Process for making resilient pad composite

• US 8,231,756 B2
• Filed: 04/12/2010
• Issued: 07/31/2012
• Est. Priority Date: 11/24/2008
• Status: Active Grant

• Current Assignee: Applied Ft Composite Solutions Inc.
• Original Assignee: Applied Ft Composite Solutions Inc.
• Inventors: Kim, Daniel
• Primary Examiner(s): Chan, Sing P
• Application Number:
  US12/758,285
• Publication Number:
  US 20100193117A1
• Time in Patent Office: 841 Days
• Field of Search: 156/247, 156/250, 156/265, 156/267, 156/299, 156/300, 156/301, 156/308.2, 156/308.4, 428/141, 428/304.1, 428/304.4
• US Class Current: 156/247
• CPC Class Codes: A41D 31/285 using layered materials
• CPC Class Codes: A63B 71/08 Body-protectors for players or sportsmen , i.e. body-protecting accessories affording protection of body parts against blows or collisions protective clothing or garments for sporting purposes A41D13/00
• CPC Class Codes: B32B 2038/047 Perforating
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/025 Polyolefin vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2437/00 Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 25/04 comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/10 characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/025 : comprising leather
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1074 : Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1093 : with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential

Abstract

The present application discloses a composite pad structure that includes a substrate bonded to a plurality of discrete, spaced-apart, resilient elements engaged to at least one reinforcing structure.

Claims

1. A method for fabricating a composite structure for use as a resilient cushion, comprising:

mounting a plurality of discrete, spaced-apart, resilient elements on a first expanse of material;

engaging at least some of the resilient elements with a reinforcing structure; and

mounting a second expanse of material to the resilient elements opposite the first expanse of material to form the composite structure;

wherein the reinforcing structure is positioned between the first and second expanses of material in the composite structure.

2. The method of claim 1, wherein the step of engaging at least some of the resilient elements with a reinforcing structure comprises engaging all of the resilient elements with a first lattice of reinforcing material and engaging at least some of the resilient elements with a second lattice of reinforcing material.

3. The method of claim 2, wherein the first and second lattices of reinforcing material are positioned between the first and second expanses of material in the composite structure.

4. The method of claim 1, further comprising using a cutter to cut a sheet of resilient material into a cut sheet of resilient material that includes the plurality of resilient elements and additional resilient material that maintains the plurality of resilient elements in a pattern.

5. The method of claim 4, wherein the cutter includes a plurality of cutting elements, each defining a space containing a biasing material, wherein after a cutting element has been used to cut a corresponding resilient element, the biasing material urges the corresponding resilient element away from the space.

6. The method of claim 1, wherein the step of engaging at least some of the resilient elements with a reinforcing structure occurs before the step of mounting the plurality of resilient elements on the first expanse of material.

7. The method of claim 6, wherein the reinforcing structure is a lattice of reinforcing material that includes a plurality of holes, and wherein the step of engaging at least some of the resilient elements with a reinforcing structure comprises pushing the plurality of resilient elements out of a cut sheet of resilient material and into the plurality of holes in the lattice of reinforcing material.

8. The method of claim 1, wherein an adhesive is used to mount the plurality of resilient elements to either the first expanse of material, the second expanse of material or both the first and second expanse of material.

9. The method of claim 8, wherein the adhesive is a heat activated adhesive that is activated by a heat platen.

10. The method of claim 1, wherein the step of engaging at least some of the resilient elements with a reinforcing structure occurs after the step of mounting the plurality of resilient elements on the first expanse of material.

