Writing implement having deformable grip

A deformable sleeve for attachment to various products for use as a grip and/or to provide a stylish appearance. The deformable sleeve features two membranes that define a cavity filled with a formable material. The deformation of the sleeve results in greater comfort for the user where the sleeve is mounted on products that are manually manipulated or are otherwise contacted by the user. In one preferred embodiment, the sleeve can be mounted on a writing instrument for use as a grip. Alternatively, the sleeve c-an be filled with a formable material that will resume its original shape after being deformed.

BACKGROUND OF THE INVENTION

This invention relates generally to improvements in deformable grips for attachment to various products, and, as in one preferred embodiment, to writing instruments with deformable grips.

Deformable grips have been known for years on various products, such as manual implements and luggage. For example, such grips are shown in U.S. Pat. Nos. 4,364,150 and 5,000,599. While the deformable grips shown in these patents are generally acceptable, these grips are intended for a specific type or types of products and are not readily removed for use as grips on other products.

One writing instrument has a conventional formable grip. The grip is located around the body of the writing instrument, adjacent to its writing end. The grip has a tubular outer membrane and a tubular metal inner sleeve mounted in a concentric relationship. The inner sleeve is rigid. Circular flanges at both ends of the grip mechanically clamp the each end of the outer membrane to a corresponding end of the metal sleeve, thereby creating an internal cavity in the space between the concentrically-mounted membrane and metal sleeve. A formable polymer is located in the cavity, between the membrane and metal sleeve. While the grip on this writing instrument is generally acceptable, the metal sleeve, membrane and flanges are relatively expensive to build and assemble. Due to the nature of the polymer materials used in the deformable grip, it is likely to need replacement after a period of time, which can in some cases be less than a year. However, the grip is not easily removed and replaced.

Accordingly, there has existed a need for an inexpensive deformable grip that can be configured for easier attachment to many types of products. The present invention satisfies this need.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now toFIG. 1of the drawings, one embodiment of the invention is a rectangular patch, or grip, indicated by the reference numeral10, for attachment to the surface12of a product, in an area14where the product will be touched by a person or gripped or manipulated by a person's hands or fingers. For example, the area14where the grip10is attached may be on the grip area of a pair of binoculars (FIG. 16) or other optical device, such as a camera (FIG. 58), a telescope, or monocular. It should be appreciated that embodiments of the patch can be made in any shape and can provide advantages in the manufacture and/or use of all types of products. For example, the shape of the patch can be contoured or shaped to correspond to a particular area of the user's body that will contact the grip. The patch can be provided in a flat shape or a tubular shape, as described below. The patch likewise can be applied to a product to provide for a stylish appearance, even in areas where contact with a user is unlikely or infrequent. Depending on the product to which the patch is attached, the area14where the patch is attached may or may not be indented. It should be appreciated that flat or sleeve type patches can be used interchangeably where both will fit on a particular area of a product.

The patch10preferably is deformable so that it will closely conform to the fingers of different users. In other applications, the patch also will conform to other parts of a user's body that contact the patch. If the patch is reformable, it is configured to resume its original shape after deformation. In particular, the patch can be deformed and hold its deformed shape for at least 5 seconds before slowly returning to its original shape. Depending on the materials used, the patch may take much longer to return to its original shape or it may stay in its deformed shape. In one embodiment, the patch deforms and will not return to its original shape for 10-60 seconds.

By conforming to the fingers of a user, the patch more evenly distributes pressure and force across the surface of the user's fingers, thereby reducing stress and fatigue and increasing the comfort of the user. One such example is illustrated inFIG. 2A. In other applications, the patch can deform from contact with other parts of the user's body, thereby evenly distributing the force of such contact over a larger area to make such contact more comfortable to the user. The patch can be permanent or temporary and can be easily removed and replaced in applications where such removal and replacement is advantageous.

As shown inFIG. 2, the deformable patch10is closed cell having an upper membrane16and a base18that encapsulate a formable material20. The upper membrane16and base18of the patch10may have rectangular or square shapes. The side edges of the upper membrane16are bonded to the side edges of the base18, thereby creating a flat edge portion22around the patch and a cavity between the membrane and the base. The cavity is filled with the formable material20to facilitate the deformation of the patch10by the displacement of the formable material by a user's fingers or through other contact.

