Covered soft foam article

Details Covered soft foam article Covered soft foam article

1989-07-20

1992-03-17

Epstein, Henry F.

Stock material or miscellaneous articles

Sheet including cover or casing

Foamed or expanded material encased

5481, 297219, 297DIG1, 428 85, 428160, 4283084, 446369, B32B 520, B32B 524

Patent

active

050967606

ABSTRACT:
A soft foam article (20) and a method for making the article are disclosed as including a permeable cover (24) of a cloth type sheet construction having an interior (26) and an exterior (28) as well as including an open cell soft polyurethane foam (30) molded in situ within the cover in direct engagement with the cover interior without permeating the cover. The soft foam article (20) is disclosed as a soft toy (22) and as seating components embodied by a seat cushion (52), a seat back (54), a headrest (56), and an armrest (58). The in situ molding of the soft polyurethane foam is achieved by the use of an aqueous gel coating (34) on the cover interior (26) so as to prevent a liquid foam mixture from permeating the cover while still permitting escape of any air within the cover and of gas generated during the foaming. Best results are achieved when the aqueous gel includes water and an acrylic acid polymer that is acid neutralized to increase its viscosity to the range of about 60,000 to 100,000 centipoise and most preferably to about 80,000 centipoise.

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