Patent ID: 6372076
Filing Date: 2002-04-16
Classification: A47C,B26D,B29C,B32B,B68G,D04H,Y10T

Abstract:
In the preparation of a convoluted fiber and foam pad, the process comprising:(a) providing a non-woven batt having incorporated therein a plurality of synthetic fibers and having a longitudinal dimension, a lateral dimension and a transverse dimension; (b) transporting said batt along said batt longitudinal dimension while compressing said batt along said batt lateral dimension; (c) concomitantly with the compression of said batt, cutting said batt transversely and along said batt lateral dimension to separate said batt into upper and lower segments with the lower surface of said upper batt segment providing a convoluted surface conforming to a convoluted surface of the upper surface of said lower batt segment; (d) providing a foam layer having a longitudinal dimension, a lateral dimension and a transverse dimension; (e) transporting said foam layer along said foam longitudinal dimension while compressing said foam layer along said foam lateral dimension; (f) concomitantly with the compression of said foam layer, cutting said foam layer transversely and along said foam lateral dimension to separate said foam layer into upper and lower segments with the lower surface of said upper foam segment providing a convoluted surface conforming to a convoluted surface of the upper surface of said lower foam segment; and (g) conforming said convoluted surface of at least one of said batt segments with said convoluted surface of at least one of said foam segments.