer hardness lower than conventional rubber
materials. For example, gel segments 12 may have a hardness on the
Shore A scale of less than about 50, from about 0.3 to about 50, or
less than about 1. TPE gels, which are thermoplastic in nature, may
be stronger, for example, five to ten times stronger in tensile
strength or yield strength, than conventional thermoset cushioning
gels such as polyurethane and silicone gels.
[0037] TPE gels may be less sticky than conventional thermoset
cushioning gels. TPE gels may not generally be adhesively sticky,
but instead may be mildly tacky. The composition of the gel
segments 12 may have a selected stickiness or tackiness. For
example, the gel segments 12 may have a lower stickiness than gel
used in conventional cushioning elements. For some applications,
stickiness may be beneficial, and more sticky formulations of TPE
gels may be used. Elimination of the plastic film in such
embodiments may allow stickiness to be exposed so that it may
function in a sticky manner as desired. In other embodiments, low
tackiness and high tensile strength (e.g., from about 1.4 MPa (200
psi) to about 14 MPa (2,000 psi)) may eliminate the need for
impermeable plastic films or sheets that are used in some
conventional cushioning elements to provide strength to gel
structures and nonadhesiveness to exposed surfaces.
[0038] TPE gel formulations may have selected thermal properties.
Solid TPE gel may have higher heat capacity and higher thermal
conductivity than foams, other cushioning materials, and/or other
temperature management materials. Heating, cooling, and other
temperature management may be a beneficial feature of cushioning
elements 10, 20, 30 including gel segments 12. Strong TPE gel
formulations having selected tackiness or stickiness may include
elastomeric gels having lightweight (e.g., lightweight
microspheres) and elastomeric gels without fillers. Fillers may
affect thermal properties. For example, hollow microspheres may
decrease the thermal conductivity by acting as an insulator because
such hollow microspheres (e.g., hollow glass microspheres or hollow
acrylic microspheres) may have lower thermal conductivity than the
bulk TPE gel. As another example, metal particles (e.g., aluminum,
copper, etc.) may increase the thermal conductivity of the
resulting material because such particles may have greater thermal
conductivity than the bulk TPE gel. As another example,
microspheres filled with wax or another phase-change material
(i.e., a material formulated to undergo a phase change near a
temperature at which a cushioning element may be used) may provide
temperature stability at or near the phase-change temperature of
the wax or other phase-change material within the microspheres
(i.e., due to the heat of fusion of the phase change). A TPE gel
including wax or another phase-change material as all or part of
the plasticizer portion of the gel may have similar properties.
[0039] Gel segments 12 may have any selected shape. As shown in
FIG. 1A, gel segments 12 may have a generally square cross section
in a plane parallel to a breathable material 18 over which the gel
segments 12 are disposed. That is, a length L of a gel segment 12
may be approximately equal to a width W of the gel segment 12.
Cross sections of gel segments 12 may have rounded corners. As
shown in FIG. 2A, gel segments 12 may be continuous rows or strips
of TPE gel. Such a configuration may be amenable to continuous
production, as described in more detail below. Cross sections of
gel segments 12 may have other shapes, for example, polygons (e.g.,
triangles, quadrilaterals, pentagons, hexagons, stars, etc.),
circles, ovals, semicircles, crescents, irregular shapes, the shape
of a company or team logo, etc.
[0040] As shown in FIGS. 3A through 3D, some gel segments 12 may
define one or more internal gaps 16 within the gel segment 12. For
example, in the cushioning element 30, each gel segment 12 defines
four internal gaps 16. The internal gaps 16 shown in FIGS. 3A
through 3D have a generally quadrilateral "arrowhead" shape, but
internal gaps 16 may have any selected shape. For example, internal
gaps 16 may have a cross section in a plane parallel to the
breathable material 18 having a polygonal shape (triangle,
quadrilateral, pentagon, etc.), a circular shape, an oval shape, an
irregular shape, the shape of a company or team logo, etc.
Polygonal cross sections of internal gaps 16 may be regular (i.e.
all angles and sides of the polygon may be congruent) or irregular
(e.g., as shown in FIG. 3A). Gel segments 12 having internal gaps
16 (e.g., as in cushioning elements 30) may have less material than
similarly sized gel segments 12 without internal gaps 16 (e.g., as
in cushioning elements 10). Thus, the cushioning element 30 may
have a lower weight, a lower production cost, and/or a higher
surface area available for bonding to other substrates than does
the cushioning element 10 (e.g., the areas of the breathable
material 18 where gel has permeated all the way through may not be
bondable with adhesives, but the areas of the internal gaps 14 free
of gel may be bondable with adhesives, as may the breathable gaps
14 around or adjacent to each gel segment 12). A wide variety of
configurations and geometries of gel segments 12 may be used in
addition to or in place of the illustrated configurations and
geometries.
