Ergonomic Support Structure for Human Body Parts and Method of Manufacturing Same

Abstract

An ergonomic support structure, particularly for supporting parts of the human body. The structure ( 1 ) comprises a main body ( 2 ) with a viscoelastic insert ( 2 ) permanently anchored thereto. The main body ( 2 ) has at least one first layer ( 4 ) made of a material selected from those having a relatively low density and a relatively high mechanical strength, which is associated to at least one second layer of polymer resin for monolithically anchoring said at least one insert ( 3 ). A process for making the above structure.

1 . An ergonomic support structure for supporting parts of the human body, said structure comprising a main body with a viscoelastic insert permanently anchored thereto, wherein said main body comprises at least one first layer formed of a metal sheet, at least one second layer of polymeric material associated to said at least one first layer, and at least one third layer of a polymeric material interposed between said first layer and said at least one viscoelastic insert, wherein said viscoelastic insert is placed over said at least one first layer to define a free contact surface (S) that is susceptible of controlled deformation, and wherein said at least one third layer is directly applied to said first layer and has suitable adhesive properties to anchor said first layer to said viscoelastic insert. 
   
   
       2 . A structure as claimed in  claim 1 , wherein said metal is selected from the group consisting of titanium, aluminum, stainless steel, and magnesium. 
   
   
       3 . A structure as claimed in  claim 1 , wherein said at least one second layer comprises one or more thermoplastic or thermosetting resins for monolithically anchoring said viscoelastic insert. 
   
   
       4 . A structure as claimed in  claim 1 , further comprising a thermoplastic cover layer placed over said viscoelastic insert. 
   
   
       5 . A structure as claimed in  claim 4 , wherein said cover layer is of the transparent type. 
   
   
       6 . A structure as claimed in  claim 1  wherein said viscoelastic insert is made of a gel material. 
   
   
       7 . A structure as claimed in  claim 6 , wherein said gel comprises a polyurethane gel. 
   
   
       8 . A process for making an ergonomic support structure as claimed in  claim 1 , said method comprising the steps of:
 a) providing a mold having an inner cavity of a predetermined shape which corresponds to the external configuration of a main body of a support structure;   b) opening said mold and laying thereon at least one first layer comprising a metal sheet;   c) placing directly over said first layer at least one third layer of a polymer material;   d) placing at least one viscoelastic insert in said mold directly over said at least one first layer;   e) placing over said at least one viscoelastic insert at least one second layer;   f) hermetically sealing said mold and heating it to a predetermined operating temperature;   g) cooling said mold to a predetermined final temperature;   h) opening said mold and removing the finished support structure therefrom;   wherein said polymeric material of said third layer has suitable adhesive properties to anchor said first layer to said at least one viscoelastic insert.   
   
   
       9 . A process as claimed in  claim 8 , further comprising a step during which a thermoplastic cover layer is placed over said at least one viscoelastic insert. 
   
   
       10 . (canceled) 
   
   
       11 . A process as claimed in  claim 8 , wherein said predetermined final temperature is of 18° C. to 50° C. 
   
   
       12 . A process as claimed in  claim 8 , wherein said predetermined operating temperature is of 20° C. to 300° C. 
   
   
       13 . A process as claimed in  claim 8 , wherein said predetermined final temperature is of about 20° C. 
   
   
       14 . A process as claimed in  claim 8 , wherein said predetermined operating temperature is about 120° C.