FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&5
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10, rule 13)
10
15
“A GEL AND CUSHIONING MATERIAL BASED ON THERMOPLASTIC
ELASTOMERS AND METHOD OF MAKING THEREOF”
20
25
COMFORT GRID TECHNOLOGIES PRIVATE LIMITED, an Indian company of
35 1st Flr, Vijay Transtech, Chandivali Village Off Saki Vihar Rd Sakinaka Andheri E,
400072, Mumbai, Mumbai City, Maharashtra, India.30
35
The following specification particularly describes the invention and the manner in which
it is to be performed
40
2
Field of Invention
The present disclosure relates to a field of thermoplastic elastomers (TPE). More specifically, the
present disclosure relates to a gel made of thermoplastic elastomers. More specifically, the present
disclosure relates to a cushioning material made of gel of thermoplastic elastomers. Further, the present
disclosure also relates to a process for making the gel and the cushioning material.5
Reference
The subject matter disclosed in the present application/invention comprises an improvement in, or a
modification of the invention claimed in the specification of the main patent granted IN345890.
10
Background
Historically, the mattress industry or the cushioning industry (sofa, chairs etc.) are dominated by foam,
cotton wool wadding, metallic springs, polyurethane foams and latex foams etc. However, in last
decade or so thermoplastic elastomeric materials and silicon are slowly but surely entering medical
field. This is because TPE compares favorably low cost and can be recycled easily, thus environment15
friendly. Since, there has not been any significant development or invention into this industry. The
present disclosure provides better solution.
Fluffy, solid, strong elastic gels exhibiting resistance to elastic deformation, capable of shape-memory
recovery, being dimensionally stable and having a density in the range 0.6- 0.99 were discovered20
around two decades back with applications into medical field. These substances are designated as
thermoplastic elastomers and combination of properties of thermoplastics in that these can be brought
into molten state and shaped and again shaped article can be brought into molten state by heating yet
retain rubber like elastic properties.
25
References are available where the thermoplastic elastomers are used in the gels for cushioning
material however, the specific gels made up of specific thermoplastic elastomers as disclosed in the
present invention is not disclosed in any of the references.
Previously reported methods and recipes for fabrication of thermoplastic elastomer-based gels as30
cushioning material were complicated and contained many ingredients, yet desired results were not
obtained. The recipe used in present disclosure does not contain as many ingredients. Blending
3
ingredients by hot melting process as suggested in some references is quite risky, as melting point of
mix specially after addition of filler becomes quite high often crossing flash point of plasticizing oil.
Whole mixing and blending in present case are done at 70o C, much below the flash point of oil.
Bleeding of oil, even after addition of expensive non-bleeding agents significantly in previous methods.
Present composition leads to non-bleeding products. This became possible after addition of5
Polypropylene (PP) to the recipe. Bleeding of oil remains a perennial problem with any of reported
recipes. To obtain required strength and stiffness often more proportion of TPE is used in the
formulation, which is not desirable, cost wise.
The presently disclosed recipe/composition and process to overcome the problem of the prior art and
results in a better product in terms of good strength and stiffness by addition of polypropylene (PP)10
without increasing thermoplastic elastomer (TPE) content.
The disclosed gel in the present invention is of low cost as compared to the conventionally available
gels, silicon-based gel and other cushioning material like latex and memory foam.
The disclosed gel has better physical and pressure relieving properties compared to traditional
cushioning material like cotton, foam, spring etc. The disclosed gel has better tensile strength,15
elongation and compression set (evaluation of sagging over time) than any other traditional cushioning
material like Memory foam, latex and foam.
The present invention also discloses a process of making gel based on thermoplastic elastomers. The
present invention also relates to a design of the mattress that helps in distributing weight.
20
The biggest issue that the present disclosure or the gel material addresses is increase in comfort and
pressure relief in cushioning materials. The present disclosure materials do not and sag over time which
is major drawback of the existing materials. Thus, the present disclosure as compared to the existing
materials show improvement in longevity and sagging property.
25
Description of the Drawings
Figure 1- Shows a color image of cushioning element with homogeneously distributed hollow
columns.
Figure 2- Shows a 2 D drawing of above structure showing partition walls for 25/25 mm. hollow
columns.30
Figure 3- Shows a 3 D drawing of a small section of cushion.
