Gel-foam body amalgamation system and method

A gel-foam body amalgamation system including a vacuum lift-table; a gel heating metal lift-table; a gel foam fusion lift-table; an overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a foam core body; an intermediary foam core body; a vacuum lift-table cover; a gel heating metal lift-table cover; and a gel foam fusion lift-table. A method of operating the gel-foam body amalgamation system for producing a dual-core foam body amalgamate including a foam core body and an intermediate foam core body. In another embodiment, a gel body amalgamation system including a vacuum table; a heating metal table, a fusion table; and overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a core body; an intermediary core body. A method including a core body and an intermediate core body for producing a dual-core body amalgamate.

FIELD OF THE DISCLOSURE

The disclosure of the present invention relates to a gel-foam body amalgamation system and method of using the gel-substrate amalgamation system to form a dual-core foam body amalgamate. The dual-core foam body amalgamate can be implemented for use in mattresses, cushions, seats, pads, pillows, stuffed toys, and a variety of types of supportive items. The disclosure of the present invention, also, relates to a core body amalgamation system and method of using the core body amalgamation system to produce a dual-core body amalgamate implemented in producing mattresses, cushions, seats, pillows, stuffed animals, and a variety of supportive items. The disclosure of the present invention, also, relates to methods for manufacturing the dual-core foam body amalgamate and the dual-core body amalgamate without requiring the use of a traditional metal mold.

DESCRIPTION OF THE RELATED ART

Healthcare and household mattresses, as well as seat cushions, pads, and other varieties of cushioned supports have increasingly utilized gel to achieve desired levels of comfort and support. Some known products have integrated such gel with a supportive foam of the type conventionally employed in mattresses and other products for supporting humans and pets.

Known methods for manufacturing supports employing both gel and foam exhibit a variety of shortcomings. Typically, the gel must first be extruded, injected, or poured into and shaped by large and expensive metal molds. These molds are usually large and quite heavy. As a result, they are difficult to maneuver into position and properly secure during the molding operation. Extracting the cooled and formed gel from the mold can also be difficult and time consuming. Moreover, the size of the molded gel support is strictly limited by the size of the available metal mold. After the gel is molded, further problems are encountered securing the gel to one or more layers of foam. Cured gel is unable to adhere directly to the foam. As a result, the gel usually must first be heat bonded to a thin textile layer of scrim. This requires the purchase and maintenance of additional manufacturing material which results in additional manufacturing steps and resultant expenses. Conventional gel support products also tend to be vertically unstable and are apt to buckle outwardly when a large load is applied. This is undesirable and can significantly reduce the usefulness, support, and lifespan of the product.

SUMMARY

The disclosure and claims herein are directed to a gel-foam body amalgamation system and method producing a dual-core foam body amalgamate. The gel-foam body amalgamation system, comprises a vacuum lift-table; a gel heating metal lift-table; a gel foam fusion lift-table; an overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a foam core body; an intermediary foam core body; a vacuum lift-table cover; a gel heating metal lift-table cover; and a gel foam fusion lift-table cover. The foam core body is manipulated whereby a series of a plurality of extended cubes are carved within the bottom core body portion of the foam core body by way of a contour saw, wherein each of the extended cubes of the series of the plurality of extended cubes are configured in symmetrical alignment a first distance from each other aligned in a plurality of rows and a plurality of columns interconnected by a plurality recessed channels bordered by an adjourned peripheral rim, wherein each of the plurality of extended cubes is configured with a cube thickness which is less than the thickness of the foam core body. The gel heated foam core body is pressed against the intermediary foam body having the gel cure to form the dual-core foam body amalgamate.

The gel-foam body amalgamation system includes a hood including a lift and place framework with a plurality of perforations allowing for a vacuum generated flow of air to suction the foam core body enabling movement and placement of the foam core body during the operation of the gel-foam body amalgamation system for producing the gel-foam body amalgamation system.

The gel-foam body amalgamation system includes a heater device into the gel-heating metal lift-table and integrated with a high strength MXene layers to provide increased thermal conductivity and metal conductivity. MXenes, a class of transition metal carbon/nitride two-dimensional (2D) materials, have attracted significant attention due to theft excellent mechanical properties, metallic conductivity, and rich chemical properties.

In one exemplary embodiment the foam core body is comprised of polyurethane, viscoelastic, or latex foam, or blends thereof. The foam core body can be any type of foam known in the art having a porous characteristic. In another exemplary embodiment, the foam core body is comprised of a plurality of layers of foam materials.

In one exemplary embodiment the gel is an elastomeric non-soy gel but could be any type of gel known known in the art. In one exemplary embodiment, the process of the method of manufacturing the dual-core foam body amalgamate described herein also represents a significant improvement over conventional techniques for manufacturing gel and foam support cushions because adhesive interconnection is not required between the foam and gel components. Rather, the extended cubes and its recessed channels carved into the foam core body are dipped into a heated gel bath and, in a next step positioned atop an intermediary foam core body to form a dual-core foam body amalgamate. This allows the gel to effectively bond directly between the plurality of heated gel extended cubes and a borderline top surface of the intermediary foam core body as the gel cures. This eliminates the need to use scrim and adhesives in order to bond the foam to the gel. Considerable time and expense are thereby saved. Moreover, an improved, more stable and comfortable dual-core foam body amalgamate is achieved. Nonetheless, it should be understood that scrim may still be applied to the composite above the gel component for use in different applications.

In another embodiment of the disclosure and claims herein are directed to a core body amalgamation system and method producing a core body amalgamate. The core body amalgamation system includes a vacuum table; a heating metal table, a fusion table; and overhead double-beam bridge crane; a hood conveyor apparatus; a hood; a core body; an intermediary core body.

The core body amalgamate is manipulated whereby a series of a plurality of extended protuberates are carved within the bottom core body portion of the core body by way of a contour saw, wherein each of the extended protuberant of the series of the plurality of extended protuberates are configured in symmetrical alignment a first distance from each other aligned in a plurality of rows and a plurality of columns interconnected by a plurality recessed channels bordered by an adjourned peripheral rim, wherein each of the plurality of extended protuberant is configured with a thickness which is less than the thickness of the core body. The extended protuberates are coated with a colloidal material and fused with an intermediary core body to form the core body amalgamate. The extended protuberates can be contoured in any one of a geometric shape, coils, helix, double helix, arcuate shape customized for a particular dual-core body amalgamate.

In this exemplary embodiment, the core body achieves improved effective support and comfort. The receptacles may be formed in the foam base portion in different number, size, depth, and layout in order to achieve various comfort and support levels and characteristics. The extended protuberates can be contoured in any one of a geometric shape, coils, helix, double helix, arcuate shape customized for a particular dual-core body amalgamate.

In an exemplary embodiment of the disclosure the colloidal matter is selected from any one of the colloidal matter comprising any one of a gelatinous matter that is characterized to consist of two phases that are intertwined with one another having a solid particle network and a liquid solvent.

The core body and the intermediate core body can be manufactured with a material selected from anyone of the group comprising, foam, silicone, vinyl foam, rubber, polyethylene, polyethylene terephthalate, polyvinyl alcohol, polypropylene, polystyrene, polycarbonate, polyamide, and resins based on any combinations thereof.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever convenient, similar reference numbers will be used throughout the drawings to refer to the same or like parts. The implementations set forth in the following description do not represent all implementations consistent with the claimed invention. Instead, they are merely some examples of systems and methods consistent with the invention.

Embodiments of a gel-foam body amalgamation system, a method of making a dual-core foam body amalgamate implementing the gel foam body amalgamation system in accordance with embodiments of the present disclosure are described with reference to the accompanying drawings, includingFIGS.1-2,4-18.

Embodiments of a core body amalgamation system for producing a dual-core body amalgamate implementing the core body amalgamation system in accordance with embodiments of the present disclosure are described with reference to the accompanying drawings, includingFIGS.3and17.

Embodiments of a Kit of a gel-foam body amalgamation system kit in accordance with embodiments of the present disclosure are described with reference to the accompanying drawings, includingFIG.18.

FIG.1is a front perspective view of a gel-foam body amalgamation system including an overhead double-beam bridge crane, a conveyor apparatus shown with a vacuum lift-table, a gel heating metal lift-table, a gel foam fusion lift-table, according to an embodiment of the present invention.

FIGS.1-2,4-16Eillustrates a gel-foam body amalgamation system and method according to an embodiment of the present invention.FIG.1is a front perspective view of a gel-foam body amalgamation system10including an overhead double-beam bridge crane18integrated with a hood conveyor apparatus20with a hood22, a vacuum lift-table12, a gel heating metal lift-table14, a gel foam fusion lift-table16, according to an embodiment of the present invention.

The gel-foam body amalgamation system10is implemented by an operator to form a dual-core foam body amalgamate600as shown inFIGS.5A,8and15E. Implementation of the gel-foam body amalgamation system10can be operated manually by an operator, directed by manual operations performed by the operator. In another embodiment of the gel-foam body amalgamation system10, the implementation of the gel-foam body amalgamation system10can be automated by an automated operation system. In another embodiment of the gel-foam body amalgamation system10the implementation of the gel-foam body amalgamation system10can be directed by a smart system including a surveillance system including a wireless fidelity and short range wireless fidelity (bluetooth) and a computer device system, as discussed, below.

With reference toFIGS.1,2,4-5A,6-8,15A-15E, the gel-foam body amalgamation system10comprises a vacuum lift-table12; a gel heating metal lift-table14; a gel foam fusion lift-table16; an overhead double-beam bridge crane18; a hood conveyor apparatus20; a hood22; a foam core body24; an intermediary foam core body26; gel87; three table covers32,34,36, including a vacuum lift-table cover32, a gel heating metal lift-table cover34, and a gel foam fusion lift-table cover36. The gel-foam body amalgamation system10is implemented with a gel extruder28; and a gel supply well30, as illustrated inFIG.5A.

As used herein, the term “foam” encompasses, but is not limited to, solid porous foams, reticulated foams, water-disengradeable foams, open-cell foams, closed-cell foams, foamed synthetic resins, cellulosic foams, natural foams, polyurethane foams, viscoelastic foams, high density foam, memory foam, and latex foams. In one embodiment the foam used for foam base portion12has an Indentation Force Deflection (“IFD”) of from about 3 to about 70.

As used herein, the term “gel” encompasses, but is not limited to, a viscoelastic or Semi-solid, jelly-like state assumed by a colloidal dispersion or a substantially dilute cross-linked system. The term “gel” encompasses a three-dimensional polymeric structure that itself is insoluble in a particular liquid but which is capable of absorbing and retaining large quantities of the liquid to form a stable, often soft and pliable, but to one degree or another a high density shape-retentive structure. When the liquid is water, the gel is typically referred to as a hydrogel. The gel may also contain additives that affect the properties of the gel. Examples of suitable additive that increase the heat absorbing properties of the gel include boron, talc, quartz, aluminum sulfate, diamond dust.

FIGS.1-2,4-5A,6depicts embodiments of the vacuum lift-table12. The vacuum-lift table12comprises a silicone table structure including a rigid silicone table top38, a rigid silicone table bottom40, a rigid front facing silicone wall42, a rigid rear facing silicone wall44, a rigid first silicone side wall46, an opposing rigid second silicone side wall48, the rigid silicone table top38is integrated with a plurality of table perforations501+Nextending therethrough the rigid silicone table bottom40.

The rigid silicone table top38is dimensioned with a surface area of at least 84×76 inches. In this manner, the vacuum lift-table can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

With reference toFIGS.1-2,4-5A, the vacuum lift-table12is depicted illustrating the rigid silicone table top38of the vacuum lift-table12integrated with a plurality of table perforations501+Nextending from the rigid silicone table top38therethrough the rigid silicone table bottom40. The plurality of table perforations501+N aresymmetrically aligned a distance apart from each other in rows and columns extending the entirety of the rigid silicone table top38and therethrough to the rigid silicone bottom40.

As shown inFIGS.1-2,4-6, the vacuum lift-table12is supported by four insulated table support columns52,54,56,58, disposed beneath the rigid silicone table top38including a first front insulated table support column52, a second front insulated table support column54, a first back insulated table support column56, a second back insulated table support column58. The four insulated table support columns52,54,56,58of the vacuum-lift table12are integrated with a vacuum table hydraulic lift device60whereby the vacuum lift-table12is lowered and raised being actuated by a vacuum lift-table controller621disposed on the second front insulated table support column54. An operator can select a customized operator height position of the vacuum lift-table. In this manner the operator can work at a comfortable position and has easy access to the vacuum lift-table12and the hood22taking in consideration the height of the operator, the length of the operator's arms, whether the operator is seated in a chair, or a wheelchair. The vacuum-lift table12, the gel heating metal lift-table14, and the gel foam fusion-lift-table meet ANSI/ASME standards (American National Standards/American Society of Mechanical Engineers) standards. The vacuum table hydraulic lift device60, a gel heating table hydraulic lift device84(discussed, below), and a gel foam fusion hydraulic lift device184(discussed below) can be acquired from a commercial vendor (BALEIGH Industrial Holdings, https://baleigh.com; GRAINGER, https://grainger.com; and other mechanical engineering product companies.

The vacuum lift-table is manufactured with a rigid silicone material, and each of the four insulated table support columns52,54,56,58can be insulated with a rubber material, or a silicone material. In this exemplary embodiment the vacuum lift-table is insulated and protected against any probability of sparks of electricity emanating from the gel heating metal lift-table14.

The vacuum lift-table controller621can include a microcontroller having wireless fidelity chip and/or a microcontroller having short range wireless (bluetooth) capabilities so that the operator can maneuver the raising and lowering of the vacuum lift-table by way of a smart device in communication with a computing device. The smart device can include a smart phone, a mobile computer device, or a computer device system with a controller, a tablet personal computer, a laptop computer, smart watch, and the like, with which embodiments may be practiced. The mobile computing device is illustrative of any suitable device operative to send, receive and process wireless communications by way of wireless fidelity or short range wireless fidelity (bluetooth). A display screen can be provided for operative displaying information and images of the gel-foam body amalgamation system10computer-executable instructions readable by a computing device. Data input to the device can be performed via a variety of suitable means, such as, touch screen input via the display screen, keyboard or keypad input via a data entry area, key input via one or more selectable controls or icons. Data may be output via the device by way of any suitable output means, including but not limited to, display on the display screen. Each of the mobile smart device and the computing device can include a processor of a general purpose computer processor for processing incoming and outgoing data, communications and operation instructions, manufacturer software applications which can be uploaded on the operator's smart device to manage each of the method steps of the method of the gel-foam body amalgamation system10where feasible.

With reference toFIGS.1,5A, and7, the gel heating metal lift-table14of the gel-foam body amalgamation system10includes a metal table structure including a flat metal table top64, a flat metal table bottom66, a front facing flat metal wall68, a rear facing flat metal wall70, a first lateral flat metal side wall72, an opposing second flat metal lateral side wall74.

The gel heating metal lift-table14of the gel-foam body amalgamation system10is supported by four insulated metal columns76,78,80,82supporting the metal table structure including a first front insulated table metal column76, a second front insulated table metal column78, a first back insulated table metal column80, a second back insulated table metal column82integrated with a gel heating table hydraulic lift device84whereby the gel heating metal lift-table14is lowered and raised being actuated by a gel heating metal lift-table controller622wherein an operator can select the customized operator height position of the gel heating metal lift-table14. In this manner the operator can work at a comfortable position and has easy access to the gel heating metal lift-table14and the hood22taking in consideration the height of the operator, the length of the operator's arms, whether the operator is seated in a chair, or a wheelchair.

In another, embodiment, the vacuum lift-table controller621, gel heating metal lift-table controller622and the gel foam fusion lift-table controller623can include a user input device, such as a remote controller for adjusting the height of the vacuum lift-table12, the gel heating metal lift-table14and the gel foam fusion lift-table16. The remote controller may include one or more icons operable to set the height of each of the three tables12,14,16. For example, the remote controller may include a raise button operable to raise the height of each of the three tables12,14,16, and a lower icon operable to lower the height of each of the three tables12,14,16. The remote controller may be in operational electrical communication with the vacuum lift-table controller621, gel heating metal lift-table controller622, and the gel foam fusion lift-table controller623such as the remote controller to control the height of the vacuum lift-table12. The remote controller can be configured to operationally communicate with the vacuum lift-table controller621wirelessly with a smart device. The smart device can include a computer network or a smart phone connected to the user's wireless fidelity (WiFI) or short range wireless fidelity network (bluetooth).

Each of the four insulated table support columns52,54,56,58can be insulated with any of the materials selected from the group comprising, rubber, silicone, thermoplastic, thermoset polyester composite. In this exemplary embodiment the gel heating metal lift-table14is insulated and protected against any probability of sparks of electricity emanating from the gel heating metal lift-table14.

