Foamex L.p.

Denys Denney

Vincent Scattolino

Michael F Hnatow

Robert Vitelli

Jose D M Contreras

Jose D Contreras

Vincenzo A Bonaddio

Jose De Contreras

David M Johnsin

Jose De Contreras Munoz

An apparatus for shaping a slab of compressible or cellular polymer material ( ), such as polyurethane foam, shapes such slab by cutting portions of the material from one surface. A moving patterned platform ( ), preferably an endless belt or a series of interconnected panels, is interposed between a compression roller ( ) and a cooperating surface ( ) and defines at least one recess ( ) or at least one projection ( ) or a combination of recesses and projections. When the slab is compressed between the compression roller and the platform, which is supported by the cooperating surface, a portion of the material fills the recess or recesses in the moving platform. At least a portion of the compressed material within the recess(es) is then cut from the surface of the slab by a blade ( ) just as the slab emerges from between the compression roller and the platform, leaving a profile-cut surface with cut-out portion(s) corresponding in pattern and shape to the recess(es) provided in the moving patterned platform. Alternatively, a portion of the material is forced away form the blade ( ) by the projection or projections ( ) so that a portion of compressed material is not cut by the blade ( ).

Continuous platform cutting apparatus

A method for shaping a slab of polyurethane foam ( ) cuts portions of the foam material from one surface. A moving patterned platform ( ) is interposed in a gap formed between a compression roller ( ) and a drive roller ( ) and defines at least one recess ( ). The slab is introduced into the gap and foam material is compressed into the recess. At least a portion of the compressed material within the recess is then cut from the surface of the slab by a blade ( ) just as the slab emerges from the gap to produce a profile-cut surface with a shaped portion corresponding to the shape of the recess in the patterned platform.

Continuous platform cutting method

An apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of a slab of the material includes a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. The blade then transversely cuts from the surface of the slab a portion of the material within the recesses in the platform just as the slab emerges from between the compression roller and the support surface. After the cut portions are removed, the resulting product has a profile-cut surface with cut-out portions corresponding in mirror image to the pattern and shape of the recesses. Depending upon the compression factor of the material, the cut-out portions will substantially correspond in depth to the recesses provided on the moving patterned platform.

Continuous platform cutting apparatus for cutting a cellular polymer surface

A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface. The cut portions then are removed leaving a profile-cut surface with cut-out portions corresponding in pattern and shape to the recesses provided on the moving patterned platform. Depending upon the compression factor of the material, the cut-out portions will substantially correspond in depth to the recesses provided on the moving patterned platform.

Method of cutting a cellular polymer surface with a continuous platform cutting apparatus

A machine for rotary cutting of continuous synthetic foam sheets while compressed between two rollers has a roller drive featuring individually adjustable roller speed to allow use of rollers of dissimilar diameter, such as a large diameter pattern roller and a small diameter compression roller. The roller drive may be selectively engaged for driving each roller with a separate drive motor or both rollers with a single motor through a gear train, allowing conversion of the machine to conventional foam convoluting using similar sized rollers.

Synthetic foam surface contouring machine

Apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of one or more slabs of material ( ) includes two compression rollers ( ), two moving patterned platforms ( ) interposed between the compression rollers, and one or more cutting blades ( ) for transversely cutting the slab or slabs just as the cellular material emerges from between the compression rollers. At least one of the moving patterned platforms, preferably an endless belt, defines a recess or pattern of recesses. When a single slab or multiple slabs of material are fed and compressed between the compression rollers, a portion of the material from one side of the slab or slabs fills the recess or recesses in one of the moving patterned belts. The blade then transversely cuts the cellular material.

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Bear, DE, United States of America

Denys Denney