Abstract: A foam contouring machine has first and second rollers mounted to a machine frame for rotation about mutually parallel axes. The first and second rollers have different diameters and define between them a nip. A cutting edge is mounted for cutting foam material drawn through the nip by rotation of the rollers. Each roller has a drive motor, and a controller is connected to each drive motor for independently controlling the speed of rotation of the rollers, the controller equalizing the speed of surface rotation of the rollers for rollers of different diameters. The first roller may be a pattern roller and the second roller may be a backup or compression roller. The machine also has a drive coupling assembly, which has selectable first and second modes of operation for converting operation of the machine between a foam surfacing and a foam profiling operation. The first mode independently couples each of the motors to a corresponding one of the rollers.

Abstract: A thermal and acoustic barrier for automotive floor pan carpeting is made by cutting synthetic foam sheet in a continuous process to create a foam surface complementary to the three dimensional shape of the floor pan surface. The cut foam sheet is bonded to the underside of the carpeting and installed with the complementary foam surface facing the floor pan.