The gel heating metal lift-table controller622can include a microcontroller having wireless fidelity chip and/or a microcontroller having bluetooth look up generic name of bluetooth capabilities so that the operator can maneuver the raising and lowering of the gel heating metal lift-table14by way of a smart device in communication with the microcontroller. With reference toFIGS.1,5A,7,12-14the gel heating metal lift-table14of the gel-foam body amalgamation system10includes a metal gel basin88to provide a vessel to contain a predetermined volume of the gel87and to provide a vessel in which to heat the gel87to be implemented in the formation of the dual-core foam body amalgamate600as depicted inFIGS.5A,8, andFIG.15E. The metal gel basin88is permanently attached on an upside of the flat metal table top64of the gel heating metal lift-table14by way of welding wherein the metal gel basin88is co-planar with the metal flat metal table top64of the gel heating metal lift-table14.

The metal gel basin88includes a cavity104to contain a predetermined volume of gel incorporated in a gel bath90. The predetermined volume of gel is dependent upon the size of the foam core body24. The metal gel basin88the gel heating metal lift-table14is configured with a metal floor92bound by four upright perimetric metal walls wherein the top flat surfaces of each of the four upright perimetric metal walls96,98,100,102provides a peripheral rectangular top metal rim94to the metal gel basin88. The four perimetric metal walls including a front facing metal wall96, a rear facing metal wall98, and two lateral facing metal walls100,102, a first lateral metal side wall100and a second lateral metal side wall102enclosing the gel bath90.

The cavity104of the metal gel basin88is configured with a cavity opening dimensioned to receive the foam core body24. The metal floor92is dimensioned with a surface area of at least 84×76 inches to accommodate a variety of sizes of the foam core body24. 84×76 inches. In this manner, the metal floor92can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

FIG.12, with reference toFIGS.1,5A and7, the metal gel basin88of the gel heating metal lift-table14includes a thermally conductive layered core having a copper plate107, wherein the copper plate107includes a superior side108and an inferior side110wherein each of the superior side108and the inferior side110is adhered to at least two layers of MXene1122+Nsuch that a copper plate MXene layered core114is formed wherein the copper plate MXene layered core114is integrally metallurgically bonded intermediate with a first stainless steel plate layer116and a second stainless steel plate layer118by way of a bonding application to form a multilayered steel copper MXene composite142wherein the thermal conductivity is increased by the multilayered steel copper MXene composite142. The MXene comprises a MXene material sheet of Ti3C2Txwherein T is a titanium atom, C is a Carbon atom and T is terminal functional atom selected from the group comprising an oxygen atom “O”, a hydroxy group “OH”, and a fluorine atom “F”. MXene films and MXene sheets are commercially available through:Nano Chemazone Catalog.cdr at Nanochemazone®| Premium Nanomaterials Manufacturer and Supplier, Alberta, Canada. https://nanochemazone.com.

In recent years, MXene has caught much attention as a novel material that has a high electrical conductivity and a high thermal conductivity. Global attention is currently focused on energy and environmental challenges. Electric vehicles and stationary batteries both require high-capacity energy conversion/storage systems, while the present energy conversion and storage techniques such as batteries, water splitting, and supercapacitors are being advanced. MXenes are also very interesting in this context as they are relatively safe, have broad interlayer spacing, are environmentally flexible, and have excellent biocompatibility.

MXenes, a broad family of the 2D transition-metal carbides or nitrides, was recently developed by Drexel University researchers. The generic formula for MXenes is Mn+1XnTx(n=1-3), where M stands for the transition metals (i.e., Ti, Zr, Ta, Nb, V, Mo, etc.) and X represents the carbon or nitrogen elements. Typically, MXenes are synthesized from the layered-structure MAX-phase bulk ceramic using fluoride-based chemicals to selectively etch (usually groups IIIA and IVA) layers, and their basal faces are frequently terminated with special surface functionalities (Tx), such as O, OH, and F. Due to their exceptional conductivity and the presence of abundant surface functionalities, MXenes with highly adjustable structural and chemical forms can perform both as fundamental active materials and carriers of additional functional materials for a variety of applications, such as photodetectors, flame-retardant polymer materials, water purification, energy conversion and storage, sensors, electro-magnetic interference shielding, gas separation, biomedical imaging and therapy, and catalysis.

As a result of their wide range of potential in the realms of energy conversion and storage, MXenes have astonished the scientific community. 2D materials MXenes exhibit good hydrophilicity, film-forming performance, and electrical conductivity. They are commonly used in supercapacitors, electro-magnetic radiation shielding, and lithium-ion batteries. MXenes refers to MnXn−1(n=2, 3, and 4) layers formed by removing interlayer “A” atoms from the metal-ceramic MAX phase (where M stands for the transition metals, A is the group IIIA or IVA elements, and X represents the C and N elements). The M and X atoms stack to form a hexagonal lattice in the MAX phase, with the atoms of X occupying the M octahedral cage center shared by its edges. When the atoms of A are removed from the layer of MnXn−1, the hexagonal-lattice of MX, rather than the cubic lattice, is preserved. Hence, the layer of MnXn−1can be produced by removing the A− atoms. As with its predecessor MAX, MXenes thin sheets are frequently oriented horizontally. The bulk of MXenes have good mechanical features and are likely to be quite durable.

Very recently, Chen et al. reported the fabrication of a fluoride-free and chloride-containing Ti3C2TxMXene film via electrochemical etching. In the synthesis process, Ti3C2Txwas delaminated via sonication in the absence of any toxic organic intercalant. The thickness of the resultant Ti3C2Txnanoflakes was −3.9 nm and their dispersion in an aqueous medium was very highly stable. The pattern of the Ti3C2Txdisplays hexagonal symmetry as a result of the hexagonal arrangement of the Ti-atoms at the 002 surface of Ti3C2TxMXene. The lattice fringe, with d-spacing of 0.27 nm, can be accredited to 100 planes of the Ti3C2TxMXene. See, Chen et.al.,High-strength MXene sheets through interlayer hydrogen bonding for self-healing flexible pressure sensor. Chemical Engineering Journal, Volume 453, Part 1, 1 Feb. 2023. Chen et.al., incorporated by reference in its entirety.

MXene is one of a two-dimensional materials and is a layered material (n) comprising a plurality of layers, each layer having a crystal lattice which is represented by M.sub.n+1X.sub.n (wherein M is at least one metal of Group 3, 4, 5, 6, or 7 Metal, (X) is a carbon atom and/or a nitrogen atom, and (n) is 1, 2, or 3), and in which each (X) is positioned within an octahedral array of (M), and having a terminal (or modifier) (T) such as a hydroxy group, a fluorine atom, an oxygen atom, or a hydrogen atom on the surface of each layer.

MXene coatings have been shown to be prepared on steel by simple spin coating with a colloidal suspension yielding a corrosion resistance by way of the MXene coatings. In particular, MXene (Ti3C2Tx) nanosheets prepared by the spin coating and etching form a 2D single-layer structure. The MXene coatings provides an anticorrosion physical barrier. Increasing the number of spin coatings, also, increases the coating thickness and anticorrosion properties of the steel. MXene can include a layered material wherein each layer includes a crystal lattice.

With reference toFIGS.1,5A, and7, the metal gel basin88includes a gel supply pipe inlet port120. The gel supply pipe inlet port120is disposed at a corner portion of the front facing wall96of the metal gel basin88. As depicted inFIG.7, the gel supply pipe inlet port120is capable of receiving a gel supply pipe122fluidly connected to a gel supply well30in cooperation with a gel extruder28to enable a stream of gel871entering the metal gel basin88. The gel supply pipe122facilitates passing of the stream of gel871from a front interior facing wall to a rear interior facing wall of the metal gel basin88to reach the predetermined volume of gel871.

The predetermined volume of gel871is indicated by a measurement bar148etched on a surface of the front interior facing wall of the metal gel basin88. The operator, also, views the measurement bar148to replenish a reduced gel volume to the predetermined volume of gel871after completion of the operation of making the dual-core foam body amalgamate600as depicted inFIGS.5A,8andFIG.15E.

The control of the flow of the stream of gel871therethrough the gel supply pipe122is controlled by a valve544, as shown inFIGS.5A and7. The valve544is operationally configured on the gel supply pipe122proximate to the gel supply well30. The valve544is open by maneuvering the valve544to be parallel to the gel supply pipe122and wherein the valve544is closed by maneuvering the valve544to be perpendicular to the valve544.

Opening the valve544of the gel supply pipe122causes the stream of gel871to flow into the metal gel basin88of the gel heating metal lift-table14, and closing the valve544causes the stream of gel871to cease flowing into the metal gel basin88of the gel heating metal lift-table14.

As shown inFIGS.1,5A and7, the gel heating metal lift-table14includes at least one variable frequency drive pump124. The at least one variable frequency drive pump124is configured to deliver a pressure of 300 horse power. The at least one variable frequency drive panel125is disposed proximate to the flat metal table bottom66of the gel heating metal lift-table14, the at least one variable frequency drive pump124including at least one in-line pipe126running parallel to the flat metal bottom of the gel heating metal lift-table14.

The at least one variable frequency drive pump124of the gel heating metal lift-table14includes a front end1261and a rear end1262wherein the front end1261of the at least one-inlet pipe126is connected to an at least one in-line pipe inlet port128centrally disposed within the front facing metal wall of the metal gel basin88, as shown inFIGS.5A and7. The at least one in-line pipe inlet port128is fluidly cooperative with the cavity104of the metal gel basin88. The rear end1262of the at least one-outlet pipe126is connected to an at least one in-line pipe outlet port130centrally disposed within the rear facing flat metal wall of the metal gel basin88such that a variable frequency pressure is pumped therethrough the at least one in-line pump pipe126into the gel bath90by way of the at least one variable frequency drive pump124whereby the predetermined volume of gel87is mixed and circulated and recirculated from the front interior facing wall to the rear interior facing wall of the metal gel basin88and therethrough the at least one in-line pipe126.

The at least one variable frequency drive pump124is controlled by a variable speed drive controller125of the at least one variable frequency drive pump124to regulate the speed of the variable pressure forced into the gel87within the gel bath90. The variable speed drive controller125of the at least one variable frequency drive pump124includes a control panel with an “ON” operating mode switch127and an “OFF” operating mode switch129, a pressure switch133, a flow switch135, and a level switch139.

As depicted inFIGS.13and14, the gel heating metal lift-table14includes at least one planar heater device1321+N.FIG.13illustrates four planar heater devices1321,1322,1323,1324fixedly attached to the flat metal table bottom66of the gel heating metal lift-table14by way of metal bolted connectors1371+N. Each of the at least one planar heater device1321+Nincludes an electric conductive metal plate1501-4including a first electric conductive metal plate1501, a second electric conductive metal plate1502, a third electric conductive metal plate1503and a fourth electric conductive metal plate15014. Each of the four electric conductive metal plates1501,1502,1503,1504includes two electrodes1341-8being electrically conductive and operationally electrically connected to an electrical connector which is connected to a power source136.

As shown inFIG.13, the first electric conductive metal plate1501includes a first electrode1341and a second electrode1342; the second electric conductive metal plate1502includes a third electrode1343and a fourth electrode1344; the third electric conductive metal plate1503includes a fifth electrode1345and a sixth electrode1346; the fourth electric conductive metal plate1504includes a seventh electrode1347and an eighth electrode1348. Each of the eight electrodes1341-8is connected to an electric connector1511+Nwherein each of the electric connectors is operationally electrically connected to the power source136by way of an electrical conduit wherein the electrical conduit137is insulated in a non-electric conductive ultrahigh molecular weight polyethylene tube138. The at least one planar heater device1321+Nbeing mounted and fixedly attached externally to an exterior surface the flat metal table bottom66of the gel heating metal lift-table14provides a controlled temperature which is generated to enable by way of thermal conduction of the copper plate MXene composite layer of the metal gel basin88to heat the gel87to a heated liquid gel871or to cool the heated liquid gel871of the gel bath90contained in the metal gel basin88. The controlled temperature of the is regulated by a temperature controller131operatively electrically connected to the at least one planar heater device1321+N.

In one exemplary embodiment the gel87is heated to a temperature within a range to include 225° F. to about 400° F.

As illustrated inFIG.14, with reference toFIG.13, each of the electric conductive metal plates1501,1502,1503,1504, of each of the at least one planar heater device1321+Nincluding the first planar heater device1321, the second planar heater device1322, the third planar heater device1323, and the fourth heater planar device1324is layered in a film1521+4encased in a sheathing1541−4.

The film1521+4is selected from MXene coating156includes a MXene film EE Ti3C2Txwherein the MXene Film film including a MXene film Ti3C2Txwherein Tis a titanium atom, C is a Carbon atom and T is terminal functional atom selected from the group comprising an oxygen atom “O”, a hydroxy group “OH”, and a fluorine atom “F”. The MXene film is provided in a multilayered high-strength film or sheets. The MXene provides high electrical conductivity and a high thermal conductivity. MXene films and MXene sheets are commercially available through Nano Chemazone Catalog.cdr at Nanochemazone®| Premium Nanomaterials Manufacturer and Supplier, Alberta, Canada. https://nanochemazone.com.

Each of the sheathings1541−4includes a framework configured with a sheathing opening155to slidably receive each of the electric conductive metal plates1501,1502,1503,1504. Each of the sheathings1541−4provides protection for the electric conductive metal plates1501,1502,1503,1504and each coating1541−8provided on each of the electric conductive metal plates1501,1502,150,1504.

Each of the sheathings1541−4can be made from any one of the materials selected from the group comprising: polyethylene, terephthalate, polyvinyl alcohol, polypropylene, polystyrene, polycarbonate, polyethylene, polyamide, resins and combinations thereof.

With reference toFIGS.1,5A and8, the gel foam fusion lift-table16includes a table structure including a rigid non-slip non-perforated table top164and a rigid non-slip non-perforated table bottom166joined by four rigid walls including a rigid front facing non-slip wall front facing rigid non-slip wall168, a rigid rear facing non-slip wall170, a first rigid non-slip side wall172and an opposing second rigid non-slip side wall174joined at four corners. The rigid non-slip table top164and the rigid non-slip table bottom166is non-perforated. The rigid non-slip table top164is dimensioned with a surface area of at least 84×76 inches. In this manner, the gel foam fusion lift-table16can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

The gel foam fusion lift-table16is supported by four insulated table support columns176,178,180,182including a first front insulated table support column176, a second front insulated table support column178, a first back insulated table support column180and a second back insulated table support column182wherein the four insulated table support columns176,178,180,182are integrated with a gel foam fusion hydraulic lift device184whereby the gel foam fusion lift-table16is lowered and raised being actuated by a gel foam fusion lift-table controller623. With this exemplary embodiment, the operator can select the customized operator height position of the gel foam fusion lift-table16. In this manner the operator can work at a comfortable position and has easy access to the gel foam fusion lift-table16and the hood22taking in consideration the height of the operator, the length of the operator's arms, whether the operator is seated in a chair, or a wheelchair.

The rigid non-slip table top164of the gel foam fusion lift-table16is dimensioned with a surface area of at least 84×76 inches. In this manner, the vacuum lift-table can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

The operations of the gel-foam body amalgamation system10is implemented with the foam core body24and intermediary foam core body26. As depicted inFIGS.5A-7and15A, the foam core body24is configured with a thickness, a length, and a width, a top core body portion186and a bottom core body portion188wherein the top core body portion186includes a top side1861having a flat top porous surface and the bottom core body portion188having a bottom side1881having a flat bottom porous surface.

As know by a person having ordinary skill in the art, the gel-foam body amalgamation system10alternative core bodies can be implemented in an alternative to the foam core body24. The gel-foam body amalgamation system10can be implemented with core bodies including, silicone, foam, silicone, vinyl foam, rubber, polyethylene, polyethylene terephthalate, polyvinyl alcohol, polypropylene, polystyrene, polycarbonate, polyamide, and resins and any combinations thereof.

The top core body portion186and the bottom body core portion188are joined by two lateral porous side walls190,192a first lateral porous side wall190and a second opposing lateral side wall192and two longitudinal porous side walls194,196a front longitudinal porous side wall194, and a rear longitudinal porous side wall196. The foam core body24is dimensioned wherein the top core body portion186includes a square footage equal to the square footage of the bottom core body portion188.

The foam core body24is manipulated to include a series of a plurality of extended cubes1981+N, as shown inFIGS.5A-8, and more particularly, inFIGS.15B-15C, and15E, which are carved within the bottom core body portion188of the foam core body24by way of a contour saw (not shown). Each of the extended cubes1981+Nof the series of the plurality of extended cubes1981+Nare configured in symmetrical alignment a first distance from each other aligned in a plurality of rows2001+Nand a plurality of columns2021+Ninterconnected by a plurality recessed channels2041+Nbordered by an adjourned peripheral rim206, wherein each of the plurality of extended cubes1981+Nis configured with a cube thickness which is less than the thickness of the foam core body24.

