Foam transfer method and apparatus for making formed laminate

A method for making a formed laminate comprising:

• spraying a quick reacting foamable liquid mixture onto a transfer member for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before substantial curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction;
• transferring reacted foam and any foamable liquid mixture that has not yet reacted from the transfer member onto a flexible cloth sheet;
• locating a liner over the foam after the transfer thereof to the flexible cloth sheet;
• and
• providing relative movement of a pair of contoured mold surfaces toward each other with the flexible cloth sheet, the liner and the foam therebetween while the foam is still in the transitory state such that the foam is collapsed and formed with the flexible cloth sheet and the liner to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible cloth sheet and to the liner to provide the formed laminate.

A method for making a formed laminate comprising:

• spraying a quick reacting foamable liquid mixture onto a transfer member for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before substantial curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction;
• applying printed matter to a flexible cloth sheet;
• clamping the flexible cloth sheet with the printed matter thereon facing downwardly;
• transferring reacted foam and any foamable liquid mixture that has not yet reacted from the transfer member downwardly onto the clamped flexible cloth sheet;
• locating a liner over and outwardly beyond the foam after the transfer thereof to the flexible cloth sheet;
• and
• providing relative movement of a pair of contoured mold surfaces toward each other with the flexible cloth sheet, the liner and the foam therebetween while the foam is still in the transitory state such that the foam is collapsed and formed with the flexible cloth sheet and the liner to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible cloth sheet and the liner to provide the formed laminate.

Apparatus for making a formed laminate comprising:

• an applicator for supplying a quick reacting foamable liquid mixture for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before substantial curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction;
• a transfer member for receiving the foamable liquid mixture from the applicator;
• a frame for supporting a flexible sheet to which reacted foam and any foamable liquid mixture that has not yet reacted is transferred from the transfer member;
• and
• a mold including a pair of mold members having associated contoured mold surfaces that are relatively movable toward each other with the flexible sheet and the foam therebetween while the foam is in the transitory state such that the foam is collapsed and formed with the flexible sheet to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible sheet to provide the formed laminate.

Apparatus for making a formed laminate, comprising:

• an applicator including a sprayer for supplying a quick reacting foamable liquid mixture for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before substantial curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction;
• a transfer member for receiving the foamable liquid mixture from the applicator;
• a frame for clamping a flexible cloth sheet to which reacted foam and any foamable liquid mixture that has not yet reacted is transferred from the transfer member;
• and
• a mold including a pair of mold members having associated contoured mold surfaces that are relatively movable toward each other with the clamped flexible cloth sheet and the foam therebetween while the foam is in the transitory state such that the foam is collapsed and formed with the flexible cloth sheet to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible cloth sheet to provide the formed laminate.

Apparatus for making a formed laminate, comprising:

• an applicator including a sprayer for supplying a quick reacting foamable liquid mixture for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before substantial curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction;
• a transfer member having a planar surface for receiving the foamable liquid mixture from the applicator, and said planar surface having a periphery including a sharp bevel;
• a frame having a clamp for clamping a flexible cloth sheet to which reacted foam and any foamable liquid mixture that has not yet reacted is transferred from the transfer member, and said clamp of the frame permitting the flexible cloth sheet to slide;
• and
• a mold including a pair of mold members having associated contoured mold surfaces that are relatively movable toward each other with the clamped flexible cloth sheet and the foam therebetween while the foam is in the transitory state such that the foam is collapsed and formed with the flexible cloth sheet to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible cloth sheet to provide the formed laminate.