Patent ID: 7871363

Claim:
A method of making an arced bumper pad comprising the steps of: providing a top ply of paper having a central portion interposed between two longitudinal flanges and a bottom ply of paper having two longitudinal edges; drawing the top ply and/or the bottom ply so that one or both passes through a gluing station which coats the longitudinal flanges of the top ply and/or the longitudinal edges of the bottom ply; drawing the top and bottom plies around a series of rollers until the plies are in close parallel alignment; providing a floating mandrel suspended between the top and bottom plies, the floating mandrel having an arced topside and flat underside; drawing the central portion of the top ply around the topside of the floating mandrel so that the central portion assumes an arc shape while the longitudinal flanges of the top ply remain flat and extend outwardly from the central portion; drawing the bottom ply along the underside of the floating mandrel; compressing the longitudinal flanges of the top ply and the longitudinal edges of the bottom ply together between a series of forming rollers and opposing suspension rollers to bond the longitudinal flanges and longitudinal edges together to provide a shaped and bonded part; and cutting the shaped and bonded part to a desired length to provide the arced bumper pad.