Method of making upholstery materials

Claim 1

THE METHOD OF MAKING UPHOLSTERY MATERIAL COMPRISING SPREADING A VINYL PLASTISOL COMPOSITION CONTAINING A BLOWING AGENT IN UNIFORM LAYER ON A SUPPORT, GENTLY HEATING SAID LAYER TO INITIATE THE BLOWING AND GELATION THEREOF, APPLYING TO THE EXPOSED SURFACE OF SAID LAYER A SECOND LAYER OF A POROUS, RESILIENT FIBROUS PADDING MATERIAL, SAID SECOND LAYER BEING APPLIED WHILE SAID FIRSTNAMED LAYER IS IN A PARTIALLY FUSED CONDITION IN WHICH SAID SECOND LAYER WILL NOT APPRECIABLY SINK INTO SAID EXPOSED SURFACE OF ITS OWN SWITHT, GENTLY PRESSING SAID SECOND LAYER INTO SAID SURFACE WITH SUFFICIENT PRESSURE TO EMBED SAID PADDING MATERIAL THEREIN BUT INSUFFICIENT TO APPRECIABLY DEFORM THE PARTIALLY FUSED SAID FIRST-NAMED LAYER, HEATING THE RESULTING ASSEMBLED LAYER TO COMPLETE THE FUSION OF SAID FIRST-NAMED LAYER, COOLING SAID ASSEMBLED LAYERS, AND STRIPPING THE RESULTING COMPOSITE, LAMINAR MATERIAL FROM SAID SUPPORT, SAID PADDING MATERIAL BEING CONSTITUTED SO AS TO BE PENETRABLE SUBSTANTIALLY COMPLETELY ANYWHERE OVER ITS TOTAL EXTENT BY SAID FIRST-NAMED LAYER UPON APPLICATION OF PRESSURE AND HEAT TO SAID LAYERS, THEREAFTER DISPOSING SAID COMPOSITE LAMINAR MATERIAL BETWEEN A PAIR OF OUTER LAYERS, APPLYING PRESSURE TO THE RESULTING ASSEMBLY LOCALIZED AT SPACED EXTENDED SEAMS, AND WHILE CONTINUING THE APPLICATION OF SAID PRESSURE SUBJECTING ALL OF THE LAYERS BETWEEN SAID SEAMS TO A SOURCE OF HEAT FOR A TIME SUFFICIENT TO SOFTEN SAID FIRST-NAMED LAYER BETWEEN EACH OF SAID SEAMS TO CAUSE THE SOFTENED PORTIONS OF SAID FIRST-NAMED LAYER TO FLOW THROUGH SAID SECOND LAYER SO AS TO CONTACT SAID OUTER LAYERS AT SAID SEAMS, REMOVING SAID SOURCE OF HEAT AND CONTINUING THE APPLICATION OF PRESSURE FOR A TIME THEREAFTER UNTIL SAID FIRST-NAMED LAYER RESOLIDIFIES TO A NON-SPONGE CONDITION TO INTEGRALLY BOND ALL OF SAID LAYERS AT EACH OF SAID SEAMS.

Claim 2

THE METHOD OF MAKING UPHOLSTERY MATERIAL COMPRISING SPREADING A VINYL PLASTISOL COMPOSITION CONTAINING A BLOWING AGENT IN UNIFORM LAYER ON A SUPPORT, GENTLY HEATING SAID LAYER TO INITIATE THE BLOWING AND GELATION THEREOF, APPLYING TO THE EXPOSED SURFACE OF SAID LAYER A SECOND LAYER OF A POROUS, RESILIENT FIBROUS PADDING MATERIAL, SAID SECOND LAYER BEING APPLIED WHILE SAID FIRSTNAMED LAYER IS IN A PARTIALLY FUSED CONDITION IN WHICH SAID SECOND LAYER WILL NOT APPRECIABLY SINK INTO SAID EXPOSED SURFACE OF ITS OWN SWITHT, GENTLY PRESSING SAID SECOND LAYER INTO SAID SURFACE WITH SUFFICIENT PRESSURE TO EMBED SAID PADDING MATERIAL THEREIN BUT INSUFFICIENT TO APPRECIABLY DEFORM THE PARTIALLY FUSED SAID FIRST-NAMED LAYER, HEATING THE RESULTING ASSEMBLED LAYER TO COMPLETE THE FUSION OF SAID FIRST-NAMED LAYER, COOLING SAID ASSEMBLED LAYERS, AND STRIPPING THE RESULTING COMPOSITE, LAMINAR MATERIAL FROM SAID SUPPORT, SAID PADDING MATERIAL BEING CONSTITUTED SO AS TO BE PENETRABLE SUBSTANTIALLY COMPLETELY ANYWHERE OVER ITS TOTAL EXTENT BY SAID FIRST-NAMED LAYER UPON APPLICATION OF PRESSURE AND HEAT TO SAID LAYERS, THEREAFTER DISPOSING SAID COMPOSITE LAMINAR MATERIAL BETWEEN A PAIR OF OUTER LAYERS, APPLYING PRESSURE TO THE RESULTING ASSEMBLY LOCALIZED AT SPACED EXTENDED SEAMS, AND WHILE CONTINUING THE APPLICATION OF SAID PRESSURE SUBJECTING ALL OF THE LAYERS BETWEEN SAID SEAMS TO A SOURCE OF HEAT FOR A TIME SUFFICIENT TO SOFTEN SAID FIRST-NAMED LAYER BETWEEN EACH OF SAID SEAMS TO CAUSE THE SOFTENED PORTIONS OF SAID FIRST-NAMED LAYER TO FLOW THROUGH SAID SECOND LAYER SO AS TO CONTACT SAID OUTER LAYERS AT SAID SEAMS, REMOVING SAID SOURCE OF HEAT AND CONTINUING THE APPLICATION OF PRESSURE FOR A TIME THEREAFTER UNTIL SAID FIRST-NAMED LAYER RESOLIDIFIES TO A NON-SPONGE CONDITION TO INTEGRALLY BOND ALL OF SAID LAYERS AT EACH OF SAID SEAMS.