Cascade Designs, Inc.

Peter Dale Haggerty

James M Lea

Richard Charles Andler

An expanded resilient product and methods for making the same are disclosed. The product is characterized as a geometric solid of resilient material that has a plurality of slits formed therein. Each slit is defined by a first surface having a protruding portion and second surface having a recess portion corresponding to the protruding portion of the first surface which together form an interlocking fit between the two. Forces are applied to the product sufficient to dislodge a protruding portion of the first surface from the complementary recess portion of the second surface, thereby forming a plurality of gaps. The product is then permitted to relax, whereupon the protruding portions compressively contact the complementary recess portions of the second surface. But because of the interlocking fit, the protruding portions are prevented from re-engaging the recess portions and thereby maintain the expanded nature of the product. A method for manufacturing the product involves the creation of the slits and subsequent physical expansion of the resilient product to produce the self-sustaining gaps or apertures.

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Mercer Island, WA, United States of America

Peter Dale Haggerty