# Patent

## Title
Method of making a gelatinous composite

## Abstract

The present invention relates to a gelatinous composite article. The article has a first and a second heat formable and heat reversible gelatinous elastomer material, a first permeable layer, and a control gap. Each of the gelatinous materials is a three-dimensional shape having an upper side, a base side and at least one connecting side. The first connecting side and the second connecting side are adjacent to each other so the first and second materials are essentially side-by-side within the same horizontal plane. The first permeable layer has a top side and a bottom side. The top side attaches to the first and second connecting side. The control gap is interspaced between the bottom side of the first permeable layer. This gap degrades the rigidity between each connecting side and provides an equivalent structural property throughout the article.

## Background
The present invention is a divisional of U.S. patent application Ser. No. 09/257,790, filed Feb. 25, 1999 now U.S. Pat. No. 6,447,865 which is a continuation-in-part patent application of U.S. patent application Ser. No. 09/120,640, filed Jul. 22, 1998 now U.S. Pat. No. 6,099,951, which are hereby incorporated by reference in their entirety.


FIELD OF THE INVENTION
The present invention joins at least two gelatinous composite articles together.
BACKGROUND OF THE INVENTION
The gelatinous elastomer material used in the present invention is fully disclosed in U.S. Pat. Nos. 4,369,284, 4,618,213, 5,262,468, 5,336,708, and 5,508,334, (the inventor in each patent is Chen) which are hereby incorporated by reference herein. These patents disclose the various embodiments of the gelatinous elastomer material. This gel material has many attributes that are sufficiently set forth in the cited patents. However, the gel material has some problems. One such problem occurs when a parallel force is applied to the gel material. The parallel force pushes the gel material so it slides and gathers as a compressed state.
In U.S. Pat. No. 5,336,708, Chen discloses a gelatinous elastomer composite article. These articles, as disclosed by Chen, “include: GMG, MGM, MG1G2M, M1M2G1G2, M2M1G1G2, G1MG1G2, MG1G2, G1G2M, G2G1M, GM1M2G, G1M1G2M2M1, M1GM2GM3GM4, (sic) ect, where G=gel and M=material. The subscript 1, 2, 3, and 4 are different and are represented by n which is a positive number. The material (M) suitable for forming composite articles with the gelatinous elastomer compositions can include foam, plastic fabric, metal, concrete, wood, wire screen, refractory material, glass, synthetic resin, synthetic fibers, and the like. Sandwiches of gel/material . . . are ideal for use as shock absorbers, acoustical isolators, vibration dampers, vibration isolators and wrappers. For example the vibration isolators can be (sic) use under research microscopes, office equipment, tables, and the like to remove background vibrations.” U.S. Pat. No. 5,336,708, col. 3, lines 35-51. Chen further discloses, “generally the molten gelatinous elastomer composition will adhere sufficiently to certain plastics (e.g., acrylic, ethylene copolymers, nylon, polybutylene, polycarbonate, polystyrene, polyester, polyethylene, polypropylene, styrene copolymers, and the like) provided the temperature of the molten gelatinous elastomer composition is (sic) sufficient high to fuse or nearly fuse with the plastic. In order to obtain sufficient adhesion to glass, ceramics, or certain metals, sufficient temperature is also required (e.g., above 250° F. [121° C.]).” U.S. Pat. No. 5,336,708, col. 9, lines 8-18 (emphasis added and brackets added for consistency of temperature comparison).
Chen provides antecedent basis for the phrase “the molten gelatinous elastomer composition” by defining it as follows: “the gelatinous elastomer composition of the present invention are prepared by blending together the components including other additives as desired at about 23° C. (73.4° F.) to about 100° C. (212° F.) forming a paste like mixture and further heating said mixture uniformly to about 150° C. (302° F.) to about 200° C. (392° F.) until a homogeneous molten blend is obtained.” U.S. Pat. No. 5,336,708, col. 6, lines 52-58 (parenthesis added for consistency of temperature comparison). As such, the term “molten” has the standard definition of “1 a obs: formed in a mold: cast b: fused or liquefied by heat: melted.” Webster's Third New International Dictionary of the English Language Unabridged 1456 (1966). In other words, the process to fabricate the gelatinous elastomer composite article requires the gelatinous elastomer material be in a melted state and formed upon the material (M). The resulting product, as illustrated in FIGS. 2a-2c, is the gelatinous elastomer material, G, lying on or within the material, M. In no instance does the gelatinous elastomer material of Chen penetrate through a first material, M1, to contact a second material, M2, underlying the first material (M). Likewise Chen fails to disclose an underlying second material, M2, that penetrates through a first material, M1, to contact a gelatinous elastomer material.
In some instances, two gelatinous articles must be joined together. Prior to this invention, articles, 102a and 102b, were merely attached along a respective side 104a, 104b of each article 102a, 102b. In many instances, the articles are attached with a common adhesive 106 to form an elongated article 108, as shown in FIG. 4 (prior art).
As shown in FIG. 5, when a person 110 lies on the elongated article 108, the article 108 is excessively rigid along the sides 104a, 104b. It is well known that the sides 104a, 104b are not structurally equivalent to the remainder of the article 108. As such, the elongated article 108 is uncomfortable to the person 110.
A problem to solve is to fabricate an elongated gelatinous article that provides equivalent structural properties when a person lies on the article. The present invention solves this problem.
SUMMARY OF THE INVENTION
The present invention relates to a gelatinous composite article. The article has a first and a second heat formable and heat reversible gelatinous elastomer material, a first permeable layer, and a control gap. Each of the gelatinous materials is a three-dimensional shape having an upper side, a base side and at least one connecting side. The first connecting side and the second connecting side are adjacent to each other so the first and second materials are essentially side-by-side within the same horizontal plane. The first permeable layer has a top side and a bottom side. The top side attaches to the first and second connecting sides. The control gap is interspaced between the bottom side of the first permeable layer. This gap degrades the rigidity between each connecting side and provides an equivalent structural property throughout the article.



