Patents by Inventor Surendra Khambete
Surendra Khambete has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11559143Abstract: A method of manufacturing a mattress that comprises forming a mattress inner core; forming a non-quilted mattress cover; and attaching the non-quilted mattress cover to the inner core without sewing. The non-quilted mattress cover may be formed of a laminate including a polymeric non-woven fabric that may be embossed and cut to include a cover top panel and a plurality of cover side panels that are unitary with and extend outward from the cover top panel. The step of attaching the non-quilted mattress cover to the inner core without sewing includes orthogonally orienting the cover side panels relative to the cover top panel and fusing portions of adjoining surfaces of adjacent cover side panels to each other to form a coffin, inserting the mattress inner core into the coffin, folding non-fused portions of the adjoining surface of the adjacent cover side panels over the mattress inner core, and bonding a bottom panel to the non-fused portions of the cover side panels and the mattress inner core.Type: GrantFiled: December 18, 2020Date of Patent: January 24, 2023Assignee: IndraTech LLCInventor: Surendra Khambete
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Publication number: 20210186229Abstract: A method of manufacturing a mattress that comprises forming a mattress inner core; forming a non-quilted mattress cover; and attaching the non-quilted mattress cover to the inner core without sewing. The non-quilted mattress cover may be formed of a laminate including a polymeric non-woven fabric that may be embossed and cut to include a cover top panel and a plurality of cover side panels that are unitary with and extend outward from the cover top panel. The step of attaching the non-quilted mattress cover to the inner core without sewing includes orthogonally orienting the cover side panels relative to the cover top panel and fusing portions of adjoining surfaces of adjacent cover side panels to each other to form a coffin, inserting the mattress inner core into the coffin, folding non-fused portions of the adjoining surface of the adjacent cover side panels over the mattress inner core, and bonding a bottom panel to the non-fused portions of the cover side panels and the mattress inner core.Type: ApplicationFiled: December 18, 2020Publication date: June 24, 2021Applicant: Indratech LLCInventor: Surendra Khambete
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Patent number: 9902609Abstract: One exemplary aspect of the present disclosure relates to, among other things, a tunable cushion including a core made of a polymer material, and at least one topper layer adjacent the core, which is also made of a polymer material. Further, the core and the at least one topper layer provide a cushion assembly having a support factor of less than or equal to 4 with an Indentation Load Deflection (ILD) determined using a 4 inch batt sample of the cushion assembly.Type: GrantFiled: July 16, 2014Date of Patent: February 27, 2018Assignee: INDRATECH, LLCInventor: Surendra Khambete
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Publication number: 20160157628Abstract: A multilayered cushion according to an exemplary aspect of the present disclosure includes, among other things, a first layer of a first material, a second layer of the first material, and a third layer of a second material between the first and second layers. The second material is stiffer than the first material.Type: ApplicationFiled: December 8, 2015Publication date: June 9, 2016Inventors: Surendra Khambete, Andrew Conrad Bambeck
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Publication number: 20160015185Abstract: An exemplary aspect of the present disclosure relates to a mattress and a method for manufacturing a mattress. The method includes, among other things, providing a batt of polymer fibers with a reduced dimension, forming a topper layer of polymer fibers having a lower surface corresponding to the reduced dimension in the batt, and arranging the topper layer relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.Type: ApplicationFiled: June 30, 2015Publication date: January 21, 2016Inventors: Surendra Khambete, Richard Conway
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Publication number: 20150020316Abstract: One exemplary aspect of the present disclosure relates to, among other things, a tunable cushion including a core made of a polymer material, and at least one topper layer adjacent the core, which is also made of a polymer material. Further, the core and the at least one topper layer provide a cushion assembly having a support factor of less than or equal to 4 with an Indentation Load Deflection (ILD) determined using a 4 inch batt sample of the cushion assembly.Type: ApplicationFiled: July 16, 2014Publication date: January 22, 2015Inventor: Surendra Khambete
