IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0717631
(2007-03-14)
|
등록번호 |
US-7416461
(2008-08-26)
|
우선권정보 |
TW-95136619 A(2006-10-02) |
발명자
/ 주소 |
|
출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
6 인용 특허 :
5 |
초록
▼
A foam product and method of making the same is disclosed in this invention. The foam product includes a foam core, at least one skin and a first covering. The foam core is composed of a plurality of foam beads bonded with one another, and comprises a first surface, a second surface, edges and at le
A foam product and method of making the same is disclosed in this invention. The foam product includes a foam core, at least one skin and a first covering. The foam core is composed of a plurality of foam beads bonded with one another, and comprises a first surface, a second surface, edges and at least one recess defined in the first surface. The skin is disposed in the recess and bonded with the foam core. The first covering is fully bonded to the first surface and edges of the foam core and the skin. Moreover, the method of making the foam product generally comprises the following steps. Firstly, a mold defining a cavity is provided. A first covering is placed in the cavity. At least one skin is provided in a predetermined position on an internal side of the first covering. Then, a suitable quantity of foam beads is introduced in the cavity and steam is injected into the cavity in order to have the foam beads, the first covering and the skin bonded together as a foam product. Finally, the foam product is removed from the cavity.
대표청구항
▼
The invention claimed is: 1. A foam product comprising: a first foam core having a first surface and a second surface opposite to the first surface, defining a recess in the first surface, and being composed of a plurality of foam beads; a skin disposed in the recess and bonded to the first foam co
The invention claimed is: 1. A foam product comprising: a first foam core having a first surface and a second surface opposite to the first surface, defining a recess in the first surface, and being composed of a plurality of foam beads; a skin disposed in the recess and bonded to the first foam core; a first covering bonded to the first surface of the first foam core and the skin; and a second foam core bonded to the second surface of the first foam core. 2. The foam product of claim 1, wherein the skin comprises at least one first foam layer having a density in a range of 1.5 to 12 pcf and a thickness in a range of 1 to 25 mm. 3. The foam product of claim 2, comprising a second covering bonded to the second foam core. 4. The foam product of claim 3, wherein the second covering comprises: a second foam layer bonded to the second foam core; and a plastic plate bonded to the second foam layer. 5. The foam product of claim 4, wherein the first covering and the plastic plate comprise patterns respectively. 6. The foam product of claim 1, comprising a first bonding film for bonding the first covering to the first surface of the first foam core and the skin, and comprising a second bonding film for bonding the second foam core to the second surface of the first foam core. 7. The foam product of claim 6, wherein the first covering comprises patterns. 8. A foam product comprising: a first foam core having a first surface and a second surface opposite to the first surface, defining a recess in the first surface, and being composed of a plurality of foam beads; a skin made of a first foam layer, disposed in the recess and bonded to the first foam core; a first covering bonded to the first surface of the first foam core and the skin; and a first bonding film for bonding the first covering to the first surface of the first foam core and the skin. 9. The foam product of claim 8 comprising: a second covering bonded to the second surface of the first foam core; and a second bonding film for bonding the second covering to the second surface of the first foam core. 10. The foam product of claim 9, wherein the second covering comprises: a second foam layer bonded to the second surface of the first foam core; and a plastic plate bonded to the second foam layer. 11. The foam product of claim 10, wherein the first covering and the plastic plate comprise patterns respectively. 12. The foam product of claim 8, wherein the first covering comprises patterns. 13. The foam product of claim 9, wherein the first and second coverings comprise patterns respectively. 14. A method of making a foam product comprising steps of: providing a mold which defines a cavity; providing a first covering which includes a first plastic film and a bonding film applied on a side of the first plastic film; placing the first covering in the cavity; placing at least one skin in a predetermined position on an internal side of the first covering; introducing suitable quantities of foam beads in the cavity; injecting steam into the cavity in order to have the foam beads, the first covering and the skin bonded together as a foam product; and removing the foam product from the cavity, wherein the foam product comprises the first covering, the skin and a foam surface. 15. The method of claim 14, comprising a step of bonding a second covering to the foam surface of the foam product. 16. The method of claim 15, wherein the first plastic film is made by steps of: providing a first film; printing patterns on the first film; and forming a second film on the first film to cover the patterns. 17. The method of claim 16, wherein the second covering is made by steps of: providing a foam layer with a density in a range of 1.5 to 12 pcf and a thickness in a range of 1 to 25 mm; providing a second plastic film, which comprises patterns; bonding a side of the second plastic film to a side of the foam layer; forming a plastic plate on another side of the second plastic film; and forming a bonding film on another side of the foam layer for bonding the foam layer to the foam surface of the foam product. 18. The method of claim 15, wherein the second covering is made by steps of: providing a foam layer with a density in a range of 1.5 to 12 pcf and a thickness in a range of 1 to 25 mm; forming a plastic plate on a side of the foam layer; and forming a bonding film on another side of the foam layer for bonding the foam layer to the foam surface of the foam product. 19. The method of claim 14, wherein the first plastic film is made by steps of: providing a first film; printing patterns on the first film; and forming a second film on the first film to cover the patterns.
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