[0041] The gel segments 12 may be disposed over the breathable
material 18, and may be secured directly or indirectly to the
breathable material 18. The breathable material 18 may include one
or more of fabric, foam, or another material. The breathable
material 18 may be stretchable in one direction but non-stretchable
in another direction. In some embodiments, the breathable material
18 may be stretchable in two or more directions, or may be
non-stretchable in two or more directions. The breathable material
18 may be a woven fabric, a knit fabric, a mesh fabric, a
three-dimensional fabric (i.e., a spacer fabric), a fabric
laminated to a vapor-transmissible film (e.g., thin thermoplastic
polyurethane), a porous foam having an open (i.e., connected) pore
network, etc. A woven fabric may include any fabric having
interlaced yarn, strands, or threads. A knit fabric may include any
fabric having a series of connected loops of yarn or thread. A
porous foam may be a natural or synthetic material having
interconnecting pores. The breathable material 18 may be tricot, a
material that may or may not have a texture on at least one side.
For example, cotton tricot may have parallel woven ribs (or ridges)
on one side, and the other side may be smooth. Alternatively,
cotton tricot may have a first set of parallel woven ribs on one
side and a second set of parallel woven ribs on the other side,
oriented perpendicular to the first set of parallel woven ribs. The
breathable material 18 may define a plurality of voids 19 extending
through the breathable material 18. In some embodiments, the
plurality of voids 19 may have an average dimension (e.g., an
average diameter, an average width, etc.) of at least about 0.01 mm
(about 0.0004 in), at least about 0.1 mm (about 0.004 in), at least
about 1.0 mm (about 0.04 in), or at least about 10 mm (about 0.4
in). The breathable material 18 may also define a smaller plurality
of voids (not shown) that may or may not extend through the
breathable material 18. In other embodiments, all of the voids may
be smaller. The breathable material 18 may be flexible and pliable
to conform to the shape of other objects.
[0042] The breathable material 18 may be permeable by molten TPE
gel and gases. The breathable material 18 may define voids or
cavities, such as interconnected pores, spaces between fibers or
threads, etc. Gases may pass through the voids or cavities,
allowing the material to "breathe." The gel segments 12 may be
heat-fused to the breathable material 18. In other words, the
breathable material 18 may be impregnated by each of the gel
segments 12. In some embodiments, a portion of each of the gel
segments 12 may permeate the breathable material 18, such as in
voids or cavities therein. The portion of gel segments 12
permeating the breathable material 18 may provide a force to
maintain the gel segments 12 and the breathable gap 14 in place. In
other embodiments, an adhesive may be disposed between the gel
segments 12 and the breathable material 18. The breathable material
18 may at least partially constrain the gel segments 12 into a
selected arrangement, a function that may be performed in
conventional cushioning elements by an impermeable film. Thus, a
cushioning element 10, 20, or 30 having a breathable material 18
may be free of a continuous barrier impermeable to gas. Without a
continuous impermeable barrier, gases may freely pass through the
cushioning element 10, 20, or 30, in both lateral and transverse
directions (i.e., both parallel and perpendicular to the breathable
material 18).
[0043] FIGS. 1B and 2B show cross-sections of the cushioning
elements 10 and 20 shown in FIGS. 1A and 2A, respectively, and
illustrate how the gel segments 12 may be secured to the breathable
material 18. A portion of TPE gel may permeate sections 18' of the
breathable material 18. The sections 18' may have similar
cross-sectional shapes to the cross-sectional shapes of the gel
segments 12. In some embodiments, the sections 18' may flare
outward or inward from the gel segments 12, such that the sections
18' are wider or narrower at their tops (in the view of FIG. 2B)
than at their bottoms. In some embodiments, the sections 18' may
have approximately vertically constant cross sections. The sections
18' may have a thickness t.sub.3 less than a thickness t.sub.2 of
the breathable material 18, as shown in FIG. 1B. In some
embodiments, the sections 18' may have a thickness equal to a
thickness t.sub.2 of the breathable material 18, as shown in FIG.
2B. The sections 18' may include a portion of the breathable
material 18 having TPE gel disposed within at least some voids or
cavities. TPE gel within the voids or cavities may inhibit the
transfer of gases through the sections 18'. In some embodiments,
the sections 18' may be impermeable to gases. Nevertheless, gases
may still pass through other portions of the breathable material
18.
[0044] FIG. 3D shows the bottom or obverse side of the cushioning
element 30 of FIG. 3A. TPE gel may penetrate through sections 18'
of the breathable material 18. The breathable material 18 may
therefore have at least some TPE gel on both sides thereof. In
other words, the section 18' may be embedded within the gel
segments 12.