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Publication number: 20140201921Abstract: A cushion assembly includes a cover having a perimeter panel providing a perimeter height. Spaced apart cover panels extend between the perimeter panels. The perimeter and cover panels together provide a cushion cavity. A cushion includes randomly oriented fibers bonded to one another to provide a core of a batt that has opposing surfaces. In one disclosed example, the fibers are polyester and include an average length randomly oriented in three dimensions. The core has a thickness that is greater than the average length to accommodate the average length in all three dimensions. The batt includes manufactured, tufted and desired design heights. A tuft extends through the cushion to the opposing surfaces to maintain the cushion in the tufted height, which is less than the manufactured height. The cushion is provided with the desired design height with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and more than the tufted height.Type: ApplicationFiled: March 24, 2014Publication date: July 24, 2014Applicant: IndraTech LLCInventor: Surendra Khambete
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Patent number: 7698817Abstract: A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.Type: GrantFiled: September 12, 2005Date of Patent: April 20, 2010Assignee: International Automotive Components Group North America, Inc.Inventors: Surendra Khambete, William Griffin, Fred Skidmore, Sandip Mehta
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Patent number: 7540307Abstract: An inventive machine and method are used for manufacturing fiber articles with a variable density across the article. The machine includes a mold providing a cavity. An inventive cover providing an opening is arranged over the cavity. In one example, the opening is provided on a belt. The size of the opening may also be adjustable. The cover and mold move relative to one another to arrange the opening over multiple portions of the cavity. A fiber feed system deposits fiber material in the multiple portions beneath the opening in varying amounts. Various sensors and other devices may be used to control the positioning of the opening to regulate the distribution of fiber deposited in the cavity.Type: GrantFiled: October 6, 2005Date of Patent: June 2, 2009Assignee: IndraTech LLCInventor: Surendra Khambete
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Patent number: 7537818Abstract: Acoustically absorptive carpeting includes a primary layer of fibrous material with yarn tufts extending outwardly therefrom and a secondary layer of thermoplastic material that forms a carpet backing. The carpet backing is rendered porous. A substrate of porous material is attached to the carpet backing. The substrate includes a layer of fine fibrous material attached to a layer of coarse fibrous material. The layers of fine and coarse fibrous material each have respective different acoustic impedances. The layer of coarse fibrous material has fibers in an open, loose configuration. The carpet backing is bonded to the layer of coarse fibrous material with a thermoplastic adhesive material such that the thermoplastic adhesive material encapsulates individual fibers of the layer of coarse fibrous material without extending therebetween.Type: GrantFiled: June 7, 2004Date of Patent: May 26, 2009Assignee: International Automotive Components Group North America, Inc.Inventors: Timothy J. Allison, Surendra Khambete, Fred Skidmore, Bill Griffin
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Patent number: 7290300Abstract: A non-woven, randomly oriented polyester fiber cushion is provided with conditioned air to regulate a temperature of the cushion assembly. The overlapping fibers form interstices through which the air is blown. The air flows through the fibers in a tortuous path.Type: GrantFiled: October 28, 2005Date of Patent: November 6, 2007Assignee: IndraTech, LLCInventor: Surendra Khambete
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Publication number: 20070240810Abstract: A machine includes a conveyer that is movable along a generally linear path. Two fiber chutes deliver fiber to the conveyer. First and second heaters and compression devices are used to provide different densities to the different fiber layers. A first heater and first compression device is used to compress a first fiber layer prior to depositing the first fiber layer onto a second fiber layer. The compressed first fiber layer and uncompressed second fiber layer are conveyed to the second heater and second compression device where both layers are heated and compressed. Aesthetic layer may also be applied to at least one of the layers. A third layer may be provided on the first layer opposite the second layer. The compression devices are adjustable by an actuator for processing fiber batts having different thicknesses on the same machine. Adjustable trimmers are used to trim the sides of the continuous fiber batts and cut the batts to a desired width, height and length.Type: ApplicationFiled: April 12, 2006Publication date: October 18, 2007Inventor: Surendra Khambete
