Cutting – Processes – With preparatory or simultaneous ancillary treatment of work
Reexamination Certificate
1999-08-16
2001-01-23
Rachuba, M. (Department: 3724)
Cutting
Processes
With preparatory or simultaneous ancillary treatment of work
C083S176000, C083S019000
Reexamination Certificate
active
06176164
ABSTRACT:
BACKGROUND OF THE INVENTION
The field of the invention is foam compression cutting and the invention relates more particularly to an improved foam cutting process capable of very detailed and sharp-edged cuts. Compression foam cutting is itself not a new process and has been carried out in various forms for many years.
U.S. Pat. No. 4,351,211 shows a foam cutting process utilizing the compression of a piece of foam between two dies, each of which support four members and a cut is made through a middle portion of the compressed foam block.
U.S. Pat. No. 5,523,040 shows a method for making a custom support cushion where a foam block is compressed by a seated person and a cut made.
U.S. Pat. No. 5,688,538 shows a foam cutting process utilizing a pair of rollers having a blade downstream of a nip between rollers.
A process utilizing a moving table that supports a template has also been used for many years and will be described below in conjunction with the drawings.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compression cutting process capable of forming a cut foam block with far more detail than heretofore thought possible.
The present invention is for a process for the compression cutting of foam of the type which utilizes a moving table which supports a template which has a shaped template cavity. An angled moving belt is supported above the template and the foam block placed on the upper surface of the template is fed under the moving belt and compressed. A moving knife is positioned downstream of the angled moving belt and makes a cut in the compressed foam block. The improvement of the present invention includes the steps of placing a second block above the foam block to be cut over the template to form a sandwiched pair of identical foam blocks. The template and sandwiched pair of identical foam blocks are passed into the lower feed area of the angled moving belt and compressed so that the moving blade cuts the foam block to be cut to create a cut foam block but does not cut the second foam block. The resulting cut foam block is removed and the second foam block is removed and placed on the upper surface of the template to make it a foam block to be cut and a new second foam block is placed on the upper surface thereof to form a new sandwiched pair of identical foam blocks. The process is then repeated. Preferably, the foam is compressed to at least a ratio of 6 to 1, and preferably, about 32 to 1. The template used in the process of the present invention preferably is made using flat base board surrounded by a wall portion with an abrasion-resistant upper surface. A plurality of removable form members are affixed to the base board. When the abrasion-resistant upper surface is worn through, a new base board and new wall portion can readily be supplied and the removable form members can be removed from the worn template and placed on the base board of the new template.
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Averill, Jr. Edgar W.
Rachuba M.
Tran Kim Ngoc
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