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Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods

  • US 10,045,633 B2
  • Filed: 04/24/2014
  • Issued: 08/14/2018
  • Est. Priority Date: 04/26/2013
  • Status: Expired due to Fees
First Claim
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1. A method of creating a mattress or seat assembly, comprising:

  • extruding at least one thermoplastic profile;

    disposing the at least one thermoplastic profile within an enclosure by suspending the at least one thermoplastic profile with at least one removable elongated member, wherein the suspending the at least one thermoplastic profile with at least one removable elongated member comprises extending the at least one removable elongated member through the at least one thermoplastic profile; and

    dispensing thermoset material within the enclosure to encapsulate the at least one thermoplastic profile to form a thermoset matrix as part of a cushioning core,wherein the cushioning core comprises the thermoset matrix encapsulating the at least one thermoplastic profile.

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