4
Figure 4a-4f – Illustrates an assembly with the developed elastomeric gel to replace foam/spring/latex
mattresses.
Figure 5a- illustrates a perspective top view of a cushioning component, in accordance with an
embodiment of the present disclosure.
5
Figure 5b- illustrates a schematic sectional view of a portion of ribs of cushioning component of Figure
5a.
Figure 6- illustrates a perspective bottom view of the cushioning component of Figure 5a and
10
Figures 7a and 7b- illustrates an exemplary schematic view of a portion of the cushioning component,
in accordance with an embodiment of the present disclosure.
Detailed Description
While the disclosure is susceptible to various modifications and alternative forms, specific aspect15
thereof has been shown by way of example and will be described in detail below. It should be
understood, however that it is not intended to limit the invention to the particular forms disclosed, but
on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within
the spirit and the scope of the invention.
20
The Applicants would like to mention that the examples are mentioned to show only those specific
details that are pertinent to understanding the aspects of the present disclosure so as not to obscure the
disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit
of the description herein.
25
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-
exclusive inclusion, such that a method that comprises a list of components does not include only those
components but may include other components not expressly listed or inherent to such process. In other
words, one or more elements in a method proceeded by “comprises... a” does not, without more
constraints, preclude the existence of other elements or additional elements in the method.30
Accordingly, the present disclosure provides a gel made of thermoplastic elastomers and a cushioning
material made of gel of thermoplastic elastomers. Further, the present disclosure provides a process for
5
making the gel and the cushioning material. The thermoplastic elastomers content in the gel material
is very less. Even after the reduction of thermoplastic elastomers, the gel material has superior
properties. The gel material of the disclosure has good strength, stiffness and is cost effective.
In one embodiment of the present disclosure, a gel material comprising thermoplastic elastomer 12-355
wt%, mineral oil 65-85 wt% and polypropylene 0-10%.
In another embodiment of the present disclosure, the polypropylene is in the range of 1-10%.
In another embodiment of the present disclosure, the total parts of the components in the thermoplastic10
elastomer add up to 100 % wt/wt.
In another embodiment of the disclosure, the thermoplastic elastomer is A-B-A triblock thermoplastic
elastomer.
In yet another embodiment of the disclosure the thermoplastic elastomer is A-B-A triblock wherein A15
represents a crystalline polymer such as such monoalkenylarene polymer and B represents elastomeric
polymer.
In yet another embodiment of the disclosure, the monoalkenylarene polymer is polystyrene but not
limited to polystyrene.
In yet another embodiment of the disclosure the thermoplastic elastomer is styrene-ethylene-butylene-20
styrene or styrene-[ethylene-(ethylene-propylene)]-styrene block copolymer.
In yet another embodiment of the disclosure, the B elastomeric polymer is polyethylene, polypropylene
or polybutylene, hydrogenated poly(isoprene), hydrogenated poly(butadiene), hydrogenated poly
(isoprene + butadiene), poly(ethylene/ propylene) or hydrogenated poly(ethylene/butylene-
ethylene/propylene) or polybutylene or combination thereof.25
In yet another embodiment of the disclosure, the polypropylene is a homopolymer polypropylene
and/or copolymer propylene.
In yet another embodiment of the disclosure, the copolymer can be block copolymer.
In yet another embodiment of the disclosure, the gel material additionally comprises filler in the range
of 1-10 wt% and antioxidant in the range of 0.05-0.5 wt%.30
6
In yet another embodiment of the disclosure, the fillers are selected from precipitated silica, china clay
and/or calcium carbonate, preferably the fillers are selected from clay, calcium carbonate (CaCO3) or
silica and more preferably the filler is CaCO3.
In yet another embodiment of the disclosure, the gel material is a cushioning material.
In yet another embodiment, an elastomer-based gel material comprising: 12-35 wt% of a thermoplastic5
elastomer, 65-85 wt% of a mineral oil, and 0-10 wt% of a polypropylene wherein the gel material is
arranged in a buckling grid structure to form a cushioning component.
