Patent Application
20120167308
Not applicable.
1. Field of the Invention
This invention relates to a composite gel and foam product for use in mattresses, cushions, seats, pads, and other types of supportive items. The invention also relates to a method for manufacturing such a product without requiring the use of a traditional metal mold.
2. Description of Related Art
Healthcare and household mattresses, as well as seat cushions, pads, and other varieties of cushioned supports have increasingly utilized gel to achieve desired levels of comfort and support. Some known products have integrated such gel with a supportive foam of the type conventionally employed in mattresses and other products for supporting humans and pets.
Known methods for manufacturing supports employing both gel and foam exhibit a variety of shortcomings. Typically, the gel must first be extruded, injected, or poured into and shaped by large and expensive metal molds. These molds are usually large and quite heavy. As a result, they are difficult to maneuver into position and properly secure during the molding operation. Extracting the cooled and formed gel from the mold can also be difficult and time consuming. Moreover, the size of the molded gel support is strictly limited by the size of the available metal mold.
After the gel is molded, further problems are encountered securing the gel to one or more layers of foam. Cured gel is unable to adhere directly to the foam. As a result, the gel usually must first be heat bonded to a thin textile layer of scrim. This requires the purchase and maintenance of additional manufacturing material which results in additional manufacturing steps and resultant expenses.
Conventional gel support products also tend to be vertically unstable and are apt to buckle outwardly when a large load is applied. This is undesirable and can significantly reduce the usefulness, support, and lifespan of the product.
The disclosure and claims herein are directed to a composite support pad comprising a foam base portion with a top surface, an opposing bottom surface substantially parallel to the top surface, and a plurality of receptacles extending from the top surface towards the bottom surface, and a top portion comprising a top layer on the top surface with a plurality of columns extending from the top layer into the receptacles.
The disclosure and claims herein are also directed to a method for producing a composite support pad, the method comprising the steps of providing a foam base portion with a top surface, an opposing bottom surface substantially parallel to the top surface, and a plurality of receptacles extending from the top surface towards the bottom surface, applying a composition to the foam base portion that forms columns of the composition in the receptacles of the foam base portion and forms a top layer on the top surface, and curing the composition wherein the curing adheres the top layer to the top surface and the columns to the receptacles.
In one exemplary embodiment the foam base portion is comprised of polyurethane, viscoelastic, or latex foam, but the foam base portion can be any type of foam known in the art. In another exemplary embodiment, the foam base portion is comprised of a plurality of layers of foam materials. In one exemplary embodiment the top portion is comprised of a gel material. In another exemplary embodiment the gel material is an elastomeric non-soy gel but could be any type of gel known in the art. In another exemplary embodiment at least one of the plurality of receptacles extends through the entire foam base portion between the top and bottom surfaces. In another exemplary embodiment the plurality of receptacles extend from the top surface to a distance from about 10% to about 100% of the distance between the top and bottom surfaces. In an exemplary embodiment the top layer substantially covers the top surface. In another exemplary embodiment the plurality of receptacles are substantially round. In yet another embodiment the plurality of receptacles are arranged in substantially aligned rows in a matrix configuration. In another exemplary embodiment the top layer and the plurality of columns are integral. In one exemplary embodiment the plurality of columns are substantially perpendicular to the top and bottom surfaces.
Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
The disclosure and claims herein are directed to a composite support pad comprising a foam base portion with a top surface, an opposing bottom surface substantially parallel to the top surface, and a plurality of receptacles extending from the top surface towards the bottom surface, and a top portion comprising a top layer on the top surface with a plurality of columns extending from the top layer into the receptacles.
The disclosure and claims herein are also directed to a method for producing a composite support pad, the method comprising the steps of providing a foam base portion with a top surface, an opposing bottom surface substantially parallel to the top surface, and a plurality of receptacles extending from the top surface towards the bottom surface, applying a composition to the foam base portion that forms columns of the composition in the receptacles of the foam base portion and forms a top layer on the top surface, and curing the composition wherein the curing adheres the top layer to the top surface and the columns to the receptacles.
The composite support pad as described in the disclosure and claims herein is described generally and may be employed in virtually any and all applications and industries including but not limited to healthcare, bedding, furniture, exercise, physical therapy, sound insulation, transportation, etc. The specific embodiments of the composite support pad discussed herein do not constitute a limitation of the disclosure and claims.
