CA1109381A - Moldable cloth, product, and method of making same - Google Patents
Moldable cloth, product, and method of making sameInfo
- Publication number
- CA1109381A CA1109381A CA292,700A CA292700A CA1109381A CA 1109381 A CA1109381 A CA 1109381A CA 292700 A CA292700 A CA 292700A CA 1109381 A CA1109381 A CA 1109381A
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- Prior art keywords
- cloth
- layer
- heat
- mold
- film layer
- Prior art date
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Abstract
A moldable cloth is provided comprising a fabric layer including a heat-fixable fiber, a flexible foam layer bonded to the fabric layer, a first urethane film layer bonded to the foam layer, a polyvinyl chloride film layer bonded to the first urethane film layer, and a second urethane film layer bonded to the polyurethane film layer. The cloth is formed by a process comprising the steps of drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic comporition layer bonded to the fabric layer; heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold. The cloth so formed retains its detailed shape and has the appearance of an intricately sewn fabric.
Description
ThLs :Lnvention relates to cloth employable as upholstery for furniture aDd vehicle seat cushions. More particularly, this invention relates to a cloth whlch is vacuum-formable and moldable such as to retain a detailed shape, articles incorporating the cloth, and the method of making same.
Cloth has many advantages, e.g. superior appearance and thermic comfort, as a covering for vehicle seats. However, high costs are entailed due to the extensive cutting and sewing operations, much by hand, normally associated with cloth upholstery. Vehicle seat cushions comprising a foam portion having integral cover, the cushion being formed by pouring in place foam within a cover which has been shaped, can be produced at signifi--cant savings and provide a superior seat. Nevertheless, efforts to employ cloth as an integral covering have been less than successful.
Synthetic fibers are required in a cloth which is to be heated and formed in a mold. Such fibers of continuous filament type materials are formed into yarn, and texturi~ed by well known processes to build mechanical elongation into the yarn, by operators commonly known as throw~
sters. The yarn is knitted or woven into cloth, inspected and cleaned to remove impurities, bleached, stretched and dried on a tentering machine, and thereafter finished. Most frequently the tentering machine temperature is 160-220C (320-428F), which temperature is higher than that generally employed in texturization processes, and mechanical elongation of the cloth is thereby reduced, the texturization becoming partially undone, and the cloth being set at a high temperature.
Several mult:L-laycr compositlons have been devLsed in the past which include a fabric layer. A particular development has been the application to vehicle 6eats of a flame-bonded sandwich consisting of a fabric, a flexible urethane foam and a urethane elastomer fllm. Neverthe-less, several problems remain, e.g., a tendency for pinholes to form, such that poured-in-place foam reaches the fabric, and particularly for delamina-tion to occur, such that a detailed, simulated sewn appearance is not re-tained.
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It is an obJect of one aspect of thls invention to provlde a cloth which employs a decorative cloth layer and which ls vacuum formable and moldable to retain a detailed shape having the appearance of an intri-cately sewn fabric.
An ob~ect of another aspect of this invention is to provide a cloth which, after vacuum forming and molding, can, by reaction with a poured-in-place foam, become water vapor permeable, thereby further increasing thermic comfort vf seat cushions having an integral covering composed of the clo~h.
An object of still another aspect of this invention is to pro-vide a very economical way of providing furniture and vehicle seat cushions with integral covers whIch en~oy the aforementioned advantages.
An object of yet another aspect of this invention is to provide a process of preparing a cloth product such that the heat-setting of the cloth occurs during the molding, whereby the achievement of the foregoing advantages is facilitated.
By one broad aspect of this invention, a process is provided for molding cloth, comprising~the steps of: drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer; heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
By another aspect of this invention, a process is provided for molding cloth, comprising the steps of: drawing the cloth into a mold, the cloth including a fabric layer having a heat fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composi-tion layer including a thermoplastic film layer; heating the cloth to at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the layer; and cooling the cloth, the process " ' .
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heat-fixing t:he heat-Eixable flber and the film layer to the shape of the mold.
By another aspect oE this in-vention, a process is provided for molding cloth comprising the steps oE: drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition including a flexible foam layer and a thermoplastic film layer; heating the cloth to at least the greater of the set temperature of the film layer and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
By a variation oE these aspects, the process includes the step of preheating the cloth prior to the drawing step.
By another aspect of this invention, a process is provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabric layer having a heat fixable fiber, and an elastic com-position layer bonded to tne fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold; heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing that heat-fixable fiber of the cloth to the shape of the mold.
By yet another aspect of this invention, a process is provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermoplastic film layer, the temperature to which the cloth is preheated being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer;
drawing the cloth into a mold; heating the cloth to at least the greater of the temperature of the film layer; and cooling the cloth, the process ,~, ,~
- heat-:Eixlng the heat-fixable flber and the film layer to the shape of the mol.d.
By still another aspect of this inventiDn, a process i5 provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabri.c layer having a heat-fixable fiber, and an elastic composition ].ayer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold; heating the cloth to at least the heat-fixable fiber set temperature; cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold and Eilling the back side of the molded cloth with foam.
By a variation thereof, the elastic composition layer has a low elastic recovery after molding to facilitate the retention of the molded shape of the cloth.
By another variation, the elastic composition layer includes a flexible foam layer formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
By a further variation, the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer.
By yet another variation, the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer; and the flexible foam layer is formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
By still another variation, the elastic composition layer includes a thermoplastic film layer.
By a further vari.ation, the thermoplastic film layer is formed - 5a -3;~
of a polymer selectecl from the group conslstlng of ~nyl chlorlde, po]y-vlnyl chloride, polyurethane, synthetlc rubber, natural rubber, a mixture oE natural and synthetic rubber, neoprene basis composltlon, and acryllc acld basls composltlon.
By yet another variation, the process includes the step of casting a flexible foam layer to an elastic film to form the elastic composltion layer.
By still another variatlon, the fabrlc layer ls of the group consisting of polyamlde, polyester, polyvinyl chloride, polyvinyl chlorlde copolymer, wool, cotton and combinations thereof.
