Method for making a cushion
First Claim
Patent Images
1. A method for producing a cushioning element comprising the steps of:
- (a) forcing molten gel into and through an extrusion die wherein said extrusion die includes forming rods, an aperture and an aperture periphery;
(i) where said forming rods are within said aperture and where said forming rods have an appearance similar to that of the desired cushioning element except that portions of said extrusion die that are solid will be represented by air in the finished cushioning element and portions of said extrusion die that are unobstructed will be represented by solidified gel in the finished cushioning element;
(ii) where the spacing of said forming rods approximates the spacing of columns in the finished cushioning element and the shape and size of said aperture periphery approximates the shape and size of the desired cushioning element;
(b) cutting said gel as it leaves said extrusion die; and
(c) allowing said cut gel to cool in a cooling medium in order to solidify said gel and thus form a cushioning element;
wherein said extrusion die is configured to produce a cushioning element having a plurality of buckling columns formed in said solidified gel.
3 Assignments
0 Petitions
Accused Products
Abstract
A method for making a cushioning element including forcing molten gel through an extrusion die, and cutting the gel as it exits the die.
72 Citations
60 Claims
-
1. A method for producing a cushioning element comprising the steps of:
-
(a) forcing molten gel into and through an extrusion die wherein said extrusion die includes forming rods, an aperture and an aperture periphery;
(i) where said forming rods are within said aperture and where said forming rods have an appearance similar to that of the desired cushioning element except that portions of said extrusion die that are solid will be represented by air in the finished cushioning element and portions of said extrusion die that are unobstructed will be represented by solidified gel in the finished cushioning element;
(ii) where the spacing of said forming rods approximates the spacing of columns in the finished cushioning element and the shape and size of said aperture periphery approximates the shape and size of the desired cushioning element;
(b) cutting said gel as it leaves said extrusion die; and
(c) allowing said cut gel to cool in a cooling medium in order to solidify said gel and thus form a cushioning element;
wherein said extrusion die is configured to produce a cushioning element having a plurality of buckling columns formed in said solidified gel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A method for producing a cushioning element comprising the steps of:
-
forcing molten gel through an extrusion die having an aperture periphery, an aperture, and a forming rod;
said forming rod being located within said aperture;
cutting said gel as it exits said extrusion die, cooling said molten in a cooling medium to form a cushioning element, said cushioning element including hollow columns, each column having a column wall, and bonding at least two of said columns together to form a bonded cushioning element, the cushioning element having a plurality of said columns, each of said columns having a longitudinal axis along its length, each of said columns having a column wall which defines a column interior, and each of said columns having two ends and wherein said columns are capable of buckling. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 26, 27, 28, 29, 30, 31)
-
-
23. The method for producing a cushioning element as recited in claim 2221, wherein securing cores secure said columns from sliding side-to-side in relation to one another.
- 24. The method for producing a cushioning element as recited in claim 2323, wherein said securing cores have non-stick surfaces.
-
32. A method for producing a cushioning element wherein the cushioning element includes a flexible, resilient, solidified gel having shape memory and being substantially solid and non-flowable at temperatures below 130 degrees Fahrenheit, comprising the steps of:
-
forcing molten gel through an extrusion die that has forming rods, an aperture and an aperture periphery, the extrusion die being shaped to extrude an elastomer gel into a cushioning element with buckling columns, cutting said gel as it exits said extrusion die, and cooling said cut gel in a liquid cooling medium until it solidifies for further handling. - View Dependent Claims (33, 34, 35, 38)
-
-
36. The method for producing a cushioning element as recited in claim 3232, wherein extrusion is into water.
-
37. The method for producing a cushioning element as recited in claim 3636, wherein said extrusion takes place in an upward direction into said water.
-
39. A method for producing a cushioning element wherein the cushioning element includes a flexible, resilient, solidified gel having shape memory and being substantially solid and non-flowable at temperatures below 130 degrees Fahrenheit comprising the steps of:
-
(a) forcing molten gel through an extrusion die having an aperture periphery, an aperture, and a forming rod;
(i) where said aperture periphery is a shape that will produce columns during an elastomer extrusion process; and
(ii) where said forming rod is within said aperture;
(b) cooling said molten gel as it traverses through said extrusion die causing said molten gel to become said solidified gel during or at some time following its departure from said extrusion die, thereby creating a tube;
(c) cutting said tube as it leaves said extrusion die, wherein cut tubes comprise said columns wherein said columns are hollow; and
(d) bonding said columns together to form the cushioning element. - View Dependent Claims (40, 41, 42, 43, 51, 56, 60)
-
-
44. The method for producing a cushioning element as recited in claim 4343, wherein said securing cores have non-stick surfaces.
-
45. The method for producing a cushioning element as recited in claim 4444, wherein said non-stick surfaces include Teflon paper.
-
46. The method for producing a cushioning element as recited in claim 4141, wherein said columns have a square shape in cross section through the longitudinal axis and wherein said contacted portions are inner surface corners of said columns.
-
47. The method for producing a cushioning element as recited in claim 4646, wherein said wherein said heating cores hold outer surfaces of corners against one another.
- 48. The method for producing a cushioning element as recited in claim 4646, wherein securing cores secure said columns from sliding side-to-side in relation to one another.
- 52. The method for producing a cushioning element as recited in claim 4141, wherein said heating core is coated with a non-stick coating.
-
54. The method for producing a cushioning element as recited in claim 3939, wherein said molten gel includes elastomer gel pre-compounded at a temperature of nto less than about 470 degrees Fahrenheit and said forcing of said molten gel through said extrusion die is at not less than about about 425 degrees Fahrenheit before said cooling occurs.
-
55. The method for producing a cushioning element as recited in claim 5454, wherein said pre-compounding and said forcing is done with an extruder screw.
-
57. The method for producing a cushioning element as recited in claim 3939, wherein extrusion takes place into water.
-
58. The method for producing a cushioning element as recited in claim 5757, wherein said extrusion is upward into said water.
-
59. The method for producing a cushioning element as recited in claim 5757, wherein said extrusion is downward into said water.
Specification