COMPOSITE MATERIAL, METHOD OF MAKING AND ARTICLES FORMED THEREBY
A composite material, method of making and articles formed thereby. The composite material can comprise a gel-infused foam material.
1 . A cushioning article, comprising:
a first material layer comprising an upper surface;
two or more spaced apart infused regions comprising a second material, different from the first material, at least partially infused into the first material and extending from the upper surface of the first material layer to a pre-determined depth from the upper surface of the first material layer; and
a barrier layer disposed adjacent to and in direct contact with the upper surface of the first material layer and an upper surface of the two or more infused regions.
2 . A cushioning article according to claim 1 , further comprising a third material layer disposed between and the upper surface of the first material layer and the barrier layer.
3 . A cushioning article according to claim 2 , wherein the second and third materials are the same.
4 . A cushioning article according to claim 2 , wherein the second and third materials are different.
5 . A cushioning article according to claim 2 , wherein the third material layer comprises embossing.
6 . A cushioning article according to claim 2 , wherein the third material layer comprises text, graphics, color and combinations thereof
7 . A cushioning article according to claim 2 , wherein the third material layer is selected from the group consisting of woven materials, non-woven materials, spacer materials, and combinations thereof.
8 . A cushioning article according to claim 1 , wherein the first material layer is an open-cell foam.
9 . A cushioning article according claim 8 , wherein the foam is selected from the group consisting of polyurethane foam, latex foam, and combinations of at least one of the foregoing.
10 . A cushioning article according to claim 1 , wherein the barrier layer is a thermoplastic elastomer (TPE).
11 . A cushioning article according to claim 1 , wherein the barrier layer is a thermoplastic polyurethane (TPU).
12 . A cushioning article according to claim 1 , wherein the barrier layer comprises an elongation of at least about 100 percent.
13 . A cushioning article according to claim 1 , wherein the barrier layer has a thickness of less than about 5 milli-inches.
14 . A cushioning article according to claim 1 , wherein the barrier layer comprises a moisture transmittable material.
15 . A cushioning article according to claim 1 , wherein the barrier layer comprises a phase changing material.
16 . A cushioning article according to claim 1 , wherein the second material is infused into the first material to a depth of about 1132 inch from the upper surface of the first material.
17 . A cushioning article according to claim 1 , wherein the second material is infused into the first material to a depth of about 1/16 inch from the upper surface of the first material.
18 . A cushioning article according to claim 1 , wherein the second material is infused into the first material to a depth of about ⅛ inch.
19 . A cushioning article according to claim 1 , wherein the second material is infused into the first material to a depth of about ¼ inch.
20 . A cushioning article according to claim 1 , wherein the cushioning article is a mattress topper.
21 . A cushioning article according to claim 1 , wherein the barrier layer comprises an active agent.
22 . A cushioning article according to claim 21 , 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.
23 . A method of making a cushioning article according to claim 1 , comprising:
providing a first material layer comprising an upper surface;
forming two or more spaced apart infused regions comprising a second material, different from the first material, by at least partially infusing the first material into the upper surface of the first material layer to a pre-determined depth from the upper surface of the first material layer; and
disposing a barrier layer adjacent to and in direct contact with the upper surface of the first material layer and an upper surface of the two or more infused regions.