By another variatlon, the process further comprises the step of bonding a flexlble foam layer to a thermoplastlc fllm layer, and bondlng the foam layer to the fabrlc layer in order to form the cloth; and the heatlng step lncludes the step of heating the cloth to at least the softening temperature of the film layer.
By another aspect of this invention, a process is provided for molding cloth comprising the steps of: bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer; bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, film layer and fabrlclayer; preheatlng the cloth to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer;
drawing the cloth lnto a mold; heatlng the cloth ln the mold to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; and coollng the cloth in the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold.
By a variation thereof, the film layer is formed of a polymer selected from the group consisting of vinyl chloride, polyvinyl chloride, polyurethane, synthetlc rubber, natural rubber, a mixture of natural and - 5b -synthetic rubber, neoprene ~asls compositLon, and acrylLc acld bQ~sls com-pos:Ltion.
~ y yet another variation, the drawing step includes the step of creatlng a vacuum between the cloth and the mold thereby to conform the cloth to the shape of the mold.
By yet a further variat:Lon, the process includes the further step of pouring foam into the mold after the cooling step.
By another aspect of th:Ls invention, a process is provided for forming a cloth covered item comprising the steps of: bonding a flexible foam layer to a thermoplastic film layer, the foam layer and fllm layer - forming an elastic composition layer; bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, the film layer and the fabric layer; preheating the cloth to a tempera-ture of at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer; drawing the cloth into a mold; heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the film layer; cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixablP fiber of the fabric layer and the film layer to the shape of the mold and filling the back side of the molded cloth with foam.
By another aspect of this invention, a moldable cloth is pro-vided comprising a fabric layer including a heat--fixable fiber;la flexible foam layer bonded to the fabric layer; a first urethane film layer bonded to the foam layer; a polyvinyl chloride film layer bonded to the first urethane film layer; and a second urethane film layer bonded to the poly-urethane film layer.
In other words, the cloth of aspects of this invention includes a decorative fabric layer. The fabric includes a heat-fixable fabric, e.g., textur:ized polyester knit, whi~h has been subjected during treatment '~
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to a maxlmum temperature which ls relatively low compAred to typical tem-pera~ures reached during molding described hereinbelow. The cloth also includes an elastic compositlon layer. ~le elastic aomposition layer can include a flexible foam, e.g., a polyester-type polyurethane, and an elastic film, e.g., a polyvinyl chloride. The film is bonded to one side of the foam, as by a casting process, and the fabric is bonded to the opposite side of the foam, as by a flame-bonding process. The cloth is employed with a mold by heating to a temperature higher than any to which the cloth had been previously sub~ected and drawing, as by a vacuum, the clot:h into the mold, the final heat-fixing of the cloth occurring ln the mold. Thereafter, a foam, e.g., a polyether-type polyurethane, can be poured-in-place to form a complete mold.
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', he cloth of aspects of thls lnvention :Lncludes a fabric layer bonded to an elastic composition. By employlng the fabric layer as an ex-terior, decorative layer, superior appearance qualities are attained and thermic comfort, due to greater air-flow through a fabric, results in a superior product where the cloth is employed in a vehicle seat or furniture cushion product. The fabrlc can be knitted or woven as by machines common-ly employed in the textile industry.
Knitted fabrics can be warp knit and circular knit, single knit and double knit. The fabric must have elasticity for mold-Lng operations and must be able to be heat-fixed during the molding operation to retaln the shape of the mold. The knitting construction provides some elasticlty for the fabrlc. The surface yarns of the knitted fabric can be natural, artificial or synthetic fibers e.g. wool, cotton, fibrane, polyamide, poly-ester, vinyl chloride and vinyl chloride-acrylonftrile copolymers and poly acryl fibers. The ground should have an elasticity comparable to that oP
the elastic compositions. Texturized yarns of heat-fixable fibers e.g.
polyamide or polyester high elasticity yarns or very high thermoplastic ' yarns e.g. vinyl chloride and vinyl chlorlde acrylonitrile (modacrylic) yarns should be employed for the ground therefore. Woven fabrics should employ texturized heat-fixable fibers. Polyamides, e.g. type 6 and 6.6, polyester, vinyl-chloride, vinyl-chloride-acrylonitrile copolymers, elastomer urethane and polyacryl fibers are suitable. The highest tempera-ture to ~;;~/', .
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-whlch the heat-flxable flber ln the fabric is subJected during processing should be relatively low, and relatively high temperatures should not be employed as, for example, during tentering. The final heat setting of the heat fixable fiber then takes place in the mold at the higher, molding tem-perature, as stated hereinbelow.
The elastic compositlon -lncludes foam lnterlayer and film layer.
The foam interlayer must have good adhesion to both the fabric layer and the film layer. The foam interlayer allows movement of the fabric layer relative to the film layer and prevents breaking of the film layer that might otherwise result from elongation of the cloth were the fabric laye-r directly attached to the film layer. The foam lnterlayer is preferably a typical soft foam, open microcell based on the reacting of polyesters with isocyanate to form a polyurethane,polyester-type. The foam preferably has a density of 30-60 kg/m3, thickness of 2.5 to 4.0 mm, and tensile strength of 300-400%. The film layer preferably is able to withstand a 400% surface deformation. The film layer may have a thickness of 0.03 mm to 0.7 mm; however, the thinner dimensions are preferable. Polyvinyl chloride, polyester-type polyurethane elastomer, unvulcanized rubber or neoprene base COmposition may be employed for the film. The po]yvinyl chloride and polyurethane elastomer films are applied to the foam by transfer process:
being applied as a liquid, the thickness being controlled by a blade, being heated to jellification, not coating, temperature by infrared lamps, having a second controlled thickness applied and .~
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heated, having polyurethane foam applled, passLng through calendar rollers at room temperature, and belng baked under infra-red lamps. The unvulcanized rubber is passed between calendar rollers heated to a temperature less than the rollers together with the foam. After the film layer is Joined to one side of the foam layer to form the elastic composition, the opposite side of the foam is heated, as in a Reeves machine, and the fabric layer joined thereto in a flame-bonded manner. It is not preferable to ~oin both the fabric and film layers to the foam by ilame-bonding, as this results in a great tendency for delamination of the film layer~ This results in the cloth being unable to retain molded details.
