U.S. patent application number 15/483267 was filed with the patent office on 2018-10-11 for method of manufacturing a laminated soft good.
The applicant listed for this patent is L&P Property Management Company. Invention is credited to Terrance L. Myers, Matthew C. Smallwood.
Application Number | 20180290442 15/483267 |
Document ID | / |
Family ID | 63710261 |
Filed Date | 2018-10-11 |
United States Patent
Application |
20180290442 |
Kind Code |
A1 |
Myers; Terrance L. ; et
al. |
October 11, 2018 |
Method of Manufacturing A Laminated Soft Good
Abstract
A layered stack is created by placing webs of adhesive on
opposite sides of web of cushioning layer and placing outer webs
outside the webs of adhesive. An outer surface of a rotating drum
is heated by heating oil inside the drum. An endless belt is heated
by at least one heater. The layered stack is pulled between the
heated endless belt and the heated rotating drum via a motorized
drive assembly which rotates the endless belt. Both sides of the
layered stack are heated enough to melt each web of adhesive when
the layered stack passes between the heated moving endless belt and
the heated rotating drum.
Inventors: |
Myers; Terrance L.; (Joplin,
MO) ; Smallwood; Matthew C.; (Webb City, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
L&P Property Management Company |
South Gate |
CA |
US |
|
|
Family ID: |
63710261 |
Appl. No.: |
15/483267 |
Filed: |
April 10, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/249981
20150401; Y10T 428/249984 20150401; Y10T 156/1727 20150115; B32B
37/12 20130101; Y10T 156/1741 20150115; B32B 37/06 20130101; B32B
2250/03 20130101; Y10T 156/1732 20150115; H01M 2/0287 20130101;
B32B 27/38 20130101; B32B 37/10 20130101; H05K 2201/012 20130101;
Y10T 428/24099 20150115; Y10T 428/31515 20150401; B32B 5/26
20130101; B32B 7/12 20130101; B32B 5/02 20130101; B32B 27/40
20130101; B32B 2305/022 20130101; B32B 15/088 20130101; Y10T
428/24999 20150401; B32B 5/245 20130101; B32B 15/20 20130101; B32B
5/18 20130101; Y10T 428/287 20150115; B32B 15/06 20130101; B32B
37/1036 20130101; B32B 2601/00 20130101; Y10T 428/2857 20150115;
Y10T 428/2887 20150115; B32B 5/32 20130101; B32B 37/20 20130101;
Y02E 60/10 20130101; B32B 2479/00 20130101 |
International
Class: |
B32B 37/12 20060101
B32B037/12; B32B 37/10 20060101 B32B037/10; B32B 37/06 20060101
B32B037/06 |
Claims
1-11. (canceled)
12. A method of manufacturing a laminated soft good, said method
comprising: creating a layered stack comprising a cushioning layer,
webs of adhesive on opposite sides of the cushioning layer and
outer layers outside the webs of adhesive; heating an endless belt
with a radiant heater; moving the heated endless belt via a
motorized drive assembly thereby pulling the layered stack between
a heated rotating drum and the heated moving endless belt
downstream; and heating both sides of the layered stack by passing
the layered stack between the heated moving endless belt and the
heated rotating drum, heat from the heated endless belt and the
heated rotating drum laminating the cushioning layer to the outer
layers to create a laminated soft good.
13. The method of claim 12, wherein the radiant heater is below the
heated endless belt.
14. The method of claim 12, wherein one of the outer layers
contacts the heated rotating drum and the other outer layer
contacts the heated endless belt.
15. The method of claim 12, wherein moving the heated endless belt
via a motorized driver includes using a motor to rotate a drive
roller.
16. The method of claim 12, wherein compressing the layered stack
comprises passing the layered stack between an adjustable pinch
roller and the drive roller.
17. The method of claim 12, wherein the heated endless belt is
driven by at least one drive roller.
18. The method of claim 12, wherein the heated endless belt passes
around several idle rollers.
19. The method of claim 12, wherein the cushioning layer comprises
at least one of foam and fiber.
