US 4,786,351 A · Process and apparatus for simultaneously shaping foam and laminating fabric thereto

Abstract

A machine for laminating fabric (123) to open cell cushion foam (124) while forming design lines in the foam is disclosed. The machine comprises a top hollow die (21) having perforations (38) and a complementary, hollow bottom die (54) which also has perforations (130). Hot melt adhesive (125) is interleaved between fabric (123) and foam (124). Top die (21) is preheated to just below the melt point of adhesive (125); then dies (21) and (54) are closed against the layered workpiece, with top die (21) contacting the face of fabric (123). A shot of superheated steam, e.g., at 80 psig and 700.degree. F., is ejected from perforations (38) and (130) to melt adhesive (125). Then a vacuum is applied to the perforations to pull ambient air through the workpiece and cool it. The resolidified ashesive (125) holds foam (124) in its deformed shape and laminates fabric (123) to the foam.

Claims55

Dependent claims

A process of shaping open cell cushion foam and simultaneously laminating steam permeable fabric thereto, comprising the following steps:

(a) placing a layer of hot melt fabric adhesive over one side of the foam,
(b) overlaying the adhesive with the fabric,
(c) pressing a contoured die against the fabric-covered side of the foam, thereby creating one or more bends or indentations in the foam, said die being perforated across substantially its entire contact surface and said contact surface being preheated to an elevated temperature, but said temperature being below the melting point of the adhesive,
(d) ejecting a shot of superheated steam through the perforations in the die at a pressure sufficient to drive the steam through the fabric and force some of the adhesive at least part way into the interior of the foam, the temperature of the steam being high enough to melt the adhesive,
(e) passing a cooling gas through the foam, until the adhesive has resolidified, thereby laminating the fabric to the foam and permanently fixing the bend(s) or indentation(s) in the foam, and
(f) disengaging the die and the resultant laminated, shaped composition.

3 more elements

An apparatus for shaping a piece of porous resilient material or for laminating steam-permeable fabric to a porous substrate, comprising

(a) means for releasably holding a workpiece of the material to be acted upon,
(b) a contoured die which is perforated across substantially its entire contact surface and which has an enclosed chamber behind its contact surface which is in communication with the perforations in the die,
(c) means for pressing the die against one side of the workpiece while the workpiece is being held by said holding means,
(d) means for preheating the die prior to pressing it against the workpiece,
(e) means for supplying steam under pressure,
(f) means for superheating the steam,
(g) a steam line for delivery of the superheated steam under pressure directly to the enclosed chamber of the contoured die while the die is pressed against the workpiece,
(h) valve means for opening and closing said steam line,
(i) means for passing a cooling gas through the workpiece while the die is pressed against it, and
(j) means for disengaging the die and the workpiece, so as to permit the finished workpiece to be withdrawn from the apparatus.

7 more elements

Dependencies are inferred from the claim text.

Process and apparatus for simultaneously shaping foam and laminating fabric thereto

Life of this patent

Process and apparatus for simultaneously shaping foam and laminating fabric thereto

Life of this patent

Abstract

Claims55