[0045] Dimensions and placement of the gel segments 12 may be
selected such that the breathable gap 14 has dimensions that allow
gas to flow between the gel segments 12 and provide support for a
cushioned object. For example, the square cross section of the gel
segments 12 shown in FIG. 1A may have a length L and a width W
(i.e., dimensions in directions generally parallel to a surface of
the breathable material 18) of from about 2.5 mm (about 0.1 in) to
about 127 mm (about 5 in), such as from about 13 mm (about 0.5 in)
to about 51 mm (about 2 in). In some embodiments, the square cross
section of the gel segments 12 shown in FIG. 1A may have a length L
and a width W of about 25.4 mm (about 1 in). The gel segments 12
shown in FIG. 3A may have lengths and widths (as measured at the
widest points of the gel segments 12) within similar ranges. The
gel segments 12 shown in FIG. 2A may have a width W of from about
2.5 mm (about 0.1 in) to about 127 mm (about 5 in), such as from
about 13 mm (about 0.5 in) to about 51 mm (about 2 in). In some
embodiments, the gel segments 12 shown in FIG. 2A may have a width
W of about 25.4 mm (about 1 in).
[0046] The portion of the gel segments 12 that does not permeate
the breathable material 18 may have a thickness t.sub.1 (i.e., a
dimension generally perpendicular to a surface of the breathable
material 18) selected to provide cushioning properties. For
example, for applications in which relatively soft cushioning
elements are beneficial, the thickness t.sub.1 of the gel segments
12 may be relatively large. For applications in which relatively
firm cushioning elements are beneficial, the thickness t.sub.1 of
the gel segments 12 may be relatively smaller. In some embodiments,
the thickness t.sub.1 of the gel segments 12 may be from about 1.3
mm (about 0.05 in) to about 76 mm (about 3 in), or from about 2.5
mm (about 0.1 in) to about 25 mm (about 1 in). For example, the
thickness t.sub.1 of the gel segments 12 may be about 3.2 mm (about
0.125 in).
[0047] Dimensions of any internal gaps 16 may be selected for their
effect on cushioning, breathability, mass, material cost, ease of
manufacturing, etc. For example, the quadrilateral internal gaps 16
shown in FIGS. 3A through 3D may have a maximum internal dimension
x of from about 1.3 mm (about 0.05 in) to about 76 mm (about 3 in),
or from about 2.5 mm (about 0.1 in) to about 25 mm (about 1 in).
For example, the maximum internal dimension x may be about 13 mm
(about 0.5 in). The internal gaps 16 may have a secondary internal
dimension y perpendicular to the maximum internal dimension x. The
internal gaps 16 may have an aspect ratio defined as the ratio of
the maximum internal dimension x to the secondary internal
dimension y (i.e., x/y). The internal gaps 16 may have aspect
ratios from about 1 to about 20, such as about 2.
[0048] As shown in FIGS. 1A and 3A, the breathable gap 14 may
include a continuous network of passages, such that when a
cushioned object covers substantially all the gel segments 12,
there remains at least one passageway between any two points within
the breathable gap 14 between gel segments 12. In other
embodiments, such as shown in FIG. 2A, the cushioning element 20
may include more than one distinct breathable gap 14. Each gel
segment 12 may be disposed between adjacent breathable gaps 14. In
such embodiments, there may be no direct gas path between adjacent
breathable gaps 14 within the cushioning element 20. However, the
breathable gaps 14 may be channels through which gases may freely
pass. The breathable gap 14 and/or the internal gaps 16 may allow
breathing (i.e. transmission of gases) both between gel segments 12
and through each gel segment 12.
[0049] The breathable gap 14 may have a width G (i.e., a minimum
dimension between adjacent gel segments 12 in a direction generally
parallel to a surface of the breathable material 18) of from about
1.3 mm (0.05 in) to about 25 mm (1 in), or from about 2.5 mm (0.1
in) to about 13 mm (0.5 in). For example, the width G of the
breathable gap 14 may be about 3.2 mm (0.125 in).
[0050] Gel segments 12 may have breathable gaps 14 around their
entire perimeter, as shown in FIGS. 1A and 3A. However, in some
embodiments, the breathable gaps 14 may be adjacent only one or two
sides of the gel segments 12. For example, as shown in FIG. 2A, the
gel segments 12 may be long rows of continuous gel of any of a wide
variety of shapes, with breathable gaps 14 between the rows. Such a
configuration may be well suited to continuous production.
[0051] In some embodiments, the cushioning elements 10, 20, or 30
may have a generally planar or otherwise cooperatively shaped top
surface, broken only by the breathable gaps between and within the
gel segments 12. For example, the top surfaces of each gel segment
12 may be coplanar. The cushioning elements 10, 20, or 30 may flex
or bend, however, and the top surface of the cushioning elements
10, 20, or 30 (i.e., as a whole, if considered as though the gaps
were filled) may be curved.
[0052] Even when not covered with a plastic film, the gel segments
12 may not break in normal use because TPE gel may be comparatively
stronger than conventional materials, such as polyurethane or
silicone gels. Furthermore, the gel segments 12 may be less sticky
than conventional materials.