The composite support pad and manufacturing the composite support pad as described herein provide a number of benefits. The foam base portion itself acts as the mold for the gel. The cost and complexity of utilizing a conventional metal mold is thereby eliminated. The need for tooling a metal mold is also eliminated. The composite support is not limited in size and configuration by available mold length limitations. Significantly, the considerable effort normally required to remove the gel from the mold is no longer needed. Additionally, no additional materials or steps are needed to adhere the gel to the foam. The molded gel is bonded to and ready for virtually immediate use with the foam comprising the mold.
Additionally, the composite support pad as described herein achieves improved effective support and comfort. The receptacles may be formed in the foam base portion in different number, size, depth, and layout in order to achieve various comfort and support levels and characteristics.
When foam and gel are bonded in accordance with this invention, the foam base portion improves the performance of the gel, and vice versa, in a manner not previously achieved. In particular, the foam effectively surrounds the gel columns so that the stability and performance of the gel is improved. The gel is vertically stable and is much less apt to buckle in an outward direction when a load is applied to a surface of the composite support pad. The gel also helps to effectively reinforce the foam. When the gel is bonded directly to the foam in the manner disclosed herein, the foam, and particularly soft foam, is not liable to bottom out under a heavy load. The gel provides for much greater stability and support.
The manufacturing process described herein also represents a significant improvement over conventional techniques for manufacturing gel and foam support cushions because adhesive interconnection is not required between the foam and gel components. Rather, the gel is poured directly onto the foam base portion and into the receptacles in the foam base portion. This allows the gel to effectively bond directly to the foam as the gel cures. This eliminates the need to use scrim and adhesives in order to bond the foam to the gel. Considerable time and expense are thereby saved. Moreover, an improved, more stable and comfortable gel and foam composite support pad is achieved. Nonetheless, it should be understood that scrim may still be applied to the composite above the gel component for use in different applications.
Referring to
As used herein, the term “foam” encompasses, but is not limited to, solid porous foams, reticulated foams, water-disintegratable foams, open-cell foams, closed-cell foams, foamed synthetic resins, cellulosic foams, natural foams, polyurethane foams, viscoelastic (“visco”) foams, and latex foams. In one embodiment the foam used for foam base portion 12 has an Indentation Force Deflection (IFD) of from about 3 to about 70.
As used herein, the term “gel” encompasses, but is not limited to, a viscoelastic or semi-solid, jelly-like state assumed by a colloidal dispersion or a substantially dilute cross-linked system. The term “gel” encompasses a three-dimensional polymeric structure that itself is insoluble in a particular liquid but which is capable of absorbing and retaining large quantities of the liquid to form a stable, often soft and pliable, but to one degree or another a shape-retentive structure. When the liquid is water, the gel is typically referred to as a hydrogel. The gel may also contain additives that affect the properties of the gel. Examples of suitable additive that increase the energy (i.e., heat) absorbing properties of the gel include boron, talc, quartz, aluminum sulfate, diamond dust, etc.
Foam base portion 12 may be available in a roll, such as roll 18 shown in
Although the disclosure and claims herein are not limited to a specific width of foam, foam base portion 12 preferably has a width from about 12 inches to about 90 inches. This allows foam base portion 12 to be continuously fed or pushed by a pusher machine, feeder machine, or conveyor known in the art so that the gel may be applied thereto as described below. In order to obtain a piece of foam base portion 12 having a selected length for use in support 10, the desired length of foam from roll 18 (shown in
As shown in
In one exemplary embodiment, receptacles 26 are formed completely through foam base portion 12 from top surface 22 to bottom surface 24, as depicted in
In one embodiment, receptacles 26 have cylindrical shapes with circular cross sections. In another embodiment, receptacles 26 may have square, rectangle, oval, star, or any other shape with any shaped cross section. In yet another embodiment, receptacles 26 could be comprised of receptacles of many different shapes with many different shaped cross sections. Receptacles 26 may be molded or manufactured directly into foam base portion 12. Alternatively, foam base portion 12 may be manufactured without receptacles 26 and receptacles 26 can be added to foam base portion 12. Receptacles 26 can be added by cutting, punching, drilling, burning, or any method for creating receptacles 26 in foam base portion 12.
