Abstract:
A method of forming an animal hide-foam laminate is disclosed comprising the steps of placing a hide layer having a treated side and an untreated side over a portion of a first surface of a substrate layer, securing the treated side of the hide layer at a first end to the substrate layer, heating a first surface of a foam layer to a melting temperature, placing the first surface of the foam layer in a facing engagement with the untreated side of the hide layer; curing the facing engagement of the foam layer and the hide layer to secure the hide layer to the foam layer. Additionally, an animal hide-foam laminate for trim applications is disclosed consisting of a foam layer having a first surface, a hide layer having a treated side and an untreated side, wherein the untreated side is in a facing engagement with the first surface, and wherein the hide layer is bonded to the foam layer by flame lamination.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of U.S. Provisional Application Serial No. 60/335,725, filed on Nov. 15, 2001, entitled ANIMAL HIDE-FOAM LAMINATES AND METHOD OF CONSTRUCTING THE SAME, and Ser. No. 60/405,628, filed on Aug. 23, 2002, entitled PRESSURE SENSATIVE ADHESIVE-FOAM LAMINATES AND METHOD OF CONSTRUCTING THE SAME. 
     
    
     
       TECHNICAL FIELD  
         [0002]    This invention relates to methods of bonding layers of a substrate, such as animal hides or adhesives, to a foam layer to form a laminate. In particular, the method relates to flame laminating layers of a substrate to a foam layer of the type used for cushions, specifically for seating and back cushions in automotive seats.  
         BACKGROUND OF THE INVENTION  
         [0003]    Multi-layered structures and materials are commonly used in numerous industries, including the automotive, boating, furniture, and medical industries. A frequent use for multilayered structures is for automobile seat cushions and headliners, panels and dashboards where multiple layers of materials are laminated together and formed into a structure having the desired physical and aesthetic or decorative properties. For example, a cover layer such as cloth, having the desired decorative surface quality may be laminated to a substrate having desirable physical characteristics, such as strength, rigidity, hardness, softness, surface quality and the like. Additional layers may be added to vary the physical and decorative characteristics.  
           [0004]    There are enumerable applications where an aesthetically pleasing and/or relatively expensive material is laminated to a low cost substrate. In the automotive industry, the trim application in automobile seats and headliners is illustrative of such laminated products. Typically, foamed materials, such as polyurethane or polyether are used as a base material. A facing fabric, such as nylon, is adhered to the base material to form a product. The product can be used for side panels, on doors, the back lumbar region of seats, package trays and the like.  
           [0005]    The method of choice for bonding of the facing fabric to the base material uses flame lamination. In the conventional flame lamination manufacturing process, the layers are placed between mirror image mold surfaces, compressed, heated to cure an incorporated thermosetting resin, and then cut to shape at their periphery. Sometimes apertures for window openings, light fixtures, sun visors and the like are cut in the panels after molding. The typical headliner is in the shape of a dome with the concave surface facing downward.  
           [0006]    Various problems exist in the assembly of the automobile seats and headliners and one of those problems is that the automobile seats and headliners include a decorative layer as the exposed surface visible to the passengers. Any folds, creases or blemishes in the visible surface create a problem for those that are marketing the vehicle. As a practical matter, it is unacceptable to have exposed blemishes.  
           [0007]    Fabric covered foam articles, such as cushions for automotive seats, generally comprise a foam pad adhesively secured to a covering fabric. Various methods for securing fabric to foam have been described. In one method, vacuum pressure has been applied to porous contoured molds in order to draw an impervious adhesive film against a cloth fabric layer to conform the cloth fabric layer and adhesive to the contours of the inner mold surface. A matching cellular foam pad is placed in mating engagement with the adhesive film as it is held to the contour of the mold surface by vacuum pressure. The foam pad may then be compressed against the mold by a perforated platen and held in place. The vacuum may be discontinued. A heated fluid, preferably steam is supplied through the porous mold to heat and diffuse the adhesive film into the adjacent fabric layer and cellular foam pad, respectively, to adhesively secure the two together. A vacuum may then be applied to remove moisture from the fabric and foam by drawing air through the perforations in the platen and through the foam pad, fabric layer and porous mold.  
