EXPANDED FOAM PRODUCTS AND METHODS FOR PRODUCING THE SAME

摘要

An expanded resilient product and methods for making the same are disclosed. The product is characterized as a geometric solid of resilient material that has a plurality of slits formed therein. One embodiment has a plurality of slits formed in a resilient material whereafter the material is extended to produce an expanded material which is then bonded to at least one surface in order to retain the expanded nature of the product. In another embodiment, each slit is defined by a first internal surface having a protruding portion and second internal surface having a recess portion corresponding to the protruding portion of the first surface which together form an interlocking fit between the two. Forces are applied to the product sufficient to dislodge a protruding portion of the first inner surface from the complementary recess portion of the second inner surface, thereby forming a plurality of gaps. The product is then permitted to relax, whereupon the protruding portions compressively contact the complementary recess portions of the second surface and thus, are prevented from re-engaging the recess portions and thereby maintain the expanded nature of the product. Methods for manufacturing the product involves the creation of the slits and subsequent physical expansion of the resilient material to produce an expanded product, or in the case of non-self-sustaining gaps, may then be bonded to an additional material to sustain the gaps.