The foam core body24and manufacturing the dual-core foam body amalgamate600as described herein provide a number of benefits. The top core body portion186of the foam core body24itself acts as the mold for the gel87. The cost and complexity of utilizing a conventional metal mold is thereby eliminated. The need for tooling a metal mold is also eliminated. The composite support is not limited in size and configuration by available mold length limitations. Significantly, the considerable effort normally required to remove the gel87from the mold is no longer needed. Moreover, no additional materials or steps are needed to adhere the gel87to the plurality of extended cubes501+Nand a border-line portion of the exterior surface of the recessed channels of the bottom core body portion188of the foam core body24. The heated gel is cured and bonded to and ready for virtually immediate use with the foam core body24providing the mold.

As depicted inFIGS.5A,8, and more particularly,FIGS.15A-15E, the intermediary foam core body26, is configured to be fused with the foam core body24to form a dual-core foam body amalgamate600as depicted inFIGS.5A,8andFIG.15E. The intermediary foam core body26is dimensioned with a square footage equal to the square footage of the foam core body24. The intermediary foam core body26includes a flat top facing wall210and a flat bottom facing wall212joined by four side walls including a flat front wall214, a flat rear wall216, joined by two flat lateral side walls218,220, a first porous flat lateral side wall218and an opposing second flat lateral side wall220wherein the flat top facing wall210includes a top porous layer and the flat bottom facing wall212includes a bottom porous layer.

The intermediary foam core body26is dimensioned with a length, a width, a thickness, an intermediary foam core body square footage which is equal to the thickness, the length, the width, and the core body square footage of the foam core body24. In this manner the intermediary foam core body26aligns symmetrically with the foam core body24to form the dual-core foam body amalgamate600, as depicted inFIGS.5A,8andFIG.15E.

As know by a person having ordinary skill in the art, the gel-foam body amalgamation system10alternative intermediary core bodies can be implemented in an alternative to the intermediary foam core body26. The gel-foam body amalgamation system10can be implemented with material which is selected from anyone of the group comprising, foam, silicone, vinyl foam, rubber, polyethylene, polyethylene terephthalate, polyvinyl alcohol, polypropylene, polystyrene, polycarbonate, polyamide, and resins based on any one of them. and any combinations thereof.

The gel-foam body amalgamation system10includes the overhead double-beam bridge crane18, as depicted inFIGS.1-8, is configured to support the hood conveyor apparatus20allowing the hood22to steadily travel along a front I-beam bridge242and a rear I-beam bridge244to each of the vacuum lift-table12, the gel heating metal lift-table14, and the gel foam fusion lift-table16during the operation of producing the dual-core foam body amalgamate600.

The overhead double-beam bridge crane18is fortified by four upright metal box columns222,224,226,228, a first upright metal box column222, a second upright metal box column224, a third upright metal box column226, a fourth upright metal box column228, and a first metal link beam230, a second metal link beam232. A front end2301of the first metal link beam230is fixedly attached to a top end2221of the first upright metal box column222by way of a first bolted column end plate234and a rear end2302of the first metal link beam230is fixedly attached to a top end2261of the third upright metal box column226by way of a second bolted column end plate236. A front end2321of the second metal link beam232is fixedly attached to a top end2241of the second upright metal box column224by way of a third bolted column end plate238and a rear end2322of the second metal link beam232is fixedly attached to a top end2281of the fourth upright metal box column228by way of a fourth bolted column end plate240.

With reference toFIGS.1-5A, the two I-beam bridges242,244of the overhead double-beam bridge crane18include the front I-beam bridge242and the rear I-beam bridge244. The front I-beam bridge242and the rear I-beam bridge244are fixedly attached a predetermined distance apart and parallel to each other oriented oligomeric to the first metal link beam230and the second metal link beam232. A first end2421of the front I-beam bridge242is fixedly attached by way of a first bolted I-beam end plate246to a first trolley end stop248disposed at the front end2301of the first metal link beam230and an opposing second end2422of the front I-beam bridge242is fixedly attached to a second trolley end stop250disposed at the front end2321of the second metal link beam232by way of a second bolted I-beam end plate252. A first end2441of the rear I-beam bridge244is fixedly attached to a third trolley end stop254disposed at the rear end2302of the first metal link beam230by way of a third bolted I-beam end plate256and an opposing second end2442of the rear I-beam bridge244is fixedly connected to a fourth trolley end stop258disposed at the rear end2322of the second metal link beam232by way of a fourth I-beam end plate260. By way of this construction of the front I-beam bridge242and the rear I-beam bridge244fixedly attached to the first metal link beam230and the second metal link beam232a major framed open space is circumscribed to abide the vacuum lift-table12, the gel heating metal lift-table14, the gel foam fusion lift-table16and the hood22being supported by the hood conveyor apparatus20, as depicted inFIGS.1and5A.

To facilitate the movement of the hood conveyor apparatus20, as depicted inFIGS.1-5A, the two I-beam bridges242,244of the overhead double-beam bridge crane18are in working operation with four trolleys262,264,266,268, a first trolley262, a second trolley264, a third trolley266, a fourth trolley268, wherein the first trolley262is operationally coupled to the front I-beam bridge242by way of a first trolley carriage270and the second trolley264is operationally coupled to the front I-beam bridge242by way of a second trolley carriage274, the third trolley266operationally coupled to the rear I-beam bridge244by way of a third trolley carriage276and the fourth trolley268operationally coupled to the rear I-beam bridge244by way of a fourth trolley carriage278.

As depicted inFIG.5B, as applied toFIGS.1-5A,6-8, each of the first trolley carriage270of the first trolley262and the second trolley carriage274of the second trolley264is configured with a first set of at least six radial rollers2801-6, a first set of at least four side rollers2821-4and a second set of at least six radial rollers2841-6, a second set of at least four side rollers2861-4to operationally couple each of the first trolley262and the second trolley264to the front I-beam bridge242, respectively, and whereby the first trolley262and the second trolley264are each moveably operational along a length of the front I-beam bridge242by way of each of the first set of at least six radial rollers2801-6and the first set of at least four side rollers2821-4of the first trolley carriage270of the first trolley262and the second set of at least six radial rollers2841-6and the second set of at least four side rollers2861-4of the second trolley carriage274of the second trolley264.

The first trolley carriage270of the first trolley262is in working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. In particular, the first trolley carriage270, the first set of the at least six radial rollers first set of at least six radial rollers2801-6of the first trolley carriage270of the first trolley262includes a series of three anterior radial rollers2801-3which is coplanar with a series of three posterior radial rollers2803-6wherein the set of three anterior radial rollers2801-3of the first trolley carriage270of the first trolley262are oriented to come in contact with an anterior side flat bearing surface288of a front I-beam track2901of the front I-beam bridge242and the three posterior radial rollers2803-6of the first trolley carriage270of the first trolley262are oriented to come in contact with a posterior side flat bearing surface292of a rear I-beam track2902of the front I-beam bridge242.

In addition, the first set of the at least four side rollers2821-4, as depicted inFIG.5B, of the first trolley carriage270of the first trolley262includes two anterior side rollers2821-2which are coplanar with two posterior side rollers2823-4. The two anterior side rollers2821-2includes a first anterior side roller colinear2821with a second anterior side roller2822. The first anterior side roller2821is operationally attached at a first anterior cut-out lead portion2941of the first trolley carriage270of the first trolley262and the second anterior side roller2822is operationally attached at an opposing second anterior cut-out lead portion2942of the first trolley carriage270of the first trolley262.

Continuing with the first trolley262, the opposing second anterior cut-out lead portion2942of the first trolley carriage270of the first trolley262is configured at a first lateral distance from the first anterior cut-out lead portion2941of the first trolley carriage270. The first anterior side roller2821and the second anterior roller2822is oriented to come in line contact with an anterior side perpendicular bearing wall296of the front I-beam bridge242. The two posterior side rollers2823-4includes a first posterior side roller2823and a second posterior side roller2824. The first posterior side roller2823is operationally attached at a first posterior cut-out lead portion2981of the first trolley carriage270and the second posterior side roller2824is operationally attached at an opposing second posterior cut-out lead portion2982of the first trolley carriage270, the opposing second posterior cut-out lead portion2982is configured at a second lateral distance from the first posterior cut-out lead portion298of the first trolley carriage270of the first trolley262. The first posterior side roller2823and the second posterior roller2842is oriented to come in line contact with an anterior side perpendicular bearing wall296of the front I-beam bridge242.

The first lateral distance between the first anterior cut-out lead portion2941and the second anterior cut-out lead portion2942is equal to the second lateral distance between the first posterior cut-out lead portion2981and the second posterior cut-out lead portion2982of the first trolley carriage270to enable an equalizing balance of the two anterior side rollers2821-2and the two anterior side rollers and the two posterior side rollers2823-4against the anterior side perpendicular bearing wall296and a posterior side perpendicular bearing wall302of the front I-beam bridge242of the overhead double-beam bridge crane18.

The first posterior side roller2823and the second posterior side roller2824of the first trolley carriage270of the first trolley262are each oriented to come in line contact with the posterior side perpendicular bearing wall302of the front I-beam bridge242, wherein when the two anterior side rollers2821-2and the two posterior side rollers2823-4of the first trolley carriage270of the first trolley262concomitantly come in contact against the anterior side perpendicular bearing wall296and the posterior side perpendicular bearing wall302of the front I-beam bridge242, respectively, the first trolley carriage270of the first trolley262is movably constrained to enable a steady horizontal movement of the first trolley carriage270of the first trolley262along the front I-beam bridge242moving in either direction towards the first trolley end stop248or towards the second trolley end stop250.

The second trolley carriage274of the second trolley264are in working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. The second set of at least six radial rollers2841-6of the second trolley carriage274of the second trolley264includes a series of three anterior radial rollers2841-3of the second trolley carriage274of the second trolley264which is coplanar with a second series of the three posterior radial rollers2803-6of the second trolley carriage274of the second trolley264wherein the series of three anterior radial rollers2841-3of the second trolley carriage274of the second trolley264are oriented to come in contact with the anterior side flat bearing surface288of the front I-beam track290of the front I-beam bridge242and the three posterior radial rollers2803-6of the second trolley carriage274of the second trolley264are oriented to come in contact with the posterior side flat bearing surface292of the rear I-beam track2902of the front I-beam bridge242of the overhead double-beam bridge crane18.

The second trolley carriage274of the second trolley274includes the second set of the at least four side rollers2861-4that is working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. The second set of the at least four side rollers2861-4of the second trolley carriage274of the second trolley264includes two anterior side rollers2861-2of the second trolley carriage274of the second trolley264which are coplanar with two posterior side rollers2863-4of the second trolley carriage274of the second trolley264.

The two anterior side rollers2861-2of the second trolley carriage274of the second trolley264includes a first anterior side roller2861of the second trolley carriage274of the second trolley264colinear with a second anterior side roller2862of the second trolley carriage274of the second trolley264. The first anterior side roller2861of the second trolley carriage274of the second trolley264is operationally attached at a first anterior cut-out lead portion3041of the second trolley carriage274of the second trolley264and the second anterior side roller2862of the second trolley carriage274is operationally attached at an opposing second anterior cut-out lead portion3042of the second trolley carriage274of the second trolley264. The opposing second cut-out lead portion3042of the second trolley carriage274being configured at a lateral distance from the first anterior cut-out lead portion3041of the second trolley carriage274of the second trolley264. The first anterior side roller2861and the second anterior side roller2862of the second trolley carriage274of the second trolley264is oriented to come in line contact with the anterior side perpendicular bearing wall296of the front I-beam bridge242.

In addition, the two posterior side rollers2863-4of the second trolley carriage274of the second trolley264includes a first posterior side roller2863and a second posterior side roller2864. The first posterior side roller2863of the second trolley carriage274of the second trolley264is operationally attached at a first posterior cut-out lead portion3061of the second trolley carriage274of the second trolley264and the second posterior side roller2864is operationally attached at an opposing second posterior cut-out lead portion3062of the second trolley carriage274of the second trolley264.

The first posterior side roller2863and the second posterior side roller2864of the second trolley carriage274of the second trolley264are each oriented to come in line contact with the posterior side perpendicular bearing wall302of the front I-beam bridge242, wherein when the two anterior side rollers2863-4of the second trolley carriage274of the second trolley264and the two posterior side rollers2863-4of the second trolley carriage274of the second trolley264concomitantly come in contact against the anterior side perpendicular bearing wall296and the posterior side perpendicular bearing wall302of the front I-beam bridge242, respectively, the second trolley carriage274of the second trolley264is movably constrained to enable a steady horizontal movement of the second trolley carriage274of the second trolley264along the front I-beam bridge242moving in either direction towards the first trolley end stop248or towards the second trolley end stop250.

Similarly, the third trolley266includes the third trolley carriage276and the fourth trolley268includes the fourth trolley carriage278in working operation with the rear I-beam bridge244of the overhead double-beam bridge crane18. The third trolley carriage276of the third trolley266and the fourth trolley carriage278of the fourth trolley268is configured with a third set of at least six radial rollers3081-6, a third set of at least four side rollers3101-4and a fourth set of at least six radial rollers3121-6, a fourth set of at least four side rollers3141-4, to operationally couple each of the third trolley266and the fourth trolley268to the rear I-beam bridge244, respectively. In this manner, the third trolley266and the fourth trolley268are each moveably operational along a length of the rear I-beam bridge244by way of the six radial rollers3081-6and the four side rollers3141-4, fixedly attached to the third trolley carriage276and the fourth trolley carriage278, respectively.

The third trolley carriage276of the third trolley266includes the third set of the at least six radial rollers3081-6band includes a series of three anterior radial rollers3081-3which is coplanar with a series of three posterior radial rollers3083-6. The three anterior radial rollers3081-3of the third trolley carriage276are oriented to come in contact with an anterior side flat bearing surface316of a rear I-beam track318of the rear I-beam bridge244and the three posterior radial rollers3083-6are oriented to come in contact with a posterior side flat bearing surface320of the rear I-beam track318of the rear I-beam bridge244.

The third set of the at least four side rollers3101-4of the third trolley carriage276of the third trolley266includes two anterior side rollers3101-2which are coplanar with two posterior side rollers3103-4. The two anterior side rollers3101-2includes a first anterior side roller3101colinear with a second anterior side roller3102wherein the first anterior side roller3101is positioned at a first anterior cut-out lead portion3241of the third trolley carriage276of the third trolley266. The second anterior side roller3102is positioned at an opposing second cut-out lead portion3242of the third trolley carriage276of the third trolley266.

The first anterior side roller3101and the second anterior side roller3102of the third trolley carriage276of the third trolley266is oriented to come in line contact with an anterior side perpendicular bearing wall3261of the rear I-beam bridge244. The second set of two posterior side rollers two posterior side rollers3103-4includes a first posterior side roller3103and a second posterior side roller3104of the third trolley carriage276of the third trolley266. The first posterior side roller two posterior side rollers3103is positioned at a first posterior cut-out lead portion3281of the third trolley carriage276of the third trolley266and the second posterior side roller3104is positioned at an opposing second posterior cut-out lead portion3282of the third trolley carriage276of the third trolley266. The first posterior side roller3103and the second posterior side roller3104are each oriented to come in line contact with a posterior side perpendicular bearing wall3261of the rear I-beam bridge224, wherein when the two anterior side rollers3261-2and the two posterior side rollers3263-4of the third trolley carriage276of the third trolley266concomitantly come in contact against the anterior side perpendicular bearing wall3261and the posterior side perpendicular bearing wall3262of the rear I-beam bridge244, respectively, the third trolley carriage276of the third trolley266is movably constrained to enable a steady horizontal movement of the third trolley carriage276of the third trolley266along the rear I-beam bridge224moving in either direction towards the third trolley end stop254or towards the fourth trolley end stop258.

The fourth trolley carriage278of the fourth trolley268includes at least six radial rollers3121-6and the least of four side rollers3141-4in working operation with the rear I-beam bridge224of the overhead double-beam bridge crane18. The at least six radial rollers3121-6of the fourth trolley carriage278of the fourth trolley268includes a series of three anterior radial rollers3121-3which is coplanar with a series of three posterior radial rollers3124-6. The set of three anterior radial rollers3121-3are oriented to come in contact with the anterior side flat bearing surface316of a rear I-beam track318of the rear I-beam bridge244and the three posterior radial rollers3124-6are oriented to come in contact with the posterior side flat bearing surface320of the rear I-beam track318of the rear I-beam bridge244.