The cloth is employed with a mold by heating and drawing the cloth into the mo:Ld. The molding temperature should be higher than the highest temperature to which the heat fixable materials therein had been previously sub~ected and at least t~e vulcani~ing temperature should the rubber film be employed. The final heat-setting of the cloth takes place in the mold, and the shape of the mold is assumed by the cloth. The molding temperature is also higher than the contemplated average ambient air temperature to which the cloth will be subjected during its intended use. After the mold has cooled to a temperature no greater than 38C, a polyester-type poly-urethane foam may be poured-in-place. After curing a complete furniture or vehicle seat cushion, for example, is obtained.
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By including TDI Ln the poured-ln-place fnam and lncluding pro-ducts containing reactive - O~l groups in the film layer, a water-producing reaction will occur between the film layer and the poured- in-place foam, heat of the reaction causing the water to vaporize, thereby causing pores to form in the film layer. The cloth~ which was tight to provide an air barrier such that the cloth could be vacuum formed and the fabric layer protected from the liquid components for the foam, thereby becomes water vapor permeable, and thermic comfort is thereby increased in seat applica-tions.
The following specific examples will serve to illustrate the moldable cloth of aspects of this invention. In a]l examples the heat-fixable fiber cDmponent of the fabric layer is processed at temperatures lower than the temperature employed in molding the final product emE)loying the cloth, which molding temperature is also higher than the amhient tem-peratures to which the final product employing the cloth will be subjected.
therefore, in all examples, the final heat- fixing of the fabric layer occurs in the mold. J
A moldable cloth was prepared in the followln~ manner. The fabric used was a double knit polyamide fabric, knitted of texturized yarn. The fabric was dyed on a Beem machine and dried on a tender frame machine, the highest temperature reached during the finishing process not exceeding 110C (230F). The fabric was applied, by flame bonding employ-ing a Reeves machine, to a polyester-type polyurethane foam, the surface of the foam having been heated to a temperature of 300C (572F). The foam was microcell, 2.5mm thick, of g _ ~.il ,.~L!$ $~
natural color, and had a density of 52 kg/m3. The foam was obtained by reactions well-known in the art of polyurethane Eoam manufacture. A poly-Einyl chloride film of 12 mils (about 0.3 mm) was formed having the follow-ing composition (% by weight of total):
Vinyl Chloride 40.0 Phosphate/phtalate plasticizers 60.0 Light and heat ~tabilizers 2.0 Epox~y 0 5 Fillers and pigrnents 7.5 The PVC film was formed having a urethane coating on both sides. The fabric and foam component was bonded to the film by a transfer coating process.
To make a cushion employing the cloth, the cloth was first cut to the re~uired size, placed in a frame and heated by air to a temperature of 160C (320F) while being pulled down into and held in a female mold with vacuum pressure. The heat at this time set the fabric and attached components to the conformation and dimensions of the mold. The mold to-gether with the cloth was allowed to cool to not more than 38C (100F).
A polyether-type polyurethane foam, cold cure, with a density of 52 kg/m3, was then poured-in-place. After expansion of the foam within the mold fo~
fifteen minutes, the product was removed from the mold. Thereafter the poured urethane cells were broken down by pressure applied by rollers, pad-dles, hand or miscellaneous mechanical means, and the product, a seat cushion, was complete.
E~AMPLE 2 A moldable cloth may be prepared in the following manner. A
single knit polyester fabric, knitted of texturized yarn, is employed which has been subjected to a maximum temperature : ~ .
of 112.8DC (235~F) durlng dyeing and Inishll-g. A polyester-type polyure-thane, microcell, 2.5 mm thick foam, having a density of 40 kg/m3, is formed. A PVC film i6 formed having a thickness of 14 mils. and a urethane coating on both sides. The foam is cast OlltO the film by a transfer process.
; The fabric is applied by flame-bonding to the side of the foam opposite the film.
The c]oth is cut to the desired size, placed in a frame, and then drawn, fabric side first, into the mold by vacuum pressure. The cloth i~
then heated from the mold side to 154.4C (310F). The cloth is set by the heat to the conformation and dimensions of the mold. After the temperature of the cloth and mold has cooled below 38C (100F), a polyether-type poly-urethane foam, cold cure, with a density of 40 kg/m3, is then poured-in-place. After e~pansion of the foam for 12 minutes, the product is removed and treated as in the previous example.
A moldable cloth may be prepared in the following manner. A
double knit fabric, 60% polyamide and 40% polyester texturized yarns, is J
employed which has been subjected to a maximum temperature of 110C (230F).
A polyester-type polyurethane microcell foam is prepared having a thickness of 3mm and a density of 45 k~/m3. A polyester-type urethane film of 0.15 mm thickness is prepared, and the foam is cast onto the film by transfer process. The fabric is then flame-bonded to the foam.
The cloth is drawn into the mold, fabric side down, and then heated, as by infra red lamps, from the film side 1'~
, ' to a temperature of 150C (300F), the cloth belng heat-fixed in the con-formation and dimensions oE the mold. After cooling of the mold and cloth as in previous examples, a completed furnLture cushion is obtained by pour-ing-in-place a polyether-type polyurethane foam of a density of 45 kg/m3, allowing 14 minutes for expansion of the foam, and then removing the furni-ture cushion from the mold.
. _ A moldable cloth may be prepared in the following manner.
A double knit fabric of texturized polyester yarns is employed which has been sub~ected to temperatures no greater than 107.2C (225F) during its processing. A polyester-type polyurethane microcell foam havlng a thlck-ness of 2.5mm and a density of 45 kg/m3 is prepared. A film of unvulcan-ized synthetics and natural rubber compound is prepared of 1.5mm thickness and having the following composition (~ by weight of total):
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Synthetic rubber, SBR 20.0 Natural rubber smoked sheet 70.5 Sulphur 1.0 Non-migrating anti-oxydizing agent 1.0 Zinc oxide 4.0-4.5 Zinc diethyl dithiocarbamate or Mercaptan MBTS 1.0-1.5 Carbon black 2.0 20 The foam is calendered onto the film, the temperature of the calendar rolls being less than the vulcanizing temperature.