           [0008]    Variations to this method of bonding fabric layers to cushions include methods and apparatuses for bonding fabric to seat cushion trenches in which portions of a fabric bag may be bonded to the seat cushion, and then manipulated to remove wrinkles before the rest of the fabric bag is bonded to the cushion. Another variation on the method and apparatus for adhesively bonding a fabric layer to cellular foam pad occurs where a heat sensitive adhesive is activated by microwave radiation.  
           [0009]    For all applications in which a fabric is adhesively bonded to a cellular foam pad, and particularly for automotive seat cushions, the adhesive must securely bond the foam and fabric together. Incomplete bonding permits the foam cushion to settle and bunch and shift position relative to the fabric. This condition causes excessive wear on the fabric and on the cushion, and causes the fabric to crease or wrinkle. Creases and wrinkles not only have an unsightly appearance, but also present areas more susceptible to wear and tear.  
           [0010]    By eliminating the use of an adhesive, a more even and complete bond may be obtained between the fabric and the foam cushion. By flame laminating the foam layer so that the upper surface melts, it is possible to then apply the fabric to the heated and melted upper surface of the foam, press the fabric to the foam to set the layers together, and then cool the layers to cure the bond between them. Such a process eliminates the need for an adhesive.  
           [0011]    Although many fabrics have been employed in the flame lamination of a fabric layer to a foam layer, animal hide has yet to be utilized. This is primarily due to one of the fundamental characteristics of hide material in general: the shape of the hide. When animal hides are supplied as fabric material, they retain a general form of the animal from which they were obtained. As such, the animal form is not conducive to the flame lamination process. Rather, the prior art usage of animal hides in this area includes the use of surge stitches and glues to provide a means by which the hide is secured to the cushioning material. Moreover, since animal hide cannot be produced or supplied in forms sufficient to permit efficient feeding into the flame lamination process, such as in the form of a large roll or spool of hide, it has heretofore been unacceptable for such use.  
           [0012]    Prior to the present invention, an animal hide-foam laminate and method of creating an animal hide-foam laminate, that satisfactorily solves the weaknesses associated with the more conventional methods, such as the use of surge stitches and glues, as well as the inability to prepare animal hide to foam laminates, in an efficient, practical and economically affordable manner has not been proposed or suggested by those skilled in the art.  
           [0013]    Thus, there is a need for a animal-hide based laminate, and particularly an animal hide-foam laminate, and a method of forming a animal-hide based laminate in the form of an automotive seat cushion or other article that overcomes the aforementioned shortcomings of the prior art.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention eliminates the above-mentioned needs for an animal-hide based laminate by providing an animal hide-foam laminate and a method of forming an animal hide-foam laminate for automotive seat cushions or other articles. Additionally, the present invention eliminates the above-mentioned needs for an animal-hide based laminate by providing a pressure sensitive adhesive-hide laminate and a method of forming a pressure sensitive adhesive-hide laminate for automotive and other applications.  
           [0015]    In accordance with the present invention, there is provided a method of forming an animal hide-foam laminate. The method includes the steps of placing a hide layer having a treated side and an untreated side over a portion of a first surface of a substrate layer, securing the treated side of the hide layer at a first end to the substrate layer, heating a first surface of a foam layer to a melting temperature, placing the first surface of the foam layer in a facing engagement with the untreated side of the hide layer, curing the facing engagement of the foam layer and the hide layer to secure the hide layer to the foam layer.  
           [0016]    The present invention is further directed to an animal hide-foam laminate for trim applications. The animal hide-foam laminate consists of a foam layer having a first surface and a hide layer having a treated side and an untreated side. The untreated side is in a facing engagement with the first surface and the hide layer is bonded to the foam layer by flame lamination.  