The at least of four side rollers3141-4of the fourth trolley carriage278of the fourth trolley268includes two anterior side rollers3141-2which are coplanar with two posterior side rollers3123-4. The two anterior side rollers3141-2includes a first anterior side roller3141colinear with a second anterior side roller3142of the fourth trolley carriage278of the fourth trolley268wherein the first anterior side roller3141is positioned at a first anterior cut-out lead portion3301of the fourth trolley carriage278of the fourth trolley268and the second anterior side roller3142is positioned at an opposing second anterior cut-out lead portion3302of the fourth trolley carriage278of the fourth trolley268. The first anterior side roller3141and the second anterior side roller3142of the fourth trolley carriage278of the fourth trolley268is oriented to come in line contact with the anterior side perpendicular bearing wall3261of the rear I-beam bridge244.

The two posterior side rollers3123-4, includes a first posterior side roller3123and a second posterior side roller3124of the fourth trolley carriage278of the fourth trolley268wherein the first posterior side roller3123is positioned at a first posterior cut-out lead portion3321of the fourth trolley carriage278of the fourth trolley268and the second posterior side roller3124is positioned at an opposing second posterior cut-out lead portion3322of the fourth trolley carriage278of the fourth trolley268, the opposing second posterior cut-out lead portion3322.

The first posterior side roller3123and the second posterior side roller3124are each oriented to come in line contact with the posterior side perpendicular bearing wall3262of the rear I-beam bridge244wherein when the two anterior side rollers3121-2and the two posterior side rollers3123-4of the fourth trolley carriage278of the fourth trolley268concomitantly come in contact against the anterior side perpendicular bearing wall3261and the posterior side perpendicular bearing wall3262of the rear I-beam bridge224, respectively, whereby the fourth trolley carriage278of the fourth trolley268is movably constrained to enable a steady horizontal movement of the fourth trolley carriage278of the third trolley266along the rear I-beam bridge224moving in either direction towards the third trolley end stop254or towards the fourth trolley end stop258of the rear I-beam bridge224.

As depicted inFIGS.1-2,4-5A,6-8, the gel-foam body amalgamation system10includes a hood conveyor apparatus20configured with structural and utilitarian frames to support the hood22as the hood22moves in a horizontal direction to each of the vacuum lift-table12, the gel heating metal lift-table14, and the gel foam fusion lift-table16and in a vertical upward direction and downward direction during the operation of the gel-foam body amalgamation system10in the formation of the dual-core foam body amalgamate600, with reference toFIG.15E.

The hood conveyor apparatus20, as depicted inFIGS.1-2,4-5A,6-8, includes an upper conveyor frame334and a lower conveyor frame338coplanar to each other fixedly joined to an anchorage conveyor frame336. The anchorage conveyor frame336is configured having a rectangular shaped structure being disposed in a transverse plane between the upper conveyor frame334and the lower conveyor frame338whereby a minor framed open space is circumscribed within the major framed open space to abide for the hood conveyor apparatus20.

The anchorage conveyor frame336includes a front joist340and a rear joist342, a first lateral side joist344, an opposing second lateral side joist346, a front cross bar360, a rear cross bar362, and four lifting masts364,366,368,370vertically oriented wherein the front joist340and the rear joist342are each fixedly attached to the first lateral side joist344and the opposing second lateral side joist346by way of four joist hanger brackets348,350,352,354whereby four corners of the anchorage conveyor frame336are formed.

A first lifting mast356of the anchorage conveyor frame336includes a superior end3561and an inferior end3562. The superior end3561of the first lifting mast356is fixedly bolted to a first joist end3401of the front joist340of the anchorage conveyor frame336by way of a first joist hanger bracket358and the inferior end3562of the first lifting mast356is fixedly bolted to a first end3601of the front cross bar360by way of a first iron face plate372.

A second lifting mast374of the anchorage conveyor frame336includes a superior end3741and an inferior end3742. The superior end of the second lifting mast374is fixedly bolted to a second end of the front joist340of the anchorage conveyor frame336by way of a second joist hanger bracket376and the inferior end3742of the second lifting mast374is fixedly bolted to a second end3602of the front cross bar360by way of a second iron face plate378.

A third lifting mast380of the anchorage conveyor frame336includes a superior end3801and an inferior end3802wherein the superior end3801of the third lifting mast380is fixedly bolted to a first end3421of the rear joist342of the anchorage conveyor frame336by way of a third joist hanger bracket382and the inferior end3802of the third lifting mast380is fixedly bolted to a first end of the rear cross bar362of the anchorage conveyor frame336by way of a third iron face plate384.

A fourth lifting mast386of the anchorage conveyor frame336includes a superior end3861and an inferior end3862wherein the superior end3861of the fourth lifting mast386is fixedly bolted to a second end3422of the rear joist342of the anchorage conveyor frame336by way of a fourth joist hanger bracket388and the inferior end3862of the fourth lifting mast386is fixedly bolted to a second end3622of the rear cross bar362of the anchorage conveyor frame336by way of a fourth iron face plate390.

The upper conveyor frame334of the hood conveyor apparatus20includes four overhead metal posts392,394,396,398which are vertically oriented, including a first overhead metal post392, a second overhead metal post394, a third overhead metal post396, a fourth overhead metal post398.

The first overhead metal post392of the upper conveyor frame334is positioned coaxial to the of first lifting mast356of the anchorage conveyor frame336. A first end3921of the first overhead metal post392is fixedly bolted to the first trolley262by way of a first trolley adapter connector400and a second end3922of the first overhead metal post392is fixedly bolted to a first end portion3401of the front joist340of the anchorage conveyor frame336by way of a first post mount bracket402.

The second overhead metal post394the upper conveyor frame334is positioned coaxial to the second lifting mast374of the anchorage conveyor frame336. A first end3941of the second overhead metal post394is fixedly bolted to the second trolley264by way of a second trolley adapter connector404and a second end3942of the second overhead metal post394is fixedly bolted to a second end portion3402of the front joist340of the anchorage conveyor frame336by way of a second post mount bracket406.

The third overhead metal post396the upper conveyor frame334is positioned coaxial to the third lifting mast380of the anchorage conveyor frame336. A first end3961of the third overhead metal396post is fixedly bolted to the third trolley266by way of a third trolley adapter connector408and a second end3962of the third overhead metal post396is fixedly bolted to a first end3421portion of the rear joist342of the anchorage conveyor frame336by way of a third post mount bracket410.

The fourth overhead metal post398of the upper conveyor frame334is positioned coaxial to the fourth lifting mast386of the anchorage conveyor frame336. A first end of the fourth overhead metal post398is fixedly bolted to the fourth trolley268by way of a fourth trolley adapter connector414and a second end3982of the fourth overhead metal post398is fixedly bolted to a second end portion3422of the rear joist342of the anchorage conveyor frame336by way of a fourth post mount bracket416.

The lower conveyor frame338of the hood conveyor apparatus20includes four lower support posts420,422,424,426being vertically oriented, a first lower support post420, a second lower support post422, a third lower support post424, a fourth lower support post426.

The first lower support post420of the lower conveyor frame338is positioned coaxial with the first lifting mast356. A first end of the first lower support post420is fixedly attached to the first end3601of the front cross bar360of the anchorage conveyor frame336by way of the first iron face plate372and a second end4202of the first lower support post420is fixedly attached to a first corner portion4281of a front facing rim wall428of the hood22by way of a first iron mounting plate430.

The second lower support post422of the lower conveyor frame338is positioned coaxial with the second lifting mast374. A first end4221of the second lower support post422is fixedly attached to the second end3602of the front cross bar360of the anchorage conveyor frame336by way of the second iron face plate378and a second end4202of the second lower support post422is fixedly attached to a second corner portion4282of the front facing rim wall428of the hood22by way of a second iron mounting plate432.

The third lower support post424of the lower conveyor frame338is positioned coaxial with the third lifting mast380. A first end4241of the third lower support post424is fixedly attached to the first end3621of the rear cross bar362of the anchorage conveyor frame336by way of the third iron face plate384and a second end4242of the third lower support post424is fixedly attached to a first corner portion4341of a rear facing rim wall434of the hood22by way of a third iron mounting plate384.

The fourth lower support post426of the lower conveyor frame338is positioned coaxial with the fourth lifting mast386. A first end4261of the fourth lower support post426is fixedly attached to the second end3622of the rear cross bar362of the anchorage conveyor frame336by way of the second iron face plate378and a second end4262of the fourth lower support post426is fixedly attached to the second corner portion4342of the rear facing rim wall434of the hood22by way of a fourth iron mounting plate436. Each of the first lower support post420, the second lower support post422, the third lower support post424, the fourth lower support post426is integrated with a rack and pinion gear system4441-4including a first rack and pinion gear system4441, a second rack and pinion gear system4442, a third rack and pinion gear system4443, a fourth rack and pinion gear system4444, respectively; wherein each of the rack and pinion gear systems4441-4includes, a lift carriage4461-4, a gear rack4481-4mechanically operative with a mateable pinion4501-4, operatively connected to a first lateral axle452, and operatively connected to a second lateral axle454.

Each of the lift carriages4461-4includes each of the gear rack4481-4which is vertically oriented and centered between a first linear guide4561+Nand a second linear guide4581+Nof each of the lift carriages4461-4, each of the gear racks4481-4having an upward end4601+Nand a downward end4621+Nwith a plurality of gear rack teeth4641+Ntherebetween.

Each of the mateable pinions4501-4is configured with a plurality of pinion teeth476circumferentially aligned around a pinion crown4801-4to enable an operable rotatable mesh between each of a corresponding plurality of gear rack teeth4641+Nof each of the gear racks4481-4of each of the first rack and pinion gear system4441, a second rack and pinion gear system4442, a third rack and pinion gear system4443, a fourth rack and pinion gear system4444, each of the mateable pinions4501-4include a pinion borehole4781-4transversely configured therethrough each of the pinion crowns4801+N.

The first lateral axle452is positioned a first vertical below and parallel to the first lateral side joist344of the anchorage conveyor frame336and the second lateral axle454is positioned a second vertical distance below and parallel to the opposing second lateral side joist346of the anchorage conveyor frame336such that the first lateral axle452and the second lateral axle454are symmetrically aligned parallel to each other.

A first end of the first lateral axle452is rotationally coupled to a first pinion borehole4781of the first mateable pinion4501of a first gear rack4481of the first rack and pinion gear system4441integrated with the first lower support post420and a second end of the first lateral axle452is rotationally coupled to a third pinion borehole4783of a third gear rack4483of the third rack and pinion gear system4443integrated with the third lower support post424, and a first end of the second axle454is rotationally coupled to a second pinion borehole4782of a second mateable pinion4502of a second gear rack4482of the second rack and pinion gear system4442integrated with the second lower support post422and a second end of the second lateral axle454is rotationally coupled to a fourth pinion borehole4784of a fourth mateable pinion4504of a fourth gear rack4484of the fourth rack and pinion gear system4444integrated with the fourth lower support post426such that as the hood22is lowered and raised the lateral first axle452and the second lateral axle454synchronously causes the first mateable pinion4501and the third mateable pinion4503, the second matealbe pinion4502and the fourth mateable pinion4504to rotate in unison enabling the operable rotatable mesh between each of a first plurality of pinion teeth4761of a first mateable pinion4501and a first plurality of gear rack teeth4641(1+N)of the first gear rack4481of the first rack and pinion gear system4441, a second plurality of pinion teeth4762of a second mateable pinion4502and a second plurality of gear rack teeth4642(1+N)of a second gear rack4482of the second rack and pinion gear system4442, a third plurality of pinion teeth4763of a third mateable pinion4503and a third plurality of gear rack teeth4643(1+N)of a third gear rack4483of the third rack and pinion gear system4442, a fourth plurality of pinion teeth4764of a fourth mateable pinion4504and a fourth plurality of gear rack teeth4644(1+N)of a fourth gear rack4484of the fourth rack and pinion gear system4444, in a vertical direction from each of the gear rack's4481-4downward ends462to their upward ends460or from each of the gear racks4481-4upward end460their downward end462.

As illustrated inFIGS.1-2,4-5A,6-8, the anchorage conveyor frame336provides structural support for two spring loaded handles438,440which provides a safe means to maneuver the hood22as the hood22moves in a horizontal direction to each of the vacuum lift-table12, the gel heating metal lift-table14, and the gel foam fusion lift-table16and in a vertical upward direction and downward direction during the operation of the gel-foam body amalgamation system10in the formation of the dual-core foam body amalgamate600, as depicted inFIGS.5A,8andFIG.15E.

The first spring loaded handle438is pivotally attached to the front cross bar360of the anchorage conveyor frame336and a second spring loaded handle440is pivotally attached to the rear cross bar362of the anchorage conveyor frame336whereby the first spring loaded handle438and the second spring loaded handle440is maneuvered to operationally raise and lower the hood22in a vertical direction and to urge the hood22in a horizontal direction along each of the front I-beam bridge242and concomitantly along the rear I-beam bridge244.

The gel-foam body amalgamation system10includes the hood22, as shown inFIGS.1-2,4-5A, andFIGS.6-8. The hood22, includes a metal rectangular pyramid structure including four cohesive triangular metal panels4661-4being integrally welded together forming an apex468and a rectangular base configured with a top opening at the apex468having a circumferential cross section and a bottom opening integrated within the rectangular base having a rectangular cross section. The bottom opening includes an exterior facing rectangular peripheral rim470having four sides, the front facing rim wall428, the rear facing rim wall434, a first lateral facing rim wall488, a second lateral facing rim wall490.

The bottom opening of the hood22, as illustrated inFIG.11, is integrated with a perforated lift and place framework492. The perforated lift and place framework492is bounded by the exterior facing rectangular peripheral rim470dimensioned with a framework surface area that is equal to the first surface area of the rigid silicone table top38of the vacuum lift-table12.

The perforated lift and place framework492is configured with a plurality of hood perforations4941+Nsymmetrically aligned a distance apart from each other in rows4961−Nand columns4981−Nextending the entirety of the perforated lift and place framework492. The plurality of hood perforations4941+Nare configured to symmetrically correlate to the plurality of table perforations501+Nof the vacuum lift-table12, as depicted inFIGS.1-2,4-5A,6-8.

As shown inFIGS.1-2,4-5A, andFIGS.6-8, the circumferential top opening at the apex468of the hood22is fluidly connected to a hood conduit502which is fluidly connected to a vacuum generator motor504configured with 1500 cubic feet per minute. The vacuum generator motor504provides a predetermined force of air flow in fluid communication with each of the plurality of hood perforations4941+Nof the perforated lift and place framework492configured to generate a predetermined vacuum pull therethrough each of the plurality of hood perforations4941+Nof the perforated lift and place framework492. The vacuum generator motor504is operationally connected to an “On”/“Off” operation switch506, wherein the predetermined vacuum pull is purged therethrough each of the plurality of hood perforations4941+Nof the perforated lift and place framework492when the vacuum generator motor504in an “On” operation, and the predetermined vacuum pull is ceased when the vacuum generator motor504is in an “OFF” operation to enable a lift and place operation of the foam core body24.

The hood conveyor apparatus20includes four spring balancers5081+Nto maintain a stable position of the hood22wherein each of the four spring balancers5081+Nis configured with a drum, a steel wire rope6061-4having a travel distance of 1.5 meters, and a pull weight of 15-25 kg capacity range, as shown inFIGS.1-2,4-5A, andFIGS.6-8.

A first spring balancer5081of the four spring balancers5081+Nincludes a first end510and a second end512. The first end510of the first spring balancer5081includes a first hook connector5141which is fixedly attached by way of a first bolted face plate5161to a first corner3401of the front joist340of the anchorage conveyor frame336. The second end512of the first spring balancer5081includes a first carabiner snap clip5181which is fixedly coupled to a corresponding first corner3601of the front cross bar360of the anchorage conveyor frame336by way of a first steel hook pad eye plate5201fixedly attached to the corresponding first corner3601of the front cross bar360.

A second spring balancer5082of the four spring balancers5081+Nincludes a first end522and a second end524. The first end522of the second spring balancer5082includes a second hook connector5142which is fixedly attached by way of a second bolted face plate5162to a second corner3402of the front joist340of the anchorage conveyor frame336. The second end524of the second spring balancer5082includes a second carabiner snap clip5182which is fixedly coupled to a corresponding second corner3602of the front cross bar360of the anchorage conveyor frame336by way of a second steel hook pad eye plate5202fixedly attached to the corresponding second corner3602of the front cross bar360.

A third spring balancer5083of the four spring balancers5081+Nincludes a first end526and a second end528. The first end526a third spring balancer5083includes a third hook connector5143which is fixedly attached by way of a third bolted face plate5163to a first corner3421of the rear joist342of the anchorage conveyor frame336. The second end528of the third spring balancer5083includes a third carabiner snap clip5183which is fixedly coupled to a corresponding first corner3621of the rear cross bar362of the anchorage conveyor frame336by way of a third steel hook pad eye plate5203fixedly attached to the corresponding second corner3622of the rear cross bar362.