The formable material20can be viscous and can include silicone-based polymers, gels, vinyl elastomers, or any other material of sufficient properties to allow the deformation of the patch10from user contact. Materials can also be used to provide a slow reformation of the original patch shape after it has been deformed and released. In this regard, a silicone gel or other non-cross-linked polymer or uncatalyzed materials may be used. It should be appreciated that the composition of the formable material could be altered for applications in which varied patch characteristics are desired (i.e. more stiffness, durability, more or less deformability and/or longer-lasting deformation). The formable material may be elastically deformed or it may be deformed by displacement, which is the actual movement or flow of the material in response to pressure, such as that from a user's fingertips. In addition, the formable material could be altered for applications in which varied temperature conditions would be encountered during the use of particular products on which the patch is mounted.

The base18can be made of any material, rigid or elastic, including various plastic or metal materials, or it can be made of a membrane formed of thin rubber-based material, deformable plastic or silicone-based materials or other elastomeric materials suitable for a given application. If the base is configured as a flexible membrane, the patch can more easily conform to the product's surface14, thereby increasing the ease with which the patch can be installed, removed, and replaced. Likewise, the upper membrane16also can be made of a thin rubber-based material, deformable plastic or silicone polymer materials, or other elastomeric materials suitable for a given application. If the base and membrane are made of silicone material, both should be from 0.50 mm to 2.5 mm in thickness. In this regard, the base may be a membrane instead of a piece of rigid material. Other thicknesses may be appropriate depending on the material used and the requirements of a particular application.

As shown inFIG. 3, an adhesive can be placed on area24, between the edges22of the upper membrane16and the base18, to bond the base to the membrane. If a glue is used, the formable material20would be placed on the central portion of the base18and glue would be applied to the edges of the base. The upper membrane can then be placed over the formable material so that the edges of the upper membrane align with the edges of the base and pressure can be applied until the glue cures to bond the membrane16to the base18. Such pressure can be applied by a mold, a press, or by hand. If the base and membrane edges do not align, they can be trimmed or cut after the membrane is bonded to the base.

Alternatively, shown inFIG. 4, raw uncatalyzed material can be applied to the area24between the side edges22of the membrane16and base18. The membrane16and base18then can be joined in a press and heated to activate the catalyst to bond the membrane to the base and melt the materials together. If a press is used, the formable material20would be placed on the base18and then the upper membrane would be placed over the formable material. The press would then be operated to apply pressure and heat to form the patch10. The membrane16and the base18may alternatively be formed of uncatalyzed material that is heated in a press until it is in a final, catalyzed state.

As shown inFIGS. 3A and 4A, the patch10alternatively need not have a flat edge portion22, depending on the requirements of a particular application. The edge areas23of the membrane16and the base18can be bonded, as shown inFIG. 3A. Alternatively, the membrane16can be melted to the base18, as shown inFIG. 4A. The patch's edge portion22also could be configured as multiple tabs projecting away from the patch. Further, depending on the application, the edge portion22may be minimized or the upper membrane16may be wrapped under the base18so as to eliminate the edge portion22.

While the way of joining base18with product patch area14can vary depending on the particular application, adhesives can be used on some or all of the bottom surface of the base18or on some or all of the edge portion of the base18. Likewise, some or all of the edge portion22can be mechanically fastened or clamped to the product patch area14. Adhesive tape or a combination of adhesive and mechanical attachment also could be used.

In applications where the patch10is attached to a product by an adhesive, various types of adhesives can be used depending on the type of product surface and the type of base material used. For example, if the base material18of the patch is silicone polymer, then cyanoacrylate glue or 3M Super Silicone brand sealant can be used. In another example, if the product surface14is a thermoplastic material and the base material18of the patch is a polyethylene plastic material, then cyanoacrylate glue or 3M Super Silicone brand sealant can be used.

