Microwave bonding of foam to fabric using water as a susceptor

• US 5,254,197 A
• Filed: 06/25/1990
• Issued: 10/19/1993
• Est. Priority Date: 06/25/1990
• Status: Expired due to Fees

• Current Assignee: Lear Seating Corp. (Lear Corporation)
• Original Assignee: Lear Seating Corp. (Lear Corporation)
• Inventors: Klems, William F.
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): Barry, Chester T.
• Application Number:
  US07/542,958
• Time in Patent Office: 1,212 Days
• Field of Search: 156/272.2, 156/275.7, 156/245, 156/285, 156/310, 156/381, 156/273.7, 219/10.55 R, 219/10.55 M
• US Class Current: 156/272.2
• CPC Class Codes: A43D 25/00 Devices for gluing shoe parts
• CPC Class Codes: A43D 25/20 Arrangements for activating or for accelerating setting of adhesives, e.g. by using heat
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 63/025 applied by a die matching with the profile of the surface of resilient articles, e.g. cushions, seat pads
• CPC Class Codes: B29C 65/1425 Microwave radiation
• CPC Class Codes: B29C 65/1432 direct heating of the surfaces to be joined
• CPC Class Codes: B29C 65/1435 at least passing through one of the parts to be joined, i.e. transmission welding
• CPC Class Codes: B29C 65/1467 at the same time, i.e. simultaneous welding
• CPC Class Codes: B29C 65/1483 coated on the article
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/4845 Radiation curing adhesives, e.g. UV light curing adhesives
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/7847 using vacuum to hold at least one of the parts to be joined vacuum work holders in general B25B11/005
• CPC Class Codes: B29C 65/7882 said parts to be joined moving in a circular path
• CPC Class Codes: B29C 66/0016 Liquid environments, i.e. the parts to be joined being submerged in a liquid
• CPC Class Codes: B29C 66/02 Preparation of the material, in the area to be joined, prior to joining or welding B29C66/32 takes precedence
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/301 Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/5326 : said single elements being substantially flat
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/729 : Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/81267 : Transparent to electromagnetic radiation, e.g. to visible light
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29D 35/00 : Producing footwear
• CPC Class Codes: B29D 99/0092 : Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2995/0027 : for light outside the visible spectrum
• CPC Class Codes: B29L 2031/58 : Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/751 : Mattresses, cushions upholstery B29L2031/58
• CPC Class Codes: B29L 2031/771 : Seats
• CPC Class Codes: B60N 2/5875 : by adhesion, e.g. gluing

Abstract

An apparatus (10, 10'"'"', 10'"'"''"'"') for adhesively bonding a fabric layer (16) to a cellular foam pad (18) using a heat-sensitive adhesive (14) to produce a seat cushion assembly (12). The apparatus (10, 10'"'"', 10'"'"''"'"') includes a microwave radiation source (22, 22'"'"', 22'"'"''"'"') for emitting microwaves to selectively heat the adhesive (14) above its melting temperature to adhesively bond the fabric layer (16) to the foam pad (18). A method is also provided for fabricating a cushion assembly (12) in accordance with the subject invention.

Claims

1. A method comprising the steps of:

positioning a steam activated adhesive sheet (14) between a fabric layer (16) and a precontoured foam pad (18) adapted for use as a seat or backrest cushion in a seat cushion assembly (12);

contacting the fabric layer (16), adhesive sheet (14) and foam pad (18) together;

supplying liquid water (W) to a surface of the adhesive sheet (14) before said contacting step and thereafter radiating the fabric layer (16), adhesive sheet (14), said water (W) and foam pad (18) with microwave radiation (M) thereby generating steam in amounts sufficient to activate the adhesive (14), and adhesively bonding the fabric layer (16) to the foam pad without damaging either the fabric layer (16) or the foam pad (18).

2. A method as set forth in claim 1 further characterized by compressing the foam pad (18) against the adhesive sheet (14) and fabric layer (16).

3. A method as set forth in claim 2 further characterized by providing a lower mold (26) having a porous contoured mold surface (30).

4. A method as set forth in claim 3 further characterized by positioning the fabric layer (16) and the adhesive sheet (14) over the contoured mold surface (30) and supplying a vacuum over the contoured mold surface (30) to urge the fabric layer (16) into conforming engagement therewith prior to radiating the adhesive sheet (14) with the microwave radiation waves (M).

5. A method as set forth in claim 4 wherein said adhesive sheet (14) is air impervious.

6. A method as set forth in claim 5 wherein said lower mold (26) is unreactive to the microwave radiation waves (M).

7. A method as set forth in claim 4 further characterized by providing a pressing fixture (44/or 44'"'"') which is unreactive to the microwave radiation waves for compressing the foam pad (18) against the adhesive sheet (14) and the fabric layer (16).

8. A method as set forth in claim 7, wherein the foam pad (18), adhesive sheet (14) and fabric layer (16) together comprise said seat cushion assembly (12), further characterized by transferring the cushion assembly (12) into a microwave chamber (52) prior to radiating the cushion assembly (12) with microwave radiation waves (M).