[0053] Methods of forming cushioning elements may include forming a
plurality of discrete gel segments 12 and providing at least one
breathable gap 14 between adjacent gel segments 12. Gel segments 12
may be formed by melting TPE gel and disposing the TPE gel within a
mold. For example, FIG. 4 shows a mold 40 that may be used to form
the gel segments 12 shown in FIG. 3A. The mold 40 includes a body
42 that defines at least one cavity 44. Walls 46 around the cavity
44 at least partially constrain molten TPE gel within the cavity
44, and may occupy a position corresponding to a position of the
breathable gap 14 of the cushioning element 30. The body 42 may be,
for example, a 1/8-inch-thick (3.2-mm-thick) plate of metal or
plastic, with the cavities 44 machined or punched partially or
completely through the body 42. The mold 40 may optionally include
a backing plate (not shown) for structural support and/or to
provide a surface of the cavities 44 if the cavities 44 are formed
completely through the body 42.
[0054] The mold 40 may be used to shape the TPE gel in the desired
final shape of the gel segments 12. For example, molten TPE gel may
be poured or injected into the mold cavities 44. Pressure may be
applied to the molten TPE gel to promote the flow of molten TPE gel
into the cavities 44. A second mold (not shown) may include a
substantially planar surface, or may include mold cavities such as
the mold cavities 44 of the mold 40. Mold cavities, if any, of the
second mold may similarly be filled with molten TPE gel. The mold
40 and second mold may each be placed over opposite sides of the
breathable material 18. The molten TPE gel may be allowed to cool
and solidify, after which the gel segments 12 formed in the
cavities 44 may be removed from the mold 40.
[0055] In some embodiments, a mold 40 may be used to shape the TPE
gel in the desired final shape of the gel segments 12 by providing
molten TPE gel in the mold cavities 44, followed by scraping the
molten TPE gel flush with the surface of the body 42 and the open
top of the cavities 44. For example, the TPE gel may be poured
into, pressurized onto, flooded onto, or metered into the cavities
44. The TPE gel may be scraped flush with the top of the mold while
still molten, or may be scraped off after cooling. For example,
cooled TPE gel may be scraped with a tool (e.g., screed, putty
knife, blade, etc.) that may be heated above the melt temperature
of the TPE gel. In some embodiments, the amount of TPE gel disposed
in each cavity 44 may be controlled to partially or precisely fully
fill the cavity 44. In such embodiments, scraping may be
unnecessary. A breathable material 18 may be pressed over the top
of the TPE gel in each cavity 44. The TPE gel may bond to the
breathable material 18 as the TPE gel solidifies.
[0056] In some embodiments, a mold 40 having cavities 44 formed
completely through the body 42 may be placed atop a breathable
material 18 prior to filling the cavities 44 with TPE gel. Molten
TPE gel may permeate a section 18' (see FIGS. 1B, 2B, and 3D) of
the breathable material 18 under the cavities 44. In other
embodiments, the breathable material 18 may be placed atop the mold
40, and molten TPE gel may be poured or injected under pressure
through the breathable material 18. Pressure may be applied to the
molten TPE gel to promote permeation of the TPE gel into the
breathable material 18 and the filling of cavities 44. The TPE gel
may bond to the breathable material 18 as the TPE gel
solidifies.
[0057] In some embodiments, the TPE gel may be provided in the
cavities 44 in solid form. For example, TPE gel may be provided as
granules or pellets, or as a continuous mass. Portions of TPE gel
may be preformed to have a selected amount of gel material. For
example, spheres, or "pillows," of TPE gel may be formed, each
having an amount of gel material sufficient to melt and fill a
single cavity 44. Individual gel spheres or pillows may be placed
into cavities 44 of a heated mold 40. The heat of the mold 40 may
melt the TPE gel, and the TPE gel may fill the cavities 44.
[0058] The walls 46 of the mold 40 may define the breathable gaps
14 to be formed in the cushioning elements 10, 20, 30. That is, the
walls 46 provide a volume or volumes that the molten TPE gel does
not occupy.
[0059] Cushioning elements 10, 20, 30 may be formed as part of a
continuous-flow operation. For example, in a process of forming gel
segments 12 using the mold 40 shown in FIG. 4, gel segments 12 may
be formed and secured to a portion of breathable material 18. The
mold 40 may be removed from the breathable material 18 and the gel
segments 12. The mold 40 and/or the breathable material 18 may be
moved relative to each other (e.g., the mold 40 may be indexed to
another location of the breathable material 18 at which there are
no gel segments 12). Additional gel segments 12 may be formed on
the breathable material 18. For example, the mold 40 may include a
rotating drum or a stationary drum. TPE gel may be applied to or
through the breathable material 18 as the breathable material 18
rotates around with the rotating drum or passes the stationary
drum. Portions of the rotating drum may be heated and/or cooled to
facilitate the formation of gel segments 12.
