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US 5,851,339 AGranted
Method of making a laminated product such as a mattress and furniture insulator pad
AssigneeFoamex L.P.
InventorJohn R. Rucker
Life of this patent
Estimating the term…
Abstract
The present invention relates to a method of making a laminated product, such as an insulator pad comprised of foam and stiffening layers held together with adhesive. A thin protective barrier foam sheet is placed between the surface of a compression roller and the sheets to be laminated together by passing them between compression rollers. The thin protective barrier foam sheet may or may not form the outer layer of the laminated product and prevents adhesive and foam material from contaminating the surface of the roller.
Claims15
A continuous method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- applying an adhesive coating directly to an upper surface of the core foam sheet;
- applying an adhesive coating directly to a lower surface of the core foam sheet;
- passing the core foam sheet coated with adhesive and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the adhesive coating that is on the upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the adhesive coating that is on the lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between the other compression roller and a second surface of the second stiffening layer;
- so that when the core foam sheet coated with adhesive on its upper and lower surfaces, the first stiffening layer, the second stiffening layer, the second foam sheet, and the third foam sheet pass between the pair of compression rollers, the first surface of the first stiffening layer adheres to the upper surface of the core foam sheet, the top surface of the second foam sheet contacts one of the compression rollers, the first surface of the second stiffening layer adheres to the lower surface of the core foam sheet, and no adhesive contacts the surfaces of the compression rollers.
3 more elements
A continuous method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- placing a hot melt film adhesive on or adjacent to an upper surface of the core foam sheet;
- placing a hot melt film adhesive on or adjacent to a lower surface of the core foam sheet;
- placing a first surface of the first stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the upper surface of the core foam sheet;
- placing a first surface of the second stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the lower surface of the core foam sheet,
- passing the core foam sheet, the hot melt adhesive films, and the stiffening layers between the pair of compression rollers;
- placing a second foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between the other compression roller and a second surface of the second stiffening layer;
- and
- applying heat to activate the hot melt film adhesive while the sheets, stiffening layers and adhesive films are between the rollers so that when the core foam sheet, the adhesive, the stiffening layers and the second and third foam sheets pass between the pair of compression rollers, the first surface of the first stiffening layer adheres to the upper surface of the core foam sheet, the first surface of the second stiffening layer adheres to the lower surface of the core foam sheet, the top surface of the second foam sheet contacts one of the compression rollers, and no adhesive contacts the surfaces of the compression rollers.
6 more elements
A continuous method of preventing contamination of the surfaces of compression rollers when first and second stiffening layers and a core foam sheet are compressed between a pair of compression rollers, comprising:
- depolymerizing an upper surface of the core foam sheet;
- depolymerizing a lower surface of the core foam sheet;
- passing the core foam sheet with depolymerized upper and lower surfaces and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the depolymerized upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the depolymerized lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between one of the compression rollers and a second surface of the first stiffening layer, and placing a third foam sheet having a top surface and a bottom surface formed from open-celled polyurethane foam with a thickness of about 1/32 inch between the other compression roller and a second surface of the second stiffening layer so that when the core foam sheet, the top surface of the second foam sheet contacts one of the compression rollers, the first and second stiffening layers and the second and third foam sheets pass between the compression rollers, the first surface of the first stiffening layer adheres to the upper surface of the core foam sheet, and the first surface of the second stiffening layer adheres to the lower surface of the core foam sheet.
1 more element
A method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- applying an adhesive coating directly to an upper surface of the core foam sheet;
- applying an adhesive coating directly to a lower surface of the core foam sheet;
- passing the core foam sheet coated with adhesive and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the adhesive coating that is on the upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the adhesive coating that is on the lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a second surface of the second stiffening layer;
- so that when the core foam sheet coated with adhesive on its upper and lower surfaces, the first stiffening layer, the second stiffening layer, the second foam sheet, and the third foam sheet pass between the pair of compression rollers, no adhesive contacts the surfaces of the compression rollers and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the second foam sheet is separated from the first stiffening layer and core foam sheet.