One non-limiting example of foam base portion 12 is now described to show an example embodiment. Foam base portion 12 is comprised of a latex foam. Foam base portion 12 is about 2 inches thick (i.e., the distance between top surface 22 and bottom surface 24 is about 2 inches). Foam base portion 12 has receptacles 26 that are substantially perpendicular to top surface 22 and bottom surface 24. Receptacles 26 are cylindrically shaped with circular cross sections and are formed completely through foam base portion 12 from top surface 22 to bottom surface 24. Receptacles 26 are arranged in substantially aligned rows in a matrix configuration. Receptacles 26 are about one inch apart and have a diameter of about ¼ of an inch.
While the above example shows one exemplary embodiment, the foam base material and thickness, and the receptacles' shape, orientation, layout, density, depth, and size can change based upon the application where composite support pad 10 will be employed and the type of foam and gel used. For example, a greater concentration of receptacles provides more support than fewer receptacles in the same type of foam because of the larger concentration of gel in the foam. The attributes of the foam and receptacles is also influenced by the type of gel used. For example, the hardness of the gel can be increased causing more support than a softer gel in the same type of foam. Thus, a composite support pad can be comprised of softer foam with more receptacles and/or harder gel and have the same supportive qualities as a composite support pad comprised of harder foam with fewer receptacles and/or softer gel.
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A simple non-limiting example is now shown to illustrate the methods described above. As shown in
After the foam base portion 12 has passed beneath applicator 32 and heated liquid gel 14 has been applied to the foam base portion, the composite support pad 10 is delivered to a cooling chamber 40. Foam base portion 12 can be transported to cooling chamber 40 after the entire portion has received gel 14. Alternatively, foam base portion 12 can be transported by the feeder, pusher, or conveyer mechanism through cooling chamber 40. In one exemplary embodiment, cooling chamber 40 entirely encompasses composite support pad 10. In an alternative exemplary embodiment, composite support pad 10 passes through cooling chamber 40. Cooling chamber 40 cools gel 14 (i.e., top layer 14a and columns 14b) so that it does not burn foam base portion 12 (step 136 in
In one exemplary embodiment, cooling chamber 40 causes air (refrigerated or room temperature) to be forced onto sides of composite support pad 10. In an alternative exemplary embodiment, cooling chamber 40 comprises a pressurized water cooling system that comprises at least one radiator in proximity to at least one side of composite support pad 10 and forces water to the radiator. The disclosure and claims extend to any way to cool or cure gel 14. Additional substances may be added to the gel to help the gel cure more quickly or change the properties of the gel. For example, a mixture of about 50% talc or baby powder and about 50% baking soda that is added to the gel after the gel is applied to the foam helps the gel cure more quickly and improves the gel (e.g., better smelling and softer to the touch).
As the gel cools, it cures and bonds to the foam to produce composite piece 10 as shown in
It is important to note that in each embodiment disclosed herein, a metal form is not needed for the composition or gel. Foam base portion 12 acts as a form for gel 14 as gel 14 is applied to foam base portion 12. Foam base portion 12 effectively serves as the mold for receiving the gel and for supporting the gel while it cures and bonds to the foam. This eliminates the need to use bulky, expensive, and difficult to operate metal molds, as are traditionally used to shape the gel.
In alternative embodiments other forms of gel and alternative means for curing and hardening the gel may be utilized. For example, thermal, photosensitive, or chemically reactive gels may be deposited in liquid or powdered form onto the foam mold. In some embodiments chemicals may be added to the gel to induce curing. Ultraviolet radiation can be employed to cure and harden photosensitive gels. In these embodiments, cooling chamber 40 would instead be a curing chamber where the gel would be cured by the means required to cure the type of gel applied.
Composite support pad 10 may be utilized in accordance with conventional and well known manufacturing techniques. For example, desired lengths of foam or completed gel and foam composite may be cut transversely as desired utilizing conventional cutting equipment. Likewise, the completed composite support pad 10 can be trimmed, shaped and sized as needed, for particular applications. After manufacture of the composite support pad is finished, the composite support pad may be installed and used in various products such as mattresses, cushions, pads and other means of support.
Although specific features of the invention are shown in some of the drawings and not others, this is for convenience only, as each feature may be combined with any and all of the other features in accordance with this invention. Since many possible embodiments may be made of the disclosure without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense.
While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
This application is based on and claims priority to U.S. Provisional Application Ser. No. 61/460,249, filed on Dec. 29, 2010, which is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61460249 | Dec 2010 | US |