20. A method of manufacturing a laminated soft good, said method
comprising: creating a layered stack comprising a cushioning layer,
webs of adhesive on opposite sides of the cushioning layer and
outer layers outside the webs of adhesive; heating a rotating drum
with oil; moving a heated endless belt via a motorized drive
assembly thereby pulling the layered stack between the heated
rotating drum and the heated moving endless belt; and heating both
sides of the layered stack by passing the layered stack between the
heated moving endless belt and the heated rotating drum, heat from
the heated endless belt and the heated rotating drum laminating the
cushioning layer to the outer layers to create a laminated soft
good.
21. The method of claim 20, wherein the heated endless belt passes
around at least three rollers.
22. The method of claim 21, wherein the at least three rollers
includes at least one drive roller and at least two idle
rollers.
23. The method of claim 20, wherein compressing the layered stack
comprises passing the layered stack between an adjustable pinch
roller and a drive roller.
24. The method of claim 20, wherein the cushioning layer comprises
at least one of foam and fiber.
25. A method of manufacturing a laminated soft good, said method
comprising: creating a layered stack comprising a cushioning layer,
webs of adhesive on opposite sides of the cushioning layer and
outer layers outside the webs of adhesive; heating an endless belt
with a first heater; heating a rotating drum with a second heater;
moving the heated endless belt via a motorized drive assembly
thereby pulling the layered stack between the heated rotating drum
and the heated moving endless belt; and heating first and second
opposite sides of the layered stack by passing the layered stack
between the heated moving endless belt and the heated rotating
drum, heat from the heated endless belt and the heated rotating
drum laminating the cushioning layer to the outer layers to create
a laminated soft good.
26. The method of claim 25, wherein the first side of the layered
stack contacts the heated rotating drum and the second side of the
layered stack contacts the heated endless belt.
27. The method of claim 25, wherein the first heater is a radiant
heater.
28. The method of claim 25, wherein the second heater heats oil
inside the rotating drum.
29. The method of claim 25, wherein compressing the layered stack
comprises passing the layered stack between an adjustable pinch
roller and a drive roller
30. The method of claim 25, wherein the cushioning layer comprises
at least one of foam and fiber.
31. The method of claim 25, wherein at least one of the first and
second heaters includes a radiant heater.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a method of manufacturing a
laminated soft good and the apparatus for performing the
method.
BACKGROUND OF THE INVENTION
[0002] In the bedding industry, the outer cover of a mattress or
box spring may be quilted with any desired pattern. Some customers
prefer a non-quilted covering. Such non-quilted coverings may be
two or more layers laminated together.
[0003] One known method for forming a laminated product is to treat
one surface of a sheet with an adhesive and pass that sheet with
another sheet between compression rollers to compress the adhesive
between the sheets. Such an apparatus takes up much floor space in
a production facility.
[0004] The assignee of the present invention has invented an
apparatus which reduces the amount of space necessary to laminate
multiple materials together. In other words, the footprint of the
apparatus is reduced. One such apparatus used by the assignee of
the present invention utilizes a heated drum containing oil and an
unheated belt. Two materials are passed between the heated drum and
the unheated belt. However, one drawback to this apparatus is that
only two layers may be secured together with a layer of adhesive
between the two layers. During its travel, the belt loses any
residual heat the moving belt may have retained from passing close
to the heated drum. Consequently, the side of the layered stack
closest to the belt is not heated enough to secure a third material
to a cushioning material. The result is that assignee's known
apparatus is only able to heat two layers together; no more.
[0005] Therefore, there is a need for a laminator which utilizes a
heated belt and a heated drum to laminate more than two layers
together.
[0006] There is further a need for a laminator which heats both
sides of a layered stack of materials to laminate more than two
layers together with more than one layer of adhesive.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved method of
manufacturing a laminated soft good. The method comprises applying
a first layer of adhesive between a web of backing material and a
first side of a web of cushioning material. The next step comprises
applying a second layer of adhesive between a web of ticking
material and a second side of the web of cushioning material to
create a layered stack. For purposes of this document the term
cushioning material includes, but is not limited to, any material
containing at least some foam or some fiber or any combination
thereof.
