US 11,518,159 B2Granted

Laminate foam and methods of making laminate foam

AssigneeNovation Iq LLC

InventorMichael Peterson

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Abstract

A method of making laminate foam material is provided. The laminate foam material includes a layer of non-foam material sandwiched between two layers of foam material. The non-foam material is bonded to the foam material, such as with a bonding agent and/or by heating respective surfaces of the foam material until the surface softens or melts. When a heating process is utilized, the non-foam material is pressed against the softened or melted foam material. As the foam material begins to cool, the non-foam material becomes bonded to the foam material. The non-foam material is narrower than the foam material and is positioned relative to the foam material such that the edges of the non-foam material are concealed by the foam material. Foam products, such as foam mats, can be formed from the laminate foam material by cutting across the width of the foam material.

Claims17

Dependent claims

A method of forming a laminate material for forming a laminate product, the method comprising:

heating a top surface of a first piece of foam material;
pressing a first piece of non-foam material against the top surface of the first piece of foam material while the top surface is still at an elevated temperature;
retaining the first piece of non-foam material in contact with the top surface of the first piece of foam material while the top surface is allowed to cool;
heating a bottom surface of a second piece of foam material;
pressing the second piece of foam material against the first piece of non-foam material while the bottom surface is still at an elevated temperature;
retaining the bottom surface of the second piece of foam material in contact with the first piece of non-foam material while the bottom surface is allowed to cool;
heating a top surface of the second piece of foam material;
pressing a second piece of non-foam material against the top surface of the second piece of foam material while the top surface is still at an elevated temperature;
retaining the second piece of non-foam material in contact with the top surface of the second piece of foam material while the top surface is allowed to cool;
heating a bottom surface of a third piece of foam material;
pressing the third piece of foam material against the second piece of non-foam material while the bottom surface is still at an elevated temperature;
retaining the bottom surface of the third piece of foam material in contact with the second piece of non-foam material while the bottom surface is allowed to cool,
wherein the first piece of foam material forms at least part of a first layer of the laminate material,
wherein the first piece of non-foam material forms at least part of a second layer of the laminate material,
wherein the second piece of foam material forms at least part of a third layer of the laminate material,
wherein the second piece of non-foam material forms at least a part of a fourth layer of the laminate material, and
wherein the third piece of foam material forms at least part of a fifth layer of the laminate material,
wherein the first, second, and third pieces of foam material each have a thickness of 0.35 inches and 0.75 inches;
wherein the total thickness of the first, second, third, fourth, and fifth layers is between 1.45 inches and 2 inches, and
wherein the first, second, and third pieces of foam material have a pre-cut width of approximately 75 inches;
and
cutting said first, second, and third pieces of foam material to a post-cut width of approximately 70-72 inches.

19 more elements

A method of forming a laminate product from a laminate material, the method comprising cutting the laminate material across an entire width of the laminate material so as to form first and second pieces of laminate material, the first piece of laminate material being sized to form a single laminate product and the second piece of laminate material being sized to form a plurality of laminate products, wherein the laminate material comprises:

a first layer having opposed top and bottom surfaces;
a second layer bonded to the top surface of the first layer;
a third layer having opposed top and bottom surfaces, the bottom surface bonded to at least one of the second layer and the top surface of the first layer;
a fourth layer bonded to the top surface of the third layer;
and
a fifth layer having a bottom surface bonded to at least one of the fourth layer and the top surface of the third layer,
wherein the first, third, and fifth layers are each formed from a foam material having a width of approximately 75 inches,
wherein the second and fourth layers are each formed from a non-foam material, and
wherein a density of the laminate product is significantly less than the density of water;
and
the method further comprising cutting the laminate material along its length at a first edge region of the laminate material so as to form a first edge of the laminate product, the first edge region of the laminate material being defined at least partially by a portion of the first and third layers of the laminate material extending beyond a first edge of the second layer of the laminate material,
wherein the resulting laminate product is approximately 70-72 inches wide.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/538,413Filed 12 Aug 2019 · division
Priority: 1 Aug 2016
Published: US 2019/0358931 A128 Nov 2019
Granted: 6 Dec 2022
Term ends: Not estimatedThe source records don’t support an estimate.

Classification30 codes

B32B 37/06
Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding: characterised by the heating method
B29C 65/103
Using hot gases or flames coming in contact with at least one of the parts to be joined: direct heating both surfaces to be joined
B29C 65/106
Using hot gases or flames coming in contact with at least one of the parts to be joined: using flames coming in contact with at least one of the…
B29C 66/1122
Single lapped joints: single lap to lap joints, i.e. overlap joints

Family

Application62/369,549Us provisional application · filed 1 Aug 2016
Application15/666,361Parent of this division · filed 1 Aug 2017
US 2019/0358931 A1Pre-grant publication · published 28 Nov 2019
US 2018/0029327 A1Published application
US 11,518,159 B2This patent

From the US filing history. Foreign family members aren’t listed.