Method for bonding a cover to a flexible pad

Claim 2

A process for securely bonding a cover having front and back surfaces to a flexible pad having a contoured appearance surface with at least one appearance depression and a peripheral side, said process comprising the steps of: positioning the back of said cover on said appearance surface to form an assembly, said back or said appearance surface being coated with a heat-activatable adhesive, mounting the assembly to a support frame, clamping said cover to the appearance surface of said pad with an assist fixture having a tubular member that forces a portion of said cover into said at least one appearance depression, with the assist fixture clamped thereon, substantially simultaneously applying both pressure and heat to substantially the entire area of the front of said cover to force said cover into engagement with substantially the entire area of the appearance surface of said pad and activate the adhesive, including initiating the flow of relatively heated fluid through said tubular member to enhance activation of said adhesive in said appearance depression, and terminating the application of heat to the assembly including terminating the flow of heated fluid through said tubular member to cure the adhesive and complete the bonding process of the cover to the appearance surface of the pad including to said appearance depression.

Claim 3

The process as claimed in claim 1, wherein the positioning step further includes securing the marginal edge portion of said cover around the peripheral side of said pad, and disposing the adhesive on the back of said cover such that during the heat-applying step the central area of said cover is bonded to the pad and the marginal edge portion of the cover is not bonded to the peripheral side of the pad but is free to allow minor flexing of the cover to inhibit the onset of creasing.

Claim 4

The process as claimed in claim 1, wherein the pressure and heat applying step includes forcing the appearance surface side of the assembly into conforming engagement with a fluidized bed of heated particles maintained fluid by an air source at a temperature sufficient to activate the adhesive.

Claim 5

The process as claimed in claim 3, wherein the clamping step includes positioning the assist fixture into releasable engagement with the assembly to force the cover into intimate engagement with the at least one appearance depression in the pad.

Claim 6

The process as claimed in claim 1, wherein the appearance surface of said pad is preformed to include a contoured surface having a plurality of appearance depressions and said assist fixture includes a corresponding plurality of tubular members adapted to be received within said appearance depressions.

Claim 7

The process as claimed in claim 5, wherein the pressure and heat applying step includes substantially simultaneously forcing relatively heated fluid through each of said tubular members.

Claim 8

The process as claimed in claim 3, wherein said flexible pad is comprised of a porous material, and further including the step of applying a vacuum to the side of said porous material opposite to said appearance surface to draw heated air from said fluidized bed through said pad to enhance activation of the adhesive.

Claim 9

The process as claimed in claim 7, including removing the assembly from the fluidized bed after the adhesive has been activated, and thereafter maintaining the vacuum for a time sufficient to enhance cooling of the cover.

Claim 10

The process as claimed in claim 1, further including the step of forcing relatively cool fluid through said tubular member after terminating the application of heat to said assembly.

Claim 11

In a process for covering the appearance surface of a flexible pad having at least one appearance depression with at least one flexible cover sheet, the steps of the method comprising: preassembling the pad onto a support fixture and securing the cover sheet onto the pad to form an assembly, positioning an assist fixture having a member relative to the assembly so that said member is aligned with said appearance depression in said pad and forcing said member against said flexible cover to force a portion of said flexible cover into said appearance depression, pressing the assembly with said assist fixture positioned thereon into a heated fluidized bed whereby the bed conforms to the contour of the appearance surface of the pad and presses the cover sheet against substantially the entire area of the appearance surface of the pad, maintaining the pressed engagement until a layer of heat-activatable adhesive between the cover sheet and the pad activates and bonds the cover sheet to the pad, removing the assembly from the bed and allowing the adhesive to cure while retained by the assist fixture, removing the assist fixture from the assembly, and removing the assembly from the support fixture.

Claim 12

In a process for covering the appearance surface of a flexible pad having at least one appearance depression with at least one flexible cover sheet, the steps of the method comprising: preassembling the pad onto a support fixture and securing the cover sheet onto the pad to form an assembly, positioning an assist fixture having a member relative to the assembly so that said member is aligned with said appearance depression in said pad and forcing said member against said flexible cover to force a portion of said flexible cover into said appearance depression, pressing the assembly with said assist fixture positioned thereon into a heated fluidized bed whereby the bed conforms to the contour of the appearance surface of the pad and presses the cover sheet against substantially the entire area of the appearance surface of the pad, maintaining the pressed engagement until a layer of heat-activatable adhesive between the cover sheet and the pad activates and bonds the cover sheet to the pad, removing the assembly from the bed and allowing the adhesive to cure while retained by the assist fixture, removing the assist fixture from the assembly, and removing the assembly from the support fixture.

Claim 13

The process as claimed in claim 10, including the step of precoating the back of said cover sheet with said heat-activatable adhesive.

