PROCESS AND APPARATUS FOR LAMINATING AND SHAPING FOAM

摘要

A machine for laminating fabric 123 to open cell cushion foam 124 while forming design lines in the foam is dis-closed. The machine comprises a top hollow die 21 having perforations 38 and a complementary, hollow bottom die 54 which also has perforations 130. Hot melt adhesive 125 is interleaved between fabric 123 and foam 124. Top die 21 is preheated to just below the melt point of adhesive 125; then dies 21 and 54 are closed against the layered workpiece, with top die 21 contacting the face of fabric 123. A shot of superheated steam, e.g., at 80 psig and 700.degree.F., is ejected from perforations 38 and 130 to melt adhesive 125. Then a vacuum is applied to the perforations to pull ambient air through the workpiece and cool it. The resolidified adhesive 125 holds foam 124 in its deformed shape and laminates fabric 123 to the foam.