[0008] The key step in the process is heating a moving endless belt
by at least one heater to create a heated moving endless belt. Each
heater is preferably a radiant heater. The layered stack is fed
between the heated moving endless belt and a heated rotating drum.
The layered stack is compressed between the heated moving endless
belt and the heated rotating drum, heat from the heated moving
endless belt and heat from the heated rotating drum laminating the
web of backing material, web of cushioning material and web of
ticking material to create a laminated soft good. Heat from the
heated moving endless belt melts a web of adhesive between the web
of backing material and the web of cushioning material. Heat from
the heated rotating drum melts the other web of adhesive between
the web of ticking material and the web of cushioning material. The
result is a three-layered laminated soft good which may be passed
to a slitter or wound up in a roll for later use.
[0009] Worded another way, the method of manufacturing a laminated
soft good having at least three layers comprises applying a first
layer of adhesive to one side of a first outer web of material. The
next step comprises placing a web of cushioning material over the
first layer of adhesive to create a sub-stack and moving the
sub-stack downstream. The next step comprises applying a second
layer of adhesive to an exposed of the web of cushioning material
and placing a second outer web of material over the second layer of
adhesive to create a layered stack.
[0010] The key step in the process is feeding the layered stack
between a heated moving endless belt and a heated rotating drum.
The moving endless belt is heated by at least one heater and driven
by a drive assembly which is preferably motorized. In one
embodiment, each heater is a radiant heater. The layered stack is
compressed between the heated moving endless belt and the heated
rotating drum. Heat from the heated moving endless belt and heat
from the heated rotating drum laminate the web of backing material,
web of cushioning material and web of ticking material to create a
laminated soft good. Heat from the heated moving endless belt melts
the second layer or web of adhesive between the web of second outer
web of material and the web of cushioning material. The rotating
drum is heated by oil located inside an interior of the drum. Heat
from the heated rotating drum melts the first layer or web of
adhesive between the web of first outer web of material and the web
of cushioning material. The result is a three-layered laminated
soft good which may be passed to a slitter or wound up in a roll
for later use.
[0011] Worded another way, the method of manufacturing a laminated
soft good having at least three layers comprises creating a layered
stack comprising a cushioning layer, webs of adhesive on opposites
side of the cushioning layer and outer layers outside the webs of
adhesive. The cushioning layer may be foam or fiber or any
combination thereof including at least one of the two components.
The next step comprises heating an endless belt with at least one
heater. In one embodiment, each heater is a radiant heater.
[0012] The heated endless belt is moved by a motorized drive
assembly which includes gears and sprockets. The motorized drive
assembly rotates a drive roller which moves the endless belt around
several other rollers, at least one of which is manually
adjustable. Rotation of the heated moving endless belt and a heated
rotating drum pulls the layered stack between the heated moving
endless belt and the heated rotating drum in a downstream
direction. Heat from the heated moving endless belt and heat from
the heated rotating drum heat both sides of the layered stack. Heat
from the heated moving endless belt melts the second layer or web
of adhesive between the web of second outer web of material and the
web of cushioning material. The rotating drum is heated by oil
located inside an interior of the drum. Heat from the heated
rotating drum melts the first layer or web of adhesive between the
web of first outer web of material and the web of cushioning
material. The result is a three-layered laminated soft good which
may be passed to a slitter or wound up in a roll for later use.
[0013] By virtue of the foregoing, there is thus provided a
laminated product having at least three layers joined by melted
adhesive. By heating the endless belt, the layered stack passing
between the endless belt and the rotating drum is heated from both
sides, melting layers of adhesive on opposite sides of a middle
cushioning layer. The product or soft good may be used as borders
or panels for bedding products or as outerwear for seats and
cushions or any other suitable use. The use of the finished product
is not intended to be limited by this document.
[0014] These and other objects and advantages of the present
invention shall be made apparent from the accompanying drawings and
the description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and, together with the general description of the
invention given above and the detailed description of the
embodiments given below, explain the principles of the present
invention.