           [0017]    The present invention is additionally directed to an animal hide-foam laminate for trim applications that consists of a foam layer having a first surface and a second surface, a hide layer having a first treated side and an first untreated side, wherein the first untreated side is in a first facing engagement with the first surface, a second layer having a second treated side and an second untreated side, wherein the second untreated side is in a second facing engagement with the second surface, and wherein the hide layer is bonded to the foam layer by flame lamination and the second layer is bonded to the foam layer by flame lamination.  
           [0018]    In accordance with the present invention, there is provided a method of forming a pressure sensitive adhesive-hide laminate. The method includes the steps of heating a first surface of a pressure sensitive adhesive layer to a melting temperature, positioning the first surface of the pressure sensitive adhesive layer in a facing engagement with an untreated side of a hide layer having a first side and a second side, and curing the facing engagement of the pressure sensitive adhesive layer and the hide layer to secure the pressure sensitive adhesive layer to the hide layer.  
           [0019]    The present invention is further directed to pressure sensitive adhesive-hide laminate for trim applications consisting of a pressure sensitive adhesive layer having a first surface, a hide layer having an untreated side and a treated side, wherein the untreated side is in a facing engagement with the first surface of the pressure sensitive adhesive layer, and wherein the pressure sensitive adhesive layer is bonded to the hide layer by flame lamination.  
           [0020]    The present invention is additionally directed to pressure sensitive adhesive-hide laminate for trim applications consisting of a pressure sensitive adhesive layer having a first surface and a second surface, a hide layer having an untreated side and a treated side, wherein the untreated side is in a first facing engagement with the first surface of the pressure sensitive adhesive layer, a substrate layer having a first side and an second side, wherein the second side is in a second facing engagement with the second surface of the pressure sensitive adhesive layer, and wherein the pressure sensitive adhesive layer is bonded to the hide layer by flame lamination and wherein the substrate layer is bonded to the pressure sensitive adhesive layer by flame lamination. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0021]    [0021]FIG. 1 is a cross-sectional view of the preferred animal hide-foam laminate of the present invention.  
         [0022]    [0022]FIG. 2 is a cross-sectional view of an alternative embodiment of the present invention illustrated in FIG. 1.  
         [0023]    [0023]FIG. 3 is a top view of the hide material layout in accordance with the preferred embodiment illustrated in FIG. 1.  
         [0024]    [0024]FIG. 4 is a cross-sectional view of the hide material layout illustrated in FIG. 3.  
         [0025]    [0025]FIG. 5 is a cross-sectional view of an alternative embodiment of the hide material layout illustrated in FIG. 3.  
         [0026]    [0026]FIG. 6 is a cross-sectional view of the pressure sensitive adhesive embodiment of the present invention.  
         [0027]    [0027]FIG. 7 is a cross-sectional view of alternative embodiment of the present invention illustrated in FIG. 6.  
         [0028]    [0028]FIG. 8 is a side view of the flame lamination process of the present invention of FIG. 1.  
         [0029]    [0029]FIG. 9 is a perspective view of the flame lamination process of the present invention of FIG. 8.  
         [0030]    [0030]FIG. 10 is a side view of the flame lamination process of the alternative embodiment of the present invention illustrated in FIG. 2. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]    Referring now to FIG. 1, a preferred embodiment of the present invention is illustrated as the animal hide-foam laminate  10 . The animal hide-foam laminate  10  generally comprises a foam layer  30  having a first surface  31  and a hide layer  20  having a treated side  21  and an untreated side  22 . The untreated side  22  is in a facing engagement with first surface  31 .  
         [0032]    Hide layer  20  may be selected from any commercially available animal hide, including but not limited to cow hide, mink hide, rabbit hide, raccoon hide, alligator hide, snake hide, and the like. Hide layer  20  also includes commercially available artificial hides or hide substitutes, such as vinyl. Typically, after an animal hide or hide substitute is obtained, it is treated in a variety of manners to create the desired appearance. In commercial applications, such as in clothing or automotive seats, it is commonplace for only one side of the hide material or hide substitute to be treated. This saves cost to the manufacturer, since the consumer does not view the untreated portion of the animal hide or hide substitute.  