[0060] In some embodiments, the breathable material 18 may be
disposed in a roll. For example, a roll of fabric may be provided
as is common in the textile industries. The fabric may be unwound
from the roll, and gel segments 12 may be formed thereon (e.g., by
passing the fabric continuously adjacent a rotating drum mold).
After forming gel segments 12, the cushioning element 10, 20, or 30
may be wound into another roll.
[0061] In some embodiments, gel segments 12 may be separately
formed, placed in a selected position, and secured over a
breathable material 18. For example, gel segments 12 may be placed
on a breathable material 18 by a pick-and-place apparatus, such as
described in U.S. Pat. No. 7,000,966, issued Feb. 21, 2006, and
entitled "Pick-and-Place Tool," the entire contents of which are
incorporated herein by reference. Breathable gaps 14 may be formed
by controlling the placement of the gel segments 12. The gel
segments 12 may be secured to the breathable material 18 by heating
the gel segments 12 and/or the breathable material 18 to a
temperature near a melting point of the TPE gel. A portion of each
gel segment 12 may penetrate the breathable material 18 and fuse
the gel segments 12 to the breathable material 18. In some
embodiments, the gel segments 12 may be secured to the breathable
material 18 with an adhesive. The adhesive may temporarily or
permanently bond the gel segments 12 to the breathable material 18.
For example, the adhesive may bond the gel segments 12 to the
breathable material 18 to maintain the position of the gel segments
12 until the gel segments 12 become permanently fused to the
breathable material 18.
EXAMPLES
Example 1
[0062] A mold 40 (see FIG. 4) is formed by machining cavities 44
into a body 42, which may be a metal or polymer plate. A top plate
is formed such that, when the top plate is fitted to the mold, each
cavity 44 is completely encapsulated (with the exception of the gel
input means, such as the runners discussed below in this Example
1).
[0063] A TPE gel is formed by mixing one part by weight SEPTON.RTM.
4055 SEEPS polymer, eight parts by weight CARNATION.RTM. White
Mineral Oil (a 70-weight straight-cut white paraffinic mineral oil,
available from Sonneborn, Inc., of Mahwah, N.J.), 0.25% by weight
EVERNOX.RTM. 76 antioxidant (available from Everspring Chemical, of
Taichung, Taiwan), 0.25% by weight EVERFOS.RTM. 168 antioxidant
(available from Everspring Chemical), and 0.25% by weight Horizon
Blue pigment (available from DayGlo Color Corp., of Cleveland,
Ohio). The mixture is heated and extruded to melt-blend the TPE
gel. The molten TPE gel is then pumped into a piston heated above a
melting temperature of the TPE gel.
[0064] A cotton tricot fabric is inserted between the mold 40
(which is heated above the melt temperature of the TPE gel) and the
top plate (which is cooled to below the melt temperature of the TPE
gel) and the top plate is closed onto the mold 40. The heated
piston is connected to a heated pipe connected to a heated
sprue-and-runner system in the heated mold 40, allowing TPE gel to
flow into each of the cavities 44 to form gel segments 12. The
piston drives the molten TPE gel to fill the cavities 44 and
permeate the fabric under pressure. The TPE gel solidifies due to
the cool temperature of the top plate. The top plate is removed,
and the fabric with molded TPE gel segments 12 is lifted out of the
mold 40. In one embodiment, the fabric (or other breathable
material 18) may be continuous. The mold 40 may then be indexed to
another section of fabric to form groups of TPE gel segments 12 in
successive locations. In one embodiment, the top plate is replaced
by a cylindrical drum and the body 42 of the mold 40 has a radius
which matches the radius of the cylindrical drum. The molding,
demolding, and indexing are performed repeatedly, and the finished
cushioning element 10, 20, or 30 is wound into a roll. The
cushioning element 10, 20, or 30 may then be transported to a point
of use, and unrolled as necessary.
[0065] Such cushioning elements 10, 20, or 30 may have a variety of
applications. For example, cushioning elements 10, 20, or 30 may be
used in the manufacture of mattresses by quilting the cushioning
elements 10, 20, or 30 together with a cover fabric (e.g., a
mattress ticking) and optionally with other cushioning elements
(e.g., foam and/or fabric), to form a top panel of a mattress.
Cushioning elements 10, 20, or 30 may be used in the manufacture of
seat cushions by bonding the cushioning elements 10, 20, or 30 to a
foam base, then placing the assembly into a cover. Cushioning
elements 10, 20, or 30 may be used in the manufacture of memory
foam mattresses by adhesively bonding the cushioning elements 10,
20, or 30 to the memory foam of the mattress, then placing the
assembly into a cover. Cushioning elements 10, 20, or 30 may be
used in the manufacture of hot-pack muscle relaxing products and/or
cold-pack pain-reducing or swelling-reducing products (e.g., in or
as a cold-wrap or hot-wrap for sprained ankles or other injured
body parts). In all these applications, the breathable gaps 14, the
internal gaps 16 (if present), and the breathable material 18 allow
air, gas, and/or vapor to pass through (i.e., the cushioning
element 10, 20, or 30 is breathable).