A fourth spring balancer5084of the four spring balancers5081+Nincludes a first end530and a second end532. The first end530includes a fourth hook connector5144which is fixedly attached by way of a fourth bolted face plate5164to a second corner3422of the rear joist342of the anchorage conveyor frame336. The second end532of the fourth spring balancer5084includes a fourth carabiner snap clip5184which is fixedly coupled to a corresponding second corner3622of the rear cross bar362of the anchorage conveyor frame336by way of a fourth steel hook pad eye plate5203fixedly attached to the corresponding second corner3622of the rear cross bar362such that the hood22can be balanced in a level posited plane parallel in relation to the of the vacuum lift-table12, the gel heating metal-lift table14, and the gel foam fusion lift-table16and to provide a uniform gel dipping treatment of the foam core body24.

As depicted inFIGS.1-2,4-5A, and6, and more particularly inFIG.8, the hood conveyor apparatus20includes four gel detection probes5341,5342,5343,5344, a first gel detection probe5341, a second gel detection probe5342, a third gel detection probe5343and a fourth gel detection probe5344. The first gel detection probe5341is disposed on a front edge of the first lateral facing rim wall488of the exterior facing rectangular peripheral rim470of the hood22and the second gel detection probe5342disposed on a front edge of the second lateral facing rim wall490of the exterior facing rectangular peripheral rim470of the hood22. The third gel detection probe is disposed on a rear edge of the first lateral facing rim wall488of the exterior facing rectangular peripheral rim470of the hood22and the fourth gel detection probe is disposed on a rear edge of the second lateral facing rim wall490of the exterior facing rectangular peripheral rim470of the hood22.

Each of the first gel detection probe5341, the second gel detection probe5342, the third gel detection probe5343, the fourth gel detection probe5344extend a downward distance from the each of the first lateral facing rim wall488of the exterior facing rectangular peripheral rim470and the second lateral facing rim wall490of the exterior facing rectangular peripheral rim470, of the exterior facing rectangular peripheral rim470of the hood22, respectively. With this configuration, wherein when the hood22is lowered the first gel detection probe5341, the second gel detection probe5342, the third gel detection probe5343, the fourth gel detection probe5344is configured to come in consubstantial contact against a top surface of the gel87contained in the metal gel basin88of the gel heating metal lift-table14such that the foam core body24being held by the hood22is dip coated within the gel87held in the gel bath90to a predetermined gel thickness to create a hydrophobic gel barrier536over each of the outer peripheral surfaces of the extended cubes1981+Nof the series of plurality of extended cubes1981+Nand outlying surfaces of each of the plurality of recessed channels2041+N. In an exemplary embodiment, the predetermined gel thickness of at least 0.0625.

When the plurality of extended cubes501+Nof the foam core body24and gel87are bonded in accordance with the exemplary embodiment, the foam core body24improves the performance of the gel87and, similarly, the gel87improves the performance of the foam core body24. In particular, the gel87coats the plurality of extended cubes501+Nand the recessed channels2041+Nand a borderline portion of the top core body portion186of the foam core body24effectively surrounds the plurality of extended cubes501+Nso that the stability and performance of the gel is improved. The gel87is vertically stable and is much less apt to buckle in an outward direction when a load is applied to a surface of the a dual-core foam body amalgamate600. The gel87also helps to effectively reinforce the foam. When the gel87is bonded directly to the foam in the manner disclosed herein, the foam, and particularly when a soft foam is utilized, is not liable to bottom out under a heavy load. The gel87provides for much greater stability and support.

The operator urges the first spring handle438of the hood22in a downward direction towards the gel bath90and gel dipping the foam core body24into a heated gel bath90contained in the metal gel basin88a distance limited by the touching of the first gel detection probe5341and the second gel detection probe5342, the third gel detection probe5343, the fourth gel detection probe5344, on the top surface of the gel87such that a hydrophobic gel barrier536of a predetermined thickness is formed on the outer peripheral surfaces of each of the plurality of extended cubes1981+Nand on the outlying surfaces of each of the recessed channels2041+Nwhile retaining the top core body portion1861of the foam core body24to be untouched by the gel bath90thereby forming a heated gel-coated foam core body24HG, as depicted inFIG.5A.

As described below, in the method of operation of the gel-foam body amalgamation system10the heated gel-coated foam core body24HGis positioned over the gel foam fusion lift-table16placing the heated gel-coated foam core body24HGagainst the top porous layer of the intermediary foam core body26having the hydrophobic heated gel coating of each of the plurality of extended cubes1981+Ncoming in contact with the entirety of the top porous layer of the intermediary foam core body26. The operator by pressing the hood22against the top porous layer of the intermediary foam core body26causes the heated gel integrated on a top peripheral exterior surface of each extended cube of the heated gel-coated foam core body24HGto adhere against a borderline of a top porous layer of the intermediary foam core body26. By way of maintaining the hood against the heated gel-coated foam core body24HGand the intermediary foam core body26in a level prone position supported by the rigid non-slip non-perforated table top164of the gel foam fusion lift-table16for at least three minutes at ambient temperature allowing the heated gel to cure causing the fusion of the heated gel-coated foam core body24HGwith the intermediary foam core body26forming a dual-core foam body amalgamate600having an intermediary borderline gel layer therebetween the heated gel-coated foam core body24HGand the intermediary foam core body26.

The gel87provides a mechanism to disperse heat and therefore a cooling mechanism for a person or animal on a mattress or cushion, and the like, manufactured with the dual-core foam body amalgamate600. The gel87is vertically stable and is much less apt to buckle in an outward direction when a person's weight is applied to a surface of a mattress or cushion and the like manufactured with the dual-core foam body amalgamate600. The gel87, also, helps to effectively reinforce the foam. When the gel87is bonded directly to the foam core body24in the manner disclosed herein, the foam of the foam core body24, and particularly if soft foam is utilized, is not liable to bottom out under a heavy load. The gel87provides for much greater stability and support.

The gel-foam body amalgamation system10includes three table covers32,34,36, a vacuum lift-table cover32, a gel heating metal lift-table cover34, and a gel foam fusion lift-table cover36wherein each of the vacuum-lift table12cover and the gel foam fusion lift-table16is manufactured with a five layer polyvinyl sheet having a non-slip top surface and a non-slip bottom surface configured to self-seal to each of the entirety of each of the rigid silicone table top38of the vacuum lift-table12and the rigid non-slip non-perforated table top164of the gel foam fusion lift-table16, and wherein the gel heating metal lift-table cover34is manufactured with a polytetrafluoroethylene (“PTFE”) coated fiberglass fabric sheet538disposed intermediate to a top five layer polyvinyl sheet5401and a bottom five layer polyvinyl sheet5402configured to self-seal onto the peripheral top metal rim of the metal gel basin88of the gel heating metal lift-table14.

An embodiment of the present invention includes a method of making the dual-core gel foam amalgamate600, as depicted inFIGS.5A,8andFIG.15E. with operation of the gel-foam amalgamation system10. The method is illustrated in the flow diagram ofFIGS.16A-16E.

A method including the Steps 1700-Step comprising: 2. A method of making a dual-core gel foam amalgamate600, comprising:

Step 1.700providing a gel-foam body amalgamation system10, comprising:a vacuum lift-table12; a gel heating metal lift-table14; a gel foam fusion lift-table16; an overhead double-beam bridge crane18; a hood conveyor apparatus20; a hood22; a foam core body24; an intermediary foam core body26; a gel extruder28; gel87; gel supply well30; three table covers32,34,36, including a vacuum lift-table cover32, a gel heating metal lift-table cover34, and a gel foam fusion lift-table cover36;Step 2.702maneuvering the valve544to be parallel to the gel supply pipe122causing the opening of the valve544of the gel supply pipe122of the gel supply well30causing a flow of gel87to enter into the metal gel basin88of the gel heating metal lift-table14;Step 3.704providing the flow of gel87to enter the metal gel basin88allowing the gel87to reach the predetermined volume of gel indicated by the measurement bar148etched on the surface of the front interior facing wall of the metal gel basin88;Step 4.706maneuvering the valve544to be perpendicular to the gel supply pipe122causing the closing of the valve544of the gel supply pipe122of the gel supply well30causing the flow of gel87to cease to enter into the metal gel basin88of the gel heating metal lift-table14;Step 5.708adjusting the temperature controller131operatively electrically connected to the at least one planar heater device1321+Nwithin a range to include 350° F.-400° F. thereby heating the gel87forming a heated liquid gel87Lof the gel bath90in the metal gel basin88;Step 6.710activating the “ON” operating mode switch127of the at least one variable frequency drive pump124causing the mixing and circulating of the heated liquid gel87Lof the gel bath90contained in the metal gel basin88;Step 7.712providing the foam core body24;

Step 8.714positioning the foam core body24on the rigid silicone table top38of the vacuum lift-table12oriented with the series of the plurality of extended cubes1981+Nin a downward facing direction and the bottom flat surface of the foam core body24in an upward facing direction such that a plurality of outer peripheral surfaces of each of the plurality of extended cubes1981+Nare contacting the rigid silicone table top38of the vacuum lift-table12integrated with the plurality of table perforations501+Nand the bottom flat surface of the foam core body24is parallel to and facing the perforated lift and place framework492of the hood22integrated with the plurality of hood perforations4941+N;Step 9.716providing an intermediary foam core body26to be fused with the foam core body24;Step 10.718positioning the intermediary foam core body26on the rigid non-slip non-perforated table top164of the gel foam fusion lift-table16oriented with the bottom porous layer coming in contact with the table top surface of the gel foam fusion lift-table while exposing the top porous layer;Step 11.720urging the first spring loaded handle438of the hood22in a vertical downward direction and positioning the perforated lift and place framework492over the entirety of the flat bottom porous surface of the bottom side of the bottom core body portion188of the foam core body24positioned on the rigid silicone table top38of the vacuum lift-table12;Step 12.722turning the vacuum generator motor504in an “ON” operation mode by way of the “ON”/“OFF” operation switch providing a vacuum pulling force therethrough each of the plurality of hood perforations4941+N;Step 13.724applying the vacuum pulling force against the entirety of bottom surface of the foam core body24such that the entirety foam core body24temporarily suctions to the perforated lift and place framework492of the hood22;Step 14.726pulling the first spring handle438of the hood22in a vertical upward direction such that the hood22and the foam core body24being temporarily suctioned to the perforated lift and place framework492is lifted a distance above and parallel to the rigid silicone table top38of the vacuum lift-table12;Step 15.728urging the first spring handle438of the hood22in a horizontal direction towards the gel heating metal lift-table14enabling moving in unison the first trolley and the second trolley264along the front I-beam bridge242concurrently with moving the third trolley266and the fourth trolley268along the rear I-beam bridge244and balanced by the four spring balancers5081+Nso that the hood22moves steadily towards the gel heating metal lift-table14;Step 16.730positioning the hood22and the foam core body24being temporarily suctioned to the perforated lift and place framework492of the hood22a distance above and parallel to the metal gel basin88of the gel heating metal lift-table14the hood22being posited in a stable parallel position over the gel bath90supported by the four spring balancers5081+Nproviding a uniform gel dipping treatment of the foam core body24;

Step 17.732urging the first spring handle438of the hood22in a downward direction towards the gel bath90and gel dipping the foam core body24into a heated gel bath90contained in the metal gel basin88a distance limited by the5343consubstantial touching of the first gel detection probe5341, the second gel detection probe5342, the third gel detection probe5343and the fourth gel detection probe5344on the top surface of the gel87such that a hydrophobic gel barrier536of a predetermined thickness is formed on the outer peripheral surfaces of each of the plurality of extended cubes1981+Nand on the outlying surfaces of each of the recessed channels2041+Nwhile retaining the top core body portion1861of the foam core body24to be untouched by the gel bath90thereby forming a heated gel-coated foam core body24HG;Step 18.734pulling the first spring loaded handle438of the hood22in an upward direction away from the gel bath90causing lifting of the foam core body24temporarily suctioned by the to the perforated lift and place framework492up from the gel bath90;Step 19.736urging the first spring loaded handle438of the hood22in a horizontal direction towards the gel foam fusion lift-table16enabling moving in unison the first trolley and the second trolley264along the front I-beam bridge242concurrently with moving the third trolley266and the fourth trolley268along the rear I-beam bridge244and balanced by the four spring balancers5081+Nso that the heated gel-coated foam core body24HGbeing held by the hood22moving steadily towards the gel foam fusion lift-table16;Step 20.738urging the handle of the hood22in a vertical downward direction and positioning the heated gel-coated foam core body24HGbeing temporarily suctioned by the perforated lift and place framework492of the hood22over the intermediary foam core body26being positioned on the gel foam fusion lift-table16;Step 21.740placing the heated gel-coated foam core body24HGagainst the top porous layer of the intermediary foam core body26having the hydrophobic heated gel coating of each of the plurality of extended cubes1981+Ncoming in contact with the entirety of the top porous layer of the intermediary foam core body26wherein the hydrophobic heated gel coating has a thickness of at least 0.0625 inches;Step 22.742pressing the hood22against the top porous layer of the intermediary foam core body26causing heated gel integrated on a top peripheral exterior surface of each extended cube of the heated gel-coated foam core body24HGto adhering against a borderline of a top porous layer of the intermediary foam core body26;Step 23.744maintaining the heated gel-coated foam core body24HGand the intermediary foam core body26in a level prone position supported by the rigid non-slip non-perforated table top164of the gel foam fusion lift-table16for at least three minutes at ambient temperature allowing the heated gel to cure causing the fusion of the heated gel-coated foam core body24HGwith the intermediary foam core body26forming a dual-core foam body amalgamate600having an intermediary borderline gel layer therebetween the heated gel-coated foam core body24HGand the intermediary foam core body26;Step 24.746turning the vacuum generator motor504to the “OFF” position causing the vacuum pull force of the vacuum generator motor504to cease moving therethrough each of the plurality of the hood perforations4941+Nof the perforated lift and place framework492whereby the dual-core gel foam amalgamate600is released from the perforated lift and place framework492of the hood22;Step 25.748pulling the first spring loaded handle438of the hood22in a vertical upward direction and moving the hood22upward from the dual-core gel foam amalgamate600;Step 26.750urging the first spring loaded handle438of the hood22in a horizontal direction towards the first end stop and positioning the hood22over the rigid silicone table top38of the vacuum lift-table12;Step 27.752securing the hood in a stationary position over the rigid silicone table top38of the vacuum lift-table12by way of a hood locking mechanism, wherein the hood locking mechanism includes a first mateable pinion4501of the first rack and pinion gear system4441integrated with a locking brake (not shown), wherein a first portion of the locking brake is rotatably connected to a latch connector on the lift carriage4461first rack and pinion gear system4441and a second portion of the locking brake is rotatably connected to a locking structure connector incorporated with the first mateable pinion4501, wherein the locking brake is configured to move the locking structure between a locked and unlocked position wherein when the locking brake is in a locked position the hood is maintained in a fixed position and wherein when the locking brake is in an unlocked position the hood22can be moved vertically in the upward and downward direction and horizontally along the front I-beam bridge242and the rear I-beam bridge244of the overhead double-beam bridge crane18;Step 28.754providing a wheeled supported mobile storage cart including a multi-level horizontal rack wherein each level includes a horizontal rack configured to hold and store a plurality of dual-core gel foam amalgamates600;Step 29756removing the dual-core gel foam amalgamate600from the gel foam fusion lift-table16and placing it prone on a first level horizontal rack having the bottom porous layer of the intermediary foam core body26in contact with a top surface of the first level horizontal rack and having the porous top side of the top core body portion of the foam core body24exposed;Step 30.758turning the gel supply pipe122to the “ON” mode of operation causing the flow of gel87to enter into the metal gel basin88and replenishing a reduced gel volume of gel87to reach the predetermined volume of gel indicated by the measurement bar148etched on the surface of the front interior facing wall of the metal gel basin30. repeating steps 1-29 until a predetermined number of dual-core gel foam amalgamates6001+Nare provided;Step 31.760closing the gel supply pipe122to the closed position by way of maneuvering the valve544of the gel supply pipe to be perpendicular to the gel supply pipe122causing the flow of gel87to cease entering into the metal gel basin88;Step 32.762repeating Steps 1-31 until a predetermined number of dual-core gel foam amalgamates are provide;Step 33.764ejecting remnant gel87RGfrom the metal gel basin88by way of one or more ejection nozzles5421+Ndisposed on the rear facing metal wall98of the to the cavity104of the metal gel basin88for ejecting remnant gel87RGby way of a portable shop vacuum (not shown);Step 34.766securing the vacuum lift-table cover32onto the rigid silicone table top38of the vacuum lift-table12;Step 35.768securing the gel heating metal lift-table cover34onto the peripheral rectangular top metal rim94to the metal gel basin88of the gel heating metal lift-table14;Step 36.770securing the gel foam fusion lift-table cover36onto the rigid non-slip non-perforated table top164of the gel foam fusion lift-table16.

