MANUFACTURE OF MOLDED FLEXIBLE PLASTIC FOAMED PRODUCT

摘要

A process for making a formed flexible plastic foam product containing a fibrous web insert. In the process, a flexible ethylene containing sheet material is rapidly heated and die formed to provide multiple parallel shells integrally attached to the sheet. A fibrous web material having an elongated corrugated shape is filled with an absorbent powder, and is die cut to individual desired shapes which are inserted into the shells. A thin fibrous facing sheet material is placed over the powder-filled web and formed shell and the facing sheet is heat sealed onto the foam shell perimeter, after which the formed and filled foam shells are die cut from the plastic foam strip to produce the individual formed products. The process advantageously provides increased production rates at 10-30 cycles/minute for the formed products.