Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1993-04-30
1995-08-08
Epstein, Henry F.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156299, 156300, 428 24, 428 79, B44F 700
Patent
active
054395380
ABSTRACT:
A decorative article and a means for making such a decorative article includes a wood base, a layer of polyethylene foam, batting, and a fabric outer surface. In forming the decorative article, a layer of polyethylene foam is adhered to a firm backing. A pattern is drawn or traced onto the outer surface of the foam. A number of smaller, pattern pieces are formed by cutting a number of slits in the foam along the lines of the pattern. After the slits have been cut in the foam, the pattern pieces are covered by batting and a knit material to form the desired pattern. Different colors may be selected for the knit materials used on various pattern pieces for the drawing. The foam must have sufficient elasticity to permit the slits to be cut in the surface and then have the slits serve as a means for securing the batting and the knit material used to cover the pattern pieces. The decorative article is divided into a number of pattern pieces to facilitate the stretching of the fabric and the smoothing of the outer surface. In order to achieve a three-dimensional effect, the foam surface may be sculpted by cutting and trimming the foam prior to installing. Individual pieces of foam may be sculpted to the desired shape and then are attached to the surface of the foam. The batting and the material are stretched over the pattern pieces and secured in the slits by the elastic resistance of the foam walls of the slit.
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