[0016] FIG. 1 is a front perspective view of the apparatus for
performing the method of manufacturing a laminated soft good in
accordance with the principles of the present invention.
[0017] FIG. 2 is a rear perspective view of the apparatus of FIG.
1.
[0018] FIG. 3 is another rear perspective view of the apparatus of
FIG. 1.
[0019] FIG. 4 is a view of the encircled area 4 of FIG. 1.
[0020] FIG. 5 is a cross-sectional view taken along the line 5-5 of
FIG. 3.
[0021] FIG. 5A is a cross-sectional view like FIG. 5 but showing
the laminated material passing to a slitter rather than a
collection spool.
[0022] FIG. 6 is an enlarged cross-sectional view of the boxed area
labeled 6 of FIG. 5.
[0023] FIG. 6A is a cross-sectional view like FIG. 5A but showing
the laminated material passing to a slitter rather than a
collection spool.
[0024] FIG. 7 is a cross-sectional view of the sub-stack before the
final two webs of material are added as shown by the encircled area
7 of FIG. 6A.
[0025] FIG. 8 is a cross-sectional view of the layered stack before
being laminated as shown by the encircled area 8 of FIG. 6.
[0026] FIG. 9 is a cross-sectional view of the finished laminated
soft good as shown by the encircled area 9 of FIG. 6A.
DETAILED DESCRIPTION OF THE DRAWINGS
[0027] With reference to FIG. 1, there is shown an apparatus 10 for
laminating three different materials together to create a laminated
soft good 5 (shown in detail in FIG. 9). For purposes of this
document, the apparatus 10 has a front or upstream end 7 and a rear
or downstream end 9. The terms upstream and downstream refer to the
flow of materials as they pass through the apparatus 10 during the
method of manufacturing the laminated soft good 5 described
herein.
[0028] The apparatus 10 comprises a base 12 adapted to rest on the
floor of a building (not shown). The base 12 comprises two parallel
runner tubes 14, a front cross tube 16 extending between the front
ends 18 of the runner tubes 14, and a rear cross tube 20 extending
between the runner tubes 14.
[0029] The apparatus 10 further comprises a front riser 22
extending upwardly from each of the runner tubes 14 behind or
downstream of the front cross tube 16. Further downstream is a
short riser 24 extending upwardly from each of the runner tubes 14
behind or downstream of the front riser 22. Even further downstream
is a tall riser 26 extending upwardly from each of the runner tubes
14 behind or downstream of the small riser 24.
[0030] As best shown in FIGS. 1-3, a front support 28 extends
transversely or from side-to-side and is removably supported by the
front risers 22. More particularly, the front support bar 28 sits
inside a downwardly extending notch 30 in each of the front risers
22. The front support bar 28 passes through a cardboard tube 31
around which backing material is rolled to create a roll of backing
material 32. As best shown in FIG. 2, when the roll 32 of backing
material runs out, the front support bar 28 may be lifted away from
the front risers 22 quickly and easily and separated from the empty
cardboard tube 31. The front support bar 28 may then be passed
through a cardboard tube of a full roll 32 of backing material and
lifted back into place residing inside the notches 30 of the front
risers 22.
[0031] As best shown in FIGS. 1-3, a middle support bar 34 extends
transversely or from side-to-side and is removably supported by the
short risers 24. More particularly, the middle support bar 34 sits
inside a downwardly extending notch 36 in each of the short risers
24. The middle support bar 34 passes through a cardboard tube 33
around which adhesive material is rolled to create a roll 38 of
adhesive. As best shown in FIG. 2, when the roll 38 of adhesive
runs out, the middle support bar 34 may be lifted away from the
short risers 24 quickly and easily before being separated from the
empty cardboard tube 33. The middle support bar 34 may then be
passed through a cardboard tube of a full roll 38 of adhesive and
lifted back into the notches 36 of the short risers 24.
