Process for shaping and covering cushion foam

A process of forming one or more permanent indentations in a piece of open cell, thermoplastic, cushion foam and simultaneously laminating steam-permeable fabric thereto, comprising the following steps:

• (a) placing the fabric over one side of the foam with a layer of hot melt fabric adhesive in between the fabric and the foam, the adhesive having a lower melting point than that of the foam,
• (b) preheating a die that has one or more protruding sections and one or more land areas and which is perforated across substantially its entire contact surface, the preheating being conducted so as to bring the land area(s) to a temperature that is elevated but is below the melt point of the adhesive, and to bring the die's protruding section(s) to a higher temperature than the die's land area(s),
• (c) pressing the preheated die against the fabric-covered side of the foam, causing the die's protrusion(s) to create one or more indentations in the foam,
• (d) ejecting a shot of steam that has been superheated to a temperature substantially higher than the die's protruding section(s) through the perforations in the die at a pressure sufficient to drive the steam through the fabric at least part way into the interior of the foam, the temperature of the steam being high enough to melt the adhesive across substantially the entire contact surface and to cause the foam to become molten and reshaped in the indentation(s), substantially without becoming molten in the land area(s),
• (e) passing a cooling gas through the foam, until the adhesive and the molten areas of the foam have resolidified, thereby laminating the fabric to the foam and permanently fixing the indentation(s) in the foam, and
• (f) disengaging the die and the resultant laminated, shaped composition.