Additional substances may be added to the gel to help the gel cure more quickly or change the properties of the gel. For example, a mixture of about 50% talc or baby powder and about 50% baking soda that is added to the gel after the gel is applied to the foam helps the gel cure more quickly and improves the gel87and diminishes a sticky characteristic of the gel87, provides an aromatic, and a smoother touch to the gel87.

In another embodiment of the present invention, with reference toFIGS.3and17, a core body amalgamation system1000comprises a vacuum table800; a heating metal table802; a core body fusion table804; an overhead double-beam bridge crane18; a hood conveyor apparatus20; a hood22.

FIGS.3,9-10and17depicts embodiments of the vacuum table800. The vacuum table800comprises a silicone table structure including a rigid silicone table top381, a rigid silicone table bottom401, a rigid front facing silicone wall421, a rigid rear facing silicone wall441, a rigid first silicone side wall461, an opposing rigid second silicone side wall481, the rigid silicone table top381is integrated with a plurality of table perforations501+N1extending therethrough the rigid silicone table bottom401. The rigid silicone table top38of the vacuum table800is dimensioned with a surface area of at least 84×76 inches. In this manner, the vacuum lift-table can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

With reference toFIGS.2-4,9-10, the vacuum table800is depicted illustrating the rigid silicone table top381of the vacuum table800is integrated with the plurality of table perforations501+N1extending therethrough the rigid silicone table bottom401, wherein the plurality of table perforations501+N1are symmetrically aligned a distance apart from each other in rows and columns extending the entirety of the rigid silicone table top381and therethrough to the rigid silicone bottom401.

As shown inFIGS.3,9and17the vacuum table800is supported by four insulated table support columns53,55,57,59, disposed beneath the rigid silicone table top381including a first front insulated table support column53, a second front insulated table support column55, a first back insulated table support column57, a second back insulated table support column59. The vacuum table800is reinforced with a front stabilizing bar391, a rear stabilizing bar392, a first side stabilizing bar393and an opposing second side stabilizing bar394to further support the vacuum table800.

FIG.10is a perspective view of the vacuum table800including the rigid silicone table top381including a variety of size markers6051-4indicated in colored lines. The variety of size markers6051-4includes King6051, Queen6052, Double6053, and Twin6054but not limited to. The variety of size markers can include any geometric shape and size to embody a size of a sofa cushion, a chair cushion, a pillow, a cushion, and soft foam structures.

Similarly, in an aspect of the vacuum lift-table12of the gel-foam body amalgamation system10the rigid silicone table top38can include the variety of size markers6051-4indicated in colored lines. The variety of size markers6051-4includes King6051, Queen6052, Double6053, and Twin6054but not limited to. The variety of size markers can include any geometric shape and size to embody a size of a sofa cushion, a chair cushion, a pillow, a cushion, and soft foam structures.

With reference toFIG.17, the heating metal table802of the core body amalgamation system1000includes a metal table structure including a flat metal table top641, a flat metal table bottom661, a front facing flat metal wall681, a rear facing flat metal wall701, a first lateral flat metal side wall721, an opposing second flat metal lateral side wall741.

The heating metal table802of the core body amalgamation system1000is supported by four insulated metal columns77,79,81,83supporting the metal table structure including a first front insulated table metal column76, a second front insulated table metal column78, a first back insulated table metal column80, a second back insulated table metal column82. The heating metal table802is reinforced with a with a front stabilizing bar751, a rear stabilizing bar752, a first side stabilizing bar753and an opposing second side stabilizing bar754to further support the heating metal table802.

With reference toFIG.17the heating metal table802of the body core amalgamation system1000includes a metal basin881to provide a vessel to contain a predetermined volume of a colloidal matter871and to provide a vessel in which to heat the colloidal matter871to be implemented in the formation of a dual-core body amalgamate1002. The metal gel basin881is permanently attached on an upside of the flat metal table top641of the gel heating metal lift-table14by way of welding wherein the metal basin881is co-planar with the flat metal table top64of the heating metal table802, the metal basin881configured with a metal basin88surface area equal to the first surface area configured to receive the core body. The colloidal matter871can be selected from any one of a colloidal gelatinous matter that is characterized to consist of two phases that are intertwined with one another having a solid particle network and a liquid solvent. The result is soft-solid materials with unique properties, including elasticity and mechanical stability, which make them attractive choices for numerous applications. The metal basin881includes a cavity1041to contain a predetermined volume of colloidal matter871therein. The metal basin881of the heating metal table802is configured with a metal floor921bound by four upright perimetric metal walls wherein the top flat surfaces of each of the four upright perimetric metal walls961,981,1001,1021provides a peripheral rectangular top metal rim941to the metal basin881. The four perimetric metal walls961,981,1001,1021include a front facing metal wall961, a rear facing metal wall981, and two lateral facing metal walls1001,1021, a first lateral metal side wall1001and a second lateral metal side wall1021enclosing the colloidal bath901.

The cavity1041of the metal basin88is configured with a cavity opening dimensioned to receive the core body24. The metal floor921is dimensioned with a surface area of at least 84×76 inches. In this manner, the vacuum lift-table can receive a variety of sizes of foam core bodies ranging to equivalent sizes of a King mattress (80×76 inches); a Queen size mattress (80×60 inches); a Double size mattress (75×73 inches); and a Twin size mattress (75×38); and for pillows, cushions, stuffed toys, and a variety of support devices.

The gel heating metal lift-table14and the metal gel basin88can be manufactured with any one of the metals selected from the group comprising, stainless steel, copper, iron, cast iron and any combination thereof.

With reference toFIG.17the metal basin88includes a supply pipe inlet port1201. The supply pipe inlet port1201is disposed at a corner portion of the front facing wall961of the metal basin881. As depicted inFIG.17, the supply pipe inlet port1201is capable of receiving a supply pipe122fluidly connected to a supply well301in cooperation with an extruder28to enable a stream of colloidal matter871entering the metal basin881. The supply pipe1221facilitates passing of the stream of colloidal matter871from a front interior facing wall to a rear interior facing wall of the metal gel basin881to reach a predetermined volume of colloidal matter871.

The predetermined volume of colloidal matter871is indicated by a measurement bar1481etched on a surface of the front interior facing wall of the metal basin881. The operator, also, views the measurement bar148to replenish a reduced colloidal matter volume to the predetermined volume of colloidal matter871after completion of the operation of making the dual-core body amalgamate1002.

The control of the flow of the stream of colloidal matter871therethrough the supply pipe1221is controlled by a valve5441, as shown inFIG.17. The valve5441is operationally configured on the supply pipe1221proximate to the supply well301. The valve5441is open by maneuvering the valve5441to be parallel to the gel supply pipe1221and wherein the valve5441is closed by maneuvering the valve5441to be perpendicular to the valve5441. Opening the valve5441of the supply pipe1221causes the stream of colloidal matter871to flow into the metal basin881of the heating metal table8021, and closing the valve5441causes the stream of gel871to cease flowing into the metal gel basin881of the heating metal table802.

The heating metal table802includes at least one variable frequency drive pump1241. The at least one variable frequency drive pump1241is configured to deliver a pressure of 300 horse power. The at least one variable frequency drive panel1251is disposed proximate to the flat metal table bottom661of the heating metal table802, the at least one variable frequency drive pump1241including at least one in-line pipe1261running parallel to the flat metal bottom of the heating metal table802.

The at least one variable frequency drive pump1241of the heating metal table802includes a front end1261and a rear end1262wherein the front end1261of the at least one-inlet pipe1261is connected to an at least one in-line pipe inlet port1281centrally disposed within the front facing metal wall of the metal basin881, as shown inFIG.17. The at least one in-line pipe inlet port1281is fluidly cooperative with the cavity104of the metal gel basin88. The rear end1262of the at least one-outlet pipe1261is connected to an at least one in-line pipe outlet port1301centrally disposed within the rear facing flat metal wall of the metal gel basin881such that a variable frequency pressure is pumped therethrough the at least one in-line pump pipe1261into the colloidal matter bath901by way of the at least one variable frequency drive pump1241whereby the predetermined volume of colloidal matter871is mixed and circulated and recirculated from the front interior facing wall to the rear interior facing wall of the metal basin881and therethrough the at least one in-line pipe1261.

The at least one variable frequency drive pump1241is controlled by a variable speed drive controller1251of the at least one variable frequency drive pump1241to regulate the speed of the variable pressure forced into the colloidal matter871within the colloidal matter bath901. The variable speed drive controller1251of the at least one variable frequency drive pump1241includes a control panel with an “ON” operating mode switch1271and an “OFF” operating mode switch1291, a pressure switch1331, a flow switch1351.

As depicted inFIG.12, the heating metal table802includes at least one planar heater device1321+N. The at least one planar heater device1321+Nincludes two electrodes1341-2being electrically conductive. Each of the two electrodes1341-2is connected to the power source136by way of an electrical conduit wherein the electrical conduit is insulated in a non-electric conductive ultrahigh molecular weight polyethylene tube138. The at least one planar heater device1321+Nis mounted externally to an exterior surface the flat metal table bottom66of the gel heating metal table802by which a controlled temperature is generated to enable by way of thermal conduction of the metal gel basin88to heat the gel87to a heated liquid gel871or to cool the heated liquid gel87Lof the gel bath90contained in the metal gel basin88. The controlled temperature of the is regulated by a temperature controller131operatively electrically connected to the at least one planar heater device1321+N. The at least one planar heater device1321+Nincludes an electric conductive metal plate1501+4.

With reference toFIGS.1,5A and8, the core body fusion table804includes a table structure including a rigid non-slip non-perforated table top1641and a rigid non-slip non-perforated table bottom1661joined by four rigid walls including a rigid front facing non-slip wall front facing rigid non-slip wall1681, a rigid rear facing non-slip wall1701, a first rigid non-slip side wall1721and an opposing second rigid non-slip side wall1741joined at four corners. The rigid non-slip table top1641and the rigid non-slip table bottom1661is non-perforated.

The core body fusion table804is supported by four insulated table support columns177,179,181,183including a first front insulated table support column177, a second front insulated table support column179, a first back insulated table support column181and a second back insulated table support column183.

The operations of the core body amalgamation system1000is implemented with a core body1024and intermediary core body1026. As depicted inFIG.70, the core body1024is configured with a thickness, a length, and a width, a top core body portion1086and a bottom core body portion1088wherein the top core body portion1086includes a top side1861having a flat top surface and the bottom core body portion1088having a bottom side10881having a flat bottom surface.

The top core body portion1086and the bottom body core portion1088are joined by two lateral side walls1090,1092a first lateral side wall1090and a second opposing lateral side wall1092and two longitudinal side walls1094,1096a front longitudinal side wall194, and a rear longitudinal side wall196.

The core body1024is manipulated to include a plurality of extended protuberates10981+N, as shown inFIG.17, which are carved within the bottom core body portion1088of the core body1024by way of a contour saw (not shown). Each of the extended protuberates10981+Nof the series of the plurality of extended protuberates10981+Nare configured in symmetrical alignment a first distance from each other aligned in a plurality of rows20001+Nand a plurality of columns20021+Ninterconnected by a plurality recessed channels20041+Nbordered by an adjourned peripheral rim2006, wherein each of the plurality of extended protuberates10981+Nis configured with a thickness which is less than the thickness of the core body1024.

The intermediary core body1026, is configured to be fused with the core body1024to form a dual-core body amalgamate1002. The intermediary core body1026is dimensioned with a square footage equal to the square footage of the core body1024. The intermediary core body1026includes a flat top facing wall2010and a flat bottom facing wall2012joined by four side walls including a flat front wall2014, a flat rear wall2016, joined by two flat lateral side walls2018,2020, a first porous flat lateral side wall2018and an opposing second flat lateral side wall2020wherein the flat top facing wall210includes a top porous layer and the flat bottom facing wall2012includes a bottom porous layer.

The core body1024and the intermediary core body1026the can be made with a material which is selected from anyone of the group comprising, foam, silicone, vinyl foam, rubber, polyethylene, polyethylene terephthalate, polyvinyl alcohol, polypropylene, polystyrene, polycarbonate, polyamide, and resins based on any one of them. and any combinations thereof.

The gel body amalgamation system1000includes the overhead double-beam bridge crane18, as depicted inFIG.17, with reference toFIGS.1-8, which is configured to support the hood conveyor apparatus20allowing the hood22to steadily travel along a front I-beam bridge242and a rear I-beam bridge244to each of the vacuum table800, the gel heating metal lift-table802, and the core body fusion table804during the operation of producing the dual-core body amalgamate1002.

The overhead double-beam bridge crane18is fortified by four upright metal box columns222,224,226,228, a first upright metal box column222, a second upright metal box column224, a third upright metal box column226, a fourth upright metal box column228, and a first metal link beam230, a second metal link beam232. A front end2301of the first metal link beam230is fixedly attached to a top end2221of the first upright metal box column222by way of a first bolted column end plate234and a rear end2302of the first metal link beam230is fixedly attached to a top end2261of the third upright metal box column226by way of a second bolted column end plate236. A front end2321of the second metal link beam232is fixedly attached to a top end2241of the second upright metal box column224by way of a third bolted column end plate238and a rear end2322of the second metal link beam232is fixedly attached to a top end2281of the fourth upright metal box column228by way of a fourth bolted column end plate240.

With reference toFIGS.17, the two I-beam bridges242,244of the overhead double-beam bridge crane18include the front I-beam bridge242and the rear I-beam bridge244. The front I-beam bridge242and the rear I-beam bridge244are fixedly attached a predetermined distance apart and parallel to each other oriented oligomeric to the first metal link beam230and the second metal link beam232. A first end2421of the front I-beam bridge242is fixedly attached by way of a first bolted I-beam end plate246to a first trolley end stop248disposed at the front end2301of the first metal link beam230and an opposing second end2422of the front I-beam bridge242is fixedly attached to a second trolley end stop250disposed at the front end2321of the second metal link beam232by way of a second bolted I-beam end plate252. A first end2441of the rear I-beam bridge244is fixedly attached to a third trolley end stop254disposed at the rear end2302of the first metal link beam230by way of a third bolted I-beam end plate256and an opposing second end2442of the rear I-beam bridge244is fixedly connected to a fourth trolley end stop258disposed at the rear end2322of the second metal link beam232by way of a fourth I-beam end plate260. By way of this construction of the front I-beam bridge242and the rear I-beam bridge244fixedly attached to the first metal link beam230and the second metal link beam232a major framed open space is circumscribed to abide the vacuum table800, the heating metal table802, the core body fusion table804and the hood22being supported by the hood conveyor apparatus20, as depicted inFIG.17.

To facilitate the movement of the hood conveyor apparatus20, as depicted inFIG.17the two I-beam bridges242,244of the overhead double-beam bridge crane18are in working operation with four trolleys262,264,266,268, a first trolley262, a second trolley264, a third trolley266, a fourth trolley268, wherein the first trolley262is operationally coupled to the front I-beam bridge242by way of a first trolley carriage270and the second trolley264is operationally coupled to the front I-beam bridge242by way of a second trolley carriage274, the third trolley266operationally coupled to the rear I-beam bridge244by way of a third trolley carriage276and the fourth trolley268operationally coupled to the rear I-beam bridge244by way of a fourth trolley carriage278.

As depicted inFIG.17with reference toFIGS.1-8, each of the first trolley carriage270of the first trolley262and the second trolley carriage274of the second trolley264is configured with a first set of at least six radial rollers2801-6, a first set of at least four side rollers2821-4and a second set of at least six radial rollers2841-6, a second set of at least four side rollers2861-4to operationally couple each of the first trolley262and the second trolley264to the front I-beam bridge242, respectively, and whereby the first trolley262and the second trolley264are each moveably operational along a length of the front I-beam bridge242by way of each of the first set of at least six radial rollers2801-6and the first set of at least four side rollers2821-4of the first trolley carriage270of the first trolley262and the second set of at least six radial rollers2841-6and the second set of at least four side rollers2861-4of the second trolley carriage274of the second trolley264.

The first trolley carriage270of the first trolley262is in working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. In particular, the first trolley carriage270, the first set of the at least six radial rollers first set of at least six radial rollers2801-6of the first trolley carriage270of the first trolley262includes a series of three anterior radial rollers2801-3which is coplanar with a series of three posterior radial rollers2803-6wherein the set of three anterior radial rollers2801-3of the first trolley carriage270of the first trolley262are oriented to come in contact with an anterior side flat bearing surface288of a front I-beam track2901of the front I-beam bridge242and the three posterior radial rollers2803-6of the first trolley carriage270of the first trolley262are oriented to come in contact with a posterior side flat bearing surface292of a rear I-beam track2902of the front I-beam bridge242.

