Integral elastomeric suspension article and manufacturing process

Abstract

A suspension article has a frame, a substantially uniplaner non-woven grid, and fasteners. The grid is integrally extruded with a pair of attachment strips, and the fasteners attach the grid to the frame through the attachment strips. In the preferred embodiment, the fasteners are a pair of J-strips integrally extruded with the attachment strips. The process for manufacturing the suspension article includes the steps of extruding a grid, extruding attachment strips integral with the grid, stretching the grid between the attachment strips, and attaching the stretched grid to the frame through the attachment strips.

We claim:  
     
         1 . A suspension article, comprising: 
 a frame;    a substantially uniplaner, non-woven grid integrally formed with a pair of attachment strips; and    a plurality of fasteners attaching said uniplaner, non-woven grid to said frame through said attachment strips.    
     
     
         2 . A suspension article according to  claim 1 , wherein said plurality of fasteners is a pair of J-strip fasteners integrally formed with said attachment strips.  
     
     
         3 . A suspension article according to  claim 1 , wherein said substantially uniplaner, non-woven grid comprises closely-spaced primary members and points of intersection, said closely-spaced primary members being connected by said points of intersection.  
     
     
         4 . A suspension article according to  claim 3  wherein said points of intersection are in line between said attachment strips, thereby forming a plurality of ribs substantially perpendicular to said closely-spaced primary members.  
     
     
         5 . A suspension article according to  claim 3  wherein said points of intersection are located at said attachment strips.  
     
     
         6 . A suspension article according to  claim 1 , wherein each of said attachment strips is comprised of a pre-stretched grid section.  
     
     
         7 . A suspension article according to  claim 1 , wherein each of said attachment strips has a wire embedded therein.  
     
     
         8 . A suspension article according to  claim 1 , wherein at least one of said plurality of fasteners is an actuated fastener attached to one of said pair of attachment strips.  
     
     
         9 . A suspension article according to  claim 8 , wherein said actuated fastener comprises an individual fastener, an actuator, and a bowden cable, said bowden cable having an unsheathed bowden cable section connecting said frame to said one attachment strip through said individual fastener and a sheathed bowden cable section connecting said frame to said actuator.  
     
     
         10 . A suspension article, comprising: 
 a frame; and    a substantially uniplaner, non-woven grid integrally formed with a pair of J-strip fasteners, said J-strip fasteners attaching said grid to said frame.    
     
     
         11 . A suspension article according to  claim 10 , wherein at least one of said J-strip fasteners is an actuated fastener.  
     
     
         12 . A suspension article according to  claim 10 , wherein said substantially uniplaner, non-woven grid comprises closely-spaced primary members and points of intersection, said closely-spaced primary members being connected by said points of intersection.  
     
     
         13 . A suspension article according to  claim 12  wherein said points of intersection are in line between said J-strip fasteners, thereby forming a plurality of ribs substantially perpendicular to said closely-spaced primary members.  
     
     
         14 . A suspension article according to  claim 12  wherein said points of intersection are located at said J-strip fasteners.  
     
     
         15 . A process for producing a suspension article for a support structure having a frame, comprising the steps of: 
 forming a grid integrally with attachment strips; and    stretching said grid between and attaching said grid to the frame through said attachment strips.    
     
     
         16 . A process according to  claim 15 , further comprising the step of: 
 inserting a wire into said parallel attachment strips while forming said grid.    
     
     
         17 . A process according to  claim 15 , wherein said attachment strips are formed intermittently.  
     
     
         18 . A process according to  claim 15 , wherein said attachment strips are a pair of J-strip fasteners.  
     
     
         19 . A process according to  claim 15 , wherein said forming step is performed by extruding said grid.  
     
     
         20 . A process according to  claim 15 , wherein said forming step is performed by injection molding said grid.