         [0033]    The untreated surface or side  22  of the hide layer  20  is rough and irregular in its texture. For this reason, the untreated surface or side  22  is particularly well suited for functioning as a bonding surface. Moreover, treated surface or side  21  is the portion of the hide that is functional as, for example, a seating surface. As shown in FIGS. 1 and 2, the untreated surface or side  22  is bonded to the foam layer  30  at a first surface  31  through the process of flame-lamination, a process well known in the art, using a flame lamination machine as illustrated in FIG. 8 described below. The foam layer may be any one of a number of commercially available foams, including but not limited to polyurethane and polyether polyols.  
         [0034]    Referring now to FIGS. 8 and 9, first surface  31  of foam layer  30  is heated to a melting temperature by flames produced by heat source  70  and exiting flame port  71 . The flames generated by heat source  70  can be variable by temperature. Such temperature variation of the flames is accomplished by user manipulation of the ratio of air-to-gas supplied to heat source  70 . It is preferred that the distance from flame port  71  to first surface  31  be between {fraction (1/8)} of an inch and an inch. Most preferably, the distance from flame port  71  to first surface  31  should be between {fraction (1/2)} and {fraction (3/4)} of an inch. Additionally, in order to adequately melt first surface  31  to form a bond, it is preferred that heat source  70  be tilted at an angle of between about 2 to about 7 degrees relative to the perpendicular angle between heat source  70  and first surface  31 . More preferably, heat source  70  is tilted at an angle of between about 3 to about 6 degrees relative to the perpendicular angle between heat source  70  and first surface  31 . Most preferably, heat source  70  is tilted at an angle of about 5 degrees relative to the perpendicular angle between heat source  70  and first surface  31 .  
         [0035]    The melting temperature generated by heat source  70  is sufficient to reduce the degree of solidity of first surface  31  to a point where it becomes substantially viscous, and is a temperature greater than 200 degrees Celsius. The viscous nature of the heated first surface  31  imbues adhesive properties to first surface  31  of foam layer  30 . When the heated first surface  31  contacts untreated side  22  of hide layer  20 , the viscous nature of the heated first surface  31  creates a bond with untreated side  22 . Thus, foam layer  30  functions as its own adhesive to secure the hide layer  20  to foam layer  30 . Heated first surface  31  contacts untreated side  22  of hide layer  20  between rollers  72  and  73 , where first surface  31  and untreated side  22  are pressed together to form a bond. After being passed through rollers  76   a, b, c,  and/or  d  and pressed between rollers  72  and  73 , foam layer  30  and hide layer  20  form animal hide-foam laminate  10 , which can be stored on take up roll  74 . It should be noted that the resulting bond between foam layer  30  and hide layer  20  cannot be re-melted or otherwise broken without the application of the melting temperature, thus permitting use of animal hide-foam laminate  10  in high ambient temperature situations, such as automotive interior trim applications.  
         [0036]    It is preferred that rollers  72  and  73  are water-cooled in order to re-solidify the viscous, heated first surface  31 , thereby facilitating a faster, stronger bond to untreated side  22 . Furthermore, rollers  72  and  73  are adjustable, capable of placing variable pressures on foam layer  30  and another layer, such as hide layer  20 . Varying pressures on foam layer  30  and another layer, such as hide layer  20  allows for the accommodation of various foam and substrate types that may be required by the user. Additionally, rollers  76   a , b, c, and d can be conventional metal rollers.  