One type of adhesive that may be used is 3M brand Super silicone sealant, which is a one-component, paste-like material that cures to a tough, elastomeric solid when exposed to atmospheric moisture. This sealant will adhere to clean, bare or painted metal, glass, non-oily wood, abraded rubber and many types of plastics. The sealant is a one-part vulcanizing silicone rubber type having the consistency of a non-sagging paste. It is made of 100% solids and has a net weight of approximately 8.3-8.7 pounds per gallon. This sealant is available in clear, white or black colors. The sealant can be extruded from an 0.125 inch orifice using a pressure of ninety pounds per square inch. Such extrusion results in a flow of approximately 350 gallons per minute.

The silicone sealant is of an acetoxy cure type. In particular, upon exposure to moisture, the silicone sealant will give off small amounts of acetic acid while the sealant cures. It is not recommended that the acetic acid vapors be inhaled. The sealant will cure in 24 hours and has a tack free time of 10-20 minutes at 77° F. (25° C.) with 50% relative humidity. The sealant's tensile strength is approximately 350 psi, its elongation property is 450%, and its hardness is approximately 25-30 Shore A. The sealant has temperature stability from −85° F. to 450° F. (−65° C. to 232° C.) and can withstand intermittent exposure to temperatures as high as 500° F. (280° C.). The sealant is believed to have good resistance to various weathering conditions, including UV radiation, rain, snow, etc., without hardening, cracking, or shrinking.

For optimum adhesion with the above adhesive, the product surface14and the lower surface of the base18should be clean, dry, and free from oil, grease or other foreign material. If necessary, metal surfaces should be wiped with a non-oily solvent. Rubber surfaces should be abraded to promote adhesion. Depending on environmental conditions, the base and product surface should be joined within 5-10 minutes, before the tack-free time of the sealant passes.

The patch10can be used on various products that are manipulated by a user's hands or fingers. For example,FIGS. 10 and 11show the patch10attached to the handle26of a golf club28. In this example, the patch10is long and narrow, thereby allowing it to wrap around the handle of the golf club. The deformable nature of the patch allows the handle of the golf club to closely conform to the hands of the user for a more comfortable grip. The patch can be used on other sports clubs, and, in particular, on the handle30of a hockey stick32or on the handle34of a tennis racquet36, as shown inFIGS. 12,13, and14. As shown inFIG. 13, the patch10is wrapped around the handle32of the hockey stick32. The patch10on the tennis racquet36allows the handle34to closely conform to the hands of the user for a more comfortable grip. The patch10is attached to the handle34of the tennis racquet36in a manner similar to that shown inFIG. 13.

Before proceeding with additional descriptions of the products that incorporate the patch10, it should be appreciated thatFIG. 5shows another embodiment of the patch300having a sleeve-type configuration (described below) that can in most cases be used instead of the patch10. Accordingly, were a patch is referred to by reference number10and a patch300will fit on a particular product, the reference number is intended to refer to both types of patches, and visa versa.

FIG. 15shows the patch10attached to the handle38of a paint brush type painting device40. In this example, the patch10is sized to wrap around the handle of the paint brush. The deformable nature of the patch allows the handle of the painting device to closely conform to the hands of different users for a more comfortable grip. It should be appreciated that the patch can be configured to attach to any type of hand-held painting device, such as roller handles, paint gun handles, or the brush-type device40shown inFIG. 15.

FIG. 16shows the patch10attached to the housing42of a binocular44. In this example, the patch10is sized to wrap around the handle of the painting implement. The deformable nature of the patch allows the handle of the binocular to closely conform to the hands of different users for a more comfortable grip. It should be appreciated that the patch10can be configured to attach to any type of hand-manipulated optical device, such as a telescope, a monocular, or various types of cameras, including 35 mm film cameras, digital cameras, and video cameras.

As shown inFIGS. 17-19, the patch10can be configured to attach to various tools that are manipulated by hand. For example, the patch10can be sized to wrap around the handle46of a saw48. The deformable nature of the patch allows the handle of the saw to closely conform to the hands of different users for a more comfortable grip. The patch10can be sized to attach to one or both of the side walls50of a tape measure housing52. The housing encloses a mechanical tape measure mechanism, but also can enclose an electronic or optical measurement system. The deformable nature of the patch allows the tape measure to closely conform to the hands of different users for a more comfortable grip. The patch10can be sized to wrap around the handle54connected to a shovel head56. The deformable nature of the patch allows the handle of the shovel to closely conform to the hands of different users for a more comfortable grip. The patch10can be attached in one or more locations on the shovel handle54. Alternatively, a rake head, a hoe head or a broom head with a brush can be substituted for the shovel head56. The patch10can be attached to the handles of the saw48and the shovel56in a manner similar to that shown inFIG. 13. It should be appreciated that the patch10can be configured to attach to any type of hand-manipulated tools, such as rakes, hoes, hedge trimmers, power saws, drills, hammers, or other types of tools.