3 more elements
A method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- applying an adhesive coating directly to an upper surface of the core foam sheet;
- applying an adhesive coating directly to a lower surface of the core foam sheet;
- passing the core foam sheet coated with adhesive and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the adhesive coating that is on the upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the adhesive coating that is on the lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a second surface of the second stiffening layer;
- so that when the core foam sheet coated with adhesive on its upper and lower surfaces, the first stiffening layer, the second stiffening layer, the second foam sheet, and the third foam sheet pass between the pair of compression rollers, no adhesive contacts the surfaces of the compression rollers and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the third foam sheet is separated from the first stiffening layer and core foam sheet.
3 more elements
A method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- placing a hot melt film adhesive on or adjacent to an upper surface of the core foam sheet;
- placing a hot melt film adhesive on or adjacent to a lower surface of the core foam sheet;
- placing a first surface of the first stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the upper surface of the core foam sheet;
- placing a first surface of the second stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the lower surface of the core foam sheet;
- passing the core foam sheet, the hot melt adhesive films, and the stiffening layers between the pair of compression rollers;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a second surface of the second stiffening layer;
- and
- applying heat to activate the hot melt film adhesive while the sheets, stiffening layers and adhesive films are between the rollers so that when the core foam sheet, the adhesive, the stiffening layers and the second and third foam sheets pass between the pair of compression rollers, no adhesive contacts the surfaces of the compression rollers, and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the second foam sheet is separated from the first stiffening layer and core foam sheet.
6 more elements
A method of preventing contamination of the surfaces of a pair of compression rollers when first and second stiffening layers and a core foam sheet are compressed between the pair of compression rollers, comprising:
- placing a hot melt film adhesive on or adjacent to an upper surface of the core foam sheet;
- placing a hot melt film adhesive on or adjacent to a lower surface of the core foam sheet;
- placing a first surface of the first stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the upper surface of the core foam sheet;
- placing a first surface of the second stiffening layer adjacent to the hot melt film adhesive that is on or adjacent to the lower surface of the core foam sheet;
- passing the core foam sheet, the hot melt adhesive films, and the stiffening layers between the pair of compression rollers;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer;
- placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a second surface of the second stiffening layer;
- and
- applying heat to activate the hot melt film adhesive while the sheets, stiffening layers and adhesive films are between the rollers so that when the core foam sheet, the adhesive, the stiffening layers and the second and third foam sheets pass between the pair of compression rollers, no adhesive contacts the surfaces of the compression rollers, and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the third foam sheet is separated from the second stiffening layer and core foam sheet.
6 more elements
A method of preventing contamination of the surfaces of compression rollers when first and second stiffening layers and a core foam sheet are compressed between a pair of compression rollers, comprising:
- depolymerizing an upper surface of the core foam sheet;
- depolymerizing a lower surface of the core foam sheet;
- passing the core foam sheet with depolymerized upper and lower surfaces and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the depolymerized upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the depolymerized lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer, and placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a second surface of the second stiffening layer so that when the core foam sheet, the first and second stiffening layers and the second and third foam sheets pass between the compression rollers, the first surface of the first stiffening layer adheres to the upper surface of the core foam sheet, and the first surface of the second stiffening layer adheres to the lower surface of the core foam sheet, and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the second foam sheet is separated from the first stiffening layer and core foam sheet.
1 more element
A method of preventing contamination of the surfaces of compression rollers when first and second stiffening layers and a core foam sheet are compressed between a pair of compression rollers, comprising:
- depolymerizing an upper surface of the core foam sheet,
- depolymerizing a lower surface of the core foam sheet,
- passing the core foam sheet with depolymerized upper and lower surfaces and the first and second stiffening layers between the pair of compression rollers with a first surface of the first stiffening layer adjacent to the depolymerized upper surface of the core foam sheet, and with a first surface of the second stiffening layer adjacent to the depolymerized lower surface of the core foam sheet;
- placing a second foam sheet having a top surface and a bottom surface between one of the compression rollers and a second surface of the first stiffening layer, and placing a third foam sheet having a top surface and a bottom surface between the other compression roller and a surface of the second stiffening layer so that when the core foam sheet, the first and second stiffening layers and the second and third foam sheets pass between the compression rollers, the first surface of the first stiffening layer adheres to the upper surface of the core foam sheet, and the first surface of the second stiffening layer adheres to the lower surface of the core foam sheet, and after the first and second stiffening layers and core foam sheet emerge from between the compression rollers, the third foam sheet is separated from the first stiffening layer and core foam sheet.
1 more element
Dependencies are inferred from the claim text.