BRIEF DESCRIPTION OF THE INVENTION
A preferred embodiment of the present invention is described in detail hereinafter with reference to the accompanying drawing, in which:
FIG. 1 is an exploded view of a gelatinous article;
FIGS. 2a-c are schematic views of the process;
FIG. 3 is an exploded view of a gelatinous composite article in a mattress unit;
FIG. 4 is view of prior art;
FIG. 5 is an alternate version of FIG. 4;
FIGS. 6a-e illustrate a method of joining two gelastic materials together;
FIGS. 7a-e illustrate an alternative embodiment of FIGS. 6a-e; 
FIG. 8 shows a cross-sectional view of an alternative embodiment of the present invention;
FIG. 8a shows an enlargement and side view of element 14c of FIG. 8;
FIG. 9 shows an alternative embodiment of FIG. 8;
FIG. 10 shows another alternative embodiment of FIG. 8; and
FIG. 11 shows an individual on the present invention.



DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a gelatinous composite article 10. Article 10 has a sealant layer 12, a permeable layer 14 and a heat formable and heat reversible gelatinous elastomer material 16. The gelatinous elastomer material 16 used in the present invention is fully disclosed in U.S. Pat. Nos. 4,369,284, 4,618,213, 5,262,468, 5,336,708, and 5,508,334, which are hereby incorporated by reference herein. The gelatinous elastomer material 16, without any material (M), is obtained from Applied Elastomerics, Incorporated of South San Francisco, Calif. Preferably, the material 16 is a lattice structure having a height ranging from about 1 cm to about 5 cm. The material 16 also has a high viscosity triblock copolymer of the general configuration poly(styrene-ethylene-butylene-styrene) and a gel rigidity of from about 20 to about 700 gram Bloom. The material 16 fuses to other surfaces at a first temperature range. The first temperature range is between 150° F. (65° C.) and 450° F. (232° C.), preferably 200° F. (93.3° C.) and 250° F. (121° C.). This material 16 by itself will go into the compressed state with any parallel force (F1).
To avoid the compressed state, the present invention uses the sealant layer 12 and permeable layer 14. The permeable layer 14 is between the sealant layer 12 and the material 16. Acceptable materials for the permeable layer 14 include polyester materials, nonwoven nylon materials and any other similar materials. The permeable layer 14 provides the support to the material 16 to prevent the compressed state. Preferably, the permeable layer 14 does not actually fuse with the material 16. Rather, the permeable layer 14 melts at a second temperature. The second temperature is greater than the first temperature range so the permeable layer 14, preferably, does not fuse to the material 16. Even though the permeable layer 14, preferably, does not fuse to the material 16 the permeable layer 14 is secured to the material 14 by the underlying sealant layer 12.
The sealant layer 12 fuses to the material 16 at a temperature within the first temperature range. The sealant material 12, when melted, permeates through the permeable layer 14 to essentially secure the layer 14 to the material 16. The inventors attempted to use various sealant materials such as SuperglueTM and other conventional adhesives. Those adhesives, however, did not sufficiently secure the layer 14 to the material 16. Polyolefins such as polyethylene and other similar polymeric compositions when melted are sealant layer 12 materials that secure the layer 14 to the material 16, for example, by thermo-bonding.
