Background of the Invention

This invention relates to a cushion or pad. More particularly, this invention relates to a cushion or pad ^" made of a composite material.

Various cushioning and energy-absorbing materials have been used to reduce injury from impact, such as rubber, cellular foams and air-inflated cushions. All of these prod¬ ucts reduce the energy transmission from impact or impart some comfort factor such as cushioning materials or mats.

As a rule, the absorbing material is a homogeneous material of a finite thickness. High-density foams will absorb more energy than low-density foams but are heavier and significantly more expensive and more difficult to bend, shape or contour.

In many cases, it is necessary to compromise by using a higher-density material which is more resistant to deformation than a low-density product, at the cost of presenting a less forgiving surface to the body contacting the material. If one attempts to offset the deficiency of a softer and lower-density material, substantial thickness increases are required to offset the deficiencies of the material. Objects of the Invention

An object of the present invention is to provide an improved cushion or pad.

Another object of the present invention is to pro¬ vide a cushion or pad with improved shock-absorbing character¬ istics.

A more particular object of the present invention is to provide a protective cushion which can absorb more energy or distribute it more uniformly.

A related object of the present invention is to pro¬ vide a cushion or pad which offers substantially better sup¬ port and/or better energy absorption than conventional cushioning material of equivalent thickness.

An additional object of the present invention is to provide a cushion or pad which can be used in a multitude of different applications and, more specifically, can be worn on the body to protect localized areas such as the leg, the elbow, etc.

A further particular object of the present inventio is to provide a cushion or pad which is light weight and resilient, yet strong and supporting.

Yet another particular object of the present inven¬ tion is to provide a cushion or pad which is easy and inex¬ pensive to fabricate. Summary of the Invention

A cushion or pad comprises, in accordance with the present invention, a first layer of a first synthetic cellular material having a first average cell volume and a second layer of a second synthetic cellular material having a second average cell volume at least ten times greater than the first average cell volume. The first layer is attached to the sec¬ ond layer so that the first layer and the second layer at least partially overlap one another to form a multilayer structure.

Pursuant to another feature of the present inven¬ tion, the second synthetic cellular material is a flexible polymeric material provided with an array of closed fluid- filled chambers. In addition., the first synthetic cellular material is preferably a foam material having open cells or closed cells.

A third layer of a foam material may be attached to either the first layer or the second layer. Like the first - layer, the third layer may have an open-cell or a closed-cell construction.

Pursuant to a further feature of the present inven¬ tion, the first layer and the second layer are attached to one another by an envelope which contains the two layers and thereby holds them in proximity to one another.

The cushion or pad may additionally comprise a cover member with a pocket. In that event, the first layer and the second layer are removably inserted in the pocket. The cover member is advantageously provided with hand grips so that it functions as a tote bag.

An alternative means of attaching the two cellular layers to one another takes the form of a layer of bonding material. As yet another alternative, the first layer and the second layer are attached to one another via heat seals or

welds.

Where the second layer takes the form of an array of fluid-filled chambers, the array is preferably a two- dimensional array.

Pursuant to yet another feature of the present invention, the cushion also comprises a third layer of essen¬ tially hard material and means for securing the first layer. and the second layer to the hard layer. The cellular layers may be connected to the hard layer on opposite sides thereof. Alternatively, the cellular layers may be connected to one another, the hard layer being fastened directly to only one of the cellular layers. The hard layer is preferably in a form molded to conform to a body part of a person. Such a combina¬ tion is utilizable as a protective device in sports activities.

Pursuant to yet another protective purpose of the present invention, the cushion is provided with fasteners for enabling a temporary securing of the cushion to a person's body.

In accordance with a specific embodiment of the invention, the multilayer structure includes a smooth surface. The smooth surface may carry at least one game board which is attached via a decal or printed on the smooth surface of the multilayer structure.

According to another embodiment of the present invention, a cushion or pad comprises one layer of a polymeric material provided with an array of closed fluid-filled cham¬ bers and another layer of a cellular foam material. The two layers are attached to one another so that they at least par¬ tially overlap one another to form a multilayer structure.