In addition, the first set of the at least four side rollers2821-4, as depicted inFIG.5B, of the first trolley carriage270of the first trolley262includes two anterior side rollers2821-2which are coplanar with two posterior side rollers2823-4. The two anterior side rollers2821-2includes a first anterior side roller colinear2821with a second anterior side roller2822. The first anterior side roller2821is operationally attached at a first anterior cut-out lead portion2941of the first trolley carriage270of the first trolley262and the second anterior side roller2822is operationally attached at an opposing second anterior cut-out lead portion2942of the first trolley carriage270of the first trolley262.

Continuing with the first trolley262, the opposing second anterior cut-out lead portion2942of the first trolley carriage270of the first trolley262is configured at a first lateral distance from the first anterior cut-out lead portion2941of the first trolley carriage270. The first anterior side roller2821and the second anterior roller2822is oriented to come in line contact with an anterior side perpendicular bearing wall296of the front I-beam bridge242. The two posterior side rollers2823-4includes a first posterior side roller2823and a second posterior side roller2824. The first posterior side roller2823is operationally attached at a first posterior cut-out lead portion2981of the first trolley carriage270and the second posterior side roller2824is operationally attached at an opposing second posterior cut-out lead portion2982of the first trolley carriage270, the opposing second posterior cut-out lead portion2982is configured at a second lateral distance from the first posterior cut-out lead portion298of the first trolley carriage270of the first trolley262. The first posterior side roller2823and the second posterior roller2842is oriented to come in line contact with an anterior side perpendicular bearing wall296of the front I-beam bridge242.

The first lateral distance between the first anterior cut-out lead portion2941and the second anterior cut-out lead portion2942is equal to the second lateral distance between the first posterior cut-out lead portion2981and the second posterior cut-out lead portion2982of the first trolley carriage270to enable an equalizing balance of the two anterior side rollers2821-2and the two anterior side rollers and the two posterior side rollers2823-4against the anterior side perpendicular bearing wall296and a posterior side perpendicular bearing wall302of the front I-beam bridge242of the overhead double-beam bridge crane18.

The first posterior side roller2823and the second posterior side roller2824of the first trolley carriage270of the first trolley262are each oriented to come in line contact with the posterior side perpendicular bearing wall302of the front I-beam bridge242, wherein when the two anterior side rollers2821-2and the two posterior side rollers2823-4of the first trolley carriage270of the first trolley262concomitantly come in contact against the anterior side perpendicular bearing wall296and the posterior side perpendicular bearing wall302of the front I-beam bridge242, respectively, the first trolley carriage270of the first trolley262is movably constrained to enable a steady horizontal movement of the first trolley carriage270of the first trolley262along the front I-beam bridge242moving in either direction towards the first trolley end stop248or towards the second trolley end stop250.

The second trolley carriage274of the second trolley264are in working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. The second set of at least six radial rollers2841-6of the second trolley carriage274of the second trolley264includes a series of three anterior radial rollers2841-3of the second trolley carriage274of the second trolley264which is coplanar with a second series of the three posterior radial rollers2803-6of the second trolley carriage274of the second trolley264wherein the series of three anterior radial rollers2841-3of the second trolley carriage274of the second trolley264are oriented to come in contact with the anterior side flat bearing surface288of the front I-beam track290of the front I-beam bridge242and the three posterior radial rollers2803-6of the second trolley carriage274of the second trolley264are oriented to come in contact with the posterior side flat bearing surface292of the rear I-beam track2902of the front I-beam bridge242of the overhead double-beam bridge crane18.

The second trolley carriage274of the second trolley274includes the second set of the at least four side rollers2861-4that is working operation with the front I-beam bridge242of the overhead double-beam bridge crane18. The second set of the at least four side rollers2863-6of the second trolley carriage274of the second trolley264includes two anterior side rollers2861-2of the second trolley carriage274of the second trolley264which are coplanar with two posterior side rollers2863-4of the second trolley carriage274of the second trolley264.

The two anterior side rollers2861-2of the second trolley carriage274of the second trolley264includes a first anterior side roller2861of the second trolley carriage274of the second trolley264colinear with a second anterior side roller2862of the second trolley carriage274of the second trolley264. The first anterior side roller2861of the second trolley carriage274of the second trolley264is operationally attached at a first anterior cut-out lead portion3041of the second trolley carriage274of the second trolley264and the second anterior side roller2862of the second trolley carriage274is operationally attached at an opposing second anterior cut-out lead portion3042of the second trolley carriage274of the second trolley264. The opposing second cut-out lead portion3042of the second trolley carriage274being configured at a lateral distance from the first anterior cut-out lead portion3041of the second trolley carriage274of the second trolley264. The first anterior side roller2861and the second anterior side roller2862of the second trolley carriage274of the second trolley264is oriented to come in line contact with the anterior side perpendicular bearing wall296of the front I-beam bridge242.

In addition, the two posterior side rollers2863-4of the second trolley carriage274of the second trolley264includes a first posterior side roller2863and a second posterior side roller2864. The first posterior side roller2863of the second trolley carriage274of the second trolley264is operationally attached at a first posterior cut-out lead portion3061of the second trolley carriage274of the second trolley264and the second posterior side roller2864is operationally attached at an opposing second posterior cut-out lead portion3062of the second trolley carriage274of the second trolley264. The first posterior side roller2863and the second posterior side roller2864of the second trolley carriage274of the second trolley264are each oriented to come in line contact with the posterior side perpendicular bearing wall302of the front I-beam bridge242, wherein when the two anterior side rollers2863-4of the second trolley carriage274of the second trolley264and the two posterior side rollers2863-4of the second trolley carriage274of the second trolley264concomitantly come in contact against the anterior side perpendicular bearing wall296and the posterior side perpendicular bearing wall302of the front I-beam bridge242, respectively, the second trolley carriage274of the second trolley264is movably constrained to enable a steady horizontal movement of the second trolley carriage274of the second trolley264along the front I-beam bridge242moving in either direction towards the first trolley end stop248or towards the second trolley end stop250.

Similarly, the third trolley266includes the third trolley carriage276and the fourth trolley268includes the fourth trolley carriage278in working operation with the rear I-beam bridge244of the overhead double-beam bridge crane18. The third trolley carriage276of the third trolley266and the fourth trolley carriage278of the fourth trolley268is configured with a third set of at least six radial rollers3081-6, a third set of at least four side rollers3101-4and a fourth set of at least six radial rollers3121-6, a fourth set of at least four side rollers3141-4, to operationally couple each of the third trolley266and the fourth trolley268to the rear I-beam bridge244, respectively. In this manner, the third trolley266and the fourth trolley268are each moveably operational along a length of the rear I-beam bridge244by way of the six radial rollers3081-6and the four side rollers3141-4, fixedly attached to the third trolley carriage276and the fourth trolley carriage278, respectively.

The third trolley carriage276of the third trolley266includes the third set of the at least six radial rollers3081-6and includes a series of three anterior radial rollers3081-3which is coplanar with a series of three posterior radial rollers3083-6. The three anterior radial rollers3081-3of the third trolley carriage276are oriented to come in contact with an anterior side flat bearing surface316of a rear I-beam track318of the rear I-beam bridge244and the three posterior radial rollers3083-6are oriented to come in contact with a posterior side flat bearing surface320of the rear I-beam track318of the rear I-beam bridge244.

The third set of the at least four side rollers3101-4of the third trolley carriage276of the third trolley266includes two anterior side rollers3101-2which are coplanar with two posterior side rollers3103-4. The two anterior side rollers3101-2includes a first anterior side roller3101colinear with a second anterior side roller3102wherein the first anterior side roller3101is positioned at a first anterior cut-out lead portion3241of the third trolley carriage276of the third trolley266. The second anterior side roller3102is positioned at an opposing second cut-out lead portion3242of the third trolley carriage276of the third trolley266.

The first anterior side roller3101and the second anterior side roller3102of the third trolley carriage276of the third trolley266is oriented to come in line contact with an anterior side perpendicular bearing wall3261of the rear I-beam bridge244. The second set of two posterior side rollers two posterior side rollers3103-4includes a first posterior side roller3103and a second posterior side roller3104of the third trolley carriage276of the third trolley266. The first posterior side roller two posterior side rollers3103is positioned at a first posterior cut-out lead portion3281of the third trolley carriage276of the third trolley266and the second posterior side roller3104is positioned at an opposing second posterior cut-out lead portion3282of the third trolley carriage276of the third trolley266. The first posterior side roller3103and the second posterior side roller3104are each oriented to come in line contact with a posterior side perpendicular bearing wall3261of the rear I-beam bridge224, wherein when the two anterior side rollers3261-2and the two posterior side rollers3263-4of the third trolley carriage276of the third trolley266concomitantly come in contact against the anterior side perpendicular bearing wall3261and the posterior side perpendicular bearing wall3262of the rear I-beam bridge244, respectively, the third trolley carriage276of the third trolley266is movably constrained to enable a steady horizontal movement of the third trolley carriage276of the third trolley266along the rear I-beam bridge224moving in either direction towards the third trolley end stop254or towards the fourth trolley end stop258.

The fourth trolley carriage278of the fourth trolley268includes at least six radial rollers3121-6and the least of four side rollers3141-4in working operation with the rear I-beam bridge224of the overhead double-beam bridge crane18. The at least six radial rollers3121-6of the fourth trolley carriage278of the fourth trolley268includes a series of three anterior radial rollers3121-3which is coplanar with a series of three posterior radial rollers3124-6. The set of three anterior radial rollers3121-3are oriented to come in contact with the anterior side flat bearing surface316of a rear I-beam track318of the rear I-beam bridge244and the three posterior radial rollers3124-6are oriented to come in contact with the posterior side flat bearing surface320of the rear I-beam track318of the rear I-beam bridge244.

The at least of four side rollers3141-4of the fourth trolley carriage278of the fourth trolley268includes two anterior side rollers3141-2which are coplanar with two posterior side rollers3123-4. The two anterior side rollers3141-2includes a first anterior side roller3141colinear with a second anterior side roller3142of the fourth trolley carriage278of the fourth trolley268wherein the first anterior side roller3141is positioned at a first anterior cut-out lead portion3301of the fourth trolley carriage278of the fourth trolley268and the second anterior side roller3142is positioned at an opposing second anterior cut-out lead portion3302of the fourth trolley carriage278of the fourth trolley268. The first anterior side roller3141and the second anterior side roller3142of the fourth trolley carriage278of the fourth trolley268is oriented to come in line contact with the anterior side perpendicular bearing wall3261of the rear I-beam bridge244.

The two posterior side rollers3123-4, includes a first posterior side roller3123and a second posterior side roller3124of the fourth trolley carriage278of the fourth trolley268wherein the first posterior side roller3123is positioned at a first posterior cut-out lead portion3321of the fourth trolley carriage278of the fourth trolley268and the second posterior side roller3124is positioned at an opposing second posterior cut-out lead portion3322of the fourth trolley carriage278of the fourth trolley268, the opposing second posterior cut-out lead portion3322.

The first posterior side roller3123and the second posterior side roller3124are each oriented to come in line contact with the posterior side perpendicular bearing wall3262of the rear I-beam bridge244wherein when the two anterior side rollers3121-1and the two posterior side rollers3123-4of the fourth trolley carriage278of the fourth trolley268concomitantly come in contact against the anterior side perpendicular bearing wall3261and the posterior side perpendicular bearing wall3262of the rear I-beam bridge224, respectively, whereby the fourth trolley carriage278of the fourth trolley268is movably constrained to enable a steady horizontal movement of the fourth trolley carriage278of the third trolley266along the rear I-beam bridge224moving in either direction towards the third trolley end stop254or towards the fourth trolley end stop258of the rear I-beam bridge224.

The core body amalgamation system1000includes a hood conveyor apparatus20configured with structural and utilitarian frames to support the hood22as the hood22moves in a horizontal direction to each of the vacuum table800, the heating metal table802, and the core body fusion table804and in a vertical upward direction and downward direction during the operation of the gel foam body amalgamation system10in the formation of the dual-core foam body amalgamate600, as depicted inFIG.15E.

The hood conveyor apparatus20, as depicted inFIG.17, with reference toFIGS.1-5A, and6-8includes an upper conveyor frame334and a lower conveyor frame338coplanar to each other fixedly joined to an anchorage conveyor frame336. The anchorage conveyor frame336is configured having a rectangular shaped structure being disposed in a transverse plane between the upper conveyor frame334and the lower conveyor frame338whereby a minor framed open space is circumscribed within the major framed open space to abide for the hood conveyor apparatus20.

The anchorage conveyor frame336includes a front joist340and a rear joist342, a

first lateral side joist344, an opposing second lateral side joist346, a front cross bar360, a rear cross bar362, and four lifting masts364,366,368,370vertically oriented wherein the front joist340and the rear joist342are each fixedly attached to the first lateral side joist344and the opposing second lateral side joist346by way of four joist hanger brackets348,350,352,354whereby four corners of the anchorage conveyor frame336are formed.

A first lifting mast356of the anchorage conveyor frame336includes a superior end3561and an inferior end3562. The superior end3561of the first lifting mast356is fixedly bolted to a first joist end3401of the front joist340of the anchorage conveyor frame336by way of a first joist hanger bracket358and the inferior end3562of the first lifting mast356is fixedly bolted to a first end3601of the front cross bar360by way of a first iron face plate372.

A second lifting mast374of the anchorage conveyor frame336includes a superior end3741and an inferior end3742. The superior end of the second lifting mast374is fixedly bolted to a second end of the front joist340of the anchorage conveyor frame336by way of a second joist hanger bracket376and the inferior end3742of the second lifting mast374is fixedly bolted to a second end3602of the front cross bar360by way of a second iron face plate378.

A third lifting mast380of the anchorage conveyor frame336includes a superior end3801and an inferior end3802wherein the superior end3801of the third lifting mast380is fixedly bolted to a first end3421of the rear joist342of the anchorage conveyor frame336by way of a third joist hanger bracket382and the inferior end3802of the third lifting mast380is fixedly bolted to a first end of the rear cross bar362of the anchorage conveyor frame336by way of a third iron face plate384.

A fourth lifting mast386of the anchorage conveyor frame336includes a superior end3861and an inferior end3862wherein the superior end3861of the fourth lifting mast386is fixedly bolted to a second end3422of the rear joist342of the anchorage conveyor frame336by way of a fourth joist hanger bracket388and the inferior end3862of the fourth lifting mast386is fixedly bolted to a second end3622of the rear cross bar362of the anchorage conveyor frame336by way of a fourth iron face plate390.

The upper conveyor frame334of the hood conveyor apparatus20includes four overhead metal posts392,394,396,398which are vertically oriented, including a first overhead metal post392, a second overhead metal post394, a third overhead metal post396, a fourth overhead metal post398.

The first overhead metal post392of the upper conveyor frame334is positioned coaxial to the of first lifting mast356of the anchorage conveyor frame336. A first end3921of the first overhead metal post392is fixedly bolted to the first trolley262by way of a first trolley adapter connector400and a second end3922of the first overhead metal post392is fixedly bolted to a first end portion3401of the front joist340of the anchorage conveyor frame336by way of a first post mount bracket402.

The second overhead metal post394the upper conveyor frame334is positioned coaxial to the second lifting mast374of the anchorage conveyor frame336. A first end3941of the second overhead metal post394is fixedly bolted to the second trolley264by way of a second trolley adapter connector404and a second end3942of the second overhead metal post394is fixedly bolted to a second end portion3402of the front joist340of the anchorage conveyor frame336by way of a second post mount bracket406.

The third overhead metal post396the upper conveyor frame334is positioned coaxial to the third lifting mast380of the anchorage conveyor frame336. A first end3961of the third overhead metal396post is fixedly bolted to the third trolley266by way of a third trolley adapter connector408and a second end3962of the third overhead metal post396is fixedly bolted to a first end3421portion of the rear joist342of the anchorage conveyor frame336by way of a third post mount bracket410.

The fourth overhead metal post398of the upper conveyor frame334is positioned coaxial to the fourth lifting mast386of the anchorage conveyor frame336. A first end of the fourth overhead metal post398is fixedly bolted to the fourth trolley268by way of a fourth trolley adapter connector414and a second end3982of the fourth overhead metal post398is fixedly bolted to a second end portion3422of the rear joist342of the anchorage conveyor frame336by way of a fourth post mount bracket416.

The lower conveyor frame338of the hood conveyor apparatus20includes four lower support posts420,422,424,426being vertically oriented, a first lower support post420, a second lower support post422, a third lower support post424, a fourth lower support post426.