The cloth is heated by air to a temperature of 150C (300F) and is drawn into the mold immediately. The rubber film is vulcanized in the mold, and the heat-fixable components of the cloth are fixed in the mold, the cloth being set in the conformation and dimensions of the mold. The mold and .
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:. '' cloth are coo:Led, as explained ln earller examples, and a polyether-type polyurethane foam is poured-in-place having a density of 40 kg/m . After 14 minutes the cushion is removed Erom the mold.
XAMPL~rj A moldable cloth may be prepared in the following manner~ A
double knit fabric of texturized polyamide yarns is employed which has been subjected to temperatures not in excess of 110C (230F). A neoprene foam is prepared having a density of 38 kg/m and a thickness of 2.5mm. A neo-prene film of 12 mils thickness is prepared according to the following composition (% by weight of total):
Polychloroprene (Neoprene) 47.25 Ethylene vinyl acetate16.55 Barium sulfate 20.50 Magnesium oxide 8.25 Anti oxygen (anti-migration and anti-soiling type) 0.80 Polyethylene wax 1.65 Fat acid oil amide 0.5 Stearic acid 0.5 Fatice product 4.0 The foam is applied to the fiLm by a transfer process, and the fabric is cast onto the foam, and bonded thereto upon curing of the foam. ~ polyurethane or acrylic adhesive may be employed to aid the bonding of the fabric to the foam.
The cloth is heated by air to 150C (300F) and immediately drawn by vacuum into the mold. The final heat-setting of the cloth takes place in the moldl the cloth assuming the conformation and dimensions of the mold.
A polyether-type polyurethane foam is poured-in-place having a density of 40 kg/m3. Polymer SBS may be included in the formulation for the film;
and the poured-in-place foam will ~ .
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then react with the fllm such that pores are formed in the film to provLde water vapor permeability.
The cloth obtalned ln the foregolng examples has a decoratlve fabric layer and nevertheless ls vacuum-formable and moldable. The cloth is finally heat-fixed in the mold and retains a detailed shape lmparted by the mold, whlch shape can have the appearance of intricate hand stltchlng.
The cloth does not have the tendency to delaminate of exclusively flame-bonded constructions. Pouring-in-place foam:Lng techniques may be employed without harming the decorative fabric layer. Furniture or vehicle seat cushion products are formed with a superior appearance of hand-sewn details, with much less cost, and with greater thermic comfort properties.
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Cloth has many advantages, e.g. superior appearance and thermic comfort, as a covering for vehicle seats. However, high costs are entailed due to the extensive cutting and sewing operations, much by hand, normally associated with cloth upholstery. Vehicle seat cushions comprising a foam portion having integral cover, the cushion being formed by pouring in place foam within a cover which has been shaped, can be produced at signifi--cant savings and provide a superior seat. Nevertheless, efforts to employ cloth as an integral covering have been less than successful.
Synthetic fibers are required in a cloth which is to be heated and formed in a mold. Such fibers of continuous filament type materials are formed into yarn, and texturi~ed by well known processes to build mechanical elongation into the yarn, by operators commonly known as throw~
sters. The yarn is knitted or woven into cloth, inspected and cleaned to remove impurities, bleached, stretched and dried on a tentering machine, and thereafter finished. Most frequently the tentering machine temperature is 160-220C (320-428F), which temperature is higher than that generally employed in texturization processes, and mechanical elongation of the cloth is thereby reduced, the texturization becoming partially undone, and the cloth being set at a high temperature.
Several mult:L-laycr compositlons have been devLsed in the past which include a fabric layer. A particular development has been the application to vehicle 6eats of a flame-bonded sandwich consisting of a fabric, a flexible urethane foam and a urethane elastomer fllm. Neverthe-less, several problems remain, e.g., a tendency for pinholes to form, such that poured-in-place foam reaches the fabric, and particularly for delamina-tion to occur, such that a detailed, simulated sewn appearance is not re-tained.
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It is an obJect of one aspect of thls invention to provlde a cloth which employs a decorative cloth layer and which ls vacuum formable and moldable to retain a detailed shape having the appearance of an intri-cately sewn fabric.
An ob~ect of another aspect of this invention is to provide a cloth which, after vacuum forming and molding, can, by reaction with a poured-in-place foam, become water vapor permeable, thereby further increasing thermic comfort vf seat cushions having an integral covering composed of the clo~h.
An object of still another aspect of this invention is to pro-vide a very economical way of providing furniture and vehicle seat cushions with integral covers whIch en~oy the aforementioned advantages.
An object of yet another aspect of this invention is to provide a process of preparing a cloth product such that the heat-setting of the cloth occurs during the molding, whereby the achievement of the foregoing advantages is facilitated.
By one broad aspect of this invention, a process is provided for molding cloth, comprising~the steps of: drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer; heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
By another aspect of this invention, a process is provided for molding cloth, comprising the steps of: drawing the cloth into a mold, the cloth including a fabric layer having a heat fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composi-tion layer including a thermoplastic film layer; heating the cloth to at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the layer; and cooling the cloth, the process " ' .
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heat-fixing t:he heat-Eixable flber and the film layer to the shape of the mold.
By another aspect oE this in-vention, a process is provided for molding cloth comprising the steps oE: drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition including a flexible foam layer and a thermoplastic film layer; heating the cloth to at least the greater of the set temperature of the film layer and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
By a variation oE these aspects, the process includes the step of preheating the cloth prior to the drawing step.
By another aspect of this invention, a process is provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabric layer having a heat fixable fiber, and an elastic com-position layer bonded to tne fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold; heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing that heat-fixable fiber of the cloth to the shape of the mold.
