Claims Analysis
Total Claims: 7
Claim 1
Independent Claim
224 words
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; and a 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.
Claim 2
Dependent Claim
224 words
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; and a 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.
Claim 3
Dependent Claim
24 words
Apparatus for making a three-dimensional formed laminate as in claim 1 wherein the mold includes a lower female mold and an upper male mold.
Claim 4
Dependent Claim
45 words
Apparatus for making a three-dimensional formed laminate as in claim 1 wherein the table, the mask, the mold and the first and second frames include alignment formations for registering the foam on the film, printing on the flexible member, and the three-dimensionally contoured mold surfaces.
Claim 5
Dependent Claim
66 words
Apparatus for making a three-dimensional formed laminate as in claim 1 further including a second mask that is positioned between the flexible sheet and the film with the foam thereon, and the second mask having an edge defining an opening of the predetermined shape of the formed laminate to prevent the foam from contacting the flexible sheet outward of the predetermined shape of the formed laminate.
Claim 6
Dependent Claim
42 words
Apparatus for making a three-dimensional formed laminate as in claim 4 further including a cutting member having an angled cutting surface that is heated and is engaged with the edge of the second mask to trim foam flash from the formed laminate.
Claim 7
Dependent Claim
34 words
Apparatus for making a three-dimensional formed laminate as in claim 1 further including a press for heat bonding a backing layer to the flexible sheet outwardly of the predetermined shape of the formed laminate.