[0032] As best shown in FIGS. 1-3, a rear support bar 40 extends
transversely or from side-to-side and is removably supported by the
tall risers 26. More particularly, the rear support bar 40 sits
inside a downwardly extending notch 42 in each of the tall risers
26. The rear support bar 40 passes through a cardboard tube 35
around which cushioning material is rolled to create a roll 44 of
cushioning material. As best shown in FIG. 2, when the cushioning
material runs out, the rear support bar 40 may be lifted away from
the tall risers 26 quickly and easily. After the cardboard tube 35
is removed from the rear support bar 40, the rear support bar 40
may be put through a cardboard tube of a full roll of cushioning
material and lifted back into the notches 42 of the tall risers
26.
[0033] The apparatus 10 further comprises two manually adjustable
paddle brakes 46, one on each side of the roll 44 of cushioning
material. The paddle brakes 46 apply friction to the outer side
surfaces of the roll 44 of cushioning material to slow the speed of
rotation of the roll 44 of cushioning material.
[0034] An upstream catwalk 48 is located downstream of the tall
risers 26. The upstream catwalk 48 comprises a generally planar
catwalk platform 50 supported off the floor by four legs 52. The
four legs 52 may be attached to the runner tubes 14 of the base 12.
The upstream catwalk 48 may be used to access portions of the
apparatus 10 for repairs or other purposes. An upstream step 54
supported by legs 56 is located on each side of the upstream
catwalk 48 to ease access to the upstream catwalk 48.
[0035] The apparatus 10 further comprises a motorized drive
assembly 60 downstream of the upstream catwalk 48. The motorized
drive assembly 60 comprises a first side frame 62 and a second side
frame 64, each being generally rectangular and box shaped. Each of
the first and second side frames 62, 64 has a hollow interior 66
defined by a bottom 68, an inside wall 70 and an outside wall 72
spaced from the inside wall 70 and a peripheral wall 74 extending
between the inside and outside walls. The bottom 68 is supported
off the floor by feet 58. Although four feet 58 are illustrated
lifting the bottom 68 of each of the first and second side frames
62, 64 off the floor (not shown), any number of feet of any desired
configuration may be used.
[0036] The apparatus 10 further comprises two mounting plates 76,
one mounting plate 76 being attached to the inside wall 70 of the
first side frame 62 and the second mounting plate 76 being attached
to the inside wall 70 of the second side frame 64.
[0037] As best shown in FIGS. 1 and 4, an adhesive roll support bar
78 extends between lower mounts 79 secured to the mounting plates
76. The adhesive roll support bar 78 passes through a cardboard
tube 37 around which adhesive material is rolled to create a roll
80 of adhesive. The lower mounts 79 (only one being shown in FIG.
4) are shaped to enable an operator to quickly and easily remove
the adhesive roll support bar 78 once the web of adhesive wound
around the adhesive roll support bar 78 is used up. Once the empty
cardboard tube is separated from the adhesive roll support bar 78,
the adhesive roll support bar 78 may then be passed through the
cardboard tube of a full roll 80 of adhesive material and then
quickly and easily lowered into engagement with the lower mounts
79. See FIG. 4.
[0038] Similarly, as best shown in FIGS. 1 and 4, an upper roll
support bar 82 extends between upper mounts 81 secured to the
mounting plates 76. The upper roll support bar 82 supports a roll
84 of ticking material. The upper roll support bar 82 extends
through a cardboard tube 39 around which ticking material is rolled
to create the roll 84 of ticking material. The upper mounts 81
(only one being shown in FIG. 4) are shaped to enable an operator
to quickly and easily remove the upper roll support bar 82 once the
web of ticking wound around the upper roll support bar 82 is used
up. Once the empty cardboard tube is separated from the upper roll
support bar 82, the upper roll support bar 82 may be passed through
the cardboard tube of a full roll of ticking material. As best
shown in FIG. 4, the upper roll support bar 82 supporting a full
roll 84 of ticking material may be then quickly and easily lowered
into engagement with the upper mounts 81.
[0039] As best shown in FIGS. 4 and 5, a rotatable lower
compression roller 86 extends between bearings 88 secured to the
inside walls 70 of the first and second side frames 62, 64.