In another embodiment of the disclosure, a method of producing the thermoplastic elastomer-based gel
material as claimed in claim 1 comprises steps of : mixing ingredients (a) 65% to 85% of mineral oil,
(b) 12% to 35% of thermoplastic elastomer; and/or (c) fillers and antioxidants in a mixer to produce a10
powder, pelletizing the powder in an extruder at a temperature of 120-160oC, to produce pellets, and
injection molding the pellets at a temperature in the range of between 120-190oC to produce the
thermoplastic elastomer-based gel material.
In yet another embodiment of the disclosure, the step of mixing is done in a sigma/ribbon mixer by
pouring mineral oil into a heated chamber of sigma/ribbon mixer; adding thermoplastic elastomer in15
the oil, and mixing till absorption of the oil into the elastomer and adding fillers, and antioxidants.
Heating the chamber increases oil absorption which is critical for producing softer and lower than 0
Shore A articles and mixing elastomer first makes a more homogenous mixture than mixing fillers,
polypropylene first
In another embodiment of the disclosure, a cushioning material comprising the thermoplastic20
elastomer-based gel material of the invention.
In yet another embodiment elastomeric based gel material with A-B-A tri-block copolymer and oil is
organized in the form of a grid.
In yet another embodiment of the disclosure, the cushioning material has a buckling mold structure
having homogeneously distributed hollow columns.25
In yet another embodiment of the disclosure, the buckling mold structure has a male component having
multiple designs of core, cavity or complimentary component of mold design.
In an embodiment of the disclosure, the gel material is arranged in a buckling grid structure to form a
cushioning element for pressure relief.
7
In another embodiment of the disclosure, the elastomer-based gel material is used in a mattress, bed
mat, sofa, chairs, baby head rest, knee pads, ankle pads, heel pads, pressure and pain relief applications
etc.
Thermoplastic elastomer in the present disclosure is sourced from various manufactures such as
SEPTON manufactured by Kuraray Corporation Japan and Aparprene by APAR Industries Ltd (India)5
is used in the present invention. In most of Septon grades the end groups are styrene while the middle
portion of tri block copolymer may be hydrogenated poly isoprene, poly butadiene or poly
isoprene/butadiene. Polystyrene contents in these thermoplastic elastomers may vary from 10 to 70%.
A range of molecular weights and physical properties are available in different grades of Septons.
10
Mineral oil is selected from but not limited to pearl 70, pearl 85, pearl 250 and pearl 300 from Apar
Industries, savanol 10, savanol 15 and savanol 20 oils from Savita Oil Technologies, oils form Gandhar
Oil Refineries Ltd.. Preferably, the mineral oil is selected such that the oil has lower kinetic viscosity.
More preferably the mineral oil is selected from white mineral oils.
15
Fillers are selected from but not limited to precipitated silica, china clay and/or calcium carbonate.
Preferably the fillers are selected from clay, calcium carbonate (CaCO3) or silica. More preferably
CaCO3 which is cost effective and gives aesthetically and better properties products.
Antioxidant is selected from but are not limited to Irganox provided by BASF. Preferably two20
Antioxidants are involved namely, primary and secondary antioxidants. The primary antioxidant is
Irganox 1010 and the secondary antioxidant is Irgafos 168.
Polypropylene can be homopolymer polypropylene and/or copolymer propylene. More preferably
impact polypropylene is used in the presently disclosed thermoplastic elastomer based gel for25
cushioning material. Further, PP with medium to high MFI impact (such as 22 to 35) gives better
combination of tensile strength and elongation and effective processing.
In the present thermoplastic elastomer gel composition, there is no need of addition of anti-bleeding
agent when the disclosed PP in the range of 1% to 10% is a part of gel recipe/composition. Hence, the
problem of oil-bleed is also overcome in the desired product. Polypropylene also help deliver better30
results on hardness, compression set which is a critical requirement in cushion/sleeping products like
mattress. The particular composition is used as per requirement of properties desired in the end product.
