US 7,007,356 B2Granted

Cushioning pads and the formation of cushioning pads

AssigneePhoenix Performance Products, Inc.

InventorsDouglas J. Cudney, Karen Breitbach

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Abstract

A method of forming a cushioning pad includes placing a component formed of polyurethane foam onto a first web of polyethylene foam. A second web of polyethylene foam is then placed over the component to sandwich the component. Heat and pressure is applied to the sandwich, which flattens the component and forms a seam between the first web and the second web encircling the component. If an unsealed cushioning pad is to be formed, a hollow needle is inserted into one of the first web or the second web. Air passes through the hollow needle and into the component, which absorbs the air and expands. Later, the needle is removed. If a sealed cushioning pad is to be formed, an insertion point of the hollow needle is in the seam, between the first web and the second web. After the component absorbs air and expands, the needle is removed and the insertion point of the hollow needle is re-seamed.

Claims15

Dependent claims

A method of forming a cushioning pad comprising the steps of:

providing a first web of a first material;
a second web of a second material;
and a component of a third material;
placing the component on the first web;
covering the component with the second web;
compressing the component to a substantially flattened state between the first web and the second web, as the first web, the component and the second web simultaneously pass through a gap formed between a pair of pressing members;
attaching the second web to the first web to form a seam completely surrounding the component, thereby encapsulating the component, as the first web, the component and the second web simultaneously pass through the gap formed between the pair of pressing members;
forming an opening in at least one of the first web, the second web, or in a seam between the first web and the second web, which opening passes to the component;
and
allowing air to pass through the opening into the component, such that the component expands in size from its substantially flattened state.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/665,601Filed 22 Sep 2003 · continuation
Priority: 18 Jun 1999
Published: US 2004/0129379 A18 Jul 2004
Granted: 7 Mar 2006
Term ends: Not estimatedThe source records don’t support an estimate.

Classification20 codes

B29C 43/305
Making multilayered or multicoloured articles: making multilayered articles
B29C 43/222
Of articles of indefinite length: characterised by the shape of the surface
B29D 99/0092
Subject matter not provided for in other groups of this subclass: producing upholstery articles, e.g. cushions, seats
B29C 43/46
Compression means for making articles of indefinite length: rollers