Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s)

Abstract

Embodiments disclosed in the detailed description include a unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a cellular thermoplastic foam and a thermoset material. The thermoset material may also be provided as cellular foam as well. In one embodiment disclosed herein, the unitary composite cushioning structure is formed from a cellular thermoplastic foam and a thermoset material. The cellular thermoplastic foam provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum is disposed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material to secure the at least a portion of the thermoset material to the at least a portion of the cellular thermoplastic foam to provide a unitary composite cushioning structure.

What is claimed is: 
     
         1 . A method for providing a unitary composite cushioning structure, comprising:
 continuously extruding a cellular thermoplastic material having at least one chamber and providing support and cushioning characteristics; and   disposing a non-solid phase of a cellular thermoset material providing a resilient structure with cushioning characteristics into the at least one chamber of the cellular thermoplastic material, such that a stratum is formed between at least a portion of the cellular thermoplastic material and at least a portion of the cellular thermoset material undergoing a transition into a solid phase to form a bond with the cellular thermoplastic material to secure the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material to form the unitary composite cushioning structure exhibiting a combination of the support and cushioning characteristics and the resilient structure with cushioning characteristics when the unitary composite cushioning structure is placed under a load.   
     
     
         2 . The method of  claim 1 , wherein disposing the non-solid phase of the cellular thermoset material comprises thermally forming a foamed thermoplastic material to form the cellular thermoplastic material. 
     
     
         3 . The method of  claim 1 , wherein disposing the non-solid phase of the cellular thermoset material comprises pouring the non-solid phase of the cellular thermoset material into the at least one chamber of the cellular thermoplastic material. 
     
     
         4 . The method of  claim 1 , further comprising curing the unitary composite cushioning structure to bond the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material. 
     
     
         5 . The method of  claim 1 , further comprising providing an adhesive in the stratum to adhere the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material. 
     
     
         6 . The method of  claim 1 , further comprising:
 foaming the thermoset material to provide a cellular thermoset foam,   wherein disposing the non-solid phase of the thermoset material into the at least one chamber comprises disposing the non-solid phase of the cellular thermoset foam into the at least one chamber.   
     
     
         7 . The method of  claim 1 , further comprising mixing at least one filler material into the cellular thermoset material to provide stability to the cellular thermoset material. 
     
     
         8 . The method of  claim 1 , further comprising encapsulating the unitary composite cushioning structure with a second cellular thermoset material. 
     
     
         9 . A method for providing a unitary composite cushioning structure, comprising:
 continuously extruding a cellular thermoplastic material providing support and cushioning characteristics; and   disposing a non-solid phase of a cellular thermoset material providing a resilient structure with cushioning characteristics on at least a portion of an external surface of the cellular thermoplastic material, such that a stratum is formed between at least a portion of the cellular thermoplastic material and at least a portion of the cellular thermoset material undergoing a transition into a solid phase to form a bond with the cellular thermoplastic material to secure the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material to form the unitary composite cushioning structure exhibiting a combination of the support and cushioning characteristics and the resilient structure with cushioning characteristics when the unitary composite cushioning structure is placed under a load.   
     
     
         10 . The method of  claim 9 , further comprising curing the unitary composite cushioning structure to bond the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material. 
     
     
         11 . The method of  claim 9 , further comprising providing an adhesive in the stratum to adhere the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material. 
     
     
         12 . The method of  claim 9 , further comprising mixing at least one filler material into the cellular thermoset material to provide stability to the cellular thermoset material. 
     
     
         13 . The method of  claim 9 , further comprising encapsulating the unitary composite cushioning structure with a second cellular thermoplastic material. 
     
     
         14 . The method of  claim 1 , wherein the disposing further comprises disposing the non-solid phase of the cellular thermoset material into the at least one chamber of the cellular thermoplastic material, such that the stratum is formed between the at least a portion of the cellular thermoplastic material and the at least a portion of the cellular thermoset material undergoing the transition into the solid phase to intermix with and form a chemical bond with the cellular thermoplastic material to secure the at least a portion of the cellular thermoset material directly to the at least a portion of the cellular thermoplastic material. 
     
     
         15 . The method of  claim 14 , wherein the chemical bond comprises a direct chemical bond. 
     
     
         16 . The method of  claim 14 , further comprising mixing a chemical bonding agent in the cellular thermoplastic material to provide the chemical bond between the at least a portion of the cellular thermoplastic material and the at least a portion of the cellular thermoset material. 
     
     
         17 . The method of  claim 1 , wherein the disposing further comprises disposing the non-solid phase of the cellular thermoset material into the at least one chamber of the cellular thermoplastic material, such that the stratum is formed between the at least a portion of the cellular thermoplastic material and the at least a portion of the cellular thermoset material undergoing the transition into the solid phase to intermix with and form a mechanical bond with the cellular thermoplastic material to secure the at least a portion of the cellular thermoset material directly to the at least a portion of the cellular thermoplastic material. 
     
     
         18 . The method of  claim 1 , further comprising forming the cellular thermoplastic material as a cellular thermoplastic material profile having the at least one chamber before disposing the non-solid phase of the cellular thermoset material into the at least one chamber of the cellular thermoplastic material profile.