8
The present disclosure gives the recipe/composition comprising of A-B-A triblock thermoplastic
elastomer (A represents a crystalline polymer such as monoalkenylarene polymer like a polystyrene ,
B being elastomeric polymer like polyethylene, polybutylene) or a SEEPS, Stryene-ethylene-
ethylene/propylene styrene co-block polymer, a thermoplastic material, plasticizing oil and other5
commonly used ingredients used in rubber compounding which can be converted into desired products
by any molding method such as open dye casting, compression molding or injection molding in the
temperature range 150- 200 degree Celsius . Mattress made from this recipe is way better than
conventional mattress material available like PU foam, memory foam, spring, latex etc. Excellent
tensile strength, more than 1000% elongation, adequate rigidity, longevity and instant regain of shape10
after removal of pressure from the object, are some of the properties which make this material
altogether different compared to common elastomers and plastics and materials used in the
cushioning/mattress industry.
There are various molding methods that can be used for fabrication of desired objects, namely open15
dye casting, compression molding and injection molding. Any method of molding can be chosen for
fabrication of the articles. Open dye casting may be method of choice for low gel content articles.
Probably due to low cost and reasonable speed this method is currently used for molding of medical
devices for physiotherapy and comfort. Compression molding is quite a slow process and it is seldom
used in commercial production. Injection molding is a preferred method for fabrication of cushioning20
elements with required speed as well as adequate stiffness in the product, which can only be achieved
by having a compound with comparatively medium to high elastomer content and special additives
like PP.
In particular application of making reasonable size cushioning material with hollow columns using all25
the three molding methods as mentioned above and different oil to elastomer ratios with additives a
unique recipe was developed, which gave good tensile strength, elongation ranging from 1000%-
2200%, adequate stiffness and excellent shape memory. The molding method ultimately chosen was
injection molding on 1600 MT capacity machine which could inject up to 15 Kg compound in one
shot.30
9
In an embodiment, the cushioning member (100) includes a plurality of first ribs (12) extending in a
first direction, and a plurality of second ribs (14) intersecting the plurality of first ribs (12) and extend
in a second direction perpendicular to the first direction. The plurality of first ribs (12) and plurality of
second ribs (14) are integrally arranged in an array to form a grid structure. The grid structure is defined
with a top portion and a bottom portion. Further, the grid structure is defined with an array of openings5
(20) such that each opening (20) is surrounded by two or more buckling walls of the plurality of first
and second ribs (12, 14). The array of openings (20) with interconnected buckling walls are configured
to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly
distributing the load across the cushioning component (100), and return to an original state upon
removal of the load. In an embodiment, the plurality of fist ribs (12) and the second ribs (14) may10
extend are defined with a predetermined height and thickness. The predetermined height of the plurality
of first ribs (12) and the second ribs (14) may range about 7 mm to 100mm. Further, a thickness of the
plurality of first ribs (12) and the second ribs (14) may range about 0.5mm to 6 mm.
In an embodiment, the cushioning component (100) further comprises, a plurality reinforcing ribs (16)15
intersects the plurality of first ribs (12) and the second ribs (14) and extends in a third direction forming
a predetermined angle with respect to the first and second direction. The plurality reinforcing ribs (16)
are integrally formed with respect to the plurality of first ribs (12) and the second ribs (14) to define
another type of grid structure formed in an array. Each of the reinforcing ribs (16) along with the
plurality first and second of ribs (12 and 14) are in a spaced apart configuration with each other to form20
the grid structure as shown in Figure 5a, 5b, 6, 7a and 7b defining plurality of openings (20). Each of
the plurality of reinforcing ribs (16) includes a predetermined height. In an embodiment, the
predetermined height of the plurality of reinforcing ribs (16) is less than the predetermined height of
the first plurality of ribs (12). In another embodiment, the predetermined height of the plurality of
reinforcing ribs (16) is less than the predetermined height of the plurality of second ribs (14). Further,25
the predetermined height of the plurality of reinforcing ribs (16) may be less than a mean of the
predetermined height of the first plurality of ribs (12) and the plurality of second ribs (14). This
configuration of the plurality of reinforcing ribs (16) provides structural rigidity to the plurality of first
