Composite material, method of making and articles formed thereby

1. A cushioning article, comprising:

a layer of open-cell foam material comprising an upper surface and a first thickness;

a layer of gel-infused foam material in direct contact with the upper surface of said layer of open-cell foam material, said layer of gel-infused foam material comprising an upper surface and having a second thickness, the gel-infused foam layer comprising a polymeric gel material infused into the open-cell foam material, extending from the upper surface of the layer of open-cell foam material to a pre-determined depth from the upper surface of the layer of open-cell foam material; and

a barrier layer disposed adjacent to the upper surface of the gel-infused foam layer, opposite the layer of open-cell foam material;

a first material layer different from the gel material and the barrier layer, disposed between the upper surface of the layer of gel-infused foam material and the barrier layer;

a first gel layer disposed between the upper surface of the layer of gel-infused foam material and the first material layer; and

a second gel layer disposed between the first material layer and the barrier layer;

wherein the upper surfaces of the open-cell foam layer and the gel-infused foam layer are coplanar, and the second thickness of the layer of gel-infused foam material is less than the first thickness of the layer of open-cell foam material.

2. A cushioning article according to claim 1 , wherein the foam is a plastic foam.

3. A cushioning article according claim 1 , wherein the foam is selected from the group consisting of polyurethane foam, latex foam, and combinations of at least one of the foregoing.

4. A cushioning article according claim 1 , wherein the barrier layer is a thermoplastic elastomer (TPE).

5. A cushioning article according claim 1 , wherein the barrier layer is a thermoplastic polyurethane (TPU).

6. A cushioning article according claim 1 , wherein the barrier layer comprises an elongation of at least about 100 percent.

7. A cushioning article according claim 1 , wherein the barrier layer has a thickness of less than about 5 milli-inches.

8. A cushioning article according claim 1 , wherein the barrier layer comprises a moisture transmittable material.

9. A cushioning article according claim 1 , wherein the barrier layer comprises a phase changing material.

10. A cushioning article according claim 1 , wherein the polymeric gel material infused into the open-cell foam material is transparent.

11. A cushioning article according claim 1 , wherein the barrier layer comprises an active agent.

12. A cushioning article according to claim 11 , wherein the active agent is selected from the group consisting of an antimicrobial active agent, an antifungal agent, and combinations of at least one of the foregoing.

13. A cushioning article according claim 1 , wherein the depth of the polymeric gel material infused into the open-cell foam material is about 1/16 inch.

14. A cushioning article according to claim 1 , wherein the depth of the polymeric gel material infused into the open-cell foam material is about ⅛ inch.

15. A cushioning article according to claim 1 , wherein the layer of gel-infused foam material and the layer of open-cell foam are coextensive.

16. A cushioning article comprising:

a layer of open-cell foam material comprising an upper surface and a first thickness;

a layer of gel-infused foam material in direct contact with the upper surface of said layer of open-cell foam material, said layer of gel-infused foam material comprising an upper surface and having a second thickness, the gel-infused foam layer comprising a polymeric gel material infused into the open-cell foam material, extending from the upper surface of the layer of open-cell foam material to a pre-determined depth from the upper surface of the layer of open-cell foam material; and

a barrier layer disposed adjacent to the upper surface of the gel-infused foam layer, opposite the layer of open-cell foam material,

wherein the upper surfaces of the open-cell foam layer and the gel-infused foam layer are coplanar, and the second thickness of the layer of gel-infused foam material is less than the first thickness of the layer of open-cell foam material; and

wherein the layer of gel-infused foam material and the layer of open-cell foam are coextensive.