By yet another aspect of this invention, a process is provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermoplastic film layer, the temperature to which the cloth is preheated being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer;
drawing the cloth into a mold; heating the cloth to at least the greater of the temperature of the film layer; and cooling the cloth, the process ,~, ,~
- heat-:Eixlng the heat-fixable flber and the film layer to the shape of the mol.d.
By still another aspect of this inventiDn, a process i5 provided for molding cloth comprising the steps of: preheating the cloth, the cloth including a fabri.c layer having a heat-fixable fiber, and an elastic composition ].ayer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold; heating the cloth to at least the heat-fixable fiber set temperature; cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold and Eilling the back side of the molded cloth with foam.
By a variation thereof, the elastic composition layer has a low elastic recovery after molding to facilitate the retention of the molded shape of the cloth.
By another variation, the elastic composition layer includes a flexible foam layer formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
By a further variation, the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer.
By yet another variation, the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer; and the flexible foam layer is formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
By still another variation, the elastic composition layer includes a thermoplastic film layer.
By a further vari.ation, the thermoplastic film layer is formed - 5a -3;~
of a polymer selectecl from the group conslstlng of ~nyl chlorlde, po]y-vlnyl chloride, polyurethane, synthetlc rubber, natural rubber, a mixture oE natural and synthetic rubber, neoprene basis composltlon, and acryllc acld basls composltlon.
By yet another variation, the process includes the step of casting a flexible foam layer to an elastic film to form the elastic composltion layer.
By still another variatlon, the fabrlc layer ls of the group consisting of polyamlde, polyester, polyvinyl chloride, polyvinyl chlorlde copolymer, wool, cotton and combinations thereof.
By another variatlon, the process further comprises the step of bonding a flexlble foam layer to a thermoplastlc fllm layer, and bondlng the foam layer to the fabrlc layer in order to form the cloth; and the heatlng step lncludes the step of heating the cloth to at least the softening temperature of the film layer.
By another aspect of this invention, a process is provided for molding cloth comprising the steps of: bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer; bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, film layer and fabrlclayer; preheatlng the cloth to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer;
drawing the cloth lnto a mold; heatlng the cloth ln the mold to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; and coollng the cloth in the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold.
By a variation thereof, the film layer is formed of a polymer selected from the group consisting of vinyl chloride, polyvinyl chloride, polyurethane, synthetlc rubber, natural rubber, a mixture of natural and - 5b -synthetic rubber, neoprene ~asls compositLon, and acrylLc acld bQ~sls com-pos:Ltion.
~ y yet another variation, the drawing step includes the step of creatlng a vacuum between the cloth and the mold thereby to conform the cloth to the shape of the mold.
By yet a further variat:Lon, the process includes the further step of pouring foam into the mold after the cooling step.
By another aspect of th:Ls invention, a process is provided for forming a cloth covered item comprising the steps of: bonding a flexible foam layer to a thermoplastic film layer, the foam layer and fllm layer - forming an elastic composition layer; bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, the film layer and the fabric layer; preheating the cloth to a tempera-ture of at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer; drawing the cloth into a mold; heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the film layer; cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixablP fiber of the fabric layer and the film layer to the shape of the mold and filling the back side of the molded cloth with foam.
By another aspect of this invention, a moldable cloth is pro-vided comprising a fabric layer including a heat--fixable fiber;la flexible foam layer bonded to the fabric layer; a first urethane film layer bonded to the foam layer; a polyvinyl chloride film layer bonded to the first urethane film layer; and a second urethane film layer bonded to the poly-urethane film layer.
In other words, the cloth of aspects of this invention includes a decorative fabric layer. The fabric includes a heat-fixable fabric, e.g., textur:ized polyester knit, whi~h has been subjected during treatment '~
- Sc -' ' ' , :" . , - - . ~ :
.
to a maxlmum temperature which ls relatively low compAred to typical tem-pera~ures reached during molding described hereinbelow. The cloth also includes an elastic compositlon layer. ~le elastic aomposition layer can include a flexible foam, e.g., a polyester-type polyurethane, and an elastic film, e.g., a polyvinyl chloride. The film is bonded to one side of the foam, as by a casting process, and the fabric is bonded to the opposite side of the foam, as by a flame-bonding process. The cloth is employed with a mold by heating to a temperature higher than any to which the cloth had been previously sub~ected and drawing, as by a vacuum, the clot:h into the mold, the final heat-fixing of the cloth occurring ln the mold. Thereafter, a foam, e.g., a polyether-type polyurethane, can be poured-in-place to form a complete mold.
- 5d --. .
', he cloth of aspects of thls lnvention :Lncludes a fabric layer bonded to an elastic composition. By employlng the fabric layer as an ex-terior, decorative layer, superior appearance qualities are attained and thermic comfort, due to greater air-flow through a fabric, results in a superior product where the cloth is employed in a vehicle seat or furniture cushion product. The fabrlc can be knitted or woven as by machines common-ly employed in the textile industry.
Knitted fabrics can be warp knit and circular knit, single knit and double knit. The fabric must have elasticity for mold-Lng operations and must be able to be heat-fixed during the molding operation to retaln the shape of the mold. The knitting construction provides some elasticlty for the fabrlc. The surface yarns of the knitted fabric can be natural, artificial or synthetic fibers e.g. wool, cotton, fibrane, polyamide, poly-ester, vinyl chloride and vinyl chloride-acrylonftrile copolymers and poly acryl fibers. The ground should have an elasticity comparable to that oP
the elastic compositions. Texturized yarns of heat-fixable fibers e.g.
polyamide or polyester high elasticity yarns or very high thermoplastic ' yarns e.g. vinyl chloride and vinyl chlorlde acrylonitrile (modacrylic) yarns should be employed for the ground therefore. Woven fabrics should employ texturized heat-fixable fibers. Polyamides, e.g. type 6 and 6.6, polyester, vinyl-chloride, vinyl-chloride-acrylonitrile copolymers, elastomer urethane and polyacryl fibers are suitable. The highest tempera-ture to ~;;~/', .
