Void cells with outwardly curved surfaces

Abstract

Implementations described and claimed herein include a cushioning structure and method for manufacturing a cellular cushioning system, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning structure comprises void cells formed in an array, which comprise multiple outwardly curved surfaces, with varying radius measurements. Stiffness in the void cells can vary by varying the radii. The outwardly curved surfaces prevent buckling and provide support for high impact by absorbing energy.

What is claimed is: 
     
         1 . An energy absorbing, elastically deformable void cell comprising:
 four sidewalls forming a rectangular outline, the sidewalls including:
 a base portion that includes only uninterrupted inwardly curved surfaces; and 
 a peak portion that includes only one uninterrupted outwardly curved surface on at least two of the sidewalls and uninterrupted inwardly curved surfaces on all of the sidewalls, wherein the outwardly curved surfaces constitute at least 20% of the overall exterior surface area of the void cell, wherein the void cell is elastically deformable over at least 10% of its stroke, wherein the void cell is open to atmosphere. 
   
     
     
         2 . The energy absorbing, elastically deformable void cell of  claim 1 , wherein a perimeter length substantially exceeds an overall outline length of a base portion of the void cell. 
     
     
         3 . The energy absorbing, elastically deformable void cell of  claim 1 , wherein an outwardly curved surface depth substantially recesses from an overall outline of a base portion of the void cell. 
     
     
         4 . The energy absorbing, elastically deformable void cell of  claim 1 , wherein the void cell includes a dome-shaped peak surface. 
     
     
         5 . The energy absorbing, elastically deformable void cell of  claim 1 , wherein radii of the outwardly curved surfaces are less than both half a length and half a width of the rectangular outline.