Additional products that incorporate the patch10are shown inFIGS. 20-25. In particular, the patch10can be sized to wrap around the spokes58of a handle60on a faucet62. The deformable nature of the patch allows the handle of the faucet to closely conform to the fingers of different users for a more comfortable grip. The patch10also can be sized to wrap around a door knob64. The deformable nature of the patch allows the door knob to closely conform to the hands of different users for a more comfortable grip. The patch10also can be sized to wrap around the handle66of a lawn mower68or the handle70of a weed trimmer72. The patch10can be attached to the handles of the lawn mower68or the weed trimmer72in a manner similar to that shown inFIG. 13. The deformable nature of the patch allows the handles of the lawn mower68and the weed trimmer72to closely conform to the hands of different users for a more comfortable grip. The patch10can be attached in one or more locations on the weed trimmer handle70.

The patch10can also be attached to the handle74of a vacuum cleaner76. For this application, the patch is wrapped around the vacuum cleaner handle74in a manner similar to that shown inFIG. 13. The patch can be mounted on the handles of other floor cleaning devices, including steam cleaners, floor polishers and carpet shampoo machines. The patch also can be attached to the armrests78of a chair80to provide a comfortable area for a user to rest his or her arms.

Additional products that can incorporate the patch10are shown inFIGS. 26-31. In particular, the patch10can be sized attach to the handle82on a kitchen knife84or to the handle86of a spatula88. The patch10also can be sized to wrap around one or more handles90of a pot92or the handle94of a pan96. It should be appreciated that the patch can be applied to other types of cookware and bakeware. For high-temperature applications where the patch components are made of silicone materials, aluminum oxide may be added to the membrane16, base18, and/or the formable material20so that the patch will survive such elevated temperatures. The aluminum oxide additive may be a 99.99% aluminum oxide sold by the Alfa Aesar company under stock number 39815. Alternatively, other additives may be used to provide durability at higher temperatures, as may be required by a particular application. The patch also can be attached to the dial98on a laundry cleaning machine100, such as a washer or dryer. The deformable nature of the patch allows the handles and dial described above to closely conform to the hands of different users for a more comfortable grip.

FIGS. 32-37show electronic products that can incorporate the patch10. In particular, the patch can be attached to the side102of a remote control104. The patch also can be attached to buttons or knobs106on an audio player108, such as an FM receive or the like. The patch can be attached in one or more locations on the handset110of telephone112, on a mobile phone114, or on a personal digital assistant116, including the sides and rear surfaces. As shown on the personal digital assistant116ofFIG. 35, the patch10can be attached on the sides118of the digital assistant and/or over its buttons120. The patch also can be attached to the sides122of a pager124. The patch could also be attached to the back126of the pager.

FIGS. 38-40show additional products incorporating various-sized patches10, including a joystick128, a computer mouse130and a letter opener132. The joystick has a base134and a pivotably mounted control stick136. Patches can be mounted on one or more surfaces on the control stick, including the side surfaces138and/or the rear surface140. Likewise, a patch can be mounted to the side and/or upper surfaces142and144of the computer mouse. The patch is mounted to the handle146of the letter opener in a manner similar to that shown inFIG. 13.

As shown inFIG. 40A, the patch10can be attached to eyeglasses148to increase the comfort of the user. The eyeglasses have a main body150with lenses152and a bridge154. Arms156extend back from the body to rest on the user's ears. Nose pads158extend downwardly from the body to rest on a user's nose. The patch can be sized for placement on the nose pads and/or the arms, near the area where the user's ears would contact the arms.

