CUSHIONING ASSEMBLIES WITH THERMOPLASTIC ELEMENTS ENCAPSULATED IN THERMOSET PROVIDING CUSTOMIZABLE SUPPORT AND AIRFLOW, AND RELATED METHODS

摘要

Embodiments disclosed herein include cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow. A cushioning assembly for a cushion provides cushioning and support for a user. Thermoplastic elements are encapsulated within a thermoset matrix to provide additional support at specific sections of the cushion. The shape and location of the thermoplastic elements may be configured to provide the support and cushioning characteristics desired by a user. The thermoplastic elements may include air passageways in communication with the outside. In this manner, support is provided precisely where needed for the user, the weight and expense of the cushion is reduced by eliminating expensive redundant support, and the heat and humidity that can cause user discomfort is reduced.

主权项

1. A method of creating a cushioning assembly, comprising:
extruding at least one thermoplastic profile; disposing the at least one thermoplastic profile within an enclosure by suspending the at least one thermoplastic profile with at least one removable elongated member; and dispensing thermoset material within the enclosure to encapsulate the at least one thermoplastic profile to form a thermoset matrix as part of a cushioning core, wherein the cushioning core comprises the thermoset matrix encapsulating the at least one thermoplastic profile.