UNITARY COMPOSITE/HYBRID CUSHIONING STRUCTURE(S) AND PROFILE(S) COMPRISED OF A THERMOPLASTIC FOAM(S) AND A THERMOSET MATERIAL(S) AND RELATED METHODS

摘要

Related methods to produce unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam and a thermoset material are also disclosed. As non-limiting examples, the thermoset material may also be provided as cellular foam. The unitary composite cushioning structure may be formed from the thermoplastic material and the thermoset material. The thermoplastic material provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum, which may be continuously produced, is formed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material as the thermoset material transforms from a non-solid to a solid phase to secure the at least a portion of the thermoset material to the at least a portion of the thermoplastic material to provide a unitary composite cushioning structure.