Cushioning structures including interconnected cells

Abstract

Cushioning articles or structures are provided including a cell layer with an array of cells interconnected with each other. Each of the cells includes at least three cell walls extending between the first and second major surfaces thereof. The cell walls are shared by the adjacent cells, and the cell layer further includes a land region located at the second major surface and connecting the at least three cell walls. A base layer is attached to the second major surface of the cell layer to form a sheet.

What is claimed is: 
     
         1 . An article comprising:
 a cell layer having a first major surface and a second major surface opposite the first major surface, the cell layer comprising an array of cells interconnected with each other, each of the cells comprising at least three cell walls extending between the first and second major surfaces thereof, the cell walls each being shared by the adjacent cells, the cell layer further comprising a land region located at the second major surface and connecting the cell walls; and   a base layer attached to the second major surface of the cell layer to form a sheet.   
     
     
         2 . The article of  claim 1 , wherein the land region extends along the second major surface and forms a continuous structure with the cell walls at the second major surface, and the land region is attached to the base layer. 
     
     
         3 . The article of  claim 1 , wherein the base layer comprises one or more layers of polystyrene based block copolymer, polyethylene, rubber, polypropylene, polyvinyl chloride, polyester, polyurethane, polyamide, or copolymers thereof 
     
     
         4 . The article of  claim 1 , wherein the continuous structure formed by the land region and the cell walls at the second major surface has no internal interface. 
     
     
         5 . The article of  claim 1 , wherein the cell layer comprises one or more thermoplastic elastomers (TPEs). 
     
     
         6 . The article of  claim 1 , wherein at least some of the cell walls each include a modulated end adjacent the first major surface of the cell layer. 
     
     
         7 . The article of  claim 6 , wherein the modulated ends include a plurality of vertices at joints of the adjacent cell walls, the vertices widening towards the second major surface of the cell layer. 
     
     
         8 . The article of  claim 6 , wherein the modulated end includes an opening on the respective cell wall, wherein the modulated end includes an opening on the respective cell wall, the percent area of the opening and the cell wall being about 10 to about 90 percent. 
     
     
         9 . The article of  claim 1 , wherein the cell walls each have a thickness tapered away from the second major surface. 
     
     
         10 . The article of  claim 9 , wherein the cell walls have a draft angle of about 0.1° to about 10°. 
     
     
         11 . The article of  claim 1 , wherein the cells each comprise six shared walls to form a honeycomb pattern. 
     
     
         12 . The article of  claim 1 , wherein the cell walls have substantially the same thickness. 
     
     
         13 . The article of  claim 1 , wherein the sheet has a thickness of about 0.125″ (about 0.3 cm) to about 0.35″ (about 0.9 cm). 
     
     
         14 . The article of  claim 1 , wherein the sheet has a density of about 0.1 g/cc to about 0.3 g/cc. 
     
     
         15 . The article of  claim 1 , wherein the sheet has a compression modulus of about 50 psi to about 150 psi. 
     
     
         16 . The article of  claim 1 , wherein the sheet has a compression yield stress of about 3 psi to about 25 psi. 
     
     
         17 . The article of  claim 1 , wherein the sheet has less than about 50% compression set. 
     
     
         18 . The article of  claim 1 , wherein the sheet is a cushioning pad or mat.