Example 2
[0066] A mold 40 having an open face is formed as described in
Example 1. Molten TPE gel is poured or pressurized into the
cavities 44, and excess TPE gel is scraped off (either while still
molten or after cooling). Alternatively, TPE gel may be metered
into the cavities so that no scraping is necessary. A fabric, foam,
or other gel-permeable breathable material 18 is laid onto the TPE
gel. Light pressure may be applied to press the breathable material
18 against the TPE gel. If the TPE gel is molten during this
process, some of the molten TPE gel may permeate the breathable
material 18. If the TPE gel is cooled or solidified prior to
placement of the breathable material 18, heat may be applied to
melt at least a top portion of the TPE gel. A portion of the melted
TPE gel may permeate the breathable material 18. Pressing means may
also include heat, for example, a heat press (e.g., a heated plate
to press onto the fabric).
Example 3
[0067] A mold 40 or a series of molds are as described in Example
2. The breathable material 18 is continuous, and the mold(s) 40 are
removed from the breathable material 18 and then brought again to
another part of the breathable material 18. For example, the
mold(s) 40 may include a tank-tread style set of molds that are
connected in a continuous circular configuration that continuously
cycles under the unrolling breathable material 18, or may include a
rotating drum. The mold(s) 40 may be flooded with molten TPE gel at
one point on the mold rotation, followed downstream with a scraping
means (e.g., a silicone rubber squeegee-type blade or a metal
blade, either of which may be heated, cooled, or maintained at room
temperature). The breathable material 18 is pressed into the top
surface of the TPE gel while the TPE gel is still in the mold
cavities. A means of pulling on the breathable material 18
translates the breathable material 18 adjacent the mold(s) 40 and
provides a force to remove the gel segments 12 from the cavities
44. The gel-laden cushioning element 10, 20, or 30 thus formed may
then be rolled onto a take-up roll. A continuous process may
minimize the costs and increase the output of manufacturing.
Example 4
[0068] A queen-size mattress core is formed by bonding a
3-inch-thick (76-mm-thick) layer of memory foam (viscoelastic
polyurethane foam) atop a 7-inch-thick (178-mm-thick) layer of
standard polyurethane cushioning foam. The core has dimensions of
60 in. (152 cm) by 80 in. (203 cm) by 10 in. (25 cm). A template is
machined from aluminum, having dimensions of 60 in. by 80 in. by
0.125 in. (3.2 mm), and having through holes with approximately
square shapes, such as the shape of the gel segments 12 shown in
FIG. 1A. The template is placed atop the memory-foam layer of the
mattress core. Molten TPE gel is flooded across all the through
holes, filling them. The molten TPE gel may or may not be allowed
to cool. A hot blade is scraped across the top surface of the
template, cutting the TPE gel on a plane coincident with the top
surface of the template. The cut-off TPE gel is removed, leaving
each cavity filled flush with the top surface of the template.
During the flooding process, a portion of the TPE gel may seep into
the porous memory foam, such as to a depth of about 0.125 in. (3.2
mm) into the foam. Thus, the total thickness of the TPE gel may be
about 0.25 in. (6.4 mm)--half within and half over the foam. The
template may be removed after the gels cools and solidifies,
leaving gel segments 12 across the top surface of the mattress core
in a similar pattern to that shown in FIG. 1A. A mattress cover may
be placed over the gel segments 12 and the core. A user may
experience reduced pressure peaks, reduced shear forces, and a
pleasant feeling of coolness when first lying on the mattress, in
contrast to a conventional memory-foam mattress. The user may
eventually perspire, and the perspiration may become vapor, which
may evaporate and/or move through the gaps between the gel segments
12. Thus, the mattress may limit or prevent moisture buildup, and
the mattress may feel more comfortable. Furthermore, a user of such
a mattress may have a smaller probability of developing decubitus
ulcers than a user of a conventional mattress (which may be a
desirable feature for medical mattresses for invalid patients).
Example 5
[0069] A cushioning element 10, 20, or 30 including gel segments 12
may be quilted into a mattress. A fabric is selected that is
stretchable in a direction transverse to a direction of the motion
through a quilting machine but non-stretchable parallel to the
direction of the motion through the quilting machine. For example,
cotton tricot is a natural material that may be inexpensive,
permeable to molten TPE gel, and breathable. Cotton tricot is
available having quiltable widths (e.g., 90 in. (2.29 m)) and
one-way stretchability transverse to the rolling direction. The
fabric is pulled uniformly through the quilting process without
stretching (i.e., because the stretchable direction is
perpendicular to the direction of pull). The stretchability in the
transverse direction may allow deformation of the TPE gel or other
materials in or under the quilting.