As shown inFIG. 41, one or more patches10can be attached to the handle160of a firearm162. Patches can be mounted on one ore more surfaces of the firearm handle, including on the side surfaces164and/or the rear surface166. The patch on the rear surface of the firearm handle can cushion the user against recoil from firing the weapon.

As shown inFIGS. 42 and 43, patches10of suitable sizes can be attached to office products, including on a stapler168and a scissors170. A rectangular patch is mounted to the upper surface172of the stapler. One or more patches also can be mounted to the handles174of the scissors. Other products that incorporate patches10are shown inFIGS. 44-47, including clippers176, tweezers178, a toothbrush180, and an electric hair dryer182. With regard to the clippers, the patch is mounted to the lower surface184. The patch is mounted to each side surface186of the tweezers. The patch can be mounted on one or more sides of the handle188of the toothbrush. The patch can be mounted on one or more sides190of the handle192of the electric hair dyer, and/or on its rear handle surface194.

As shown inFIG. 48, patches10of suitable sizes can be attached to various parts of an automobile interior, including wrapped around a steering wheel196, on a shifter198, on an armrest200. The patch also can be attached to a seat202, and in particular on the seat back204and/or on the seat bottom206. The patch can also be applied decoratively to other portions of the interior.

As shown inFIG. 49, one or more of the patches10can be attached to a glove208. The glove has a palm portion210that includes a patch10. The glove also has finger portions212that each include a patch10. Finally, the glove has a thumb portion214that also includes a patch10mounted thereon.

The patch10also can be used on safety equipment, as is shown inFIGS. 50-52.FIG. 50shows an elbow guard216that has two straps218and a guard plate220. The straps can be adjustable or elastic so as to fit over the arms of a user. The patch10is attached to the guard plate to cushion impacts.FIG. 51shows a knee guard222that has a strap224and a guard plate226. The patch10is mounted on the guard plate. The patch also can be used on shin guards.FIG. 52shows a helmet228that has a strap230and a helmet body232and/or the strap. One or more patches10can be mounted to the helmet body. Examples of helmets that can be fitted with the patch are bicycle, motorcycle, football, baseball and hockey helmets. As shown inFIGS. 53 and 54, the patch10also can be attached to bicycle components. In particular, the patch can be mounted to bicycle handlebars234and/or a bicycle seat236.

As shown inFIGS. 55 and 56, the patch can be attached to a cup238and/or mug240. The cup238has a curved body with an exterior surface242to which one or more patches10can be attached. The patch may extend all the way around the exterior surface of the cup. Likewise, the mug240has a curved exterior surface244with a handle246. Patch10is mounted to the handle246. Aluminum oxide can be added to the patch materials to provide for increased survivability in high temperature environments, such as dishwashers.

FIG. 57shows a deformable athletic mouthguard248. The mouthguard is filled with formable material20and has a cross-section similar to that shown inFIG. 3A. The upper membrane16and the base18are made of flexible silicone material having a thickness sufficient to resist rupturing from dental pressure.

FIG. 58shows a camera250that includes two deformable patches10. The camera has an optical lens assembly252to capture images. An activation button254is located on the top of the camera and a flash until256is located adjacent to the lens assembly. The patches10can alternatively be configured to have, increased width near the lens assembly, so as to provide increased room for the user's fingers. The dotted lines inFIG. 58represent his optional patch size. It should be appreciated that the patch10could be mounted on cameras of any type, including digital and tape video cameras, still cameras and other optical recording devices.

A dental tool258incorporating the deformable patch10is shown inFIG. 59. The dental tool has a hard pointed end260for treating teeth. Aluminum oxide can be added to the patch material to increase the patch's resistance to high sterilization temperatures. Various shaped deformable patches can be attached to various dental tools, including drills, polishers, x-ray equipment, work station patches, and the like.

FIG. 60shows the patch10attached to the handle262of a hammer264. In this example, the patch10is sized to wrap around the handle of the hammer. The hammer has a metal head266configured to drive nails or the like. It should be appreciated that the patch can be configured to attach to any type of hand-held hammer device, such as a sledge hammer, ball-peen hammers, or mallets. The patch can likewise be applied to other tools that have handles.

