Patent ID: 8871122

Claim:
A method of fabricating a cellular cushion, said method comprising: injecting material into a mold in an injection molding process to substantially simultaneously integrally form a cushion first layer with a plurality of hollow cells extending outward from the first layer and with a thickness that is substantially constant through the plurality of hollow cells and across the first layer, such that each of the plurality of cells extends only from a root defined at the first layer to a tip, and such that the plurality of cells extending from the first layer are coupled together in flow communication via a plurality of channels aligned substantially within the same plane and extending between adjacent hollow cells, and wherein the plurality of hollow cells are configured to expand only radially outward towards each other as an operating pressure within the cells is increased; coupling a second layer to the first layer such that a plurality of fluid control devices are defined between the first and second layers, each of the plurality of fluid control devices positioned against at least one of said plurality of channels are pressurizable to stop flow communication between at least two of the plurality of hollow cells; coupling an injection stem in flow communication to the plurality of hollow cells to enable an operating pressure within only the plurality of hollow cells extending from the same layer to be changed; and coupling a third layer to at least one of the first layer and the second layer wherein the plurality of fluid control devices are coupled together in flow communication, and wherein each fluid control device is substantially centered with respect to a center intersection of the plurality of channels positioned in an X-shape between adjacent hollow cells for selectively controlling flow communication independently to each of the plurality of hollow cells.