         [0037]    As is illustrated in FIG. 2, a third layer  40  may be added to the animal hide-foam laminate  10  to form an animal hide-foam-third layer laminate  100 . The third layer  40  may include a treated side  41  and an untreated side  42 . As with the first surface  31 , in this embodiment the second surface  32  is also heated to a melting temperature. This melting temperature is also sufficient to reduce the degree of solidity of the second surface  32  to a point where it becomes substantially viscous. The viscous nature of the heated second surface  32  also imbues adhesive properties to the second surface  32  of the foam layer  30 . When the heated second surface  32  contacts the untreated side  42  of the third layer  40 , the viscous nature of the heated second surface  32  creates a bond with the untreated side  42  as well. Thus, the foam layer  30  functions as its own adhesive to secure the third layer  40 . As a result, the foam layer  30  becomes a core to animal hide-foam-third layer laminate  100 .  
         [0038]    It is preferred that flame-lamination be used to apply heat to obtain a melting temperature for the first surface  31  or the second surface  32  of the foam layer  30  in the manner shown in FIGS. 8 and 9 and described above. As is illustrated in FIG. 3, the hide  20  is irregularly shaped as  20   a , and may be shaped in the form of the source animal. The irregular nature of animal hide  20  and its limited surface area prevent the direct feed to a flame-lamination machine. Thus, as is shown in FIGS. 3, 4, and  5 , the preferred embodiment has a first end  25  of the hide  20  that is temporarily fastened to a substrate layer  60  by temporary fasteners  50 . Temporary fasteners  50  can include double-sided adhesives, single-sided adhesives, and glues. It is preferred that temporary fasteners  50  be placed along first end  25 , thus permitting any slack in hide  20  to be substantially eliminated by the flame-lamination machine process (shown in FIGS. 8 and 9 and described above). First end  25  can include the leading edge and portions thereof, the perimeter and portions thereof, the trailing edge and portions thereof, of hide  20 . An example of a trailing edge is illustrated as trailing edge  25   a.    
         [0039]    In practicing the method of the preferred embodiment the hide layer  20  is placed on the substrate layer  60 . The treated side  21  of the hide layer  20  is placed in contact with a portion of the substrate layer  60 , thereby allowing the untreated side  22  to contact the first surface  31  of the foam layer  30 . The hide layer  20  is secured to the substrate layer  30  at the first end  25  of the hide layer  20 . The temporary fasteners  50  temporarily secure the first end  25  to the substrate layer  60 . As described above, the temporary fasteners  50  can include double-sided adhesives, single-sided adhesives, and glues. This process is repeated so that multiple hides may be positioned on a web of substrate layer  60 . In one embodiment, once the hides are temporarily secured, the substrate layer is rolled up, with the hides, for use with a feed mechanism for a flame-lamination machine. In another embodiment, the temporarily secured hides  20  are then fed directly to the flame-lamination machine. The temporarily secured hides  20  may be fed through a conveyor system.  
         [0040]    Referring again to FIGS. 8 and 9, it is preferred that roll  75  of substrate layer  60  with the temporarily secured hides is fed into the flame-lamination machine. Simultaneously, the foam layer  30  is also fed into the flame-lamination machine. The foam layer  30  comes within a user-defined, predetermined distance of the flames of the flame-lamination machine. The flames of the flame-lamination machine, factored with the variables of the distance the foam layer  30  is from the flame, the degree of heat of the flame, and the speed with which the foam layer  30  is fed, melt the first surface  31  of the foam layer  30 . It is preferred that the speed at which layers are fed be between about 1 to about 70 yards/minute. More preferably, the speed at which layers are fed should be between about 20 to about 65 yards/minute. Most preferably, the speed at which layers are fed is between about 30 to about 60 yards/minute. As stated above, it is more preferred that the distance from flame port  71  to first surface  31  be between {fraction (1/2)} and {fraction (1/4)} of an inch. Additionally, in order to adequately melt first surface  31  to form a bond, it is preferred that heat source  70  be tilted at an angle of between about 2 to about 7 degrees relative to the perpendicular angle between heat source  70  and first surface  31 . More preferably, heat source  70  is tilted at an angle of between about 3 to about 6 degrees relative to the perpendicular angle between heat source  70  and first surface  31 . Most preferably, heat source  70  is tilted at an angle of about 5 degrees relative to the perpendicular angle between heat source  70  and first surface  31 . The melted first layer  31  contacts the untreated surface  22  of the hide layer  20 , forming a facing engagement with the untreated surface  22 . The flame-lamination process results in foam additionally bonding to the portions of substrate layer  60  not covered by hide layer  20 . The animal hide used in the animal hide-foam laminate  10  is many times more expensive than foam layer  30 , and thus it is desirable to utilize as much of the animal hide as possible. For this reason, an excess of foam layer  30  is used to ensure that the entire animal hide  20  is covered. The excess foam is lost when the animal hide-foam laminate  10  is further processed. Although this excess foam is lost, it is inexpensive and readily available so as to not limit the commercial viability of animal hide-foam laminate  10 .  