FIG. 61shows an embodiment of the patch10that has a arc-like, or accurate, curved shape. Such a curved shape is well suited to receiving the user's fingertips, which tend to make contact with objects not in a straight line, but instead along a curved “footprint.” The components of this patch10are the same as those described above and shown inFIG. 2. The patch has an optional edge portion22that can be configured as shown inFIG. 3or4. Alternatively, the edge portion can be configured as shown inFIG. 3Aor4A. A patch of this shape can be placed on a variety of products having differently shaped surfaces while still maintaining a generally curved area that is sized to accommodate the natural placement of the user's fingertips.

Next, several alternative ways of attaching the patch10to the product12will be discussed.FIG. 62shows an embodiment of the patch10and product12wherein the patch fits within a cavity268with an opening270. The opening of the cavity is defined by overhanging edges272. Adhesive may be used to hold the patch in the cavity, as may be required by a particular application. In addition, the overhanging edges need not be integral parts of the product12. Instead the overhanging edges may be separate parts attached to the product12.

FIG. 63shows an alternative configuration for the edge portion22of the patch10. In particular, the edge portion may be configured to have a “T” shaped end274. The “T” shaped end fits in a corresponding “T” shaped channel276in the surface of the product12. Although the “T” shaped end and channel may adequately fasten the patch to the product, adhesive or mechanical fasteners may also be used.

FIG. 64shows yet another alternative configuration for the edge portion22of the patch10. In particular, the edge portion may be configured to have an “L” shaped end278that fits in a corresponding “L” shaped channel280in the surface of the product12. Although the “L” shaped end and channel may adequately fasten the patch to the product, adhesive or mechanical fasteners may also be used, such as screw282, which fits into hole284.

FIG. 65shows yet another alternative method for attaching the edge portion22of the patch10to the product12. In particular, the edge portion may be held between a rectangular member286and a corresponding channel288in the surface of the product12. Adhesive or mechanical fasteners may also be used to compress the edge portion between the member and the channel, such as screw290, which fits into hole292.

FIG. 66shows yet another alternative method for attaching the edge portion22of the patch10to the product12. In particular, the edge portion may be held between a rod294and a corresponding channel296in the surface of the product12. The channel has overhanging edges298. Adhesive or mechanical fasteners may also be used to compress the edge portion between the member and the channel, but the rod also may be sized to snap between the overhanging edges298of the channel296.

FIGS. 67 and 68show an alternative steering wheel grip400that can be substituted for the steering wheel grip ofFIG. 48. In particular, the grip has a flexible upper membrane16and a flexible membrane base18, with the formable material20located therebetween. The grip400is mounted on the upper portion of the steering wheel402. Although the steering wheel is shown as hollow in cross section, the grip may be mounted on a solid steering wheel or other steering wheel designs. Each edge portion of the grip has an indented “L” shaped end404that conforms to a mating surface406on the steering wheel. A mounting strip408fastened by screws410holds the “L” shaped ends of the side portion against the mating surface406of the steering wheel. A series of holes412sized to accept the screws is located along the underside of the upper portion of the steering wheel. The holes preferably are spaced about 1 inch apart. The mounting strip can be flexible or rigid. The grip400has two ends414, each of which is held to the steering wheel by a circular ring416. The grip400can be formed by an extrusion process and the ends414of the grip400can be formed by bonding the upper membrane to the base so as to enclose the formable material. The ends414of the grip look similar to the ends330of the sleeve shown inFIG. 5. The thickness of the formable material20preferably is 0.1 to 0.150 inch and the thickness of the upper membrane16preferably is 0.05 inch. The above described materials may be used for the grip400.

A tubular patch embodiment300is shown inFIGS. 5-9. This sleeve300is suitable for attachment to products, such as a pen302or a pencil304with handles that are cylindrical or that otherwise have a curved or oval cross-section. The sleeve300preferably is deformable so that it will closely conform to the fingers of different users. If the sleeve is configured to resume its original shape, the sleeve can be deformed and hold its deformed shape for at least 5 seconds before slowly returning to its original shape. However, depending on the materials used, the sleeve may take much longer to return to its original shape or it may stay in its deformed shape. By conforming to the fingers of each user, the sleeve evenly distributes pressure to the user's fingers, thereby reducing stress and fatigue and increasing the comfort of the user. The sleeve can be permanent or temporary and can be easily removed and replaced in applications where such removal and replacement is advantageous.

