Abstract: The subject matter of this invention relates to a method of making glass fiber mat reinforcement material with a thermoplastic adhesive powder. Fiberglass strands are chopped and randomly air dropped onto a Teflon.RTM. coated conveyor belt to form a loose mat. A water mist is then applied to the loose mat and transport belt, before a powdered adhesive is dispensed. Heat is applied to plasticize the adhesive and finally the adhesive is solidified by cooling. The adhesive will then release from the transport belt and is adhered to the material forming the fiberglass reinforcement mat.

Abstract: A method of coating the surface of semi-rigid porous materials such as open cell foam or fibrous compositions with a thermoplastic adhesive in powder form which will reactivate. The powdered adhesive in a size range of 0-600 microns will remain on the surface of such materials even when cell diameter of the foam or space between fibers is larger than adhesive particle size. High porosity is maintained in the coated product. First a thermoplastic adhesive in powder form is dispensed uniformly onto the surface of a carrier belt which is coated with a release agent and is moving continuously. The adhesive advances to a preheating station where the adhesive is plasticized and will adhere to the carrier belt to prevent movement, after which the foam or fibrous material is placed on the adhesive which is adhered to the belt. The adhesive and material advance to a second heating station where the adhesive is fully melted to allow the adhesive to bridge cells in the foam or space between fibers.

Abstract: A thermoformable mat, e.g., a mat of resinated fiberglass, is compressed and shaped into a contoured object, e.g., a shell for an automobile headliner, by this process. The mat is compressed between two dies that have been preheated. At least one of the dies is perforated. Superheated steam (e.g., at 80 psig and 600.degree. F.) is ejected from the perforations into the mat, thereby quickly raising the mat temperature to its thermoforming point. After the mat is set into the contoured shape, the dies are reopened and the formed mat is removed. If the mat that is used contains a thermoplastic adhesive, the mat is cooled to below the adhesive's melt print before the dies are opened. This can be done by applying a vacuum to the perforated die and pulling ambient air through the mat.

Abstract: A piece of fabric, preferably foam-backed, is laminated to a concave, rigid substrate, such as a fiberglass shell for an automobile headliner, by:a) coating the back of the fabric with a heat activable adhesive, e.g., a powdered polyamide;b) placing the adhesive side of the fabric against the concave side of the substrate;c) preheating a perforated male die having a complementary shape to that of the substrate;d) pressing the die against the fabric;e) ejecting a shot of superheated vapor, preferably steam, through the fabric, thereby activating the adhesive;f) cooling the adhesive until it sets; andg) releasing the laminated article from the die.The treatment with the superheated vapor permanently stretches the fabric in the concavities, preventing delamination after the article is released from the die.

Abstract: Two sheets of material are laminated together using a heat-activatable or moisture-curing adhesive by:(a) forming a layered composite of the material with a layer of the adhesive in between;(b) passing steam (preferably superheated) through one sheet of material into the adhesive layer;(c) compressing the heated composite before the adhesive sets;(d) releasing the pressure on the composite; and(e) allowing the adhesive to fully cure.A laminating machine is disclosed that pulls the composite between two open weave belts, past narrow jets of the steam.

Abstract: Fabric is glued to a foam cushion, while design lines are formed in the cushion, by pressing a hot, perforated die against a layered composition of foam, hot melt adhesive, and fabric. Protruding ridges in the die are heated to a higher temperature than the land area. Superheated steam is ejected through the perforations, causing the foam to melt and form the design lines, and causing the layer of adhesive to become molten. The composition is then cooled, for example by pulling air through it, to resolidify the adhesive and the molten foam under the ridges. The process is useful for forming automobile seats. It requires less labor than forming the design lines by sewing, and without damaging the fabric.

Abstract: A machine for laminating fabric (123) to open cell cushion foam (124) while forming design lines in the foam is disclosed. The machine comprises a top hollow die (21) having perforations (38) and a complementary, hollow bottom die (54) which also has perforations (130). Hot melt adhesive (125) is interleaved between fabric (123) and foam (124). Top die (21) is preheated to just below the melt point of adhesive (125); then dies (21) and (54) are closed against the layered workpiece, with top die (21) contacting the face of fabric (123). A shot of superheated steam, e.g., at 80 psig and 700.degree. F., is ejected from perforations (38) and (130) to melt adhesive (125). Then a vacuum is applied to the perforations to pull ambient air through the workpiece and cool it. The resolidified ashesive (125) holds foam (124) in its deformed shape and laminates fabric (123) to the foam.

Abstract: A steam pressing machine comprising a perforated steam platen and means for pre-heating the platen, e.g., an electric heater, is improved by providing it with a source of superheated steam for ejection out of the platen, rather than saturated steam. This allows the use of lower platen temperatures, and, therefore, lower fabric temperatures. Pressing is faster, because the fabric takes less time to cool, and nap-crushing and shining are less of a problem.