Cushioning support device and method of making the same

Abstract

A cushioning support device and a method for making the same are disclosed. The device comprises a first polyurethane foam having a non-slip sheet attached on a surface of the first foam, a second polyurethane foam having a resting sheet attached on a surface of the second foam, and a compound pressure-redistributing body. The first and second polyurethane foams are arranged one over another into a stack which is welded and envelops to form at least an internal pocket along a weld line. The internal pocket houses the pressure-redistributing body, and it comprises a foam and a solid gel attached on a top surface of the foam, wherein the solid gel is securely positioned by way of melting. Dips of the gel can lodge into the small interstices of the foam material during the melting process; the gel gets into a solid state after solidification.

Claims

1. A method for making a cushioning support device used in supporting a human body, comprising: a. providing a compound pressure-redistributing body, the compound pressure-redistributing body comprising a foam and a solid gel attached on a top surface of the foam, wherein parts of the solid gel lodge into small interstices of the foam material, and the area of the foam of the compound pressure-redistributing body is larger than the area of the foam of the solid gel; b. providing and heating a thermo-pressing mold, the thermo-pressing mold comprising a bottom mold and a top mold, wherein the bottom mold has a number of standing bottom separating boards, and between every two neighboring bottom separating boards there is created a depth-defining cavity, top ends of the bottom separating boards are arrayed along a predetermined trail of a weld line, and at least a part of the weld line winds around a periphery at a predetermined location on the cushioning support device for use in supporting a human body weight to define a space for an internal pocket; c. covering a second polyurethane foam on the top ends of the bottom separating boards of the bottom mold; d. disposing the compound pressure-redistributing body on top of the second polyurethane foam, subject to the compound pressure-redistributing body being located at a position corresponding to a position of the internal pocket, the solid gel being disposed facing downward; e. covering the first polyurethane foam on top of the second polyurethane foam and sandwiching the compound pressure-redistributing body between the first polyurethane foam and the second polyurethane foam; and f. pressing the top mold against the top of the first polyurethane foam, subject to the first polyurethane foam and the second polyurethane foam becoming mutually welded together at a pressing zone at the top end of the bottom separating board of the bottom mold to form a weld line.

2. The method for making a cushioning support device according to claim 1, wherein a top surface of the second polyurethane foam has a resting sheet, the resting sheet is a soft and breathable cloth.

3. The method for making a cushioning support device according to claim 1, wherein a bottom surface of the first polyurethane foam has a non-slippery sheet.

4. The method for making a cushioning support device according to claim 1, wherein the top mold is heated to about 180220 Celsius degrees, and the bottom mold is heated to about 180220 Celsius degrees.

5. The method for making a cushioning support device according to claim 1, wherein the top mold has a planar pressure-applying surface, and the planar pressure-applying surface is applicable for entirely covering the top ends of the bottom separating boards.

6. The method for making a cushioning support device according to claim 1, wherein the compound pressure-redistributing body is covered by a plastic film, such that mineral oils of the solid gel is prevented from spilling.

7. The method for making a cushioning support device according to claim 1, wherein the top mold has multiple standing separating boards, between every two neighboring top separating boards there is formed another depth-defining cavity, top ends of the top separating boards are arrayed along a predetermined trail of another weld line, and at least a part of the another weld line winds around a periphery at a predetermined location on the cushioning support device for use in supporting a human body weight to define a space for another internal pocket, the another weld line corresponds to the weld line of the bottom mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a first example of the thermo-pressed cushioning device according to the present invention;

(2) FIGS. 2A and 2B show a first example of the thermo-pressed cushioning device according to the present invention;

(3) FIG. 3 is a cross-sectional view of the thermo-pressed cushioning device according to the present invention;

(4) FIG. 4 is exemplary of the third example of the thermo-pressed cushioning device according to the present invention;

(5) FIG. 5 shows an example of the present invention, showing a schematic view of the components for the cushioning support device;

(6) FIG. 6 shows an example of the present invention, showing an isometric view of the cushioning support device;

(7) FIG. 7A shows a view of FIG. 6 along the provisional section defined by III-III;

(8) FIG. 7B demonstrates a user using the present invention, showing a cross-sectional view of the cushioning support device when it is subject to compression;