         [0041]    The facing engagement is then cured in order to secure the hide layer  20  to the foam layer  30 . Curing of the facing engagement is accomplished through the application of a curing temperature. The curing temperature is a temperature that is below the melting temperature. The curing temperature re-solidifies the melted first surface  31  of the foam layer  30 , thereby securing the facing engagement between the untreated surface  22  of the hide layer  20  and the first surface  31  of the foam layer  30 .  
         [0042]    The curing temperature can be applied through a variety of conventional manners, such as through the application metal rollers  72  and  73  cooled to below the melting temperature with an internal water system, air-cooling with air having a temperature below the melting temperature, and the like. After the curing temperature is applied to the animal hide-foam laminate  10 , the animal hide-foam laminate  10  may either be stored or further processed into the required shapes. The animal hide-foam laminate  10  may also be further processed by adding a third layer  40  to the second surface  32  of the foam layer  30 . Utilizing the method detailed above and further shown in FIG. 10, third layer  40  is positioned by rollers  78   a , b, c, and d and subsequently partially melted by heat source  70   a  via heat exiting flame port  71   b  and placed in a second facing engagement with the foam layer  30 . This second facing engagement is cured as above, thus creating the three-layer animal hide-foam-third layer laminate  100 . The third layer  40  can be attached to foam layer  30  simultaneously to the attachment of hide layer  20 . The third layer  40  can include animal hide, vinyl, foam, insulation, or the like.  
         [0043]    Referring now to FIG. 6, an embodiment of the present invention is illustrated as the pressure sensitive adhesive-hide laminate  10   a . The pressure sensitive adhesive-hide laminate  10   a  generally comprises a pressure sensitive adhesive layer  30   a  having a first surface  31   a  and a hide layer  20   a  having a treated side  21   a  and an untreated side  22   a . The untreated side  22   a  is in a facing engagement with first surface  31   a.    
         [0044]    Pressure sensitive adhesive layer  30   a  may be selected from any commercially available pressure sensitive adhesive.  
         [0045]    The untreated surface or side  22   a  of the hide  20   a  is particularly suited for functioning as a bonding surface, as stated above. Moreover, second surface or side  32   a  is the portion of the pressure sensitive adhesive that is functional as, for example, for adhering of another (non-hide) surface. As shown in FIGS. 6 and 7, the untreated surface or side  22   a  is bonded to the pressure sensitive adhesive layer  30   a  at a first surface  31   a  through the process of flame-lamination, using a flame lamination machine as shown in FIG. 8 and discussed above.  
         [0046]    The first surface  31   a  of pressure sensitive adhesive layer  30   a  is heated to a melting temperature. The melting temperature is sufficient to reduce the degree of solidity of first surface  31   a  to a point where it becomes substantially viscous. The viscous nature of the heated first surface  31   a  imbues adhesive properties to first surface  31   a  of pressure sensitive adhesive layer  30   a . When the heated first surface  31   a  contacts untreated side  22   a  of hide layer  20   a , the viscous nature of the heated first surface  31   a  creates a bond with untreated side  22   a . Thus, pressure sensitive adhesive layer  30   a  functions as its own hot melt adhesive to secure the hide layer  20   a  to pressure sensitive adhesive layer  30   a.    