Claim 14

The process as claimed in claim 10, including the step of inserting a separate sheet of heat-activatable adhesive between the cover sheet and the appearance surface of the pad, prior to the step of pressing the support fixture into the fluidized bed.

Claim 15

The process as claimed in claim 10, wherein the member of said assist fixture comprises a tubular frame, and further including the step of passing fluid through said tubular frame during said heating and curing steps.

Claim 16

The process as claimed in claim 13, wherein heated air is passed through said tubular frame during said heat-applying step and ambient cooling air is passed through said tubular frame during said curing step.

Claim 17

The process as claimed in claim 13, including the step of positioning a tubular conduit in said heated fluidized bed, said tubular conduit having a first end connectable to a source of air and a second end connectable to said tubular frame, whereby air passed through the tubular frame is heated by the heated fluidized bed.

Claim 18

The process as claimed in claim 15, including the step of controlling the temperature of the air passed through said tubular conduit while said assembly is pressed into the fluidized bed.

Claim 19

The process as claimed in claim 10, wherein said preassembling step further includes connecting a vacuum source to the support fixture so that heated air is drawn through the assembly when the assembly is pressed into the fluidized bed to enhance activation of the adhesive.

Claim 20

The process as claimed in claim 17, including the step of continuing to draw air through said assembly after removal of said assembly from said fluidized bed and prior to removal of said assist fixture to facilitate cooling of the bonded cover sheet prior to removal of said assembly from said support fixture.

Claim 21

The process as claimed in claim 17, wherein the preassembling step includes securing the marginal edge portion of the cover sheet adjacent to the rear side of said pad.

Claim 22

The process as claimed in claim 10, further including the steps of providing above the fluidized bed a ram and first and second rails each having a terminal end adjacent to the ram and opposite terminal ends spaced from one another, mounting a first and a second support fixture, respectively, on said first and second rails, loading a first assembly onto said first support fixture while pressing a second assembly previously loaded onto said second support fixture and transferred from said second rail to said ram, into said fluidized bed, removing said second assembly from said fluidized bed and transferring said second support fixture from said ram to said second rail, transferring said first support fixture from said first rail to said ram and pressing said first assembly into said fluidized bed while said second assembly is unloaded from said second support fixture and a third assembly is loaded onto said second support fixture, removing said first assembly from said fluidized bed and transferring said first support fixture from said ram to said first rail, and transferring said second support fixture from said second rail to said ram and pressing said third assembly into said fluidized bed while said first assembly is unloaded from said first support fixture and a fourth assembly is loaded onto said first support fixture.

Claim 23

The process as claimed in claim 10, including preforming the foam pad to include a plurality of laterally spaced appearance depressions in said appearance surface, and wherein said assist fixture has a corresponding plurality of members configured to align with said appearance depressions, and further wherein said positioning step includes forcing respective members of the assist fixture against said cover sheet and into said respective depressions.

Claim 24

A process for securely bonding a cover to a flexible pad, said pad having a contoured front appearance surface, a back side and peripheral sides, said process comprising the steps of: positioning the back of said cover on said appearance surface and over said peripheral sides of said pad and securing the marginal edge portions of said cover to the back side of said pad to form an assembly, mounting the assembly to a support frame including the step of clamping an assist fixture connected to the support frame into releasable engagement with the assembly to mount the assembly to the support frame and maintain the fabric cover in proper registration with the pad; and with the assist fixture clamped thereon, substantially simultaneously applying both pressure and heat to substantially the entire area of the front of said cover to force said cover into engagement with substantially the entire area of the front appearance surface of said pad until a layer of heat-activatable adhesive between said cover and the front appearance surface of said pad activates and bonds said cover to the pad.

Claim 25

A process for securely bonding a cover to a flexible pad, said pad having a contoured front appearance surface, a back side and peripheral sides, said process comprising the steps of: positioning the back of said cover on said appearance surface and over said peripheral sides of said pad and securing the marginal edge portions of said cover to the back side of said pad to form an assembly, mounting the assembly to a support frame including the step of clamping an assist fixture connected to the support frame into releasable engagement with the assembly to mount the assembly to the support frame and maintain the fabric cover in proper registration with the pad; and with the assist fixture clamped thereon, substantially simultaneously applying both pressure and heat to substantially the entire area of the front of said cover to force said cover into engagement with substantially the entire area of the front appearance surface of said pad until a layer of heat-activatable adhesive between said cover and the front appearance surface of said pad activates and bonds said cover to the pad.

Claim 26

The process as claimed in claim 22, wherein the adhesive is disposed on the back of the central area of said cover such that during the heat-applying step the central area of said cover is bonded to the pad and the marginal edge portions of said cover are not bonded to the peripheral sides of the pad but are free to allow minor flexing of said cover to inhibit the onset of creasing.

