The invention relates to a method for producing a cushion for an orthopedic device, the cushion having at least one fluid-filled volume, wherein the method includes compression molding of a three-dimensional first cushion component made of at least a first material, which is preferably elastic, in a mold that comprises an inner mold and an outer mold, and bonding the first cushion component to at least a second cushion component in such a way that the fluid-filled volume is created.

A support cushion liner includes a liner body having a cavity disposed between an outer layer and an inner layer and a plurality of artificial muscles disposed in the cavity of the liner body. Each of the plurality of artificial muscles include a housing having an electrode region and an expandable fluid region, a dielectric fluid housed within the housing, and an electrode pair positioned in the electrode region of the housing. The electrode pair includes a first electrode fixed to a first surface of the housing and a second electrode fixed to a second surface of the housing. The electrode pair is actuatable between a non-actuated state and an actuated state such that actuation from the non-actuated state to the actuated state directs the dielectric fluid into the expandable fluid region, expanding the expandable fluid region thereby applying pressure to the outer layer of the liner body.

A comfort layer for a bedding or seating product has liquid pods sandwiched between plies of fabric. The plies of fabric are joined with seams thereby creating pockets, at least one liquid pod being inside each pocket. Each seam joining opposed plies of fabric around each of the liquid pods of the comfort layer may be segmented or solid, depending upon the fabric and type of seam.

Variable stiffness apparatuses using an interconnected dual layer fluid-filled cell array. One example of the present apparatuses comprises: a substrate having a first side and a second side; and a plurality of structures coupled to the substrate, where each structure comprises: a flexible first portion having a first end, a second end, and a sidewall extending between the first end and the second end, the first portion defining a first chamber; and a second portion having a first end, a second end, and a sidewall extending between the first end and the second end, the second portion defining a second chamber in fluid communication with the first chamber; where each of the plurality of structures is coupled to the substrate such that the first portion is disposed on the first side of the substrate, and the second chamber is disposed on the first side or the second side of the substrate.

A gel-foam body amalgamation system including a vacuum lift-table; a gel heating metal lift-table; a gel foam fusion lift-table; an overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a foam core body; an intermediary foam core body; a vacuum lift-table cover; a gel heating metal lift-table cover; and a gel foam fusion lift-table. A method of operating the gel-foam body amalgamation system for producing a dual-core foam body amalgamate including a foam core body and an intermediate foam core body. In another embodiment, a gel body amalgamation system including a vacuum table; a heating metal table, a fusion table; and overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a core body; an intermediary core body. A method including a core body and an intermediate core body for producing a dual-core body amalgamate.

A seat adjuster may include a support member and a fluid bladder. The support member may have a first end and a second end. The first end and the second end may be connectable to a seat frame such that the support member is disposed at least partially below a suspension portion of said seat frame. The fluid bladder may be disposed at least partially between the support member and said suspension portion. The fluid bladder may be configured to support said suspension portion. A change or adjustment of a volume of the fluid bladder may change or adjust the support provided to said suspension portion.

A support cushion liner includes a liner body having a cavity disposed between an outer layer and an inner layer and a plurality of artificial muscles disposed in the cavity of the liner body. Each of the plurality of artificial muscles include a housing having an electrode region and an expandable fluid region, a dielectric fluid housed within the housing, and an electrode pair positioned in the electrode region of the housing. The electrode pair includes a first electrode fixed to a first surface of the housing and a second electrode fixed to a second surface of the housing. The electrode pair is actuatable between a non-actuated state and an actuated state such that actuation from the non-actuated state to the actuated state directs the dielectric fluid into the expandable fluid region, expanding the expandable fluid region thereby applying pressure to the outer layer of the liner body.

The present invention provides systems, methods, and articles for temperature conditioning a surface. An article is formed from a first layer having a plurality of openings and a second layer having a corresponding plurality of openings. At least one interior chamber constructed and configured to retain a fluid without leaking is defined between an interior surface of the first layer and an interior surface of the second layer. At least one flexible fluid supply line delivers the fluid to the at least one interior chamber. At least one flexible fluid return line removes the fluid from the at least one interior chamber. At least one control unit that is operable to selectively cool or heat the fluid is attached to the at least one flexible fluid supply line and the at least one flexible fluid return line.

A mattress or mattress topper includes a cushioning element having an elastomeric material forming intersecting buckling walls that define hollow columns, and a knitted fabric disposed over the cushioning element and configured to move independently of the buckling walls. The elastomeric material includes an elastomeric polymer and a plasticizer. The knitted fabric includes a first layer of stretchable material; a second layer of stretchable material; and a layer of stretchable fill material between the first layer of stretchable material and the second layer of stretchable material. The first layer of stretchable material is knitted together with the second layer of stretchable material as a unitary sheet of fabric including the layer of stretchable fill material. A method of forming a mattress or mattress topper includes disposing a knitted fabric over a cushioning element comprising intersecting buckling walls and configuring the knitted fabric to move independently of the buckling walls.

The present invention discloses a lightweight gel sleeve, which comprises a top gel layer, a bottom gel layer and a lateral gel layer, wherein the top gel layer defines a middle cavity, and the lateral gel layer extends upward from the outer edge of the bottom gel layer to connect the bottom gel layer to the top gel layer; the top gel layer, the bottom gel layer and the lateral gel layer enclose an internal space, and the bottom gel layer defines a central opening communicated with the internal space through the gel layers, the central opening provides a passage through the gel layers and the internal space, and the top gel layer, the bottom gel layer and the lateral gel layer are integrally formed.