In an additional embodiment of the present inven¬ tion, a cushion comprises a layer of a synthetic cellular material having open cells and an attached layer of a synthetic cellular material having closed cells.

A cushion in accordance with yet another embodiment of the present invention comprises two layers of synthetic cellular materials attached to one another and an envelope with a pocket, the two layers being removably inserted in the pocket. The envelope is provided with graspable members such

as straps or loops for enabling a manual carrying of the envelope in suspension.

A mat comprises, in accordance with the present invention, a first layer of a first synthetic cellular material and a second layer of a second synthetic cellular material attached to one another. A third layer defining a smooth surface is provided with a plurality of printed game boards, the third layer being fastened to one of the first layer and the second layer.

A cushion or pad pursuant to the instant invention has improved shock-absorbing characteristics. It can absorb more energy or distribute it more uniformly than conventional cushions and can therefore serve as a protective cushion. More specifically, a pad or cushion pursuant to the invention offers substantially better support and/or better energy absorption than conventional cushioning material of equivalen thickness.

A cushion or pad in accordance with the invention is light weight and resilient, yet strong and supporting. More¬ over, it is easy and inexpensive to fabricate.

A cushion, pad or mat in accordance with the present invention has a broad range of uses including knee pads and shin guards, exercise mats, beach pads, stadium seat cushions, wheelchair cushions, and bathtub liners. In addition, the cushion may be used in luggage handles and pads for shoulder straps. The multilayer cushion material may also be used as a liner material for gloves, -for example, as padding in a baseball glove or along the fingers of a glove. In the case of a shin guard, two or more layers of fluid-filled polymeric cellular materials can be bonded or otherewise attached to each other and fixed to the body with hook-and-loop-type fasteners (e.g., VEL-CRO) . As the cushion receives an impact, the different layers compress differently to absorb and dis¬ tribute the impact energy.

In the application of seating cushions, exercise mats, beach pads, etc., polymeric foam material is layered with a fluid-filled polymeric cellular material in one or more layers to provide firm, yet comfortable, support arising from the different compression characteristics of the different

cellular materials.

A particular multilayer product in accordance with the invention comprises a layer of the Dow Company's ETHAFOAM 221 bonded to a layer of Polyair Corporation's solar pool cover material. Brief Description of the Drawing

Fig. 1 is a partial cross-sectional view of a multi¬ layer cushion in accordance with the present invention.

Fig. 2 is a partial top view of a bubble-wrap-type layer of the cushion of Fig. 1.

Fig. 3 is partial cross-sectional view of another multilayer cushion in accordance with the present invention.

"Fig. 4 is a partial cross-sectional view of yet another multilayer cushion in accordance with the present invention.

Fig. 5 is a top view of a pad or mat using the mul¬ tilayer cushion material of Fig. 4, showing printed matter on a smooth surface of the pad or mat.

Fig. 6 is a partial cross-sectional view of a fur¬ ther multilayer cushion in accordance with the present inven¬ tion.

Fig. 7 is a schematic perspective view of a tote bag with a cushion, in accordance with the present inventtion.

Fig. 8 is a partial cross-sectional view of an addi¬ tional multilayer cushion in accordance with the present invention, showing a hard preformed shell and a strap for attaching the cushion to a person.

Fig. 9 is a partial cross-sectional view of yet another multilayer cushion in accordance with the present invention.

Fig. 10 is a schematic perspective view of a cushioning device for attachment to a body part, in accordance with the present invention.

Fig. 11 is a partial cross-sectional view of a fluid-filled sheet member for use in a multilayer cushion in accordance with the present invention.

Fig. 12 is a partial cross-sectional view of another fluid-filled sheet member for use in a multilayer cushion in accordance with the present invention.

Fig. 13 is a top view of the sheet member of Fig.

12.

Fig. 14 is a partial cross-sectional view of yet another fluid-filled sheet member for use in a multilayer cushion in accordance with the present invention.

Fig. 15 is a top view of the sheet member of Fig. 14.

Fig. 16 is a top plan view of a removable hand grip cushion in accordance with the present invention.

