Patent Application
20190219329
The present invention relates generally to foam drying devices. More particularly the present invention relates to a system which draws air over/through a foam piece having adhesive on or in it as well as heating the foam. This combination of air flow and heat dries the adhesive rapidly.
When assembling foam pieces using adhesives, time must be spent allowing the adhesive to dry. Such foam pieces include, but are not limited to foam assemblies having multiple pieces of foam adhered together, a single foam piece adhered to itself, a foam piece having a material adhered to its exterior, and the like. Often this drying is done by allowing the foam pieces to rest under ambient conditions before packaging. This takes time, and as a result slows down the manufacturing process.
Therefore, what is needed is a device that may increase the speed of the drying/curing of adhesives.
The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article.
In one aspect, a foam dryer assembly is provided. The foam dryer assembly is formed by a frame which defines a cavity and an opening allowing air to enter the cavity. The cavity is sized and configured to receive a foam piece having a quantity of adhesive on or it in. An air blower is connected to the foam dryer and configured to draw air through the opening into the cavity to be conveyed over and/or through the foam piece. A heater is configured to heat the foam piece when positioned in the cavity.
In another aspect, a foam dryer assembly is provided. In this aspect, the dryer is formed by a frame which defines a cavity and an opening allowing air to enter the cavity. A foam piece comprising foam and a quantity of adhesive is positioned within this cavity. A heater is attached to the frame and configured to direct heat at the foam piece to heat it. An air blower is attached to the frame and configured to draw air through the opening, into the cavity, and through an outlet. In so doing, air is conveyed over and/or through the foam piece, causing the adhesive to rapidly dry (cure, etc.).
The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and does not represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments.
Generally, the present invention concerns a foam drying system which uses heat and air flow to dry foam pieces which have wet adhesive on or within. The foam dryer has a frame that defines a cavity. Foam pieces may be placed in the cavity to be dried. A heater is positioned to direct heat to an item within the cavity. An air blower is configured to draw air into the cavity and expel it from an outlet. In one embodiment, the foam drying system may only use an air blower. In another embodiment, the foam drying system may only use a heater. However, in most embodiments, a combination of the heater and air blower is used. In other embodiments, the heater and air blower may cycle in alternate operations. In many embodiments, the goal of the present invention is draw generally ambient conditioned air over/through a heated foam piece, though other variations and modes of operation of the present invention are not excluded.
The term adhesive is used herein to refer to both stages of the adhesive: when it is wet and uncured, and when it has dried/cured and is a finished product. The adhesive contemplated herein may be any adhesive capable of being disposed on or in a foam to adhere another material to the foam. Typically, the adhesive is water based, however any other solvent material may also be used in the adhesive. The term “dry” refers to driving off not only water but other solvent content as well, and generally refers to the process of curing the adhesive regardless of adhesive type.
The foam pieces referred to herein may be any foam elements having a quantity of adhesive. For example, the foam piece may be two foam elements adhered together. In another example a foam piece may be a foam element with a fabric or other cover adhered to it. Generally, the foam piece may be any foam with wet adhesive in or on it to be dried.
Turning now to
The sizing of the foam dryer may vary without straying from the scope of the present invention. Typically the cavity may be large enough to receive 1-5 foam seat cushions. In one embodiment, foam pieces may range in size from six inches to ten inches in thickness, with lengths and widths ranging between twenty to sixty inches. However, smaller and larger configurations may be utilized. In a particular embodiment, the front opening may be approximately six feet wide and three feet tall. Depending on configuration, the cavity may be of similar size, or may be wider or taller.
In one embodiment, the heat output of the heater may be 3000 Watts. In another embodiment, the heater may be a 208 volt, 3000 Watt electric infrared heater that has a surface temperature of approximately 1,600 F. In another embodiment, the air blower may have a capacity of approximately 2500-3000 CFM. In yet another embodiment, the ratio of heater power to air blower volume flow may be approximately 1.3-0.9 W/CFM. In another embodiment, the ratio of heater power to air blower volume flow may be approximately 1.2-1 W/CFM. Other embodiments may include a closure to partially close off the frame to provide more directed air inlet through an opening. For example, a door may cover a top portion of the opening of
While several variations of the present invention have been illustrated by way of example in preferred or particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present invention, or the inventive concept thereof. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, and are inclusive, but not limited to the following appended claims as set forth.