Example 6
[0070] A cushioning element 10, 20, or 30 including gel segments 12
is glued onto a mattress core in such a way as to be directly
underneath a mattress cover. The cushioning element 10, 20, or 30
is positioned onto the mattress core (e.g., a foam core) so that
the breathable material 18 is above the gel segments 12 (i.e., the
gel segments 12 are adjacent the foam core). Placement of the gel
segments 12 adjacent the foam core may allow fabric of the cover to
more easily slip across the surface of the breathable material 18
so as not to bind up or cause wrinkles or other distortions in the
cover. The breathable material 18 over the breathable gaps 14 and
internal gaps 16 may therefore be spaced apart from the foam core,
and adhesive bonding between the breathable material 18 and the
mattress core may not be practical. In such a case, the breathable
material 18 may extend beyond the gel segments 12 and may be
secured (e.g., adhesively bonded, sewn, etc.) to the tops and/or
sides of the foam core. Securing the cushioning element 10, 20, or
30 only at a perimeter of the cushioning element 10, 20, or 30 may
limit the possibility of an adhesive layer interfering with the
cushioning function of the mattress. Another layer of material
(e.g., fabric or other relatively slippery material) may be
likewise secured at least around the edges over the top of the
cushioning element 10, 20, or 30 to further promote slippage of the
cover.
Example 7
[0071] The breathable material 18 of a cushioning element 10, 20,
or 30 including gel segments 12 is adhesively bonded to the top of
a mattress core so that the gel segments are oriented up (away from
the mattress core). The entire assembly (mattress core and
cushioning element 10, 20, or 30) is covered with a fabric, such as
a flame-retarding knitted fabric. A cover is applied over the
fabric. The fabric thus applied may adhere to the gel, and may
allow the cover to slip over the fabric.
[0072] Additional non-limiting example embodiments of the
disclosure are described below.
Embodiment 1
[0073] A cushioning element comprising a breathable material
configured to allow gases to pass through at least a portion
thereof, and a plurality of discrete segments of thermoplastic
elastomeric gel heat-fused to the breathable material. The
thermoplastic elastomeric gel comprises an elastomeric polymer and
a plasticizer. A ratio of a weight of the plasticizer to a weight
of the elastomeric polymer is from about 0.3 to about 50. The
plurality of discrete segments defines at least one breathable gap
between adjacent discrete segments.
Embodiment 2
[0074] The cushioning element of Embodiment 1, wherein the
plurality of discrete segments comprises a plurality of segments
each having a generally square cross section.
Embodiment 3
[0075] The cushioning element of Embodiment 1 or Embodiment 2,
wherein the plurality of discrete segments comprises a plurality of
continuous segments.
Embodiment 4
[0076] The cushioning element of any of Embodiments 1 through 3,
wherein at least one discrete segment of the plurality defines at
least one internal gap within the segment.
Embodiment 5
[0077] The cushioning element of Embodiment 4, wherein the at least
one internal gap has an aspect ratio of from about 1 to about
20.
Embodiment 6
[0078] The cushioning element of Embodiment 4 or Embodiment 5,
wherein the at least one discrete segment of the plurality
comprises a thermoplastic elastomeric gel material disposed between
adjacent internal gaps.
Embodiment 7
[0079] The cushioning element of any of Embodiments 1 through 6,
wherein a portion of each of the discrete segments permeates the
breathable material.
Embodiment 8
[0080] The cushioning element of any of Embodiments 1 through 7,
wherein each segment of the plurality has a thickness of less than
about 25.4 mm (1.0 in).
Embodiment 9
[0081] The cushioning element of Embodiment 8, wherein each segment
of the plurality has a thickness of less than about 12.7 mm (0.50
in).
Embodiment 10
[0082] The cushioning element of any of Embodiments 1 through 9,
wherein the plurality of discrete segments defines a generally
planar surface, broken by the at least one breathable gap between
adjacent discrete segments.
Embodiment 11
[0083] The cushioning element of any of Embodiments 1 through 10,
wherein the cushioning element is free of a continuous impermeable
barrier.
Embodiment 12
[0084] The cushioning element of any of Embodiments 1 through 11,
wherein the elastomeric polymer comprises an A-B-A triblock
copolymer.
Embodiment 13
[0085] A method of forming a cushioning element comprising forming
a plurality of discrete segments of thermoplastic elastomeric gel,
securing each discrete segment of thermoplastic elastomeric gel to
a breathable material configured to allow gases to pass through at
least a portion thereof, and providing a gas path through the
breathable material and between adjacent discrete segments of
thermoplastic elastomeric gel. The thermoplastic elastomeric gel
comprises an elastomeric polymer and a plasticizer. A ratio of a
weight of the plasticizer to a weight of the elastomeric polymer is
from about 0.3 to about 50.
