A method and an apparatus for manufacturing a cushion mat and a cushion mat thus manufactured are disclosed. An apparatus for manufacturing a cushion mat may include: a lower mold that has a cavity formed in its upper surface and is configured to receive a first sheet and a inner filler sequentially, where the first sheet may be disposed such that a boundary of the first sheet is exposed at a periphery part of the cavity; an upper mold that is configured to heat-seal the first sheet and a second sheet onto both sides of the inner filler by mating with the lower mold while the second sheet is disposed between the upper mold and the inner filler; and air suction nozzles that are disposed at the periphery part of the cavity of the lower mold to remove residual air from between the second sheet and the inner filler.

A method of manufacturing a folding mat includes: suctioning a first film onto a lower mold, in which a downwardly concave slit groove is formed at one end of a cavity such that a portion of the first film forms a unit fold part; inserting the unit filler over the first film; disposing a second film on an upper side of the lower mold to cover the unit filler; attaching the edge parts of the first and the second films together by using an upper mold mating with the lower mold; trimming an attachment part of the unit mats thus fabricated; fusing the unit fold part of the unit mat with the unit fold part of an adjacent unit mat; and fusing the attachment part of one of the two unit mats thus connected with the attachment part or the unit fold part of another unit mat.

A pad is provided for supporting heavy loads and is capable of supporting loads of 100 tons or more. The pad has a core having a bi-directional grid formed from parallel fiberglass materials, with a first set of material at right angle to a second set of fiberglass materials and which grid surrounds a closed cell material, which is infused with resin to form a core. A fiberglass top surface, bottom surface and at least one sidewall is provided. The result is a pad able to distribute very heavy loads, is resistant to bending, durable and light weight.

A welding process of an inflatable product is provided that includes using isolating members between first and second portions of weldable tensioning members to resist the first and second portions of the weldable tensioning structures being welded together during welding of the first portions to a first sheet of weldable material and welding of the second portions to a second sheet of weldable material.

A durable pet having a flat polyurethane foam core, a first polyurethane layer bonded to the top surface of the core, and a second polyurethane layer bonded to the sides of the core, and a method for making such a bed. The first polyurethane layer has a thickness of about 0.05 to 0.25 inches and a hardness of about 20 to 70 durometers. The second polyurethane layer has a thickness of about 0.05 to 0.3 inches and a hardness of about 50 to 100 durometers. The pet bed may have a third polyurethane layer bonded to the bottom of the core, the third layer having a thickness of about 0.05 to 0.25 inches and a hardness of about 20 to 100 durometers. The first, second and third layers typically completely encase the core.

Mattresses and methods for processing a flexible foam material for use in a mattress to provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and/or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen against the foam pad or placing the foam pad between one or more rollers.

A method of making a foamed article comprises (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (gel) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.

The invention relates to a method for transporting foamed thermoplastic polymer particles (3) from a container (5, 9) through at least one pipe (7,9), wherein, for transporting the foamed thermoplastic polymer particles (3), a gas stream is applied through the pipe (7, 11). The foamed thermoplastic polymer particles (3) are wetted with a water comprising lubricant.

Implementations described and claimed herein include a cushioning material layer and method for manufacturing a cushioning material layer, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning material layer comprises void cells formed in an array, which comprise multiple outwardly facing curvatures, with varying radius measurements. Stiffness in the void cells can vary by varying the radiuses. The outwardly facing curvatures prevent buckling and provide support for high impact by absorbing energy.