Fig. 17 is a schematic cross-sectional view of a pa for a shoulder strap, in accordance with the invention.

Fig. 18 is a schematic perspective view of a bumper cushion attached to a docking post, in accordance with the present invention.

Fig. 19 is a schematic plan view of a glove provide with cushioning material in accordance with the present inven tion. Detailed Description

As ilustrated in Fig. 1, a cushion or pad comprises a first layer 10 of a polymeric foam material of either open cell or closed cell construction. That first layer 10 is bonded via a layer 12 of adhesive, heat welds or ultrasonic welds to a second layer 14 of a polymeric foam material of either open cell or closed cell construction. The polymeric material of layers 12 and 14 may have the same molecular structure, e.g., polyethylene or polyvinyl chloride or polypropylene, but it is advantageous in some applications to have one layer 12 or 14 of open cell construction and the other layer 14 or 12 of closed cell construction.

The second layer 14 is bonded via a layer 16 of adhesive, heat welds or ultrasonic welds to a layer of sheet material 18 having a multiplicity of cylindrical fluid-filled pockets or chambers 20 disposed in a planar array (see Fig. 2) . Sheet material 18 specifically comprises, as depicted in detail in Fig. 1, a backing web 22 of air-impermeable polymeric material such as polyethylene, polyvinyl chloride or polypropylene to which a bubble layer 24 is adhesively or ultra-sonically bonded.

For many applications it is contemplated that layer

10 may be omitted from the cushion of Fig. 1. Basically, then, a cushion comprises a layer 14 of a polymeric foam material of either open cell or closed cell construction bonded to a layer of sheet material 18 having a multiplicity of cylindrical fluid-filled pockets or chambers 20. xxx

As illustrated in Fig. 2, chambers 20 are disposed in a regular array. Alternatively, as described in U.S. Patent No. 5,034,998, the disclosure of which is hereby incor¬ porated by reference herein, chambers 20 may have a varying size and distribution selected in accordance with the expected forces experienced by different areas of sheet 18. More particularly, in the event that the multilayer material is used as or in a protective device for a human being, those areas of sheet 18 juxtaposed to projecting bone parts are expected to encounter elevated magnitudes of force owing to the absence of natural padding at those areas. Accordingly, such areas of expected elevated forces are preferably designed to absorb and dissipate greater shocks. As shown in U.S. Patent No. 5,034,998, a high density of relatively small bub¬ bles or chambers is believed better suited to accomodate the elevated force magnitudes. The small bubbles may be inter¬ spersed, however, with larger bubbles, whereby several stages of shock absorption and dissipation may be effectuated.

As depicted in Fig. 3, another multilayer cushion comprises a middle layer of sheet material 26 having a multi¬ plicity of cylindrical fluid-filled pockets or chambers 28 disposed in a planar array (see Fig. 2) . Sheet material 26 specifically comprises, as depicted in detail in Fig. 3, a backing web 30 of air-impermeable polymeric material such as polyethylene, polyvinyl chloride or polypropylene to which a bubble layer 32 is adhesively or ultra-sonically bonded. The multilayer cushion of Fig. 3 further comprises two outside layers 34 and 36 of polymeric foam material of either open cell or closed cell construction attached to sheet material 26 on opposite thereof via respective layers 38 and 40 of adhesive, heat welds or ultrasonic welds.

As illustrated in Fig. 4, a multilayer cushion or pad comprises a layer 42 of a polymeric foam material of either open cell or closed cell construction. Foam layer 42

is bonded via an adhesive or weld layer 44 to a layer of fluid-filled sheet material 46 having a multiplicity of cylindrical fluid-filled pockets or chambers 48 disposed in a planar array (see Fig. 2) . Sheet material 46 specifically comprises a backing web 50 of air-impermeable polymeric material such as polyethylene, polyvinyl chloride or polypropylene to which a bubble layer 52 is adhesively or ultra-sonically bonded. The multilayer cushion of Fig. 4 als comprises an outer layer or web 54 of polymeric material such as polyethylene, polyvinyl chloride or polypropylene attached to bubble sheet 46 via an adhesive or weld layer 56 or via other fastening means such as hook and loop strips (VEL- CRO) (not illustrated) .