Embodiment 14
[0086] The method of Embodiment 13, further comprising permeating
the breathable material with at least a portion of each of the
discrete segments of thermoplastic elastomeric gel.
Embodiment 15
[0087] The method of Embodiment 14, wherein permeating the
breathable material with at least a portion of each of the discrete
segments of thermoplastic elastomeric gel comprises applying
pressure to the thermoplastic elastomeric gel.
Embodiment 16
[0088] The method of Embodiment 14 or Embodiment 15, wherein
permeating the breathable material with at least a portion of each
of the discrete segments of thermoplastic elastomeric gel comprises
permeating a fabric with at least a portion of the discrete
segments of thermoplastic elastomeric gel.
Embodiment 17
[0089] The method of any of Embodiments 13 through 16, wherein
forming a plurality of discrete segments of thermoplastic
elastomeric gel comprises providing molten thermoplastic
elastomeric gel within a mold, and solidifying the molten
thermoplastic elastomeric gel.
Embodiment 18
[0090] The method of Embodiment 17, further comprising moving at
least one of the mold and the breathable material such that the
mold is adjacent a portion of the breathable material substantially
free of the thermoplastic elastomeric gel.
Embodiment 19
[0091] The method of any of Embodiments 13 through 18, further
comprising securing at least a portion of the breathable material
to another cushioning element.
Embodiment 20
[0092] The method of any of Embodiments 13 through 19, wherein
forming the plurality of discrete segments of thermoplastic
elastomeric gel comprises continuously forming the plurality of
discrete segments of thermoplastic elastomeric gel on a roll of the
breathable material.
Embodiment 21
[0093] The method of any of Embodiments 13 through 20, wherein
forming a plurality of discrete segments of thermoplastic
elastomeric gel comprises selecting the elastomeric polymer to
comprise an A-B-A triblock copolymer.
Embodiment 22
[0094] The method of any of Embodiments 13 through 21, further
comprising quilting at least a portion of the breathable material
to a cover.
Embodiment 23
[0095] A method of forming a cushioning element comprising
disposing a permeable material adjacent a mold, providing at least
a first portion of a molten thermoplastic elastomeric gel within
the mold, providing at least a second portion of the molten
thermoplastic elastomeric gel within the permeable material,
solidifying the molten thermoplastic elastomeric gel to form
discrete segments of thermoplastic elastomeric gel, and separating
the mold from at least a portion of the permeable material. The
thermoplastic elastomeric gel comprises an elastomeric polymer and
a plasticizer. A ratio of a weight of the plasticizer to a weight
of the elastomeric polymer is from about 0.3 to about 50.
Embodiment 24
[0096] The method of Embodiment 23, wherein disposing the permeable
material adjacent the mold and separating the mold from at least a
portion of the permeable material each comprises translating the
permeable material adjacent a rotating drum.
Embodiment 25
[0097] The method of Embodiment 23, further comprising unwinding
the permeable material from a first roll and winding the permeable
material having discrete segments of thermoplastic elastomeric gel
to form a second roll.
Embodiment 26
[0098] The method of any of Embodiments 23 through 25, wherein
providing at least a first portion of a molten thermoplastic
elastomeric gel within the mold comprises selecting the elastomeric
polymer to comprise an A-B-A triblock copolymer.
Embodiment 27
[0099] A cushioning element comprising a breathable material
configured to allow gases to pass through at least a portion
thereof and a plurality of discrete segments of thermoplastic
elastomeric gel attached to the breathable material. The plurality
of discrete segments is heat-fused to the breathable material. The
plurality of discrete segments and the breathable material together
define at least a portion of at least one void. The thermoplastic
elastomeric gel comprises an elastomeric polymer and a plasticizer,
and a ratio of a weight of the plasticizer to a weight of the
elastomeric polymer is from about 0.3 to about 50.
Embodiment 28
[0100] The cushioning element of Embodiment 27, wherein the
breathable material comprises a material selected from the group
consisting of a woven fabric, a knit fabric, a mesh fabric, a
spacer fabric, a fabric laminated to a vapor-transmissible film,
and a porous foam having an open-pore network.
Embodiment 29
[0101] The cushioning element of Embodiment 27 or Embodiment 28,
wherein the elastomeric polymer comprises an A-B-A triblock
copolymer
[0102] Embodiments of the disclosure may be susceptible to various
modifications and alternative forms. Specific embodiments have been
shown in the drawings and described in detail herein to provide
illustrative examples of embodiments of the disclosure. However,
the disclosure is not limited to the particular forms disclosed
herein. Rather, embodiments of the disclosure may include all
modifications, equivalents, and alternatives falling within the
scope of the disclosure as broadly defined herein. Furthermore,
elements and features described herein in relation to some
embodiments may be implemented in other embodiments of the
disclosure, and may be combined with elements and features
described herein in relation to other embodiments to provide yet
further embodiments of the disclosure.
* * * * *