Composite foam laminate and method
AssigneeDetroit Gasket Company
InventorRalph G. Doerfling
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Abstract
The method of this disclosure permits the application of a foam layer, in fluid form, to a relatively porous substrate and the formation of a contoured foam laminate using a relatively rigid foam. The method includes heating the substrate prior to application of the fluid foam and forming the laminate in a die prior to completion of foaming. The laminate includes a flexible substrate, preferably a polyurethane foam layer and a lattice skrim located between the substrate and the exposed surface of the foam layer.
Claims13
A method of permanently applying a plastic foam backing to a relatively porous substrate, including the steps of:
- a. heating the relatively porous substrate to which the foam is to be applied;
- b. applying a layer of foaming plastic in fluid form to the heated substrate surface, the plastic foam on the heated substrate providing a blow barrier at the foam-substrate interface;
- c. completing the foaming of said foam plastic layer and curing into an integral homogeneous foam-substrate laminate.
A method of forming a contoured laminate, comprising the steps of:
- a. a heating a relatively porous carpet,
- b. applying a foamable relatively rigid polyurethane, including a foaming agent, to the back face of said carpet,
- c. forming the polyurethane-fabric laminate in a die under pressure and heat, prior to complete foaming of the polyurethane, simultaneously curing and completing the foaming of the polyurethane layer and forming the contoured shape in the laminate, without wrinkling the carpet substrate.
Dependencies are inferred from the claim text.