The gelatinous composite article 10 is manufactured in a three-step process as shown in FIGS. 2a-c. The first step, as shown in FIG. 2a, entails arranging the elements 12, 14, and 16 in order. This order is as follows: the gelatinous elastomer material 16 is over the permeable layer 14 which is over the sealant layer 12; preferably, the gelatinous elastomer material 16 is on the permeable layer 14 which is on the sealant layer 12. The second step requires heating a heating element 98, such as an iron, within the first temperature range as shown in FIG. 2b. The third step, illustrated in FIG. 2c, entails applying the heated heating element to the underside 18 of the article 10. The heating element transfers sufficient heat to the sealant layer 12 that the sealant layer 12 melts. The melted sealant layer 12 penetrates through the permeable layer 14 without effecting the layer 14, such as by melting layer 14, and contacts the material 16. Upon contact the melted sealant layer 12 fuses with the material 16 by melting the underside 18 of the material 16.
Turning to FIG. 3, another embodiment of the present invention is illustrated. In this embodiment, the article 10 is used in a mattress unit such as the mattress unit identified as 170. The other components 172-190, excluding 180, of the mattress unit 170 are fully disclosed in U.S. Pat. No. 5,794,289, which is hereby incorporated by reference. Two of those components are an upper crib 178 and a lower crib 176. A conventional adhesive secures the upper crib 178 and the lower crib 176 together.
The area of the permeable layer 14 is greater than the area of the gelatinous elastomer material 16. Preferably, the gelatinous elastomer material 16 has a length and width equal to or less than the area encompassed by the inner perimeter 99 of the upper crib 178 so the material 16 fits within the crib 178. In contrast, the permeable layer 14 has a length and width greater than the area encompassed by the inner perimeter 99 of the crib 178. As for the position of the material 16 in relation to the layer 14, the perimeter of the gelatinous elastomer material 16 does not contact the periphery of the permeable layer 14. The periphery of the permeable layer 14, not the material 16, is securely attached between the adhesively connected upper crib 178 and lower crib 176. As such, the cribs 178, 176 secure the article 10 into place within the mattress unit 170.
The mattress unit 170 also comprises a mattress 180. Mattress 180 is any conventional mattress such as those made with springs, air, liquid, or gel. In any case, mattress 10 fits within the crib 178 and upon article 10. Article 10 prevents mattress 180 from sliding and also prevents decubitus ulcers from forming on bed-ridden individuals.
FIG. 6a shows how to join two heat-formable and heat-reversible gelatinous elastomer materials 16a, 16b together. Each gelatinous material 16a, 16b is a three-dimensional shape having an upper side 200a, 200b, a base side 210a, 210b and at least one connecting side 8a, 8b. The second material 16b is placed upon the first material 16a so the first connecting side 8a and the second connecting side 8b are in the same plane as shown.
The permeable layer 14 has a top side 88, a bottom side 89 and the top side 88 attaches to the connecting sides 8a, 8b. In this embodiment, the permeable layer 14 has a length greater than the height of the connecting sides 8a, 8b as shown in FIG. 6A. This extra material is referred to as extension 67. The attachment method is shown as item 44a and can be any type of method, such as the method illustrated in FIGS. 1-2 or by other conventional methods. Examples of these other conventional methods include, and not limited to, polyolefin films (melted), nails, velcro, magnetism, screws, adhesives like glue or other polymeric curing agents set forth, and in some cases the gelastic material 16 itself if it contains sufficient amounts of oil (melted).
As shown in FIG. 6b, the materials 16a, 16b are repositioned so the base side 210b is in the same horizontal plane as the upper side 200a. The resulting effect is that materials 16a, 16b are in the same horizontal plane, connecting sides 8b, 8a are adjacent to each other, and the bottom side 89 of the layer 14 contacts itself.
