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Breathable gel

Active Publication Date: 2015-11-26
PURPLE INNOVATION LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

This barrier may cause difficulties such as discomfort, such as when body heat and / or perspiration accumulate between the user's body and the gel layer.

Method used

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  • Breathable gel
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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0062]A mold 40 (see FIG. 4) is formed by machining cavities 44 into a body 42, which may be a metal or polymer plate. A top plate is formed such that, when the top plate is fitted to the mold, each cavity 44 is completely encapsulated (with the exception of the gel input means, such as the runners discussed below in this Example 1).

[0063]A TPE gel is formed by mixing one part by weight SEPTON® 4055 SEEPS polymer, eight parts by weight CARNATION® White Mineral Oil (a 70-weight straight-cut white paraffinic mineral oil, available from Sonneborn, Inc., of Mahwah, N.J.), 0.25% by weight EVERNOX® 76 antioxidant (available from Everspring Chemical, of Taichung, Taiwan), 0.25% by weight EVERFOS® 168 antioxidant (available from Everspring Chemical), and 0.25% by weight Horizon Blue pigment (available from DayGlo Color Corp., of Cleveland, Ohio). The mixture is heated and extruded to melt-blend the TPE gel. The molten TPE gel is then pumped into a piston heated above a melting temperature o...

example 2

[0066]A mold 40 having an open face is formed as described in Example 1. Molten TPE gel is poured or pressurized into the cavities 44, and excess TPE gel is scraped off (either while still molten or after cooling). Alternatively, TPE gel may be metered into the cavities so that no scraping is necessary. A fabric, foam, or other gel-permeable breathable material 18 is laid onto the TPE gel. Light pressure may be applied to press the breathable material 18 against the TPE gel. If the TPE gel is molten during this process, some of the molten TPE gel may permeate the breathable material 18. If the TPE gel is cooled or solidified prior to placement of the breathable material 18, heat may be applied to melt at least a top portion of the TPE gel. A portion of the melted TPE gel may permeate the breathable material 18. Pressing means may also include heat, for example, a heat press (e.g., a heated plate to press onto the fabric).

example 3

[0067]A mold 40 or a series of molds are as described in Example 2. The breathable material 18 is continuous, and the mold(s) 40 are removed from the breathable material 18 and then brought again to another part of the breathable material 18. For example, the mold(s) 40 may include a tank-tread style set of molds that are connected in a continuous circular configuration that continuously cycles under the unrolling breathable material 18, or may include a rotating drum. The mold(s) 40 may be flooded with molten TPE gel at one point on the mold rotation, followed downstream with a scraping means (e.g., a silicone rubber squeegee-type blade or a metal blade, either of which may be heated, cooled, or maintained at room temperature). The breathable material 18 is pressed into the top surface of the TPE gel while the TPE gel is still in the mold cavities. A means of pulling on the breathable material 18 translates the breathable material 18 adjacent the mold(s) 40 and provides a force to ...

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Abstract

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.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61 / 465,911, filed Mar. 25, 2011, and entitled “Breathable Gel for Cushioning and / or Temperature Management,” the disclosure of which is incorporated herein by reference in its entirety.FIELD[0002]Embodiments of the disclosure relate generally to cushioning elements comprising a gel component, to products including such cushioning elements, and to methods of making and using such cushioning elements.BACKGROUND[0003]Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and / or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B3/16B68G5/00B29C65/02
CPCB68G5/00A47C27/10B29L2031/7138B29L2031/58B29C65/48B29C66/30325B29C66/30326B29C66/472B29C66/71B29C66/727B29C66/729B29C66/7392B29L2031/751B29C65/02B29C66/73181D06N7/0092D06N2203/042D06N2211/14D06N3/106D06N2209/123D06N2201/042A47C27/15A47C27/20Y10T428/24802Y10T428/24314Y10T428/2481Y10T428/24273Y10T428/24331Y10T428/24322B29K2021/003B32B3/22A47C27/00B32B3/16A47C31/116B32B3/266
Inventor PEARCE, TONY M.WHATCOTT, RUSSELL B.BENNETT, LAVON LEE
Owner PURPLE INNOVATION LLC
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