(9) FIG. 8 is another example of the present invention, showing an interconnecting passage between at least two internal pockets;

(10) FIG. 9 is another example of the present invention, showing a frontal view of another cushioning support device;

(11) FIG. 10 is another example of the current invention, showing a frontal view of another cushioning support device;

(12) FIG. 11 shows a flowchart for a method of making according to the present invention;

(13) FIG. 12 shows an example according to the present invention, showing a schematic view of the components of the thermo-pressed molds;

(14) FIG. 13 is a view highlighting operation for the method of making according to the present invention, showing top ends of bottom separating boards of a bottom mold;

(15) FIG. 14 is a view highlighting operation for the method of making according to the present invention, showing using the bottom mold and a top mold to perform thermo-pressing to make the cushioning support device;

(16) FIG. 15 is a view highlighting operation for the method of making according to the present invention, showing making of a compound pressure-redistributing body; and

(17) FIG. 16 is an example of the present invention, showing another component configuration for the cushioning support device, wherein there is a plastic film covering the top end of the solid gel of the compound pressure-redistributing body.

(18) FIG. 17 is an example of the present invention, showing that the top and bottom molds each is disposed with a separating board.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(19) Referring to FIGS. 1-4, the illustrated invention provides a cushioning support device comprising a covering sheet 1, wherein the covering sheet has a first major surface 11 and a second major surface 12, and the first major surface 11 of the covering sheet 1 has a tufted surface; a topping sheet of cushioning material 3, wherein the topping sheet of cushioning material has a first major surface 31 and a second major surface 32, wherein the second major surface 32 of the covering sheet 1 is attached onto the first major surface 31 of the topping sheet of cushioning material 3; a non-slip sheet 2, wherein the non-slip sheet has a first major surface 21 and a second major surface 22, wherein the first major surface 21 of the non-slip sheet 2 is slip resistant; a substrate sheet of cushioning material 9, wherein the substrate sheet of cushioning material has a first major surface 91 and a second major surface 92, wherein the second major surface 22 of the non-slip sheet 2, is attached onto the second major surface 92 of the substrate sheet of cushioning material 9; at least one padding 4, which is attached onto a predetermined location situated between the second major surface 32 of the topping sheet of cushioning material 3 and the first major surface 91 of the substrate sheet of cushioning material 9.

(20) As per manufacturing the thermo-pressed cushioning support device, the foregoing covering sheet 1, topping sheet of cushioning material 3, non-slip sheet 2, substrate sheet of cushioning material 9, and padding 4 are hound together through a thermo-pressing treatment that subjects thermo-pressing apparatus 5 on the first major surface 11 of the covering sheet 1 and the first major surface 21 of the non-slip sheet 2 to a heat pressing process which performs the binding around the neighborhood of the padding 4, causing the topping sheet of cushioning material 3 and the substrate sheet of cushioning material 9 to be melted and melded together. Until about the temperature condition cools off, thermo-binding lines or regions of geometric shapes 111 are formed on the covering sheet 1 and the topping sheet of cushioning material 3 in addition to internal pockets 112 formed therefrom, wherein support padding 4 is enclosed.

(21) In one notable aspect, the covering sheet 1 is made from fabric, linen, or leather. In another notable aspect, the non-slip sheet 2 is used for the purpose of reducing a prescribed slippery condition, and the non-slip sheet 2 is made from fabric, linen, leather, or a similar non-slip material that can provide the same slipperiness-reduction functionality.

(22) Furthermore, the topping sheet of cushioning material 3 and the substrate sheet of cushioning material 9 are made from polyurethane (PU) foam. The PU foam has a chemical property of turning liquid and viscous when heated to an elevated temperature. This property gives benefit to tightly glue together the topping sheet of cushioning material 3 and the substrate sheet of cushioning material 9, and allows for moldable depression on the topping sheet. 3 and the substrate sheet 9 as the PU foam cools down on locations where deformations are created post the thermo-pressing treatment. The solidified PU foam stays in this structural configuration after the cooling.