[0040] As best shown in FIGS. 4 and 5, a rotatable pinch roller 90
extends between clevis ball bearings 92 secured to the inside walls
70 of the first and second side frames 62, 64. The location of the
clevis ball bearings 92 and hence the location of the rotatable
pinch roller 90 may be adjusted by two air cylinders 94 located in
the interiors 66 of the first and second side frames 62, 64,
respectively. See FIGS. 2 and 3.
[0041] As best shown in FIGS. 6 and 6A, the apparatus 10 further
comprises a rotatable oil drum 96 having a hollow interior at least
partially filled with oil 98. The rotatable oil drum 96 is mounted
on a rotatable shaft 100. A plurality of heating elements 102
extend through the hollow interior 104 of the rotatable oil drum 96
to heat the oil 98 which in turn heats the exterior surface 106 of
the rotatable oil drum 96. As best shown in FIG. 2, a heat shield
108 is located inside the interior 66 of the first side frame 62.
The heat shield 108 protects the wiring (not shown) which heats the
heating elements 102 extending through the hollow interior 104 of
the rotatable oil drum 96.
[0042] As best shown in FIGS. 1 and 4, the apparatus 10 further
comprises a circuit box 110 which houses some of the electronics,
as one skilled in the art will appreciate.
[0043] Referring to FIGS. 1 and 3, the motorized drive assembly 60
functions to rotate an endless belt 112 described in more detail
below. The motorized drive assembly 60 comprises a motor 114, a
gearbox 116, a pulley 118 driven by a gear (not shown) in the
gearbox 116. As best seen in FIG. 3, the pulley 118 drives a
sprocket 120 which rotates a drive roller 122. As best seen in FIG.
3, the motor 114, a gearbox 116, pulley 118 and sprocket 120 are
located inside the hollow interior 66 of the first side frame 62.
As best seen in FIGS. 6 and 6A, rotation of the sprocket 120
rotates a drive roller 122 extending between the first and second
side frames 62, 64.
[0044] As best shown in FIGS. 6 and 6A, the drive roller 122
rotates in a clockwise direction, thereby moving the endless belt
112 in a generally clockwise direction. The endless belt 112 passes
around the drive roller 122, as shown in FIGS. 6 and 6A, around
three other rollers including idle roller 124 located at the same
generally vertical level as drive roller 122 but further
downstream.
[0045] An adjustable tension roller 126 is located generally above
the heated rotatable oil drum 96. The position of the tension
roller 126 changes the tension on the endless belt 112. The
position of the tension roller 126 is changed or adjusted via a
hand crank 128 shown in FIG. 3. As best shown in FIG. 6, rotation
of the hand crank 126 rotates a pinion gear 130 which moves a rack
gear 132 in a front-to-back direction, thereby moving the position
of the adjustable tension roller 126. As best shown in FIG. 6, the
fourth roller around which the endless belt 112 passes is another
idle roller 134.
[0046] As best shown in FIGS. 6 and 6A, the apparatus 10 further
comprises a radiant heater 136 residing beneath the lower
horizontally oriented portion of endless belt 112. Although only
one radiant heater 136 is shown, any number of heaters of any known
type may be used to heat the endless belt 112 before the heated
portion of the endless belt 112 contacts the layered stack of
materials to be laminated. As best shown in FIGS. 6 and 6A, the
radiant heater 136 has two electrodes 138.
[0047] As best shown in FIGS. 6 and 6A, the apparatus 10 further
comprises another idle roller 140 downstream of the rotatable oil
drum 96. The finished laminated soft good 5, shown in cross-section
in detail in FIG. 9, passes between the idle roller 140 and a nip
roller 142. The position of the nip roller 142 is controlled by two
air cylinders 144 (only one being shown in FIGS. 6 and 6A). As best
shown in FIGS. 6 and 6A, the apparatus 10 further comprises another
roller 146 which is used with an upper roller 148 to pass the
finished laminated soft good 5 further downstream. The apparatus 10
further comprises a distance counter 150.