As shown in Fig. 5, an outer, smooth, surface 58 of web 54 may be printed with a multiplicity of game boards 60. Alternatively, outer layer or web 54 may be a decal carrying the game boards 60. Accordingly, the cushion, pad or mat of Figs. 4 and 5 may be used as a multipurpose support, for exam¬ ple, at a beach. Players using one or more of the game boards 60 may sit on the pad or mat while playing one or more of the games. It is t be understood that game boards 60 may take the form of outlines for games such as maze-type games.

As shown in Fig. 6, another cushion or pad includes a pair of polymeric cellular layers 62 and 64 enclosed and held in juxtaposition to one another by an envelope or cover 66. Polymeric cellular layers 62 and 64 may each take the form of a closed cell or open cell foam material. Alterna¬ tively, one of the layers 62 or 64 may take the form of a bubble-wrap-type sheet material similar or identical to sheets 18, 26, 46 (Figs. 1, 3, 4, respectively). In the cushion or pad of Fig. 6, the different polymeric cellular layers 62 and 64 are attached to one another via envelope 66.

As depicted in Fig. 7, a multilayer cushion or pad 68 as described herein (Figs. 1, 3, 4, 6, 7) is inserted into a pocket of a-bag 70 provided with a pair of handles or grips 72 for facilitating a carrying of the bag in a suspended state. Bag 70 with cushion insert 68 may be used as a seat without removing the cushion. Alternatively, cushion or pad 68 may be removed from bag 70 for separate use.

Fig. 8 illustrates a multilayer cushion or pad which includes a hard exterior shell 74 form molded to conform to a body part of a person. An adhesive or weld layer 76 serves to attach a layer of sheet material 78 to shell 74. Sheet material 78 includes a backing web 80 and a bubble layer 82 bonded thereto. A polymeric foam layer 84 is attached to backing layer 80 via an adhesive or weld layer 86. As dis-. cussed hereinabove, fluid-filled chambers 88 of sheet material 78 may have a varying size and distribution selected in accordance with the expected forces experienced by different areas of sheet 78. Those areas of sheet 78 juxtaposed to projecting bone parts are preferably designed to absorb and dissipate greater shocks and may therefore incorporate a high density of relatively small bubbles or chambers.

A strap 87 attached to shell 74 is provided with a connector element 89 such as a VELCRO strip for facilitating the atachment of the cushion or pad of Fig. 8 to a person's elbow, shin, or other body part.

As illustrated in Fig. 9, another multilayer cushion or pad includes a pair of polymeric cellular layers 90 and 92 bonded to one another by an adhesive or weld layer 94. Layer 90 is made of a foam material of open cell construction, while layer 92 is made of a foam material of a closed cell construc¬ tion.

Any of the multilayer cushions or pads discussed hereinabove may be temporarily fastened to a person for pro¬ tective purposes. As shown in Fig. 10, a multilayer cushion or pad 96 is provided with a multiplicity of straps, ties or connectors 98 (e.g., VELCRO strips) for facilitating a temporary securing of the cushion or pad to a body part of a person.

As depicted in Fig. 11, a bubble-wrap-type sheet material 100 usable in any of the cushions or pads of Figs. 1, 3, 4, 6, 7, 8, or 10 may comprise two layers 102 and 104 of bubbles or fluid filled chambers 106 and 108. Each layer 102 and 104 is formed by a respective web 110 and 112 of polymeric material bonded to a respective bubble film 114 and 116. The two layers are separated by an additional web 118 to which bubble films 114 and 116 may be bonded by the application of

adhesive, heat treatment or ultrasonic energy.

As illustrated in Figs. 12 and 13, another enhanced protective sheet material 120 utilizable in a fall protection device in accordance with the present invention includes two layers 122 and 124 of bubbles or fluid filled chambers 126 and 128. Each layer 122 and 124 is formed by a respective web 130 and 132 of polymeric material bonded to a respective bubble film 134 and 136. Bubble layers 122 and 124 are staggered with respect to one another so that the chambers 126 of bubble layer 122 are disposed in the interstices between chambers 128 of bubble layer 124 and conversely chambers 128 of bubble layer 124 are disposed in the interstices between chambers 126 of bubble layer 122.

