Apparatus and process for shaping and covering cushion foam

B - Operations – Transporting – 32 – B

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B32B 5/18 (2006.01) B29C 44/56 (2006.01) B29C 51/14 (2006.01) B29C 51/26 (2006.01) B29C 51/42 (2006.01) B29C 65/02 (2006.01) B29C 51/10 (2006.01) B29C 65/10 (2006.01)

Patent

CA 1264649

Apparatus and Process for Shaping and Covering Cushion Foam 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 a land area (37) and protruding ridge sections (39). The land area is perforated with holes (38) and the ridge sections are perforated with holes (41). Also provided is a complementary, hollow lower die (54) which also has perfora- tions (130). Hot melt adhesive is interleaved between fabric (123) and foam (124). Land area (37) of top die (21) is preheated to just below the melt point of the adhesive, e.g., about 240° F; ridge sections (39) are heated by embedded electric resistance heaters (160) to still a higher tempera- ture, e.g., about 280° F. The two dies are then 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 600° F., is ejected from ridge perforations (41) to partially melt the foam in the regions underneath the ridges (39); then lower temperature superheated steam, e.g., 500° F. and 80 psig, is ejected from all the perforations (38, 41 and 130) to melt the adhesive. Then a vacuum is applied to the land area perforations (38) to pull ambient air through the workpiece and cool it. The resolidified adhesive holds the foam (124) in its curved shape and laminates the fabric (123) to the foam. The resolidified indentations in the foam underneath the ridges (39) hold their shape as well.

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