(23) In another notable aspect, the padding 4 is made from gels, latex, silica gels, or other elastomeric materials so as to enabling the padding 4 ability to distribute any perceived applied impact, and therefore offering an embodiment of the present invention that is supportive, capable of absorbing mechanical vibration, dispersing external pressure, and buffering impact. Furthermore, the foregoing elastomeric materials can be prepared in various surface pattern configurations depending on consumers' request, such as spider-webs, gridlines, blocks, perforations, raised-bubbles or embossed indentions.

(24) In another aspect, the padding 4 is made from memory foam, enabling the padding 4 to change its structural shape subject to user's body temperature. More specifically, this means that the padding 4 is responsive to receiving changes in objects subject to the present invention's support.

(25) In another aspect, the thermo-pressing apparatus 5 includes a male binding member 51 and a female binding member 52, wherein the female binding member 52 has a flat surface 521, and one surface of the male binding member 51 has a plurality of grooved regions 511, wherein each of which has a size corresponding a padding 4. The male binding member 51 and the female binding member 52 compress against each other when the thermo-pressing process is underway, where the male binding member 51 moves in such a way to act on the first major surface 11 of the covering sheet 1, while the female binding member 52 moves in a directly opposite way to act on the first major surface 21 of the non-slip sheet 2. After the pressing process is performed a plurality of thermo-binding lines or regions 111 having geometric patterns are created on the first major surface 11 of the covering sheet 1, while in the same time as the padding 4 pushes upward against the covering sheet 1 and the topping sheet of cushioning material 4 to produce an internal pocket 112 outlining the neighboring thermo-binding lines or regions 111.

(26) Furthermore, the padding 4 described herein is arranged partially between the topping sheet of cushioning material 3 and the substrate sheet of cushioning material 9, therefore is lighter in weight and is easy to carry.

(27) The reader will appreciate that the aforementioned support device could be further processed to be configured for use in various occasions, including but not limited to, mattress topper, seat cushion, or couch cushion.

(28) In reference to FIG. 4, the padding 4 comprises a shock absorbing compound 41 overlaying upon a modeling compound 42, which instills in the padding 4 functionalities including but not limited to ability to support, absorb vibration, disperse external pressure, buffer impact, and transform in response to heat.

(29) In one notable aspect, the shock absorbing compound 41 is made from gels, latex, silica gels, or other elastomeric materials. The modeling compound 42 can be made from memory foam. In practice, implementation of the foregoing materials can be realized in ways including one wherein the shock absorbing compound 41 provides a means to take in tension and distributively transfer the tension, and further the modeling compound 42 transforms its shape in response to elevated temperature. Accordingly, this can provide desired benefits to the present invention, including comfort support and tension reduction around a users neck, back, waist, and legs portion when the thermo-pressed cushioning support device is applied into furniture including but not limited to mattress topper, seat cushion, or hack cushion.

(30) In another aspect, the relative position of the shock absorbing compound 41 and modeling compound 42 within a stack having both compounds is receptive to change upon demand.

(31) In reference to FIGS. 5 and 6, an example showing the structure of the present invention is shown, in which the disclosed cushioning support device comprises a first polyurethane foam 10, a second polyurethane foam 20, the second polyurethane foam 20 has on its top surface a resting sheet 30. The first polyurethane foam 10 has on its bottom surface a non-slip sheet 40. The resting sheet 30 and the non-slip sheet 40 are all comfortable stretch fabrics. The resting sheet 30 is attached to the top surface of the second polyurethane foam 20 by way of sticking or other processing means. The non-slip sheet 40 can provide a non-slip capability, the non-slip sheet 40 is selected from any of woven, elastic knitted fabric, leather or non-slip material.