and second ribs (12, 14). More specifically, the grid structure formed in combination of the plurality
of ribs first and second (12, 14) and with plurality of reinforcing ribs (16) provides denser grid structure30
at the bottom portion of the cushioning component (100) as shown in Figure 6. Accordingly, the grid
structure formed by the plurality of first and second ribs (12, 14) defined with height greater than the
10
plurality of reinforcing ribs (16) forms less dense grid at the top portion of the cushioning component
(100), as seen from in Figure 5a. In an embodiment, the predetermined height of the plurality of first
and second ribs (12, 14) and the reinforcing ribs (16) can be same. The density of the grid structure can
be varied based on an application of usage of the cushioning component (100). This is possible by
providing the grid structure of cushioning component (100) which is integrally formed by at least one5
of plurality of first and second ribs (12,14) and the plurality of reinforcing ribs (16). A predetermined
height of the reinforcing ribs (16) may range between 7 mm to 100mm. Further, a thickness of the each
of the plurality of reinforcing ribs (16) range between 0.5mm to 6 mm. The plurality of first and second
ribs (12,14) and the plurality of reinforcing ribs (16) is defined with a draft angle with respect to a
vertical axis (A-A) of the cushioning component (100). In an embodiment, the draft angle is ±5° with10
respect to the vertical axis (A-A) of the cushioning component (100). More particularly as seen in
Figure 6, the plurality of reinforcing ribs (16) may have a second end having a thickness larger than a
thickness of the rib at the top end. This facilitates ease of the removal of the grid from a mold post
manufacturing, thereby reducing cycle time and thus aids in reducing cost of material and
manufacturing as an overall thickness of buckling walls is reduced.15
The process of compounding is described in following steps;
Mixing of Ingredients- First required quantity 65% to 85% of oil was poured into heated chamber of
sigma/ribbon mixer. Preferably first put the SEEPS copolymer in the range of 12% to 35% in the oil20
and mix it as this will ensure proper absorption of the oil into the SEEPS co-polymer then put other
fillers, Polypropylene and antioxidants to the sigma/ribbon mixer. Mixer was run after each addition
for few minutes till the additive appeared to be evenly dispersed in the oil. Small portions of required
amount of Septon 4055 were added to running sigma mixer and the whole mass was churned for few
tens of minutes till a fluffy solid mass was obtained. The process also ensures higher oil absorption of25
the oil to the extent of oil to the extent of 3 to 8 times of the preferred TPE like Septon 4055. Thus,
mixing method of putting Septon first into oil and mixing it before mixing ant other fillers, polymers
or additives.
The step of mixing wherein the TPE (Septon 4055 and Septon 4077) is first adding to the oil results in
a more homogenous mixture and the adsorption of oil is better.30
Pelletization- The fluffy mass obtained as above was converted to 2 mm dia. and 3 mm. long cylinders
using a continuous screw injector having L/D ratio of 20 or above. Temperature across the screw was
kept between 120-160 C. The process recommended is to keep the temperature lower during extrusion.
A cutter was deployed at the exit point of screw extruder, which operated at a set speed to give cylinders
of desired length. The exit point of extruder was cooled by passage of chilled water for solidification5
of compound.
Injection Molding- Injection molding was done using a 1600 MT capacity machine. The temperature
across the length varied between 120-190 C in six zones. The temperature increased from hopper to
injection point in a pre-decided sequence. Multi-channel injection was adopted and all the delivery10
lines from extruder to mold were heated between 120-150oC. The mold was provided with cooling
channels for rapid cooling of compound in the mold by passing chilled water, after injection. One cycle
took around 1-4 minutes. There may be cooling channels across each of the inserts of the mold to have
a cooling time of less than 1 minute. Also, inject the material in the mold via a hot runner system with
multiple points in less than 1 min, more preferably less than 30 sec.15
The injection molding step of the invention has the various advantages over the compression moulding
and hand moulding. The output article from recommended process has:
a) better texture,
b) more consistency,
c)less rejection,20
d) more economical,
e) less labor intensive and
f) better quality
The present invention discloses a process and recipe for making of a yieldable thermoplastic elastomer
gel for cushioning material that includes a flexible, resilient, gel cushioning media having shape25
memory and being substantially solid and non-flowable at temperatures below 90 degree Celsius. The
process as comprises preparation of compound in an appropriate form suitable for injection molding.