The two-layered sheet materials 100 and 120 of Figs. 11-13 increase the effectiveness of cushioning devices in accordance with the present invention. The double layered sheet material increases the shock absorption and kinetic energy dissipation capability of the devices. Accordingly, the use of double layers is especially indicated in areas of hard impacts.

As illustrated in Figs. 14 and 15, another sheet material 140 for use in any of the cushions or pads of Figs. 1, 3, 4, 6, 7, 8, or 10 includes a first web 142 of polymeric material bonded to a second web 144 formed with a multiplicity of fluid filled bubbles or chambers 146. In contrast to the fluid filled chambers of Figs. 11-13, chambers 146 are not discrete but are rather connected to one another via a network of channels 148. Upon the application of external pressure to sheet material 140, for example, in the course of a fall of a person wearing a cushionign device incorporating sheet material 140, fluid (e.g., air) is forced through channels 148, thereby providing resistance to the force and dissipating the force by the movement of the fluid.

Of course, it is not necessary for all of the cham¬ bers 146 to be connected to one another. Some chambers 146 may remain discrete, while others communicate with each other via channels 148.

The fluid filled chambers of the bubble-wrap layers in the cushions or pads described herein may be provided with

rupturable walls. More particularly, the chambers have walls of different thicknesses and different strengths, for ruptur¬ ing upon application of different magnitudes of force.

Although air is the preferred fluid with which the shock-absorbing chambers are filled, it is of course possible to use other gases or even liquids. More particularly, some or all of the pockets or chambers in areas of high impact expectancy may be filled with a liquid such as water, while other chambers, spaced from the higher danger zones, are preferably filled with air.

Tint may be applied to the fluid filling the cham¬ bers. Thus, upon rupture of a chamber and the escape of the enclosed fluid, the chamber changes color and thereby alerts a user or supervisory personnel to the lowered protection avail¬ able from the particular fall protection device.

It is to be noted that the fluid-filled chambers of the bubble wrap layers have average cell volumes at least ten times as large as the average cell volumes of the adjacent foam layers. Thus, the. average cell volume of chambers 20 of sheet material 18 in Fig. 1 are at least ten times the average cell volumes of the cells of foam layers 10 and 12.

As illustrated in Fig. 16, a hand grip attachment 150 includes a body member 152 in the form of an H, a pad 154 attached to the cross-bar 156 of the H-shaped body member 152, and a plurality of VELCRO hook and loop fasteners 158 for ena¬ bling a releasable coupling of the grip attachment to a suitcase handle 160. Alternatively, pad 154 may be coex¬ tensive with H-shaped body member 152 or may itself form the body member.

Fig. 17 shows a strip 162 of cushioning material as described hereinabove with reference to Figs. 1-4, 9 and 11-5. Strip 162 is rolled into a cylinder about a valise strap 164. The rolled or cylindrical configuration of strip 162 is main¬ tained by at least two cofunctioning VELCRO hook and loop fasteners 166.

Fig. 18 depicts a strip 168 of cushioning material as described hereinabove with reference to Figs. 1-4, 9 and 11-5. Strip 168 is rolled into a cylinder about a docking post 170. The rolled or cylindrical configuration of strip

168 is maintained by cooperating VELCRO hook and loop fasteners (not illustrated) .

Fig. 19 shows a glove 172 provided along at least one of its fingers 174 with one or more pads 176 of multilayer cushioning material as described hereinabove with reference to Figs. 1-4, 9 and 11-5. An additional pad 178 of similar mul¬ tilayer material is provided in the palm area 180 of glove 172. Pads 176 and 178 may be attached to an outer surface of glove 172 or may be disposed inside the glove. The pads may be bonded or sewn to the body of the glove. Glove 172 can be a work glove for the performance of manual labor or a sports glove, e.g., a baseball glove.

Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the draw¬ ings and descriptions herein are proferred by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.