(32) The second polyurethane foam 20 and the first polyurethane foam 10 are arranged one over another in a top-down manner into a stack and are welded together along a trail of weld line L. The winding of the weld line L1 between the first polyurethane foam 10 and the second polyurethane foam 20 forms at least an internal pocket 50 (see FIG. 7A). Basically the weld line L still maintains its course of expansion along the periphery of the cushioning support device. The internal pocket 50 is located at a position on the cushioning support device for use in supporting a human body, and the quantity and location of the internal pocket 50 vary depending on the purpose of the cushioning support device. In other words, there may be more than one internal pocket 50. The cushioning support devices shown in FIG. 5, FIG. 8, and FIG. 9 are use for installment as seat cushions on seats, there is disposed on the left and right sides of the seat cushions to correspond to a user's bottom, such design is intended to support a user's body weight. As shown in FIG. 10 for another cushioning support device, which shows a backrest cushioning support for installment as backrest cushions on backrest, there is disposed on the left and right sides of the seat cushions to correspond to a user's vertebral column. Each internal pocket 50 has within itself a compound pressure-redistributing body 60. The storage volume of the internal pocket 50 can be larger than the compound pressure-redistributing body 60, allowing the compound pressure-redistributing body 60 has room permitting shape change. The compound pressure-redistributing body 60 comprises a foam 61 and a solid gel 62 attached to the top surface of the foam 61. The area of the foam 61 is a little larger than or equal to the area of the solid gel 62. In other words, the solid gel 62 is located inside the foam 61's center and creates an interstice between itself and a foam 61's side. (FIG. 5). As shown in FIG. 7B, any compound pressure-redistributing body 60 subject to compression and resulting in radially shooting outwardly can still be supported by the foam 61 having larger area. Additionally, because the storage room of the internal pocket 50 is larger than the compound pressure-redistributing body 60, which makes the compound pressure-redistributing body have an excellent room for shape changing, thereby helping the compound pressure-redistributing body 60 preserve excellent pressure-reducing and shock-damping capabilities, and ultimately creating a cushioning support device that is capable of redistribute pressure as well as offering breathable and heat-transferring effects.

(33) As shown in FIG. 8, which shows another example of the present invention, the cushioning support device has multiple internal pockets 50a and internal pockets 50b, wherein there is formed an interconnecting passage 51 between at least two internal pocket 50a and internal pocket 50b. The internal pocket 50a, internal pocket 50b and the passage 51 are formed by the winding of one weld line L1. In other words, the internal pocket 50a and the internal pocket 50b are between the first polyurethane foam 10 and the second polyurethane foam 20, and are regions enclosed by the same weld line L1. When the compound pressure-redistributing body 60 inside any of internal pocket 50a and internal pocket 50b is subject to compression, the solid gel 62 that is expanding longitudinally and outwardly can still be supported by the foam 61 and expands along the passage 51, which can change its shape to redistribute the pressure applied on the solid gel 62.

(34) As shown in FIG. 11, the present invention further provides a method for making a cushioning support device, comprising the steps of:

(35) a. providing a compound pressure-redistributing body, the compound pressure-redistributing body 60 comprising a foam 61 and a solid gel 62 attached on a top surface of the foam 61, wherein parts of the solid gel 62 lodge into small interstices of the foam 61 material, a solid gel 62 is formed on the foam 61 after the welded solid gel hardens, wherein the solid gel 62 and the foam 61 are firmly combined together, and the area of the foam 61 is larger than the area of the solid gel 62;

(36) b. providing and heating a thermo-pressing mold, as shown in FIG. 12, the thermo-pressing mold comprising a bottom mold 80 and a top mold 90, wherein the bottom mold has a number of standing bottom separating boards 81, and between every two neighboring bottom separating boards 81 there is created a depth-defining cavity 82, top ends 810 of the bottom separating boards 81 are arrayed along a predetermined trail of a weld line L, and at least a part of the weld line L winds around a periphery at a predetermined location on the cushioning support device for use in supporting a human body weight to define a space for an internal pocket, wherein the top mold 90 has a planar pressure-applying surface 901, and the planar pressure-applying surface 901 is applicable for entirely covering the top ends 810 of the bottom separating boards 81, heating the top mold 90 to a Celsius degree of about 200 degrees, and heating the bottom mold 80 to a Celsius degree of about 140 degrees (which may be performed by way of electric heating);

(37) c. covering a second polyurethane foam 20 having the resting sheet 30 on the top ends 810 of the bottom separating boards 81 of the bottom mold 80;