Extruded objects remain usable below 90 degree Celsius that is well above normal atmospheric
temperatures. The tensile strength of extruded material varies between 1.2-2.5 N/mm2. Elongation30
measured was more than 1000. Shrinkage during molding was found 1-3%. Specific gravity of molded
rubber was 0.6- 0.9 g/cm3. Shore A hardness of the gel is between 0 and 0, more preferred gel is
12
between 0 to 1. The shape of the cushion with buckling column helps in air circulation and pressure
reduction on different body parts.
Steps of a process for making thermoplastic elastomer-based gel
Mineral oil in sigma mixer,5
Heated with stirring
Add only Septon in 3 batches for proper mixing and absorption of oil
Stir for few minutes.10
Add filler and PP
stir for few minutes after each addition.
15
Add antioxidant
Fluffy Powder20
Pelletization in Extruder at less than 160 ºC
25
Regular size pellets
Injection Molding
30
Thermoplastic elastomer-based gel (Cushioning Material)
13
Examples
The present invention is now described by way of the following non-limited examples. While preferred
aspects and example configurations have been shown and described below, it is to be understood that
various further modifications and additional configurations are under development which may be5
apparent to those skilled in the art. It is intended that examples disclosed are illustrative of the preferred
nature of the disclosure and should not be interpreted as limitations on the scope of the disclosure.
Example 1
The gel material composition of example 1 comprises Septon 4055, 17%, CaCO3: 7%, PP 320: 3%,10
Oil: 71%. The gel material of example 1 is compared with the gel material without having the ADC
(Comparative Example-1). The properties of both the gels are shown below in table 1.
Table 1:
Composition Example 1
Comparative
Example-1
Septon 4055 17% 17%
CaCO3 7%, 8%,
PP 320 3%, 3%,
Oil 71%, 72%,
ADC 1.5% 0 %
Properties Unit Standard
Shore A ASTM D2240 0 0
Tensile Kg/cm2 ASTM D 412 1.2 0.9
Elongation % ASTM D 412 >1150 884
Specific gravity ASTM D 792 0.81 0.89
Compression set after 50%
compression % Variation IS 7888-1976 3.74% 15.33%
15
Example 2:
The gel material composition of example 2 comprises Septon 4055: 16%- 19%, CaCO3: 5% - 8%,
polypropylene: 3%, mineral oil: 70% - 75% and ADC varied as 1.5%, 1% and 0%.
The Comparative Examples , 3 (a), and 3(b) of the gel material composition without polypropylene
and ADC. The properties of these gel materials are tabulated below in table 2.20
14
Table 2:
Composition
Comparative
Example 3 (a)
Comparative
Example 3 (b)
Septon 4055 14% 14%
CaCO3 8%, 8%
PP320 3% 0 %
Oil 75% 78%
Properties Unit Standard
Shore A
ASTM
D2240 0 0
Tensile Kg/cm2
ASTM D
412 1.1 0.8
Elongation %
ASTM D
412 1000 1100
Specific
gravity
ASTM D
792 0.89 0.87
Compression
set after 50%
compression
%
variation
IS 7888-
1976 15.33% 10%
Also, through experiments, it has been found that thermoplastic elastomers (TPE) content of 12% -
35% is suitable for obtaining desired set of properties such as tensile strength, elongation, and specific
gravity. The optimum levels of thermoplastic elastomers (TPE) for Septon 4077 is 15% - 20% and5
Septon 4055 is 20% to 35% of the total composition.
Table 3:
Composition Example 4a Example 4b
SEBS6159 15% 15%
SEBS6151 3% 3%
Talc HFM 5%, 5%
PP320 2% 0%
Oil 75% 77%
Properties Unit Standard
Shore A
ASTM
D2240 0
0
Tensile Kg/cm2
ASTM D
412 0.8
0.7
Elongation %
ASTM D
412 1081
1154
Specific
gravity
ASTM D
792 0.87
0.87
15
Another embodiments with grid structure made from SEBS show desirable results for tensile strength,
elongation and the stickiness of the molded product.
Also, through experiments, it has been found that thermoplastic elastomers (TPE) content of 12% -
35% is more suitable for obtaining desired set of properties such as tensile strength, elongation, and5
specific gravity. The preferable range of thermoplastic elastomers (TPE) for Septon 4077 is 12% - 20%
and Septon 4055 is 12% to 35% of the total composition.