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Publication number: 20070151658Abstract: A method of manufacturing an article having controlled density, such as a decoupler for attenuating sound in a vehicle, is disclosed. The method comprises the conveying of material into a mold to form a preform having a shape of the mold, heating the preform to a temperature such that adjacent materials bond to one another upon cooling, and forming the heated preform in the mold into a predetermined three-dimensional configuration. The mold may have a perforated section and at least one panel movably attached to the mold so as to selectively expose portions of the perforated section. The density of the preform may be varied as the at least one panel is moved to expose the perforated section of the mold. A contoured mold for manufacturing articles such as decouplers is also disclosed.Type: ApplicationFiled: September 12, 2005Publication date: July 5, 2007Inventors: Surendra Khambete, William Griffin, Fred Skidmore, Sandip Mehta, Robert Queen
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Publication number: 20060246799Abstract: Sound attenuating laminates for use within vehicles are provided that include a substrate and polyurethane attached to selected portions of the substrate. The polyurethane is non-porous and serves as a barrier to attenuate sound passing through the substrate. Additional non-porous polyurethane may be added to one or more selected portions of the polyurethane layer to enhance sound attenuation characteristics in the one or more selected portions. Sound attenuating laminates for use within vehicles are provided that include a substrate and breathable polyurethane attached to selected portions of the substrate. The polyurethane serves as an absorber of sound (e.g., sound generated within a vehicle compartment). Additional breathable polyurethane may be added to one or more selected portions of the polyurethane layer to enhance sound absorption characteristics in the one or more selected portions.Type: ApplicationFiled: June 27, 2006Publication date: November 2, 2006Inventors: Anthony Messina, Surendra Khambete, Girma Gebreselassie
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Publication number: 20060208379Abstract: A method of manufacturing an article having controlled density, such as a decoupler for a vehicle interior trim component, is disclosed which uses an indexing, preferably rotary, apparatus. The method comprises the conveying of materials, preferably fibers, into an enclosure to form a preform having a shape of the enclosure, transferring the preform to a mold on an indexing apparatus where the preform is heated to a temperature such that adjacent fibers bond to one another upon cooling, and moving the mold to a press where the heated preform is molded into a predetermined three-dimensional decoupler configuration. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is removed to expose the perforated portion of the enclosure.Type: ApplicationFiled: September 12, 2005Publication date: September 21, 2006Inventors: Surendra Khambete, William Griffin, Fred Skidmore, Sandrip Mehta
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Publication number: 20060208378Abstract: A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.Type: ApplicationFiled: September 12, 2005Publication date: September 21, 2006Inventors: Surendra Khambete, William Griffin, Fred Skidmore, Sandip Mehta
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Publication number: 20060182935Abstract: A method of manufacturing an article, such as a decoupler for a vehicle interior trim component, is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles, such as decouplers, of the present invention is also disclosed.Type: ApplicationFiled: September 12, 2005Publication date: August 17, 2006Inventors: Graham Tompson, Surendra Khambete, William Griffin, Fred Skidmore, Sandip Mehta
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Patent number: 7055649Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.Type: GrantFiled: August 30, 2004Date of Patent: June 6, 2006Assignee: Collins & Aikman Products Co.Inventors: Graham Tompson, Surendra Khambete, Fred Skidmore, Bill Griffin
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Publication number: 20060075615Abstract: An aesthetic cushion assembly includes an aesthetic layer and a fiber cushion bonded to the aesthetic layer. In one example, the aesthetic layer extends beyond a periphery of the fiber cushion to provide flaps that can be used to secure the aesthetic cushion assembly to a commercial product, such as a chair. The flaps can also be used to form a finished product such as a mattress. The aesthetic cushion assembly can be manufactured using a variety of methods. In one example, the fiber is blown onto the aesthetic layer and the fiber and aesthetic layer are heated together. In another example, the fiber is blown into a cavity and separately heated or a simple batt is generated by non-woven manufacturing methods. The fibers are molded into a desired article shape to form a fiber cushion. The fiber cushion and/or aesthetic layer are then trimmed, if necessary, to provide a finished article shape. The aesthetic cushion can then be shipped to a customer and only requires installation onto a commercial product.Type: ApplicationFiled: October 27, 2005Publication date: April 13, 2006Inventor: Surendra Khambete
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Patent number: 7017250Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.Type: GrantFiled: December 3, 2003Date of Patent: March 28, 2006Assignee: Collins & Aikman Products Co.Inventors: Girma Gebreselassie, Matt Starling, Anthony J. Messina, Surendra Khambete