Claim 27

The process as claimed in claim 22, wherein the pressure and heat applying step includes forcing the front of the assembly into conforming engagement with a fluidized bed of heated particles maintained fluid by compressed air at a temperature sufficient to activate the adhesive.

Claim 28

The process as claimed in claim 24, wherein the appearance surface of the pad is preformed to include at least one appearance depression, and the clamping step includes forcing a selected tubular member of the assist fixture into said depression.

Claim 29

The process as claimed in claim 25, wherein the pressure and heat applying step includes simultaneously forcing air at a predetermined temperature through said tubular member to enhance bonding of the cover in said depression.

Claim 30

The process as claimed in claim 26, wherein the appearance surface of said pad is preformed to include a contoured surface having a plurality of appearance depressions, and said clamping member includes a corresponding plurality of tubular members configured to be received within said plurality of the appearance depressions.

Claim 31

The process as claimed in claim 24, wherein said pad is comprised of a porous material, and said positioning step further includes the step of applying a vacuum to the back side of said porous material so that heated air is drawn through said porous material when the assembly is forced into said fluidized bed to enhance activation of said adhesive.

Claim 32

The process as claimed in claim 28, including removing the assembly from the fluidized bed after the adhesive has been activated, and thereafter maintaining the vacuum for a time sufficient to enhance cooling of the cover and curing of the adhesive.

Claim 33

In a process for covering the appearance surface of a flexible pad having at least one appearance depression with at least one flexible cover sheet, the steps of the method comprising: preassembling the pad onto a support fixture and securing the cover sheet onto the pad to form an assembly, positioning an assist fixture having a tubular frame member relative to the assembly so that said tubular frame member is aligned with said appearance depression in said pad and forcing said tubular frame member against said flexible cover to force a portion of said flexible cover into said appearance depression, pressing the assembly with said assist fixture positioned thereon into a heated fluidized bed whereby the bed conforms to the contour of the appearance surface of the pad and presses the cover sheet against substantially the entire area of the appearance surface of the pad, maintaining the pressed engagement until a layer of heat-activatable adhesive between the cover sheet and the pad activates and bonds the cover sheet to the pad, passing heated fluid through said tubular frame member to enhance activation of said adhesive in said appearance depression, removing the assembly from the bed, terminating the flow of heated fluid through said tubular member, and allowing the adhesive to cure while retained by the assist fixture, removing the assist fixture from the assembly, and removing the assembly from the support fixture.

Claim 34

In a process for covering the appearance surface of a flexible pad having at least one appearance depression with at least one flexible cover sheet, the steps of the method comprising: preassembling the pad onto a support fixture and securing the cover sheet onto the pad to form an assembly, positioning an assist fixture having a tubular frame member relative to the assembly so that said tubular frame member is aligned with said appearance depression in said pad and forcing said tubular frame member against said flexible cover to force a portion of said flexible cover into said appearance depression, pressing the assembly with said assist fixture positioned thereon into a heated fluidized bed whereby the bed conforms to the contour of the appearance surface of the pad and presses the cover sheet against substantially the entire area of the appearance surface of the pad, maintaining the pressed engagement until a layer of heat-activatable adhesive between the cover sheet and the pad activates and bonds the cover sheet to the pad, passing heated fluid through said tubular frame member to enhance activation of said adhesive in said appearance depression, removing the assembly from the bed, terminating the flow of heated fluid through said tubular member, and allowing the adhesive to cure while retained by the assist fixture, removing the assist fixture from the assembly, and removing the assembly from the support fixture.

Claim 35

The process as claimed in claim 30, including the step of precoating the back of said cover sheet with said heat-activatable adhesive.

Claim 36

The process as claimed in claim 30, including the step of inserting a separate sheet of heat-activatable adhesive between the cover sheet and the appearance surface of the pad, prior to the step of pressing the support fixture into the fluidized bed.

Claim 37

The process as claimed in claim 30, further including the step of passing cooling fluid through said tubular frame member during said curing step.

Claim 38

The process as claimed in claim 30, wherein said preassembling step further includes connecting a vacuum source to the support fixture so that heated air is drawn through the assembly when the assembly is pressed into the fluidized bed to enhance activation of the adhesive.

Claim 39

The process as claimed in claim 34 including the step of continuing to draw air through said assembly after removal of said assembly from the fluidized bed and prior to removal of said assist fixture to facilitate cooling of the bonded cover sheet prior to removal of said assembly from said support fixture.

Claim 40

The process as claimed in claim 34, wherein the preassembling step includes securing the marginal edge portion of the cover sheet adjacent to the rear side of said pad.

Claim 41

The process as claimed in claim 10, wherein the pad has a contoured front appearance surface, a back side and peripheral sides, and the step of securing the cover sheet onto the pad comprises securing the marginal edge portions of the cover to the back side of the pad to form the assembly.