Deep draw method of making impact and vibration absorbing articles and the articles formed thereby

Abstract

The present disclosure relates to cushioning members, methods of making and methods of using, particularly to cushioning members comprising a plurality of spaced apart pillars comprising a polymeric material.

What is claimed is: 
     
         1 . A cushioning member, comprising:
 a multilayer material comprising a barrier layer, a polymeric material layer disposed adjacent to the barrier layer, and a stabilization layer disposed adjacent to and opposite the barrier layer;   a plurality of pillars disposed in the multilayer material, each of the plurality of pillars comprising an upper surface and a sidewall extending downwardly from the upper surface to define a radiused upper edge disposed between the upper surface and the sidewall;   a plurality of spacer regions disposed between the plurality of pillars, each of the plurality of spacer regions comprising a spacer region width;   wherein each of the plurality of pillars comprises a height and a base width, and the ratio of the pillar height to the pillar base width is about 0.125:1 to about 8:1.   
     
     
         2 . The cushioning member of  claim 1 , wherein the plurality of pillars have a thickness of less than about 3 inches, and the plurality of spacer regions have a thickness of about 0.005″. 
     
     
         3 . The cushioning member of  claim 1 , wherein the plurality of pillars have a thickness of less than about 3 inches, and the plurality of spacer regions have a thickness of about 0.250″. 
     
     
         4 . The cushioning member of  claim 1 , wherein the barrier layer is selected from the group consisting of textiles, textile composites, thermoplastic elastomer (TPE) materials, and combinations comprising at least one of the foregoing. 
     
     
         5 . The cushioning member of  claim 4 , wherein the barrier layer is a thermoplastic polyurethane (TPU). 
     
     
         6 . The cushioning member of  claim 1 , wherein the barrier layer comprises an elongation of at least about 100 percent. 
     
     
         7 . The cushioning member of  claim 1 , wherein the barrier layer has a thickness of less than or equal to about 5 mil. 
     
     
         8 . The cushioning member of  claim 1 , wherein the barrier layer has a thickness of greater than or equal to about 5 mil. 
     
     
         9 . The cushioning member of  claim 1 , wherein the barrier layer comprises a moisture transmittable material. 
     
     
         10 . The cushioning member of  claim 1 , wherein the barrier layer comprises a phase changing material. 
     
     
         11 . The cushioning member of  claim 1 , wherein the barrier layer comprises an active agent. 
     
     
         12 . The cushioning member of  claim 11 , wherein the active agent is selected from the group consisting of an antimicrobial active agent, an antifungal agent, and combinations comprising at least one of the foregoing. 
     
     
         13 . The cushioning member of  claim 1 , further comprising a fabric material layer disposed between the polymeric material layer and the stabilization layer. 
     
     
         14 . The cushioning member of  claim 13 , wherein the fabric layer comprises knits, wovens, non-wovens, synthetics, non-synthetics, and combinations comprising at least one of the foregoing. 
     
     
         15 . The cushioning member of  claim 1 , wherein at least one of the barrier layer and the stabilization layer comprise a fabric material layer comprising an elongation of at least about 100 percent. 
     
     
         16 . The cushioning member of  claim 15 , wherein the fabric layer comprises knits, wovens, non-wovens, synthetics, non-synthetics, and combinations comprising at least one of the foregoing. 
     
     
         17 . The cushioning member of  claim 16 , wherein the fabric layer is fluid-permeable. 
     
     
         18 . The cushioning member of  claim 1 , further comprising an adhesive disposed between the polymeric material layer and the stabilization layer. 
     
     
         19 . The cushioning member of  claim 18 , wherein the adhesive is disposed on a support layer. 
     
     
         20 . The cushioning member of  claim 19 , wherein the support layer is a TPE. 
     
     
         21 . The cushioning member of  claim 1 , wherein the stabilization layer is removable from the cushioning material. 
     
     
         22 . The cushioning member of  claim 1 , wherein the ratio of the pillar thickness to the pillar width is about 8:1. 
     
     
         23 . The cushioning member of  claim 1 , wherein the sidewall extends perpendicularly downwardly from the upper surface. 
     
     
         24 . The cushioning member of  claim 1 , wherein the sidewall undercuts the upper surface.