Conforming Air Cell Design and Method of Manufacture

Abstract

A design and method of manufacture for a conforming air cell device to be used for seating, vibration and shock isolation, custom fitting and other applications. Interconnected air cells are formed from two thin sheets of highly resilient thermoformed plastic, so that once inflated, the air cells readily conform to the shape of the user while equalizing pressure from cell to cell. The manufacturing method simultaneously thermoforms both halves of the cell structure, followed immediately by joining these halves while still at the material's forming temperature. The result is a relatively complex matrix of air cells, interconnecting passages and one or more inflation features in a single manufacturing process, greatly simplifying the manufacturing process over previous methods. The design and method of manufacture result in an extremely lightweight, flexible and compactable system that quickly inflates and deflates, and can easily be taken and used anywhere it is needed.

1 . A conforming and supportive air cell cushioning device comprising:
 a) upper and lower sheets of plastic that are each formed into a plurality of air cell halves;   b) said formed sheets joined at a common parting line to form a plurality of air-tight cells;   c) said air cells being interconnected with air flow passages to equalize pressure from cell to cell and;   d) overall pressure of interconnected cells controlled by means of one or more inflation valves.   
   
   
       2 . The cushion of  claim 1  manufactured through the process of twin-sheet thermoforming, wherein said upper and lower sheets of plastic are simultaneously heated in an oven, then are vacuum formed against specialized molds to form upper and lower air cell surfaces, and sealed together at the common parting line by bringing said molds together while at the plastic's forming temperature. 
   
   
       3 . The cushion of  claim 2  where the forming process includes creating one or more features for attachment of inflation valves. 
   
   
       4 . The cushion of  claim 2  wherein flash material is trimmed off when upper and lower molds are pressed together. 
   
   
       5 . The cushion of  claim 2  wherein multiple parts are made with each forming cycle. 
   
   
       6 . The cushion of  claim 1  such that the common parting line of the air cells serves to stabilize each air cell from side to side, to minimize the likelihood of shearing over when under load. 
   
   
       7 . The cushion of  claim 1  where the parting line can be either in the middle or off to one half of the air cells to create a specific cushioning effect. 
   
   
       8 . The cushion of  claim 1  such that individual air cells are generally hexagonal in shape extending from the parting line, with rounded outer edges and angled side walls as necessary so that when compressed under load there remains a flow path of air along the outer cushion surface to the surface of the user, in order to prevent heat buildup. 
   
   
       9 . The cushion of  claim 1  such that individual air cells are generally rounded in shape extending from the parting line, with rounded outer edges and angled side walls as necessary so that when compressed under load there remains a flow path of air along the outer cushion surface to the surface of the user, in order to prevent heat buildup. 
   
   
       10 . The cushion of  claim 1  wherein holes or slots are added between air cells to allow for the vertical flow of air down and away from the user. 
   
   
       11 . The cushion of  claim 1  such that interconnected air passages are of a narrowed eye shape, to allow for flexibility between air cells and easier vacuum forming. 
   
   
       12 . The cushion of  claim 1  such that interconnected air passages are slightly larger where needed to facilitate faster inflation and deflation. 
   
   
       13 . The cushion of  claim 1  where interconnected passages are grouped from side to side or from front to back in order to enhance stability of the user, such that quadrants of air cells can remain separated with separate inflation features, or remain connected through orificed passages. 
   
   
       14 . The connected orificed passages of  claim 13  where said orificing produces a “breathing” sound when the user shifts their supported weight. 
   
   
       15 . The cushion of  claim 1  where additional ports are used to mate multiple cushions together, creating a larger supporting surface as needed. 
   
   
       16 . The cushion of  claim 1  where cooling or heating air is made to pressurize the device and flow it at the same time, by orificing pressurant air through an overboard bleed valve. 
   
   
       17 . The cushion of  claim 1  wherein said sheet of plastic are comprised of “soft-handed”, highly compliant materials such as polyurethane, vinyl, polyurethane/vinyl blends, or polypropylene. 
   
   
       18 . The cushion of  claim 1  wherein said sheets of plastic are between 0.010″ and 0.040″ thick.