Grip enhancing structure having vacuum adhesion micro, miniature_suction cups and method and apparatus for making same

Abstract

A vacuum adhesion-gripping surface is provided by an array of miniature suction cups. The surface is provided on a glove or other object for which an improved grip is desired. The miniature suction cups are of very small sizes and high densities. The vacuum adhesion micro suction cups are formed with a tooling structure having a pair of plates. A first plate includes a plurality of holes and a second plate includes a plurality of pins. When the plates are placed together, small cavities are created between the holes and pins for forming an array of vacuum adhesion micro suction cups using a molding or similar process. Alternatively a glove, such as a medical glove, utilizing the micro suction cup gripping design can be made using a dipping process.

1 . A grip enhancing vacuum adhesion structure comprising of: 
 a flexible base material; and    a plurality of vacuum adhesion micro suction cups extending from the same base material, the vacuum adhesion micro suction cups having a diameter less than 0.055 inches.    
   
   
       2 . The grip enhancing vacuum adhesion structure according to  claim 1 , wherein the plurality of vacuum adhesion micro suction cups is formed jointly with the flexible base material.  
   
   
       3 . The grip enhancing structure according to  claim 1 , wherein each of the vacuum adhesion micro suction cups include: 
 a stem extending from the base material; and    a concave cup extending from the stem opposite the base.    
   
   
       4 . The grip enhancing structure according to  claim 3 , wherein the concave cup includes: 
 a convex conical surface facing the base material having a first angle relative to the base material;    a concave conical surface, having a second angle relative to the base material, wherein the first angle and second angle could be the same; and    a sidewall extending cylindrically between the convex conical surface and the concave conical surface.    
   
   
       5 . The grip enhancing structure according to  claim 4 , wherein the concave conical surface extends substantially to a point, flat or radius.  
   
   
       6 . The grip structure material according to  claim 4 , wherein the concave cup includes a flat, circular surface in the center of the concave conical surface.  
   
   
       7 . The grip enhancing structure according to  claim 4 , wherein the concave cup includes a flat, ring surface between the side wall and the concave conical surface.  
   
   
       8 . The grip enhancing structure according to  claim 1  further comprising of a material that can be absorbed into the surface of an object.  
   
   
       9 . The grip enhancing structure according to  claim 8 , wherein the surface allows absorption and transfer molding into the material substrate of a glove.  
   
   
       10 . A tooling system for creating at least one suction cup, the tooling system comprising of: 
 a first plate having at least one hole extending through the plate; and    a second plate, attachable to the first plate, having at least one pin extending therefrom positioned to be disposed within at least one hole when the second plate is attached to the first plate.    
   
   
       11 . The tooling system according to  claim 10 , wherein when at least one hole and at least one pin are sized such that a suction cup shaped space is formed when the second plate is attached to the first plate.  
   
   
       12 . The tooling system according to  claim 11 , wherein at least one hole includes a first portion of a first diameter and a second portion of a second diameter less than the first diameter, and wherein at least one pin has a diameter of the first diameter and is positioned within the first portion of at least one hole when the second plate is attached to the first plate.  
   
   
       13 . The tooling system of  claim 10 , wherein at least one hole includes a plurality of holes and wherein at least one pin includes a plurality of pins.  
   
   
       14 . The tooling system according to  claim 13 , wherein the plurality of holes is arranged in an array and the plurality of pins are arranged in an array.  
   
   
       15 . A method for forming a tooling system for forming at least one suction cup, the method comprising the steps of: 
 forming at least one hole in a casting plate, at least one hole not extending completely through the casting plate;    casting a second plate on the casting plate such that at least one pin is formed in at least one hole;    a first plate is made such that when at least one hole is deeper than the pin of the second plate. A through hole is then added to the first plate such that when at least one pin of the second plate is inserted in at least one hole of the first plate, a suction cup shaped cavity remains within at least one hole.    
   
   
       16 . A method for forming suction cups using a tooling system having a first plate with holes therethrough and a second plate with pins thereon, the first and second plates being attachable such that the pins extend within a portion of the holes and leave suction cup shaped cavities within a portion of the holes, the method comprising the steps of: 
 attaching the second plate to the first plate such that the pins are disposed within the holes;    depositing a viscous material on a surface of the first plate opposite the second plate so that a portion of the material passes within the suction cup shaped cavities and a portion of the material remains on a surface of the first plate;    curing the material to solidify the material;    removing the second plate from the first plate; and    removing the cured material from the first plate.    
   
   
       17 . A method for forming a medical glove having a plurality of vacuum adhesion micro suction cups on a portion thereof, the method comprising the steps of: 
 creating a glove form with a plurality of suction cup shaped cavities in the glove form at the portions thereof;    forming a glove using a dipping process.