Separable apparatus to cushion and dampen vibration and method

Abstract

A separable apparatus to cushion and dampen vibration and method for making such separable apparatus. The separable apparatus comprises an overmold composed of a mixture of an elastrometric material and a foaming agent. The overmold comprises a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer.

What is claimed is:  
     
         1 . A separable apparatus to cushion and dampen vibration, comprising: 
 an overmold member composed of a mixture of an elastomeric material and a foaming agent, comprising:    a first non-foam layer; and    a second non-foam layer, in conjunction with the first layer, enveloping a micro-cellular foam layer.    
     
     
         2 . The separable apparatus of  claim 1 , wherein the elastomeric material is selected from a group comprising thermoplastic olefins, thermoplastic rubbers, thermoplastic polyurethanes, polyvinylchlorides, styrenic block copolymers, and combinations of such materials.  
     
     
         3 . The separable apparatus of  claim 1 , wherein the two non-foam layers and the foam layer are integrally molded with each other by injection molding of resin.  
     
     
         4 . The separable apparatus of  claim 1 , further comprising a substrate member coupled to the overmold member.  
     
     
         5 . The separable apparatus of  claim 4 , wherein the overmold member is mechanically attached to the substrate member.  
     
     
         6 . The separable apparatus of  claim 4 , wherein at least one of the non-foam layers is bonded to the substrate member.  
     
     
         7 . The separable apparatus of  claim 4 , wherein the substrate member is selected from a group of materials including: wood, metal, thermoplastic resin, thermoset resin, epoxy, ceramic, glass, and a combination of any two such materials.  
     
     
         8 . The separable apparatus of  claim 1 , wherein the thickness of the foam layer exceeds the combined thickness of the non-foam layers.  
     
     
         9 . The separable apparatus of  claim 1 , wherein the combined thickness of the non-foam layers exceeds the thickness of the foam layer.  
     
     
         10 . The separable apparatus of  claim 1 , wherein the combined thickness of the non-foam layers is equal to the thickness of the foam layer.  
     
     
         11 . The separable apparatus of  claim 1 , wherein the overmold is configured in a predetermined shape.  
     
     
         12 . A tool comprising: 
 a tool-head;    a grip coupled to the tool-head, with the grip having a base; and,    a separable overmold member disposed on the grip, with the overmold composed of a mixture of an elastomeric material and a foaming agent, comprising a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer.    
     
     
         13 . The tool of  claim 12 , wherein the elastomeric material is selected from a group comprising thermoplastic olefins, thermoplastic rubbers, thermoplastic polyurethanes, polyvinylchlorides, styrenic block copolymers, and combinations of such materials.  
     
     
         14 . The tool of  claim 12 , wherein the base is selected from a group of materials including: wood, metal, thermoplastic resin, thermoset resin, epoxy, ceramic, glass, and a combination of any two such materials.  
     
     
         15 . The tool of  claim 12 , wherein the two non-foam layers and the foam layer are integrally molded with each other by injection molding of resin.  
     
     
         16 . The tool of  claim 12 , wherein the overmold member is mechanically attached to the base.  
     
     
         17 . The tool of  claim 12 , wherein at least one non-foam layer is bonded to the base.  
     
     
         18 . The tool of  claim 12 , wherein the base has a plurality of pockets in the grip portion, wherein the separable overmold member is contained.  
     
     
         19 . The tool of  claim 12 , wherein the thickness of the foam layer exceeds the combined thickness of the non-foam layers.  
     
     
         20 . The tool of  claim 12 , wherein the combined thickness of the non-foam layers exceeds the thickness of the foam layer.  
     
     
         21 . The tool of  claim 12 , wherein the combined thickness of the non-foam layers is equal to the thickness of the foam layer.  
     
     
         22 . The tool of  claim 12 , wherein the separable overmold member is configured in a predetermined shape.  
     
     
         23 . A method to make a separable apparatus for a tool in a mold, the separable apparatus to cushion and dampen vibration, with the separable apparatus including an overmold composed of a mixture of an elastomeric material and a foaming agent, comprising a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer, the method comprising the steps of: 
 providing a substrate member in the mold;    molding the overmold on the substrate member, wherein the apparatus is made;    removing the apparatus from the mold; and,    controlling environmental conditions to which the apparatus is subjected during one of a time the apparatus is in the mold and a time after the apparatus is removed from the mold.    
     
     
         24 . The method of  claim 23 , including the step of removing the apparatus from the substrate member.  
     
     
         25 . The method of  claim 24 , including the step of controlling the time the apparatus is on the substrate member.  
     
     
         26 . The method of  claim 23 , including the step of controlling the temperature of the elastomeric material.  
     
     
         27 . The method of  claim 23 , including the step of controlling the mold temperature.  
     
     
         28 . The method of  claim 23 , including the step of controlling the time the apparatus is in the mold.  
     
     
         29 . The method of  claim 23 , including the step of controlling the thickness of the elastomeric material by configuring the geometry of one of the substrate member and mold.  
     