         [0047]    As is illustrated in FIG. 7, a third layer  40   a  may be added to the pressure sensitive adhesive-hide laminate  10   a  to form a hide-pressure sensitive adhesive-third layer laminate  100   a . The third layer  40   a  may include a second side  41   a  and a first side  42   a . As with the first surface  31   a , in this embodiment either the second surface  32   a  or first side  42   a  is also heated to a melting temperature. This melting temperature is also sufficient to reduce the degree of solidity of the second surface  32   a  or first side  42   a  to a point where it becomes substantially viscous. The viscous nature of the heated second surface  32   a  or first side  42   a  also imbues adhesive properties to the second surface  32   a  of the pressure sensitive adhesive layer  30   a  or first side  42   a . When the heated second surface  32   a  contacts the first side  42   a  of the third layer  40   a  or heated first side  42   a  contacts second surface  32   a , the viscous nature of the heated surface or side  32   a  or  42   a  creates a bond with either the first side  42   a  or second surface  32   a , respectively. Thus, the heated layer  30   a  or  40   a  functions as its own adhesive to secure the third layer  40   a  to  30   a . As a result, the pressure sensitive adhesive layer  30   a  becomes a core to hide-pressure sensitive adhesive-third layer laminate  100   a.    
         [0048]    It is preferred that flame-lamination be used to apply heat to obtain a melting temperature for the first surface  31   a  or the second surface  32   a  of the pressure sensitive adhesive layer  30   a . It is also preferred that the roll of pressure sensitive adhesive (and third layer  40   a ) be fed into the flame-lamination machine. The pressure sensitive adhesive layer  30   a  comes within a user-defined, predetermined distance of the flames of the flame-lamination machine. The flames of the flame-lamination machine, factored with the variable of the distance the pressure sensitive adhesive layer  30   a  is from the flame and the speed with which the pressure sensitive adhesive layer  30   a  is fed, melt the first surface  31   a  of the pressure sensitive adhesive layer  30   a . The melted first layer  31   a  contacts the first surface  22   a  of the hide layer  20   a , forming a facing engagement with the first surface  22   a.    
         [0049]    The facing engagement is then cured in order to secure the hide layer  20   a  to the pressure sensitive adhesive layer  30   a . Curing of the facing engagement is accomplished through the application of a curing temperature. The curing temperature is a temperature that is below the melting temperature. The curing temperature re-solidifies the melted first surface  31   a  of the pressure sensitive adhesive layer  30   a , thereby securing the facing engagement between the untreated surface  22   a  of the hide layer  20   a  and the first surface  31   a  of the pressure sensitive adhesive layer  30   a.    
         [0050]    The curing temperature can be applied through a variety of conventional manners, as detailed above, such as through the application metal rollers cooled to below the melting temperature with an internal water system, air-cooling with air having a temperature below the melting temperature, and so forth. After the curing temperature is applied to the hide-pressure sensitive adhesive laminate  10   a , the hide-pressure sensitive adhesive laminate  10   a  may either be stored or further processed into the required shapes. The pressure sensitive adhesive-foam laminate  10   a  may also be further processed by adding a third layer  40   a  to the second surface  32   a  of the foam layer  30   a . Utilizing the method detailed above, the second surface  32   a  is melted and placed in a second facing engagement with the third layer  40   a , or a portion of third layer  40   a  can be melted instead second surface  32   a . This second facing engagement is cured as above, thus creating the three-layer pressure sensitive adhesive-foam-third layer laminate  100   a . The third layer  40   a  can be attached to pressure sensitive adhesive layer  30   a  simultaneously to the attachment of hide layer  20   a . The third layer  40   a  can include pressure sensitive adhesive, hide, vinyl, foam, insulation, or the like.  
         [0051]    Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that numerous modifications are to the exemplary embodiments are possible without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.