The first lower support post420of the lower conveyor frame338is positioned coaxial with the first lifting mast356. A first end of the first lower support post420is fixedly attached to the first end3601of the front cross bar360of the anchorage conveyor frame336by way of the first iron face plate372and a second end4202of the first lower support post420is fixedly attached to a first corner portion4281of a front facing rim wall428of the hood22by way of a first iron mounting plate430.

The second lower support post422of the lower conveyor frame338is positioned coaxial with the second lifting mast374. A first end4221of the second lower support post422is fixedly attached to the second end3602of the front cross bar360of the anchorage conveyor frame336by way of the second iron face plate378and a second end4202of the second lower support post422is fixedly attached to a second corner portion4282of the front facing rim wall428of the hood22by way of a second iron mounting plate432.

The third lower support post424of the lower conveyor frame338is positioned coaxial with the third lifting mast380. A first end4241of the third lower support post424is fixedly attached to the first end3621of the rear cross bar362of the anchorage conveyor frame336by way of the third iron face plate384and a second end4242of the third lower support post424is fixedly attached to a first corner portion4341of a rear facing rim wall434of the hood22by way of a third iron mounting plate384.

The fourth lower support post426of the lower conveyor frame338is positioned coaxial with the fourth lifting mast386. A first end4261of the fourth lower support post426is fixedly attached to the second end3622of the rear cross bar362of the anchorage conveyor frame336by way of the second iron face plate378and a second end4262of the fourth lower support post426is fixedly attached to the second corner portion4342of the rear facing rim wall434of the hood22by way of a fourth iron mounting plate436. Each of the first lower support post420, the second lower support post422, the third lower support post424, the fourth lower support post426is integrated with a rack and pinion gear system4441-4including a first rack and pinion gear system4441, a second rack and pinion gear system4442, a third rack and pinion gear system4443, a fourth rack and pinion gear system4444, respectively; wherein each of the rack and pinion gear systems4441-4includes, a lift carriage4461-4, a gear rack4481-4mechanically operative with a mateable pinion4501-4, operatively connected to a first lateral axle452, a second lateral axle454.

Each of the lift carriages4461-4includes each of the gear rack4481-4which is vertically oriented and centered between a first linear guide4561+Nand a second linear guide4581+Nof each of the lift carriages4461-4, each of the gear racks4481-4having an upward end4601+Nand a downward end4621+Nwith a plurality of gear rack teeth4641+Ntherebetween.

Each of the mateable pinions4501-4is configured with a plurality of pinion teeth476circumferentially aligned around a pinion crown4801-4to enable an operable rotatable mesh between each of a corresponding plurality of gear rack teeth4641+Nof each of the gear racks4481-4of each of the first rack and pinion gear system4441, a second rack and pinion gear system4442, a third rack and pinion gear system4443, a fourth rack and pinion gear system4444, each of the mateable pinions4501-4include a pinion borehole4781-4transversely configured therethrough each of the pinion crowns4801+N.

The first lateral axle452is positioned a first vertical below and parallel to the first lateral side joist344of the anchorage conveyor frame336and the second lateral axle454is positioned a second vertical distance below and parallel to the opposing second lateral side joist346of the anchorage conveyor frame336wherein the second distance is equal to the first distance such that the first lateral axle452and the second lateral axle454are symmetrically aligned parallel to each other.

A first end of the first lateral axle452is rotationally coupled to a first pinion borehole4781of the first mateable pinion4501of a first gear rack4481of the first rack and pinion gear system4441integrated with the first lower support post420and a second end of the first lateral axle452is rotationally coupled to a third pinion borehole4783of a third gear rack4483of the third rack and pinion gear system4443integrated with the third lower support post424, and a first end of the second axle454is rotationally coupled to a second pinion borehole4782of a second mateable pinion4502of a second gear rack4482of the second rack and pinion gear system4442integrated with the second lower support post422and a second end of the second lateral axle454is rotationally coupled to a fourth pinion borehole4784of a fourth mateable pinion4504of a fourth gear rack4484of the fourth rack and pinion gear system4444integrated with the fourth lower support post426such that as the hood22is lowered and raised the lateral first axle452and the second lateral axle454synchronously causes the first mateable pinion4501and the third mateable pinion4503, the second matealbe pinion4502and the fourth mateable pinion4504to rotate in unison enabling the operable rotatable mesh between each of a first plurality of pinion teeth4761of a first mateable pinion4501and a first plurality of gear rack teeth4641(1+N)of the first gear rack4481of the first rack and pinion gear system4441, a second plurality of pinion teeth4762of a second mateable pinion4502and a second plurality of gear rack teeth4642(1+N)of a second gear rack4482of the second rack and pinion gear system4442, a third plurality of pinion teeth4763of a third mateable pinion4503and a third plurality of gear rack teeth4643(1+N)of a third gear rack4483of the third rack and pinion gear system4442, a fourth plurality of pinion teeth4764of a fourth mateable pinion4504and a fourth plurality of gear rack teeth4644(1+N)of a fourth gear rack4484of the fourth rack and pinion gear system4444, in a vertical direction from each of the gear rack's4481-4downward ends462to their upward ends460or from each of the gear racks4481-4upward end460their downward end462.

The anchorage conveyor frame336provides structural support for two spring loaded handles438,440which provides a safe means to maneuver the hood22as the hood22moves in a horizontal direction to each of the vacuum table800, the heating metal table802, and the core body fusion table804and in a vertical upward direction and downward direction during the operation of the gel foam body amalgamation system10in the formation of the dual-core body amalgamate1002.

The first spring loaded handle438is pivotally attached to the front cross bar360of the anchorage conveyor frame336and a second spring loaded handle440is pivotally attached to the rear cross bar362of the anchorage conveyor frame336whereby the first spring loaded handle438and the second spring loaded handle440is maneuvered to operationally raise and lower the hood22in a vertical direction and to urge the hood22in a horizontal direction along each of the front I-beam bridge242and concomitantly along the rear I-beam bridge244.

The gel foam body amalgamation system10includes the hood22, as shown inFIGS.1-5A, andFIGS.6-8. The hood22, includes a metal rectangular pyramid structure including four cohesive triangular metal panels4661-4being integrally welded together forming an apex468and a rectangular base configured with a top opening at the apex468having a circumferential cross section and a bottom opening integrated within the rectangular base having a rectangular cross section. The bottom opening includes an exterior facing rectangular peripheral rim470having four sides, the front facing rim wall428, the rear facing rim wall434, a first lateral facing rim wall488, a second lateral facing rim wall490.

The bottom opening of the hood22is integrated with a perforated lift and place framework492, as shown inFIG.11. The perforated lift and place framework492is bounded by the exterior facing rectangular peripheral rim470dimensioned with a framework surface area that is equal to the first surface area of the rigid silicone table top381of the vacuum table800.

The perforated lift and place framework492is configured with a plurality of hood perforations4941+Nsymmetrically aligned a distance apart from each other in rows4961−Nand columns4981−Nextending the entirety of the perforated lift and place framework492.

The circumferential top opening at the apex468of the hood22is fluidly connected to a hood conduit502which is fluidly connected to a vacuum generator motor504configured with 1500 cubic feet per minute. The vacuum generator motor504provides a predetermined force of air flow in fluid communication with each of the plurality of hood perforations4941+Nof the perforated lift and place framework492configured to generate a predetermined vacuum pull therethrough each of the plurality of hood perforations4941+Nof the perforated lift and place framework492. The vacuum generator motor504is operationally connected to an “On”/“Off” operation switch506, wherein the predetermined vacuum pull is purged therethrough each of the plurality of hood perforations4941+Nof the perforated lift and place framework492when the vacuum generator motor504in an “On” operation, and the predetermined vacuum pull is ceased when the vacuum generator motor504is in an “OFF” operation to enable a lift and place operation of the foam core body24.

As depicted inFIG.17, with reference toFIGS.1-8, the hood conveyor apparatus20includes four spring balancers5081+Nto maintain a stable position of the hood22wherein each of the four spring balancers5081+Nis configured with a drum, a steel wire rope6061-4having a travel distance of 1.5 meters, and a pull weight of 15-25 kg capacity range.

A first spring balancer5081of the four spring balancers5081+Nincludes a first end510and a second end512. The first end510of the first spring balancer5081includes a first hook connector5141which is fixedly attached by way of a first bolted face plate5161to a first corner3401of the front joist340of the anchorage conveyor frame336. The second end512of the first spring balancer5081includes a first carabiner snap clip5181which is fixedly coupled to a corresponding first corner3601of the front cross bar360of the anchorage conveyor frame336by way of a first steel hook pad eye plate5201fixedly attached to the corresponding first corner3601of the front cross bar360.

A second spring balancer5082of the four spring balancers5081+Nincludes a first end522and a second end524. The first end522of the second spring balancer5082includes a second hook connector5142which is fixedly attached by way of a second bolted face plate5162to a second corner3402of the front joist340of the anchorage conveyor frame336. The second end524of the second spring balancer5082includes a second carabiner snap clip5182which is fixedly coupled to a corresponding second corner3602of the front cross bar360of the anchorage conveyor frame336by way of a second steel hook pad eye plate5202fixedly attached to the corresponding second corner3602of the front cross bar360.

A third spring balancer5083of the four spring balancers5081+Nincludes a first end526and a second end528. The first end526a third spring balancer5083includes a third hook connector5143which is fixedly attached by way of a third bolted face plate5163to a first corner3421of the rear joist342of the anchorage conveyor frame336. The second end528of the third spring balancer5083includes a third carabiner snap clip5183which is fixedly coupled to a corresponding first corner3621of the rear cross bar362of the anchorage conveyor frame336by way of a third steel hook pad eye plate5203fixedly attached to the corresponding second corner3622of the rear cross bar362.

A fourth spring balancer5084of the four spring balancers5081+Nincludes a first end530and a second end532. The first end530includes a fourth hook connector5144which is fixedly attached by way of a fourth bolted face plate5164to a second corner3422of the rear joist342of the anchorage conveyor frame336. The second end532of the fourth spring balancer5084includes a fourth carabiner snap clip5184which is fixedly coupled to a corresponding second corner3622of the rear cross bar362of the anchorage conveyor frame336by way of a fourth steel hook pad eye plate5203fixedly attached to the corresponding second corner3622of the rear cross bar362such that the hood22can be balanced in a level posited plane parallel in relation to the of the vacuum table800, the heating metal table802, and the core body fusion table804and to provide a uniform colloidal matter dipping treatment of the core body1024.

The hood conveyor apparatus20includes two colloidal matter detection probes5341C-5342Ca first colloidal detection probe5341Cand a second colloidal matter detection probe5342C. The first colloidal detection probe5341Cis disposed on the first lateral facing rim wall488of the exterior facing rectangular peripheral rim470of the hood22and the second colloidal matter detection probe5342Cis disposed on the second lateral facing rim wall490of the exterior facing rectangular peripheral rim470of the hood22. Each of the first colloidal matter detection probe5341Cand the second colloidal matter detection probe5342Cextend a downward distance from the each of the first lateral facing rim wall488of the exterior facing rectangular peripheral rim470and the second lateral facing rim wall490of the exterior facing rectangular peripheral rim470, respectively. With this configuration, wherein when the hood22is lowered the first colloidal detection probe5341Cand the second colloidal detection probe5342Cis configured to come in contact against a top surface of the colloidal matter871contained in the metal gel basin88of the gel heating metal lift-table14such that the foam core body24being held by the hood22is dip coated within the colloidal matter871held in the metal basin metal basin881to a predetermined gel thickness to create a hydrophobic colloidal matter barrier536CBover each of the outer peripheral surfaces of the plurality of extended protuberant10981+Nand outlying surfaces of each of the plurality of recessed channels20041+N.

In another embodiment the gel-foam body amalgamation system10and a core body amalgamation system1000can be integrated with an automation system. The gel-foam body amalgamation system can include a motorized drive means to concomitantly control the horizontal movement of the first trolley262and the second trolley264along the front I-beam bridge242and the third trolley266and the fourth trolley268along the rear I-beam bridge244thereby moving the hood conveyor apparatus20carrying the hood22. In addition, a supplemental motorized drive means would direct the vertical upward and downward movement of each of the four rack and pinion gear systems4441-4.

The gel-foam body amalgamation system10can be equipped with an automated motorized drive configured within each of the front I-beam bridge and the rear I-beam bridge of the overhead double-beam bridge crane18being configured with motion sensors and switches.

Each of the trolley carriages of the four trolleys262,264,266,268, can be configured with motion sensors which engage complementary resistance features with switches built into each of the front I-beam bridge and the rear I-beam bridge. Each of the trolley carriages can be configured with motion sensors built into each of the radial rollers and side rollers of each of the trolley carriages of the four trolleys262,264,266,268. In one aspect of the embodiment, this can be accomplished by known means in the art of an automated motorized drive integrated into the anterior track and the posterior track of the front I-beam bridge242and the rear-I beam bridge244whereby the contact with the set of three anterior radial rollers and the posterior radial rollers are integrated with motion sensors which are oriented to come in contact with switches built into each of the anterior side flat bearing surface316and the posterior side flat bearing surface of the rear I-beam track318of the front I-beam bridge and the rear I-beam bridge244. Similarly, each of the anterior side rollers and the posterior side rollers are built with motion sensors which are oriented to come in contact with switches built into the posterior side flat bearing surface320of the rear I-beam track318of the rear I-beam bridge244. The concerted movement of each of the four trolleys262,264,266,268can be controlled by a single actuator.

Similarly, each of the four rack and pinion gear systems4441-4of the gel-foam body amalgamation system10can be configured with the automated motorized gear device built with motion sensors and switches. Sensors can be built into four mateable pinions4441-4which are in communication with switches built into each of the four gear racks gear racks4481-4each of the four gears racks4481-4. Each of the motion sensors of the four mateable pinions4441-4of the and pinion gear systems4441-4indicating a level of the vertical upward and downward movement of the four rack and pinion systems4441-4as the four rack and pinion gear systems4441-4lower and lift the hood during the operation of the gel-foam body amalgamation system10. In this aspect of the embodiment the four rack and pinion gear systems4441-4can be controlled by the single actuator.

In another aspect of the embodiment, a conveyor belt can be integrated among the vacuum-lift table12, the gel heating metal lift-table14and the gel foam fusion lift-table16, the vacuum table800; the heating metal table802; and the core body fusion table804.

In another embodiment of the gel-foam body amalgamation system10and the core body amalgamation system1000can be integrated with a smart system and a smart device, a surveillance device. Temperature sensor, motion sensor for horizontal movement and vertical movement of each of the four trolleys, vertical motion sensors for each of the four rack and pinon gear systems, gel detection probe sensors for each of the four motion sensor for presence of object or person near the gel-foam body amalgamation system10and the core body amalgamation system1000, and an identification verification module for the operator of the gel-foam body amalgamation system10.

In another embodiment of the present invention, a kit900, is disclosed comprising: a gel-foam body amalgamation system10, comprising:the gel foam amalgamation system10comprises a vacuum lift-table12; a gel heating metal lift-table14; a gel foam fusion lift-table16; an overhead double-beam bridge crane18; a variety of metal bolted connectors908; a variety of bolted face plates910; a variety of bolted column end plates912; a variety of bolted I-beam end plates914; a variety of joist hanger brackets916; a variety of iron face plates918; a variety of post mount brackets912; a hood conveyor apparatus20; a hood22; a foam core body24; an intermediary foam core body26; a gel extruder28; gel87; gel supply well30; three table covers32,34,36, including a vacuum lift-table cover32; a gel heating metal lift-table cover34; and a gel foam fusion lift-table cover36; a gel subscription for gel recurring delivery902; a foam core body subscription for recurring foam core body delivery service920; an intermediary foam core body subscription for recurring intermediary foam core body delivery service922; a gel-foam body amalgamation system instruction manual904; Occupational Safety and Health Association (“OSHA”) Guidelines Standard Number 1910.269—Electric power generation, transmission, and distribution for a planar heater device906, available at: 1910.269—Electric power generation, transmission, and distribution. Occupational Safety and Health Administration (osha.gov).

All of the features disclosed, claimed, and incorporated by reference herein, and all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification may be omitted or replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Certain features may sometimes be used to advantage without a corresponding use of other features. Thus, unless expressly stated otherwise, each feature disclosed is an example only of a generic series of equivalent or similar features. Inventive aspects of this disclosure are not restricted to the details of the foregoing embodiments, but rather extend to any novel embodiment, or any novel combination of embodiments, of the features presented in this disclosure, and to any novel embodiment, or any novel combination of embodiments, of the steps of any method or process so disclosed.

Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples disclosed. This disclosure is intended to cover adaptations or variations of the present subject matter. Applicants intend to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of the exemplary embodiments. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the illustrative aspects. The above-described embodiments are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the inventive aspects.