Method for molding ear cushions
First Claim
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1. A method of forming an ear cushion from porous foam material, the steps comprising:
- cutting an ear cushion blank from a flexible porous thermal formable foam material;
compressing the ear cushion blank with a forming tool to a selected shape; and
forcing a gas which is heated to within the thermal forming temperature range through the porous foam material such that the ear cushion retains a desired shape when the forming tool is removed.
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Abstract
Ear cushions for headphones are formed from an open cell polyurethane foam material. An ear cushion blank is cut from the material and compressed to a desired shape between a holder and a forming tool. Heated air is forced through the porous material to set it to a contoured shape. The molding process can be performed quickly without damaging the cellular structure.
29 Citations
7 Claims
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1. A method of forming an ear cushion from porous foam material, the steps comprising:
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cutting an ear cushion blank from a flexible porous thermal formable foam material; compressing the ear cushion blank with a forming tool to a selected shape; and forcing a gas which is heated to within the thermal forming temperature range through the porous foam material such that the ear cushion retains a desired shape when the forming tool is removed. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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Specification