[0048] The apparatus 10 further comprises a rack 152 downstream of
the cylinders 146, 148. The rack 152 comprises two arms 162 secured
to the first and second side frames 62, 64, two extension arms 164
extending rearwardly from arms 162, an upstream rack roller 154
extending between the extension arms 164, a middle roller 156
extending between hangers 160 and a downstream rack roller 158
extending between the extension arms 164. The rack 152 further
comprises rear legs 166.
[0049] The apparatus 10 further comprises a downstream catwalk 168
is located underneath the rack 152. The downstream catwalk 168
comprises a generally planar catwalk platform 170 supported off the
floor by four legs 172. The downstream catwalk 168 may be used to
access portions of the apparatus 10 for repairs or any other
desired purpose. A downstream step 174 supported by legs 176 is
located on each side of the downstream catwalk 168 to ease access
to the downstream catwalk 168.
[0050] In use, referring to FIGS. 5 and 5A, a web of backing
material 178 is unwound from the roll 32 of backing material and
pulled downstream. A first web of adhesive 180 is unwound from the
roll 38 of adhesive and pulled downstream. As shown in FIG. 7, the
first web of adhesive 180 is above the web of backing material 178
as the webs are pulled downstream. Simultaneously, a web of
cushioning material 182 is unwound from the roll 44 of cushioning
material and pulled downstream. As shown in FIG. 7, the web of
cushioning material 182 is above the first web of adhesive 180 as
the webs are pulled downstream. As shown in FIG. 7, the three webs
of material 178, 180, 182 form a sub-stack 184 which is pulled
upwardly or downstream by the operation of the drive assembly
60.
[0051] As best shown in FIGS. 6 and 6A, as the sub-stack 184 is
pulled downstream by the operation of the drive assembly 60, a
second web of adhesive 186 is unwound from the roll 80 of adhesive
and pulled downstream adjacent the web of cushioning material 182.
As shown in FIG. 8, the second web of adhesive 186 is above the web
of cushioning material 182 as the webs are pulled downstream.
Simultaneously, a web of ticking material 188 is unwound from the
roll 84 of ticking material and pulled downstream. As shown in FIG.
8, the web of ticking material 188 is above the second web of
adhesive 186 as the webs are pulled downstream. As shown in FIG. 8,
the five webs of material 178, 180, 182, 186, 188 form a layered
stack 190 comprising five layers which is pulled upwardly or
downstream by the operation of the drive assembly 60.
[0052] By virtue of the foregoing, there is thus provided a
finished laminated soft good 5 shown in FIG. 9. FIG. 9 shows a
first outer layer or ticking layer 192, a middle cushioning layer
194 and a second outer layer or backing layer 196. The heat applied
from both sides melts the layers of adhesive of the layered stack
during the manufacturing process.
[0053] As shown in FIGS. 5 and 5A, after the finished laminated
soft good 5 passes over the frame 152 and more particularly, over
upstream rack roller 154 extending between the extension arms 164,
under middle roller 156 extending between hangers 160 and over
downstream rack roller 158 extending between the extension arms
164, the finished laminated soft good 5 may extend to a collection
spool 198 as shown in FIG. 5 or to a slitter 200. FIGS. 6 and 6A,
show the finished laminated soft good 5 passing generally to either
a collection spool 198 or to a slitter 200.
[0054] Although encircled areas 7, 8 and 9 are shown on FIG. 6A,
they may just as well be on FIG. 6. It does not matter whether the
finished laminated soft good 5 passes to a collection spool 198 or
to a slitter 200; either way the inventive aspects of the present
invention are the same. The heated endless belt 112 enables five
layers, as opposed to only three layers in the prior art, to be
laminated together using a heated oil drum.
[0055] While the present invention has been illustrated by the
description of embodiments thereof, and while the embodiments have
been described in considerable detail, it is not intended to
restrict or in any way limit the scope of the appended claims to
such detail. Additional advantages and modifications will readily
appear to those skilled in the art. For example, more than five
layers may be laminated together. The invention in its broader
aspects is, therefore, not limited to the specific details,
representative apparatus and method, and illustrative examples
shown and described. Accordingly, departures may be made from such
details without departing from the spirit or scope of the general
inventive concept.
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