A spacer 55 is inserted between the contacting bottom side 89, as shown in FIG. 6c. The spacer 55 can be any material that fits and separates the contacting bottom side 89.
The extension 6l extends beyond the second material 16b, and as shown in FIG. 6d attaches to the base side 210a. The attachment is shown as 44b. Attachment 44bis selected from the same material as 44a, except the attachment 44b may be the same or different material than attachment 44a. 
After the extension 67 is secured to base side 200b, then spacer 55 is removed to form a control gap 77. The control gap 77 degrades the rigidity between each connecting side 8a, 8b and provides an equivalent structural property throughout the article 10 when the upper side 200a contacts the base side 210b along corresponding side 8a, 8b.as shown in FIG. 6e. 
Obviously, the extension 67 can extend beyond the first material 16a. Thereby, the extension 67 would bind to the upper side 200a. 
FIGS. 7a-e are extremely similar to FIGS. 6a-e, except there is no extension 67. FIG. 7d-e use a second permeable layer 14a that connects the upper side 200b to the base side 210a. The second permeable layer 14a is selected from the same materials as permeable layer 14, except the second layer 14a may be the same or different from the layer 14.
Turning to FIG. 8, the present invention secures to the mattress crib 176, 178 by alternative embodiments. The gelastic material 16c, 16d is a triblock material with numerous apertures 87. The gelastic material 16c, 16d moves about the mattress unit 170, therefore, the material 16c, 16d must be secured.
The material 16c secures to the upper crib by the method described for FIG. 2. To secure the underlying material 16d to the lower crib 176, applicants have created an alternative permeable layer 14c. The alternative layer 14c has a palm-base 61 attached to the underside of the lower crib 176, and a set of finger-like structures 62 as shown in FIG. 8a. Returning to FIG. 8, each finger-like structure 62 extends from the bottom side of the material 16d, through a corresponding aperture 87, to the topside of the lower crib 176. The palm-base 61 attaches to the lower crib 176 by attachment 44c. Attachment 44c is selected from the same material as 44a, except the attachment 44c may be the same or different material than attachment 44a. 
Likewise, each finger-like structure 62 attaches to the lower crib 176 by attachment 44d. Attachment 44d is selected from the same material as 44a, except the attachment 44d may be the same or different material than attachment 44a. 
In yet another embodiment of the present invention shown in FIG. 8a, the palm-base 61 and the distal portion of the finger-like structures 62 have apertures 63 that ensure the respective attachment 44d, 44c permeates to other adjacent structures, 172,178.
Other embodiments of the present invention include those shown in FIGS. 9 and 10. FIGS. 9 and 10 show alternative embodiments of the elements 44a-d. Elements 44a-d can be a melted film 12 or a melted gelastic material 16. If the film 12 is used, as shown in FIG. 9, the film 12 is originally positioned between the permeable layer 14 and gelastic material 16. As shown in FIGS. 2a-c, the user melts the film 12 so it adheres to the material 16 and layer 14.
In some cases as shown in FIG. 10, the gelastic material 16 contains a sufficient quantity of oil wherein the film 12 is not necessary. In those cases, the user places the permeable layer 14 to the gelastic material 16, and melts the gelastic material 16. The melted gelastic material 16 adheres to the permeable layer 14.
In any of these embodiments described above, the user 110 lies upon a mattress unit 10 having equivalent structural properties as shown in FIG. 11.
Although a particular preferred embodiment of the invention has been illustrated and described in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the invention defined by the claims.
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

