Peeling process for making resilient pad composite

• US 9,604,442 B2
• Filed: 04/29/2010
• Issued: 03/28/2017
• Est. Priority Date: 11/24/2008
• Status: Active Grant

• Current Assignee: Applied Ft Composite Solutions Inc.
• Original Assignee: Applied Ft Composite Solutions Inc.
• Inventors: Kim, Daniel
• Primary Examiner(s): Schatz, Christopher
• Application Number:
  US12/770,403
• Publication Number:
  US 20100206472A1
• Time in Patent Office: 2,525 Days
• Field of Search: 156/247, 156/249, 156/230, 156/234, 156/250, 156/308.4
• US Class Current: 1/1
• CPC Class Codes: A41D 31/285 using layered materials
• CPC Class Codes: A63B 71/08 Body-protectors for players or sportsmen , i.e. body-protecting accessories affording protection of body parts against blows or collisions protective clothing or garments for sporting purposes A41D13/00
• CPC Class Codes: B32B 2038/047 Perforating
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/025 Polyolefin
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2437/00 Clothing
• CPC Class Codes: B32B 25/04 comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/10 characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/025 : comprising leather
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1074 : Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1093 : with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential

Abstract

The present application discloses a composite pad structure that includes a substrate bonded to a plurality of discrete, spaced-apart, resilient elements engaged to at least one reinforcing structure.

Claims

1. A method of making a composite structure for use as a resilient cushion comprising:

(a) providing a sheet of resilient material having opposing sides of a first side and a second side;

(b) applying an adhesive to the first side and optionally the second side of the sheet of resilient material;

(c) providing a cutter having a surface and a plurality of cutting elements extending from the surface in a predetermined pattern;

(d) pressing the cutter into the sheet of resilient material, thereby forming a cut sheet of resilient material comprising a plurality of discrete, spaced-apart, resilient elements and excess resilient material;

(e) withdrawing the cutter from the cut sheet of resilient material;

(f) either removing the adhesive from the excess resilient material on the first side of the cut sheet of resilient material, leaving adhesive on the plurality of discrete, spaced-apart, resilient elements, or blocking a portion of the adhesive on the excess resilient material, then;

(g) bonding a first substrate to the first side of the cut sheet of resilient material resulting in bonding of the plurality of discrete, spaced-apart, resilient elements to the first substrate; and

then (h) separating the excess resilient material from the cut sheet of resilient material, leaving the plurality of discrete, spaced-apart, resilient elements bound to the first substrate, forming a resilient material assembly.

2. The method according to claim 1, comprising

(i) placing a second substrate onto the second side of the resilient material assembly;

and

(j) heating the second substrate with a heat platen to activate the adhesive on the plurality of resilient elements on the second side, whereby the second substrate adheres to the plurality of discrete, spaced-apart, resilient elements on the second side.

3. The method according to claim 1, comprising:

(i) providing a sheet of reinforcing material;

(j) pressing the cutter into the sheet of reinforcing material, thereby forming a cut sheet of reinforcing material comprising a plurality of reinforcing elements and at least one partial or full lattice of reinforcing material;

(k) withdrawing the cutter from the cut sheet of reinforcing material;

(l) separating the lattice of reinforcing material from the reinforcing elements, whereby the lattice of reinforcing material is left with a plurality of holes through the reinforcing material where the reinforcing elements used to be;

(m) engaging at least one partial or full lattice of reinforcing material to the resilient elements in (h).

4. The method according to claim 3, comprising:

(n) placing a second substrate onto the second side of the resilient material assembly; and

(o) heating the second substrate with a heat platen to activate the adhesive on the plurality of resilient elements on the second side, whereby the second substrate adheres to the plurality of discrete, spaced-apart, resilient elements to form the composite material, wherein the at least one partial or full lattice of reinforcing material is positioned between the first and second sheets of the substrate.

5. The method according to claim 1, comprising making the composite structure for use as a resilient cushion without a die.

6. The method according to claim 1, wherein in step (f),

the removing of the adhesive is carried out by peeling off the adhesive layer, chemically dissolving the adhesive material bound only to the excess resilient material, treating the adhesive on the excess resilient material with chemically treated masks;

or wherein the blocking of the portion of the adhesive on the excess resilient material is carried out with paper or material that does not bond to the adhesive.

7. The method according to claim 6, wherein the removing adhesive layer step is carried out by peeling off the adhesive layer.

8. The method according to claim 3, wherein height of the lattice of reinforcing material is relatively higher, lower or equal compared to height of the resilient elements.

9. The method according to claim 8, wherein the height of the lattice of reinforcing material is relatively lower compared to the height of the resilient elements.

10. The method according to claim 1, wherein the substrate is sheet of fabric or mesh.

11. The method according to claim 1, comprising:

(i) placing a second substrate onto the second side of the resilient material assembly; and

(j) bonding the second substrate to the second side of the plurality of resilient elements, whereby the second substrate adheres to the plurality of discrete, spaced-apart, resilient elements on the second side.

12. The method according to claim 3, comprising:

(n) placing a second substrate onto the second side of the resilient material assembly; and

(o) bonding the second substrate to the second side of the plurality of resilient elements, whereby the second substrate adheres to the plurality of discrete, spaced-apart, resilient elements on the second side.

13. The method according to claim 1, wherein the first substrate is fabric or mesh.

14. The method according to claim 2, wherein the second substrate is fabric or mesh.

15. The method according to claim 4, wherein the second substrate is fabric or mesh.

16. The method according to claim 11, wherein the second substrate is fabric or mesh.

17. The method according to claim 12, wherein the second substrate is fabric or mesh.