초록 ▼

The present invention provides a unique and rapid method of producing a laminated foam article having permanent, pliable, decorative embossed lines or patterns which produce a relief-like article such as an embossed seat cushion or the like. In one aspect, the present invention comprises the steps o

The present invention provides a unique and rapid method of producing a laminated foam article having permanent, pliable, decorative embossed lines or patterns which produce a relief-like article such as an embossed seat cushion or the like. In one aspect, the present invention comprises the steps of coating the surface of a foam layer with an adhesive, placing a sheet or layer of cover material on the adhesive-coated foam layer surface, compressing the covered foam layer with a die having heated projection such that regions of the foam layer adjacent the hot die melt to form embossed lines which are permanent yet pliable. Since the embossed lines are actually collapsed, melted regions of the foam layer, thick, high density foam layers may be embossed using the present invention. In another aspect, a trilaminate structure is fabricated by additionally bonding a backing layer to the side of said foam layer opposite that to which said cover material is bonded. In one embodiment, the adhesive is cured during the embossing step by the heat from a heated platen and press.

대표청구항 ▼

A method for making a laminated foam article comprising the steps of: applying an adhesive to one surface of a compressible foam layer, said adhesive applied in a concentration of about 30 to 150 grams of adhesive per square meter; directly contacting said adhesive-bearing surface of said foam layer

A method for making a laminated foam article comprising the steps of: applying an adhesive to one surface of a compressible foam layer, said adhesive applied in a concentration of about 30 to 150 grams of adhesive per square meter; directly contacting said adhesive-bearing surface of said foam layer with a layer of cover material selected from the group consisting of natural fabrics and synthetic fabrics to form a bilayer; placing said bilayer on a platen; contacting said cover material layer of said bilayer with at least one heated projection at a temperature from about 150°to about 250°C.; producing relative movement of said platen and said heated projection to compress regions of said foam layer adjacent said heated projection; melting and collapsing said compressed regions of said foam layer using the heat of said projections for a period from about 30 to about 90 seconds to form permanent embossed lines in said bilayer; and removing said projections from said bilayer and solidifying said melted collapsed regions of said foam layer.