Areas of application: The disclosed invention can have applications in cushions, mattresses, medical
devices for physiotherapy, operation theatre and ICU implement, toys, and shoe accessories.10
Advantages of the Invention:
The gel material disclosed in the present invention provides:
• good strength and stiffness;
• low cost;15
• better physical and pressure relieving properties;
• better tensile strength, elongation and compression set (evaluation of sagging over time).
20
16
We Claim:
1. An elastomer-based gel material comprising
12% to 35% of a thermoplastic elastomer,
65-85 wt% of a mineral oil, and
0-10 wt% of a polypropylene.5
2. The elastomer-based gel material as claimed in claim 1, wherein the polypropylene is in the
range of 1-10wt%.
3. The elastomer-based gel material as claimed in claim 1, wherein the thermoplastic elastomer is10
A-B-A triblock thermoplastic elastomer.
4. The elastomer-based gel material as claimed in claim 1 or 3, wherein A represents a crystalline
polymer such monoalkenylarene polymer, and B represents elastomeric polymer.
15
5. The elastomer-based gel material as claimed in claim 1 to 4, wherein monoalkenylarene
polymer is polystyrene.
6. The elastomer-based gel material as claimed in claim 1 to 5, wherein the thermoplastic
elastomer is styrene-ethylene-butylene-styrene or styrene-[ethylene-(ethylene-propylene)]-20
styrene block copolymer.
7. The elastomer-based gel material as claimed in claim 1 to 5, wherein the B elastomeric polymer
is polyethylene, polypropylene or polybutylene, hydrogenated poly(isoprene), hydrogenated
poly(butadiene), hydrogenated poly (isoprene + butadiene), poly(ethylene/ propylene) or25
hydrogenated poly(ethylene/butylene-ethylene/propylene), or combination thereof.
8. The elastomer-based gel material as claimed in claims 1or 7, wherein the polypropylene is a
homopolymer polypropylene and/or copolymer propylene.
30
9. The elastomer-based gel material as claimed in claims 1, wherein the gel material additionally
comprises filler in the range of 1-10 wt% and antioxidant in the range of 0.05-0.5 wt%.
17
10. The elastomer-based gel material as claimed in claim 4, wherein the fillers are selected from
precipitated silica, china clay and/or calcium carbonate, preferably the fillers are selected from
clay, calcium carbonate (CaCO3) or silica and more preferably the filler is CaCO3.
11. The elastomer-based gel composition as claimed in claim 1, wherein the gel material is a5
cushioning material.
12. An elastomer-based gel material comprising
12-35 wt% of a thermoplastic elastomer,
65-85 wt% of a mineral oil, and10
0-10 wt% of a polypropylene.
wherein the gel material is arranged in a buckling grid structure to form a cushioning
component.
13. A cushioning material comprising the thermoplastic elastomer-based gel material as claimed in15
claims 1 to 12.
14. The cushioning material as claimed in claims 13, wherein the structure of the cushioning
material is a buckling wall structure having homogeneously distributed hollow columns.
20
15. The cushioning material as claimed in claims 14, wherein the buckling mold structure has a
male component having multiple designs of core, cavity or complimentary component of mold
design.
16. The cushioning material as claimed in claim 12, wherein the cushioning component (100)25
comprises:
a plurality of first ribs (12) extending in a first direction; and
a plurality of second ribs (14) intersecting the plurality of first ribs (12) and
extending in a second direction perpendicular to the first direction,
the plurality of first ribs (12) and the second ribs (14) forming a grid structure having a30
top portion and a bottom portion, wherein the grid structure defines an array of openings
(20) with interconnected buckling walls,
wherein the array of openings (20) with interconnected buckling walls
configured to buckle when a load applied on at least one of the top portion and the
18
bottom portion, for uniformly distributing the load across the cushioning component
(100), and return to an original state upon removal of the load.
17. The cushioning material as claimed in claim 16, wherein the cushioning component (100)
comprises a plurality of reinforcing ribs (16) intersecting the plurality of first ribs (12) and the5
second ribs (14) and extending in a third direction forming a predetermined angle to the first
and second direction.
18. The elastomer-based gel material as claimed in claims 1-12 as and when is used in a mattress,
bed mat, sofa, chairs.10