. .
~ 3~t`'~
.,.............................. . ~ _, .
-whlch the heat-flxable flber ln the fabric is subJected during processing should be relatively low, and relatively high temperatures should not be employed as, for example, during tentering. The final heat setting of the heat fixable fiber then takes place in the mold at the higher, molding tem-perature, as stated hereinbelow.
The elastic compositlon -lncludes foam lnterlayer and film layer.
The foam interlayer must have good adhesion to both the fabric layer and the film layer. The foam interlayer allows movement of the fabric layer relative to the film layer and prevents breaking of the film layer that might otherwise result from elongation of the cloth were the fabric laye-r directly attached to the film layer. The foam lnterlayer is preferably a typical soft foam, open microcell based on the reacting of polyesters with isocyanate to form a polyurethane,polyester-type. The foam preferably has a density of 30-60 kg/m3, thickness of 2.5 to 4.0 mm, and tensile strength of 300-400%. The film layer preferably is able to withstand a 400% surface deformation. The film layer may have a thickness of 0.03 mm to 0.7 mm; however, the thinner dimensions are preferable. Polyvinyl chloride, polyester-type polyurethane elastomer, unvulcanized rubber or neoprene base COmposition may be employed for the film. The po]yvinyl chloride and polyurethane elastomer films are applied to the foam by transfer process:
being applied as a liquid, the thickness being controlled by a blade, being heated to jellification, not coating, temperature by infrared lamps, having a second controlled thickness applied and .~
" ' ''- ' ~ , '' ' ' ~^r~
heated, having polyurethane foam applled, passLng through calendar rollers at room temperature, and belng baked under infra-red lamps. The unvulcanized rubber is passed between calendar rollers heated to a temperature less than the rollers together with the foam. After the film layer is Joined to one side of the foam layer to form the elastic composition, the opposite side of the foam is heated, as in a Reeves machine, and the fabric layer joined thereto in a flame-bonded manner. It is not preferable to ~oin both the fabric and film layers to the foam by ilame-bonding, as this results in a great tendency for delamination of the film layer~ This results in the cloth being unable to retain molded details.
The cloth is employed with a mold by heating and drawing the cloth into the mo:Ld. The molding temperature should be higher than the highest temperature to which the heat fixable materials therein had been previously sub~ected and at least t~e vulcani~ing temperature should the rubber film be employed. The final heat-setting of the cloth takes place in the mold, and the shape of the mold is assumed by the cloth. The molding temperature is also higher than the contemplated average ambient air temperature to which the cloth will be subjected during its intended use. After the mold has cooled to a temperature no greater than 38C, a polyester-type poly-urethane foam may be poured-in-place. After curing a complete furniture or vehicle seat cushion, for example, is obtained.
.
.
. , ' ' .
3~
By including TDI Ln the poured-ln-place fnam and lncluding pro-ducts containing reactive - O~l groups in the film layer, a water-producing reaction will occur between the film layer and the poured- in-place foam, heat of the reaction causing the water to vaporize, thereby causing pores to form in the film layer. The cloth~ which was tight to provide an air barrier such that the cloth could be vacuum formed and the fabric layer protected from the liquid components for the foam, thereby becomes water vapor permeable, and thermic comfort is thereby increased in seat applica-tions.
The following specific examples will serve to illustrate the moldable cloth of aspects of this invention. In a]l examples the heat-fixable fiber cDmponent of the fabric layer is processed at temperatures lower than the temperature employed in molding the final product emE)loying the cloth, which molding temperature is also higher than the amhient tem-peratures to which the final product employing the cloth will be subjected.
therefore, in all examples, the final heat- fixing of the fabric layer occurs in the mold. J
A moldable cloth was prepared in the followln~ manner. The fabric used was a double knit polyamide fabric, knitted of texturized yarn. The fabric was dyed on a Beem machine and dried on a tender frame machine, the highest temperature reached during the finishing process not exceeding 110C (230F). The fabric was applied, by flame bonding employ-ing a Reeves machine, to a polyester-type polyurethane foam, the surface of the foam having been heated to a temperature of 300C (572F). The foam was microcell, 2.5mm thick, of g _ ~.il ,.~L!$ $~
natural color, and had a density of 52 kg/m3. The foam was obtained by reactions well-known in the art of polyurethane Eoam manufacture. A poly-Einyl chloride film of 12 mils (about 0.3 mm) was formed having the follow-ing composition (% by weight of total):
Vinyl Chloride 40.0 Phosphate/phtalate plasticizers 60.0 Light and heat ~tabilizers 2.0 Epox~y 0 5 Fillers and pigrnents 7.5 The PVC film was formed having a urethane coating on both sides. The fabric and foam component was bonded to the film by a transfer coating process.
To make a cushion employing the cloth, the cloth was first cut to the re~uired size, placed in a frame and heated by air to a temperature of 160C (320F) while being pulled down into and held in a female mold with vacuum pressure. The heat at this time set the fabric and attached components to the conformation and dimensions of the mold. The mold to-gether with the cloth was allowed to cool to not more than 38C (100F).
A polyether-type polyurethane foam, cold cure, with a density of 52 kg/m3, was then poured-in-place. After expansion of the foam within the mold fo~
fifteen minutes, the product was removed from the mold. Thereafter the poured urethane cells were broken down by pressure applied by rollers, pad-dles, hand or miscellaneous mechanical means, and the product, a seat cushion, was complete.
E~AMPLE 2 A moldable cloth may be prepared in the following manner. A
single knit polyester fabric, knitted of texturized yarn, is employed which has been subjected to a maximum temperature : ~ .
of 112.8DC (235~F) durlng dyeing and Inishll-g. A polyester-type polyure-thane, microcell, 2.5 mm thick foam, having a density of 40 kg/m3, is formed. A PVC film i6 formed having a thickness of 14 mils. and a urethane coating on both sides. The foam is cast OlltO the film by a transfer process.
; The fabric is applied by flame-bonding to the side of the foam opposite the film.
