Patent ID: 6076582
Filing Date: 2000-06-20
Classification: A41D,B29C,B29K,B32B

Abstract:
Apparatus for making a three-dimensionally formed laminate having a periphery of a predetermined shape, comprising:a rotatable table;a first frame for supporting a film on the rotatable table for rotation therewith;a mask that is positioned on the table above the film for rotation therewith and that has an opening approximately of the predetermined shape to expose the film upwardly through the opening;a foam spray gun for spraying a foamable liquid mixture down-wardly onto the exposed film during rotation thereof with the table for reaction of the mixture on the film to provide a foam that, after substantial completion of the expansion but before substantial curing, has a transitory state when the liquid mixture is still viscous and encloses gas bubbles generated by the reaction;a second frame for supporting a flexible sheet; anda mold including a pair of mold members having three-dimensionally contoured mold surfaces movable between: an open position spaced from each other to receive the flexible sheet and the film with the foam therebetween after separation of the mask from the film; and a closed position to which the mold surfaces are moved when the foam is in said transitory state to form the flexible sheet and provide a collapsed foam layer that is bonded to the flexible sheet with the predetermined shape as the three-dimensionally formed laminate.