(38) d. disposing the compound pressure-redistributing body 60 on top of the second polyurethane foam 10, subject to the compound pressure-redistributing body 60 being located at a position corresponding to a position of the internal pocket 50, wherein the solid gel 62 of the compound pressure-redistributing body 60 being disposed facing downward, in other words, the solid gel 62 is located beneath the foam 61, such that the compound pressure-redistributing body 60 and the cavity 82 of the bottom mold 80 correspond to each other, wherein the cavity 82 is larger than the volume of the compound pressure-redistributing body 60;

(39) e. covering the first polyurethane foam 10 having the non-slip sheet 40 on a predetermined location on top of the second polyurethane foam 20 and sandwiching the compound pressure-redistributing body 60 between the first polyurethane foam 10 and the second polyurethane foam 20; and

(40) f. pressing the top mold 90 against the top of the non-slip sheet 40, subject to the resting sheet 30, the second polyurethane foam 20, the first polyurethane foam 10 and non-slip sheet 40 becoming mutually welded together at a pressing zone at the top end 810 of the bottom separating board 81 of the bottom mold 80 to form a weld line L and L1.

(41) Because during the process of using the thermo-pressing mold to perform thermo-pressing, the compound pressure-redistributing body 60 is enclosed between the first polyurethane loam 10 and the second polyurethane 20, and the first polyurethane foam 10 and the second polyurethane 20 are stacked together to form a certain thickens, so the cavity 82 formed by the circling of the bottom separating boards 81 should have enough space to accommodate the first polyurethane foam 10 and the second polyurethane 20, as well as the compound pressure-redistributing body 60 enclosed therein. Therefore, according to an example of the present invention, the size of the foam 61 of the compound pressure-redistributing body 60 is a little smaller than the cavity 82 formed by the circling of the bottom separating boards 81 (the cavity 82 concerns the cavity 82 located at the internal pocket 50). In other words, if the foam 61 is inserted into the corresponding cavity 82 of the bottom mold 80, the periphery of the foam 61 would not touch the bottom separating boards 81 that circle the cavity 82. This preserves a spacing between the periphery of the foam 61 and the bottom separating boards 81 circling the cavity 82. This spacing can accommodate the thickness created by the staking of the first polyurethane foam 10 and the second polyurethane 20 (See FIG. 14).

(42) The invention has been described herein by illustration of a preferred exemplary embodiment. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. Further, it will be apparent to those skilled in the art that other embodiments having equivalent modification and change are possible within the scope of the invention.

(43) Because the first polyurethane foam 10, the second polyurethane 20, the resting sheet 30 and the non-slip sheet 40 are all made of an elastic material, after the cushioning support device is made according to the above method, the compound pressure-redistributing body 60 enclosed therein would push these elastic materials outward, making the spots having compound pressure-redistributing body 60 on the two sides of the cushioning support device have a protruding appearance.

(44) There is also presented an example for the method of making the compound pressure-redistributing body 60 comprising a foam 61, the foam 61 is a material having numerous pores. The top surface of the foam 61 is disposed with a mold device 63, there is injected at the mold 63 welded gel material 64 (see FIG. 1.5), making a fraction of the gel material sip into the pores of the foam, and forming a solid gel 62 after the gel material cools down and hardens. The area of the top surface of the foam is a little larger than the area of the solid gel 62.

(45) FIG. 16 shows another example of the present invention, which further comprises a plastic film 70. In the above method, the plastic film 70 covers on the surface of the solid gel 62 of the compound pressure-redistributing body 60, so as to prevent the oil of the solid gel 62 from spilling.

(46) Additionally, as depicted in FIG. 17, the top mold 90 does not necessarily have be a planar surface, but can also have multiple standing separating boards 93, between every two neighboring top separating boards there is formed a depth-defining cavity 94, top ends of the top separating boards 93 are arrayed along a predetermined trail of a weld line, and at least a part of the weld line winds around a periphery at a predetermined location on the cushioning support device for use in supporting a human body weight to define a space for an internal pocket, the weld line corresponds to the weld line of the bottom mold 80.

(47) The present invention has been disclosed as intended to illustrate its examples, and not intended to be restrictive to those as described. A person skilled in the relevant art may make minor modification or adjustment without departing from the spirit or scope of the present invention, accordingly scope of claim sought to be protected by the current invention is to be determined on the basis of the claims as defined by the current specification.