As shown inFIGS. 6 and 7A, the deformable sleeve300is closed cell having an outer membrane306and an inner base308that cooperatively encapsulate a formable material310, like that described above. The base and membrane can be formed of any suitable material, including those described above. As shown inFIGS. 8 and 9, the sleeve can be attached to writing instruments, such as a pen302or a pencil304. The sleeve300can be attached to other manual implements that have handles suitable for receiving the tubular-shaped patch300.

FIGS. 7A and 7Billustrate the assembly of the sleeve300. The sleeve can be formed by folding a long tubular member312. The member312can be made of molded silicone material and has a larger diameter portion314and a smaller diameter portion316separated by a transition area318, as shown inFIG. 7B. In order to form the sleeve300ofFIG. 7A, the smaller diameter portion316is pulled inside the larger diameter portion314until the end320of the smaller diameter portion is aligned with the end322of the larger diameter portion. This can be accomplished by placing the end of a cylindrical tool (not shown) inside the end320of the smaller diameter portion316and then by moving the larger diameter portion314toward the tool and the end of the smaller diameter portion. The tool may be tapered so as to fold the end of the smaller diameter portion radially inwardly, into a position where the end forms a 180° fold and points toward the end of the larger portion. The larger diameter portion is then moved relatively to the smaller portion so the folded end of the smaller portion moves inside the larger portion until the end of the smaller portion is aligned with the end of the larger portion, there by forming one end324of the sleeve300ofFIG. 7A. The other end326of the sleeve300has a 180° fold328and thus does not need any bonding or fastening in order to hold the formable material310. If the smaller diameter portion316is made of rigid material, the larger diameter portion could be folded 180° radially outwardly and pulled over the smaller diameter portion.

When the ends320and322of the smaller and larger diameter portions316and314are aligned, the larger diameter portion314forms the outer membrane306and the smaller diameter portion316forms the base308. The cavity for the formable material310is located in the radial space between the base and the outer membrane, which are positioned in a concentric relationship. A small tube350can be used to inject the formable material310between the ends320and322of the portions and into the cavity. In order to allow air bubbles to escape, the folded end328of the sleeve300can be placed below the other end324of the sleeve. When the formable material310has filled the cavity, the tube350is removed and the ends of the larger and smaller portion can then be sealed by heat or adhesive, as described above. In addition, before the open end324of the sleeve300is sealed, a mold may be used to squeeze the outer membrane306so as to drive any trapped air out of the sleeve prior to sealing. Alternatively, the sleeve300can be formed by placing uncatalyzed material in a press, filling the uncatalyzed material with formable material, and then heating the uncatalyzed material in a heat press to form inner and outer membranes306and308.

The length of the smaller diameter portion316can be slightly longer than that of the larger diameter portion314so as to create flat edge portions330at either end of the sleeve300. When assembled, the sleeve300has a radially inner surface332that preferably is cylindrical so as to fit over a product such as a writing instrument body. The sleeve can be held in place by simple friction fit, by adhesives or by mechanical fasteners that hold the flat edge portions330at the ends of the sleeve300. It should be appreciated that, depending on the application, the sleeve may be configured so that the edge portions330are minimized or even eliminated. The sleeve need not have such flat edge portions, depending on the requirements of a particular application. Mechanical fasteners may be used to hold the sleeve300even if it is configured without flat edge portions330. The sleeve's edge portions330also could be configured as multiple tabs projecting away from each end of the sleeve. The sleeve can be formed by extruding, molding, or other suitable manufacturing processes.

Because the patches identified above can be made with colored materials, the patches can be used to provide an aesthetically pleasing product appearance without much additional increase to the manufacturing cost of the product. In addition, in particular applications such as in the chair ofFIG. 25, the patches can provide a comfortable surface for a user to rest his or her arms.

While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Thus, although the invention has been described in detail with reference only to the preferred embodiments, those having ordinary skill in the art will appreciate that various modifications can be made without departing from the invention. Accordingly, the invention is not intended to be limited, and is defined with reference to the following claims.