The c]oth is cut to the desired size, placed in a frame, and then drawn, fabric side first, into the mold by vacuum pressure. The cloth i~
then heated from the mold side to 154.4C (310F). The cloth is set by the heat to the conformation and dimensions of the mold. After the temperature of the cloth and mold has cooled below 38C (100F), a polyether-type poly-urethane foam, cold cure, with a density of 40 kg/m3, is then poured-in-place. After e~pansion of the foam for 12 minutes, the product is removed and treated as in the previous example.
A moldable cloth may be prepared in the following manner. A
double knit fabric, 60% polyamide and 40% polyester texturized yarns, is J
employed which has been subjected to a maximum temperature of 110C (230F).
A polyester-type polyurethane microcell foam is prepared having a thickness of 3mm and a density of 45 k~/m3. A polyester-type urethane film of 0.15 mm thickness is prepared, and the foam is cast onto the film by transfer process. The fabric is then flame-bonded to the foam.
The cloth is drawn into the mold, fabric side down, and then heated, as by infra red lamps, from the film side 1'~
, ' to a temperature of 150C (300F), the cloth belng heat-fixed in the con-formation and dimensions oE the mold. After cooling of the mold and cloth as in previous examples, a completed furnLture cushion is obtained by pour-ing-in-place a polyether-type polyurethane foam of a density of 45 kg/m3, allowing 14 minutes for expansion of the foam, and then removing the furni-ture cushion from the mold.
. _ A moldable cloth may be prepared in the following manner.
A double knit fabric of texturized polyester yarns is employed which has been sub~ected to temperatures no greater than 107.2C (225F) during its processing. A polyester-type polyurethane microcell foam havlng a thlck-ness of 2.5mm and a density of 45 kg/m3 is prepared. A film of unvulcan-ized synthetics and natural rubber compound is prepared of 1.5mm thickness and having the following composition (~ by weight of total):
.
Synthetic rubber, SBR 20.0 Natural rubber smoked sheet 70.5 Sulphur 1.0 Non-migrating anti-oxydizing agent 1.0 Zinc oxide 4.0-4.5 Zinc diethyl dithiocarbamate or Mercaptan MBTS 1.0-1.5 Carbon black 2.0 20 The foam is calendered onto the film, the temperature of the calendar rolls being less than the vulcanizing temperature.
The cloth is heated by air to a temperature of 150C (300F) and is drawn into the mold immediately. The rubber film is vulcanized in the mold, and the heat-fixable components of the cloth are fixed in the mold, the cloth being set in the conformation and dimensions of the mold. The mold and .
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. . , . : . . :
.
:. '' cloth are coo:Led, as explained ln earller examples, and a polyether-type polyurethane foam is poured-in-place having a density of 40 kg/m . After 14 minutes the cushion is removed Erom the mold.
XAMPL~rj A moldable cloth may be prepared in the following manner~ A
double knit fabric of texturized polyamide yarns is employed which has been subjected to temperatures not in excess of 110C (230F). A neoprene foam is prepared having a density of 38 kg/m and a thickness of 2.5mm. A neo-prene film of 12 mils thickness is prepared according to the following composition (% by weight of total):
Polychloroprene (Neoprene) 47.25 Ethylene vinyl acetate16.55 Barium sulfate 20.50 Magnesium oxide 8.25 Anti oxygen (anti-migration and anti-soiling type) 0.80 Polyethylene wax 1.65 Fat acid oil amide 0.5 Stearic acid 0.5 Fatice product 4.0 The foam is applied to the fiLm by a transfer process, and the fabric is cast onto the foam, and bonded thereto upon curing of the foam. ~ polyurethane or acrylic adhesive may be employed to aid the bonding of the fabric to the foam.
The cloth is heated by air to 150C (300F) and immediately drawn by vacuum into the mold. The final heat-setting of the cloth takes place in the moldl the cloth assuming the conformation and dimensions of the mold.
A polyether-type polyurethane foam is poured-in-place having a density of 40 kg/m3. Polymer SBS may be included in the formulation for the film;
and the poured-in-place foam will ~ .
3~:~
then react with the fllm such that pores are formed in the film to provLde water vapor permeability.
The cloth obtalned ln the foregolng examples has a decoratlve fabric layer and nevertheless ls vacuum-formable and moldable. The cloth is finally heat-fixed in the mold and retains a detailed shape lmparted by the mold, whlch shape can have the appearance of intricate hand stltchlng.
The cloth does not have the tendency to delaminate of exclusively flame-bonded constructions. Pouring-in-place foam:Lng techniques may be employed without harming the decorative fabric layer. Furniture or vehicle seat cushion products are formed with a superior appearance of hand-sewn details, with much less cost, and with greater thermic comfort properties.
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Claims (22)
1. A process for molding cloth comprising the steps of:
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer;
heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer;
heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
2. A process for molding cloth comprising the steps of:
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermo-plastic film layer;
heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermo-plastic film layer;
heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
3. A process for molding cloth comprising the steps of:
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition including a flexible foam layer and a thermoplastic film layer;
heating the cloth to at least the greater of the set tempera-ture of the film layer and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition including a flexible foam layer and a thermoplastic film layer;
heating the cloth to at least the greater of the set tempera-ture of the film layer and the softening temperature of the layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
4. A process as claimed in claims 1, 2 or 3 further comprising the step of preheating the cloth prior to the drawing step.
5. A process for molding cloth comprising the steps of:
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold;
heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing that heat-fixable fiber of the cloth to the shape of the mold.
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold;
heating the cloth to at least the heat-fixable fiber set temperature; and cooling the cloth, the process heat-fixing that heat-fixable fiber of the cloth to the shape of the mold.
6. A process for molding cloth comprising the steps of:
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermoplastic film layer, the temperature to which the cloth is preheated being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer;
drawing the cloth into a mold;
heating the cloth to at least the greater of the temperature of the film layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the elastic composition layer including a thermoplastic film layer, the temperature to which the cloth is preheated being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the film layer;
drawing the cloth into a mold;
heating the cloth to at least the greater of the temperature of the film layer; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
7. A process for forming a cloth-covered item comprising the steps of:
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold;
heating the cloth to at least the heat-fixable fiber set temperature;
cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold and filling the back side of the molded cloth with foam.
preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature to which the cloth is preheated being at least the heat-fixable fiber set temperature;
drawing the cloth into a mold;
heating the cloth to at least the heat-fixable fiber set temperature;
cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold and filling the back side of the molded cloth with foam.