## Claims

1. A method of fabricating an elastomer composite article comprising:
providing a first elaslomer material having an upper side, a base side and at least one connecting side; 
providing a second elastomer material having an upper side, a base side and at least one connecting side; 
providing a first permeable layer having first and second opposing surfaces; 
attaching a first portion of the first surface of the first permeable layer to the at least one connecting side of the first material and attaching a second portion of the first surface of the first permeable layer to the at least one connecting side of the second material; 
positioning the first and second materials so that a first portion of the second surface of the first permeable layer faces a second portion of the second surface in between the at least one connecting sides of the first and second materials; and 
forming a control gap interspaced between the first portion and the second portion of the second surface of the first permeable layer.

2. The method of claim 1 wherein the first and second portions of the first surface of the first permeable layer attach to the at least one connecting sides of the first and second materials by an attachment device.

3. The method of claim 2 wherein the attachment device is selected from the group consisting of an adhesive, nail, hook and loop fasteners, magnetism, and screws.

4. The method of claim 1 wherein the first and second materials comprise a high viscosity triblock copolymer of the general configuration poly(styrene-ethylene-butylene-styrene).

5. The method of claim 1 wherein a third portion of the second surface of the first permeable layer attaches to the base side of either the first or second material.

6. The method of claim 1 wherein a second permeable layer attaches to at least a portion of the base side of each first and second material and at least a portion of the first permeable layer.

7. The method of claim 1 further comprising the steps of:
arranging a sealant layer that melts within a first temperature range upon the second surface of the first permeable layer, wherein the first permeable layer melts at a second temperature greater than the first temperature range, and the first and second heat materials melt within the first temperature range; and 
applying a heating element having a temperature within the first temperature range to the sealant layer so the sealant layer and first and second materials fuse together to secure the first permeable layer to the first and second materials.

8. The method of claim 7 wherein the first temperature range is between 250° and 450° F.

9. A method of fabricating a gelatinous composite article comprising the steps of:
placing a first heat formable and heat reversible gelatinous elastomer material having an upper side, a base side and at least one connecting side upon an upper side of a second heat formable and heat reversible gelatinous elastomer material having an upper side, a base side and at least one connecting side, wherein the at least one connecting side of the first material and the at least one connecting side of the second material are in the same plane; 
attaching a first portion of a top side of a first permeable layer to the at least one connecting side of the first material and attaching a second portion of the top side of the first permeable layer to the at least one connecting side of the second material; 
positioning the first and second materials side-by-side so that a first portion of a bottom side of the first permeable layer faces a second portion of the bottom side in between the at least one connecting sides of the first and second materials; 
inserting a spacer between the at least one connecting side of the first material and the at least one connecting side of the second material so the spacer contacts at least the first and second portions of the bottom side of the first permeable layer; 
securing the base side of the first material to the base side of the second material; and 
removing the spacer to form a control gap interspaced between the first portion and the second portion of the bottom side of the permeable layer.

10. The method of claim 9 wherein the first and second portions of the top side of the first permeable layer attach to the at least one connecting sides of the first and second materials by an attachment device.

11. The method of claim 10 wherein the attachment device is selected from the group consisting of an adhesive, nail, hook and loop fasteners, magnetism, and screws.

12. The method of claim 9 wherein the gelatinous elastomer material comprises a high viscosity triblock copolymer of the general configuration poly(styrene-ethylene-butylene-styrene).

13. The method of claim 9 wherein a third portion of the bottom side of the first permeable layer attaches to the base side of either the first or second material.

14. The method of claim 9 wherein a second permeable layer attaches to at least a portion of the base side of each first and second material and at least a portion of the first permeable layer.

15. The method of claim 9 further comprising the steps of:
arranging a sealant layer that melts within a first temperature range upon the bottom side of the first permeable layer, wherein the first permeable layer melts at a second temperature greater than the first temperature range, and the first and second heat formable and heat reversible gelatinous elastomer materials melt within the first temperature range; and 
applying a heating element having a temperature within the first temperature range to the sealant layer so the sealant layer and first and second heat formable and heat reversible gelatinous elastomer materials fuse together to secure the first permeable layer to the first and second heat formable and heat reversible gelatinous elastomer materials.

16. The method of claim 15 wherein the first temperature ranges between 250° and 450° F.