Deep draw method of making impact and vibration absorbing articles and the articles formed thereby

• US 9,254,591 B2
• Filed: 04/14/2009
• Issued: 02/09/2016
• Est. Priority Date: 04/14/2008
• Status: Active Grant

• Current Assignee: PolyWorks, LLC
• Original Assignee: PolyWorks, Inc.
• Inventors: Fox, Richard B., Wyner, Daniel M., Waksman, Jack, Gaudet, James E.
• Primary Examiner(s): Loney, Donald J
• Application Number:
  US12/423,174
• Publication Number:
  US 20090255625A1
• Time in Patent Office: 2,492 Days
• Field of Search: 428/120, 428/172, 267/142, 248/562, 248/634, 36/34.A, 36/44, 564/5, 565/55, 573/1, 574/0
• US Class Current: 1/1
• CPC Class Codes: A43B 13/145 Convex portions, e.g. with a bump or projection, e.g. 'Masai' type shoes
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: B29C 44/146 Shaping the lining before foaming
• CPC Class Codes: B29D 35/142 Soles
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/00 Coating on the layer surface
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/06 Vegetal fibres
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2266/0207 Materials belonging to B32B25/00
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/0292 Thermoplastic elastomer
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/56 : Damping, energy absorption
• CPC Class Codes: B32B 2307/58 : Cuttability
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2307/726 : Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2307/746 : Slipping, anti-blocking, low friction
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 2437/04 : Caps, helmets
• CPC Class Codes: B32B 25/045 : of foam
• CPC Class Codes: B32B 25/14 : comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2555/00 : Personal care
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/16 : specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/283 : comprising polysiloxanes
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 29/007 : next to a foam layer
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/20 : foamed in situ
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/24174 : including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface

Abstract

The present disclosure relates to cushioning members, methods of making and methods of using, particularly to cushioning members comprising a plurality of spaced apart pillars comprising a polymeric material.

Claims

1. A cushioning member, comprising:

a multilayer material comprising a barrier layer, a polymeric material layer disposed adjacent to the barrier layer, and a stabilization layer disposed adjacent to and opposite the barrier layer;

a plurality of pillars disposed in the multilayer material, each of the plurality of pillars comprising an upper surface and a sidewall extending downwardly from and undercutting the upper surface to define a radiused upper edge disposed between the upper surface and the sidewall;

a plurality of spacer regions disposed between the plurality of pillars, each of the plurality of spacer regions comprising a spacer region width of about 0.002 inch.

2. The cushioning member of claim 1, wherein the thickness of at least two of the plurality of pillars is different.

3. The cushioning member of claim 1, wherein the shape of at least two of the plurality of pillars is different.

4. The cushioning member of claim 1, wherein the thickness and the shape of at least two of the plurality of pillars is different.

5. The cushioning member of claim 1, wherein the plurality of pillars have a thickness of less than about 3 inches, and the plurality of spacer regions have a thickness of about 0.002″

.

6. The cushioning member of claim 1, wherein the plurality of pillars have a thickness of less than about 3 inches, and the plurality of spacer regions have a thickness of about 0.250″

.

7. The cushioning member of claim 1, wherein the barrier layer is selected from the group consisting of textiles, textile composites, thermoplastic elastomer (TPE) materials, and combinations comprising at least one of the foregoing.

8. The cushioning member of claim 7, wherein the barrier layer is a thermoplastic polyurethane (TPU).

9. The cushioning member of claim 1, wherein the barrier layer comprises an elongation of at least about 100 percent.

10. The cushioning member of claim 1, wherein the barrier layer has a thickness of less than or equal to about 5 mil.

11. The cushioning member of claim 1, wherein the barrier layer has a thickness of greater than or equal to about 5 mil.

12. The cushioning member of claim 1, wherein the barrier layer comprises a moisture transmittable material.

13. The cushioning member of claim 1, wherein the barrier layer comprises a phase changing material.

14. The cushioning member of claim 1, wherein the barrier layer comprises an active agent.

15. The cushioning member of claim 14, wherein the active agent is selected from the group consisting of an antimicrobial active agent, an antifungal agent, and combinations comprising at least one of the foregoing.

16. The cushioning member of claim 1, further comprising a fabric material layer disposed between the polymeric material layer and the stabilization layer.

17. The cushioning member of claim 16, wherein the fabric layer comprises knits, wovens, non-wovens, synthetics, non-synthetics, and combinations comprising at least one of the foregoing.

18. The cushioning member of claim 1, wherein at least one of the barrier layer and the stabilization layer comprise a fabric material layer comprising an elongation of at least about 100 percent.

19. The cushioning member of claim 18, wherein the fabric layer comprises knits, wovens, non-wovens, synthetics, non-synthetics, and combinations comprising at least one of the foregoing.

20. The cushioning member of claim 18, wherein the fabric layer is fluid-permeable.

21. The cushioning member of claim 1, further comprising an adhesive disposed between the polymeric material layer and the stabilization layer.

22. The cushioning member of claim 21, wherein the adhesive is disposed on a support layer.

23. The cushioning member of claim 22, wherein the support layer is a TPE.

24. The cushioning member of claim 1, wherein the stabilization layer is removable from the cushioning material.

25. The cushioning member of claim 1, wherein the ratio of the pillar thickness to the pillar width is about 8:

1.

26. The cushioning member of claim 1, wherein the sidewall extends perpendicularly downwardly from the upper surface.

27. A cushioning member, comprising:

a multilayer material comprising a barrier layer, a polymeric material layer disposed adjacent to the barrier layer, and a stabilization layer disposed adjacent to and opposite the barrier layer;

a plurality of pillars disposed in the multilayer material, each of the plurality of pillars comprising a thickness and a width, and an upper surface and a sidewall extending downwardly from and undercutting the upper surface;

a plurality of spacer regions disposed between the plurality of pillars, each of the plurality of spacer regions comprising a spacer region thickness and a width of about 0.002 inch;

wherein the ratio of the pillar thickness to the pillar width is between about 2;

1 and about 8;

1.

28. The cushioning member of claim 27, wherein the thickness of at least two of the plurality of pillars is different.

29. The cushioning member of claim 27, wherein the shape of at least two of the plurality of pillars is different.

30. The cushioning member of claim 27, wherein the thickness and the shape of at least two of the plurality of pillars is different.

31. The cushioning member of claim 27, wherein the plurality of pillars has a thickness of less than about 3 inches, and the thickness of the plurality of spacer regions is about 0.002″

.

32. The cushioning member of claim 27, wherein the plurality of pillars has a thickness of less than about 3 inches, and the thickness of the plurality of spacer regions is about 0.250″

.

33. The cushioning member of claim 27, wherein the barrier layer is selected from the group consisting of textiles, textile composites, thermoplastic elastomer (TPE) materials, and combinations comprising at least one of the foregoing.

34. The cushioning member of claim 33, wherein the barrier layer is a thermoplastic polyurethane (TPU).

35. The cushioning member of claim 27, wherein the barrier layer comprises an elongation of at least about 100 percent.

36. The cushioning member of claim 27, wherein the barrier layer has a thickness of less than or equal to about 5 mil.

37. The cushioning member of claim 27, wherein the barrier layer has a thickness of greater than or equal to about 5 mil.

38. The cushioning member of claim 27, wherein the barrier layer comprises a moisture transmittable material.

39. The cushioning member of claim 27, wherein the barrier layer comprises a phase changing material.

40. The cushioning member of claim 27, wherein the sidewall extends perpendicularly downwardly from the upper surface.