Method and apparatus for bonding fabric to a foam pad

A method of fabricating a cushion assembly (50, 50') comprising the steps of;

• placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a cellular foam pad (12) in facing engagement with the adhesive film (16), compressing the foam pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the foam pad (12) is compressed against the mold surface (18), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).

A method of fabricating an assembly (50, 50') comprising the steps of;

• placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a pad (12) in facing engagement with the adhesive film (16), compressing the pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the pad (12) is compressed against the mold surface (18), heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).

A method of fabricating a cushion assembly (50, 50') comprising the steps of;

• placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and the urge the fabric layer (14) against the mold surface (18), utilizing a mold (18) having a contoured mold surface, and moving a preformed foam pad (12) having the opposite contoured surface over the adhesive film contoured to the mold surface and into mating and non-slipping engagement therewith, placing a cellular foam pad (12) in facing engagement with the adhesive film (16), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).

A method of fabricating an assembly (50,50') comprising the steps of;

• placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), characterized by placing a pad (12) in facing engagement with the adhesive film (16), and heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).