11. A method of making a composite structure for use as resilient cushion comprising:

(a) providing at least one sheet of resilient material having opposing sides;

(b) applying an adhesive to either or both sides of the sheet of resilient material;

(c) providing a first cutter having a surface and a plurality of cutting elements extending from the surface in a predetermined pattern;

(d) pressing the first cutter into the sheet of resilient material, thereby forming a cut sheet of resilient material comprising a plurality of resilient elements and an excess resilient material;

(e) withdrawing the cutter from the cut sheet of resilient material;

(f) providing at least one sheet of reinforcing material;

(g) pressing a second cutter into the sheet of reinforcing material, thereby forming a cut sheet of reinforcing material comprising a plurality of reinforcing elements and a lattice of reinforcing material;

(h) withdrawing the cutter from the cut sheet of reinforcing material;

(i) separating the at least one lattice of reinforcing material from the reinforcing elements, whereby the lattice of reinforcing material is left with a plurality of holes through the reinforcing material where the reinforcing elements used to be;

(j) placing the cut sheet of resilient material adjacent to the lattice of reinforcing material, and aligning the cut sheet of resilient material so that the plurality of resilient elements are positioned adjacent to the plurality of holes in the lattice of reinforcing material;

(k) providing a pusher having a plurality of push elements that form a pattern corresponding to the pattern of the resilient elements in the cut sheet of resilient material;

(l) aligning the plurality of push elements with the plurality of resilient elements, and using the pusher to push the resilient elements out of the at least one cut sheet of resilient material, whereby the plurality of resilient elements are pushed into the plurality of holes in the lattice of reinforcing material, thereby forming a resilient material assembly comprising the plurality of resilient elements at least partially surrounded by the at least one lattice of reinforcing material;

(m) placing the resilient material assembly next to a heat platen, if heat-activated adhesive material is applied to a side of the resilient material;

(n) placing a first sheet of fabric or mesh substrate onto one side of the resilient material assembly, wherein steps (m) and (n) are optionally reversible in order; and

(o) heating the first fabric or mesh sheet substrate with the heat platen to activate the adhesive on the plurality of resilient elements, whereby the first fabric or mesh sheet substrate adheres to the plurality of resilient elements to form the composite material.

12. The method according to claim 11, comprising (p) removing the at least one lattice of reinforcing material so as to result in a first fabric or mesh sheet substrate bonded to resilient elements.

13. The method according to claim 12, comprising

(q) placing a second sheet of fabric or mesh substrate onto the opposite side of the resilient material assembly;

and

(r) heating the second sheet of fabric or mesh substrate with the heat platen to activate the adhesive on the plurality of resilient elements on the opposite side, whereby the second sheet of fabric or mesh substrate adheres to the plurality of resilient elements on the opposite side.

14. The method according to claim 11, comprising

(p) placing a second sheet of fabric or mesh substrate onto the opposite side of the resilient material assembly;

and

(q) heating the second sheet of fabric or mesh substrate with the heat platen to activate the adhesive on the plurality of resilient elements on the opposite side, whereby the second sheet of fabric or mesh substrate adheres to the plurality of resilient elements on the opposite side.

15. The method according to claim 11, wherein in step (g), the second cutter comprises a plurality of perimetral edges to cut a defined area on the sheet of reinforcing material to result in multiply perimetrally cut sheet of reinforcing material.

16. The method according to claim 15, wherein after step (m), unneeded portion of the multiply perimetrally cut sheet of reinforcing material is removed along the perimetrally cut boundary.

17. The method according to claim 11, wherein the first cutter and second cutter are the same cutters.

18. A method of making a composite structure for use as resilient cushion comprising:

(a) providing a sheet of resilient material having opposing sides;

(b) providing a cutter having a surface and a plurality of cutting elements extending from the surface in a predetermined pattern;

(c) pressing the cutter into the sheet of resilient material, thereby forming a cut sheet of resilient material comprising a plurality of resilient elements and excess resilient material;

(d) withdrawing the cutter from the cut sheet of resilient material;

(e) coating resilient elements selectively with adhesive;

(f) bonding a first fabric or mesh substrate to the first side of the cut sheet of resilient material resulting in bonding between the resilient elements to the first substrate; and

(h) separating the excess resilient material from the cut sheet of resilient material, leaving the plurality of resilient elements bound to the first substrate.