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Method for making embossed laminated foam articles

  • US 5,490,890 A
  • Filed: 08/29/1994
  • Issued: 02/13/1996
  • Est. Priority Date: 11/25/1991
  • Status: Expired due to Term
First Claim
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1. A method for making a laminated foam article comprising the steps of:

  • providing a compressible foam layer;

    directly contacting a 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 to rapidly melt the foam at the compressed area, said temperature about 115°

    C. to 220°

    C.;

    heating said platen to a temperature above ambient and less than said projection and below the melt temperature of said foam;

    providing a press including said projection, heating said press and said projection and heating said press to have a temperature at about or slightly greater than the melt temperature of the foam such that the temperature of the projection and the press are different and said press being adjacent said cover material layer;

    then producing relative movement of said platen and said press with 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 projection to bond said layers together and to form permanent embossed lines in said bilayer;

    melting said foam layer in the area of the press using the heat of the press to bond said layers together and maintaining the temperatures of the projection and press during melting of said foam layer; and

    removing said melted collapsed regions of said foam material.

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