     
         30 . The method of  claim 23 , including the step of controlling the ambient air temperature around the apparatus after removal from the mold.  
     
     
         31 . The method of  claim 23 , including the step of mixing the elastomeric material and foaming agent in a predetermined ratio.  
     
     
         32 . The method of  claim 23 , including the step of selectively restraining the overmold.  
     
     
         33 . A tool comprising: 
 a tool-head;    a grip coupled to the tool-head, with the grip defining a void; and,    a separable overmold member configured to fill the void, with the overmold composed of a mixture of an elastomeric material and a foaming agent, comprising a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer.    
     
     
         34 . The tool of  claim 33 , wherein the elastomeric material is selected from a group comprising thermoplastic olefins, thermoplastic rubbers, thermoplastic polyurethanes, polyvinylchlorides, styrenic block copolymers, and combinations of such materials.  
     
     
         35 . The tool of  claim 33 , wherein the two non-foam layers and the foam layer are integrally molded with each other by injection molding of resin.  
     
     
         36 . The tool of  claim 33 , wherein the overmold member is mechanically attached to the grip.  
     
     
         37 . The tool of  claim 33 , wherein at least one non-foam layer is bonded to the grip.  
     
     
         38 . The tool of  claim 33 , wherein the grip has a plurality of pockets configured to contain the separable overmold member.  
     
     
         39 . The tool of  claim 33 , wherein the thickness of the foam layer exceeds the combined thickness of the non-foam layers.  
     
     
         40 . The tool of  claim 33 , wherein the combined thickness of the non-foam layers exceeds the thickness of the foam layer.  
     
     
         41 . The tool of  claim 33 , wherein the combined thickness of the non-foam layers is equal to the thickness of the foam layer.  
     
     
         42 . The tool of  claim 33 , wherein the separable overmold member is configured in a predetermined shape.  
     
     
         43 . A tool comprising: 
 a means for working;    a means for holding coupled to the means for working, with the means for holding defining a void; and,    a separable overmold member configured to fill the void, with the overmold composed of a mixture of an elastomeric material and a foaming agent, comprising a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer.    
     
     
         44 . The tool of  claim 43 , wherein the elastomeric material is selected from a group comprising thermoplastic olefins, thermoplastic rubbers, thermoplastic polyurethanes, polyvinylchlorides, styrenic block copolymers, and combinations of such materials.  
     
     
         45 . The tool of  claim 43 , wherein the two non-foam layers and the foam layer are integrally molded with each other by injection molding of resin.  
     
     
         46 . The tool of  claim 43 , wherein the overmold member is mechanically attached to the means for holding.  
     
     
         47 . The tool of  claim 43 , wherein at least one non-foam layer is bonded to the means for holding.  
     
     
         48 . The tool of  claim 43 , wherein the means for holding has a plurality of pockets configured to contain the separable overmold member.  
     
     
         49 . The tool of  claim 43 , wherein the thickness of the foam layer exceeds the combined thickness of the non-foam layers.  
     
     
         50 . The tool of  claim 43 , wherein the combined thickness of the non-foam layers exceeds the thickness of the foam layer.  
     
     
         51 . The tool of  claim 43 , wherein the combined thickness of the non-foam layers is equal to the thickness of the foam layer.  
     
     
         52 . The tool of  claim 43 , wherein the separable overmold member is configured in a predetermined shape.  
     
     
         53 . A handle for a tool, comprising: 
 a base having a grip portion and a tool-head portion; and,    a separable overmold member associated with the grip portion, with the overmold composed of a mixture of an elastomeric material and a foaming agent, comprising a first non-foam layer and a second non-foam layer, in conjunction, enveloping a micro-cellular foam layer.    
     
     
         54 . The handle of  claim 53 , wherein the elastomeric material is selected from a group comprising thermoplastic olefins, thermoplastic rubbers, thermoplastic polyurethanes, polyvinylchlorides, styrenic block copolymers, and combinations of such materials.  
     
     
         55 . The handle of  claim 53 , wherein the base is selected from a group of materials including: wood, metal, thermoplastic resin, thermoset resin, epoxy, ceramic, glass, and a combination of any two such materials.  
     
     
         56 . The handle of  claim 53 , wherein the two non-foam layers and the foam layer are integrally molded with each other by injection molding of resin.  
     
     
         57 . The handle of  claim 53 , wherein the separable overmold member is mechanically attached to the base.  
     
     
         58 . The handle of  claim 53 , wherein at least one non-foam layer is bonded to the base.  
     
     
         59 . The handle of  claim 53 , wherein the base defines at least one pocket in the grip portion configured to receive the separable overmold member.  
     
     
         60 . The handle of  claim 53 , wherein the thickness of the foam layer exceeds the combined thickness of the non-foam layers.  
     
     
         61 . The handle of  claim 53 , wherein the combined thickness of the non-foam layers exceeds the thickness of the foam layer.  
     
     
         62 . The handle of  claim 53 , wherein the combined thickness of the non-foam layers is equal to the thickness of the foam layer.  
     
     
         63 . The handle of  claim 53 , wherein the overmold is configured in a predetermined shape.