8. A process as claimed in claims 5, 6 or 7 wherein the elastic composition layer has a low elastic recovery after molding to facilitate the retention of the molded shape of the cloth.
9. The process as claimed in claims 1, 5 or 7 wherein the elastic composition layer includes a flexible foam layer formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
10. A process as claimed in claims 1, 5 or 7 wherein the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer.
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer.
11. The process as claimed in claims 1, 5 or 7 wherein the elastic composition layer comprises:
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer;
and wherein the flexible foam layer is formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
a flexible foam layer bonded to the fabric layer; and an elastic film bonded to the foam layer;
and wherein the flexible foam layer is formed of a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
12. A process as claimed in claims 1, 5 or 7 wherein the elastic composition layer includes a thermoplastic film layer.
13. A process as claimed in claims 1, 5 or 7 wherein the elastic composition layer includes a thermoplastic film layer and wherein the thermoplastic film layer is formed of a polymer selected from the group consisting of vinyl chloride, polyvinyl chloride, polyurethane, synthetic rubber, natural rubber, a mixture of natural and synthetic rubber, neo-prene basis composition, and acrylic acid basis composition.
14. A process as claimed in claims 1, 5 or 7 further comprising the step of casting a flexible foam layer to an elastic film to form the elastic composition layer.
15. A process as claimed in claims 1, 5 or 7 wherein the fabric layer is of the group consisting of polyamide, polyester, polyvinyl chloride, polyvinyl chloride copolymer, wool, cotton and combinations thereof.
16. A process as claimed in claims 1, 5 or 7 wherein:
the process further comprises the step of bonding a flexible foam layer to a thermoplastic film layer, and bonding the foam layer to the fabric layer in order to form the cloth; and the heating step includes the step of heating the cloth to at least the softening temperature of the film layer.
the process further comprises the step of bonding a flexible foam layer to a thermoplastic film layer, and bonding the foam layer to the fabric layer in order to form the cloth; and the heating step includes the step of heating the cloth to at least the softening temperature of the film layer.
17. A process for molding cloth comprising the steps of:
bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer;
bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, film layer and fabric layer;
preheating the cloth to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer;
drawing the cloth into a mold;
heating the cloth in the mold to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; and cooling the cloth in the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold.
bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer;
bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, film layer and fabric layer;
preheating the cloth to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer;
drawing the cloth into a mold;
heating the cloth in the mold to at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; and cooling the cloth in the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold.
18. A process as claimed in claims 2, 6 and 17 wherein the film layer is formed of a polymer selected from the group consisting of vinyl chloride, polyvinyl chloride, polyurethane, synthetic rubber, natural rubber, a mixture of natural and synthetic rubber, neoprene-basis composi-tion, and acrylic acid basis composition.
19. A process as claimed in claims 1, 5 or 17 wherein the draw-ing step includes the step of creating a vacuum between the cloth and the mold thereby to conform the cloth to the shape of the mold.
20. A process as claimed in claims 17 5 or 17 further comprising the step of pouring foam into the mold after the cooling step.
21. A process for forming a cloth-covered item comprising the steps of:
bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer;
bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, the film layer and the fabric layer;
preheating the cloth to a temperature of at least the greater of the set temperature of the heat-fixable fiber and the softening tempera-ture of the film layer;
drawing the cloth into a mold;
heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the film layer;
cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold and filling the back side of the molded cloth with foam.
bonding a flexible foam layer to a thermoplastic film layer, the foam layer and film layer forming an elastic composition layer;
bonding the foam layer to a fabric layer having a heat-fixable fiber, the cloth comprising the foam layer, the film layer and the fabric layer;
preheating the cloth to a temperature of at least the greater of the set temperature of the heat-fixable fiber and the softening tempera-ture of the film layer;
drawing the cloth into a mold;
heating the cloth to at least the greater of the set tempera-ture of the heat-fixable fiber and the softening temperature of the film layer;
cooling the cloth; and pouring foam into the mold, the process heat-fixing the heat-fixable fiber of the fabric layer and the film layer to the shape of the mold and filling the back side of the molded cloth with foam.
22. A moldable cloth comprising:
a fabric layer including a heat-fixable fiber;
a flexible foam layer bonded to said fabric layer;
a first urethane film layer bonded to said foam layer;
a polyvinyl chloride film layer bonded to said first urethane film layer; and a second urethane film layer bonded to said polyurethane film layer.
a fabric layer including a heat-fixable fiber;
a flexible foam layer bonded to said fabric layer;
a first urethane film layer bonded to said foam layer;
a polyvinyl chloride film layer bonded to said first urethane film layer; and a second urethane film layer bonded to said polyurethane film layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA292,700A CA1109381A (en) | 1977-12-08 | 1977-12-08 | Moldable cloth, product, and method of making same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA292,700A CA1109381A (en) | 1977-12-08 | 1977-12-08 | Moldable cloth, product, and method of making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1109381A true CA1109381A (en) | 1981-09-22 |
Family
ID=4110239
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA292,700A Expired CA1109381A (en) | 1977-12-08 | 1977-12-08 | Moldable cloth, product, and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1109381A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0220002A2 (en) * | 1985-10-16 | 1987-04-29 | Uniroyal Plastics Company, Inc. | Laminated fabric structure |
-
1977
- 1977-12-08 CA CA292,700A patent/CA1109381A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0220002A2 (en) * | 1985-10-16 | 1987-04-29 | Uniroyal Plastics Company, Inc. | Laminated fabric structure |
| EP0220002A3 (en) * | 1985-10-16 | 1988-03-02 | Uniroyal Plastics Company, Inc. | Laminated fabric structure |
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