APPARATUS AND PROCESS FOR SHAPING AND COVERING CUSHION FOAM

摘要

An apparatus and process for laminating fabric (123) to open cell cushion (124) while forming design lines in the foam. The apparatus comprises a top hollow die (21) having a land area (37) protruding ridge sections (39) and a complementary, hollow lower die (54). Hot melt adhesive is interleaved between fabric (123) and foam (124). Land area (37) of top die (21) and ridge sections (39) are heated. The two dies are then closed against the layered workpiece. A shot of superheated steam, is ejected from ridge perforations (41) to partially melt the foam in the regions underneath the ridges (39); then lower temperature superheated steam is ejected from all the perforations (38, 41 and 130) to melt the adhesive. Then a vacuum is applied to the land area perforations (38) to pull ambient air through the workpiece and cool it.