Back to results
US 11,780,208 B2Granted
Moulded composite article formed from laminates
AssigneeSilueta (Private) Limited
InventorsSanje Mahasivam, Pasan Mihijaya, Sulochana Kumari, Nilusha Gunawardena
Life of this patent
Estimating the term…
Abstract
Disclosed herein is a molded article made from two different polyurethane foam laminate materials, which displays both softness and resilience to machine washing. Also disclosed herein is a method of making said foam article.
Claims15
A molded composite article, comprising:
- a first foam laminate formed from a fabric and a polyurethane foam;
- a second foam laminate formed from a fabric and a polyurethane foam;
- and
- an adhesive bonding the first and second laminates together, wherein:
- the molded composite article has been subjected to compression molding;
- the polyurethane foam of the first foam laminate has a density of from 10 to 25 kg/m3 before compression molding, and a hardness of from 2 to 20 before compression molding, as measured using an Asker type F Durometer;
- the polyurethane foam of the second foam laminate has a hardness of from 45 to 90 before compression molding, as measured using an Asker type F Durometer;
- the first foam laminate of the molded composite article is from 7 to 15% thinner relative to the same material before compression molding and the second foam laminate of the molded composite article is from 25 to 60% thinner relative to the same material before compression molding;
- and
- wherein the composite article comprises one or both of the following:
- (i) after ten machine wash and dry cycles, the composite article displays less than 3% shrinkage in a length and width directions, as compared to the original length and width dimensions of the composite article;
- and
- (ii) after twenty-five machine wash and dry cycles, the composite article does not exhibit any delamination.
10 more elements
A method of forming a molded composite article comprising the steps of:
- (a) providing a first foam laminate formed from a fabric and a polyurethane foam having a density of from 10 to 25 kg/m3 and a hardness of from 2 to 20 and a second foam laminate formed from a fabric and a polyurethane foam having a hardness of from 45 to 90, wherein each laminate has a foam side and a fabric side, wherein the hardness is measured using an Asker type F durometer;
- (b) subjecting the second foam laminate to thermoforming to provide a molded outer panel having a thickness that is from 25 to 60% thinner relative to the same material before thermoforming;
- (c) applying an adhesive to the foam side of the first foam laminate and adhering the resulting adhesive-covered foam side of the first foam laminate to the foam side of the molded outer panel to form an intermediate product;
- (d) subjecting the intermediate product to thermoforming to form the composite article, wherein the first foam laminate forms an inner panel of the composite article and has a thickness that is 7 to 15% thinner relative to the same material before thermoforming,
- wherein the composite article comprises one or both of the following:
- (i) after ten machine wash and dry cycles, the composite article displays less than 3% shrinkage in a length and width directions, as compared to the original length and width dimensions of the composite article;
- and
- (ii) after twenty-five machine wash and dry cycles, the composite article does not exhibit any delamination.
5 more elements
Dependencies are inferred from the claim text.