US4264386A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for molding a cloth in a hot mold and molding a cloth covered foam filled product
Assignee: Sears Manufacturing Co
•
Filing: 1979-03-19
•
Granted: 1981-04-28
•
Expires: 1999-03-19
Abstract
Abstract A method of molding cloth. A special multi-layer cloth is first preheated and then drawn into a heated mold by means of a vacuum between the cloth and the mold. The cloth includes a fabric layer having a heat-fixable fiber, a polyurethane foam layer and a polyvinyl chloride film layer bonded together. The cloth is preheated to at least the greater of the set temperatures of the fabric layer and the polyvinyl chloride film. The mold is heated to at least the same temperature. After the cloth has conformed to the contours of the mold, the cloth is cooled in the mold. The steps of heating the cloth in the mold and then cooling the cloth sets the stitch of the fabric to the contours of the mold. Polyurethane foam may then be poured into the mold and allowed to expand to form a seat cushion or the like.
Inventors
- 👤 I. Weir Sears, Jr.
- 👤 Raoul Quertain
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 21:03
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/245; B29; B29C; B29C51/00; B29C51/14; B29C51/145; B32B27/00; B32B27/06; B32B27/065; B32B27/08; B29K; B29K2313/00
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
92 words
A process for molding cloth comprising the steps of: drawing the cloth into a heated mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
Claim 2
Dependent Claim
92 words
A process for molding cloth comprising the steps of: drawing the cloth into a heated mold, the cloth including a fabric layer having a heat-fixable fiber, and an elastic composition layer bonded to the fabric layer, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
Claim 3
Dependent Claim
128 words
A process for molding cloth comprising the steps of: drawing the cloth into a heated 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 thermoplastic film layer, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 4
Dependent Claim
128 words
A process for molding cloth comprising the steps of: drawing the cloth into a heated 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 thermoplastic film layer, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 5
Dependent Claim
132 words
A process for molding cloth comprising the step of: drawing the cloth into a heated 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, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 6
Dependent Claim
132 words
A process for molding cloth comprising the step of: drawing the cloth into a heated 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, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 7
Dependent Claim
22 words
A process as in claim 1, 2 or 3 further comprising the step of preheating the cloth prior to the drawing step.
Claim 8
Dependent Claim
111 words
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 heated mold, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
Claim 9
Dependent Claim
111 words
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 heated mold, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber of the cloth to the shape of the mold.
Claim 10
Dependent Claim
160 words
The 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 heated-fixable fiber and the softening temperature of the film layer; drawing the cloth into a heated mold, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 11
Dependent Claim
160 words
The 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 heated-fixable fiber and the softening temperature of the film layer; drawing the cloth into a heated mold, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; and cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.
Claim 12
Dependent Claim
129 words
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 heated mold, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; 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.
Claim 13
Dependent Claim
129 words
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 heated mold, the temperature of the mold being at least the heat-fixable fiber set temperature; heating the cloth to at least the heat-fixable fiber set temperature, including the step of transferring energy from the heated mold to the cloth; 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.
Claim 14
Dependent Claim
32 words
A process as in claim 1, 5 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.
Claim 15
Dependent Claim
38 words
The process as in claim 1, 2, 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.
Claim 16
Dependent Claim
33 words
A process as in claim 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.
Claim 17
Dependent Claim
30 words
The process as in claim 10 wherein the flexible foam layer is formed from a polymer selected from the group consisting of urethane, vinyl chloride, polyvinyl chloride, polychloroprene and rubber.
Claim 18
Dependent Claim
19 words
A process as in claim 1, 5 or 7 wherein the elastic composition layer includes a thermoplastic film layer.
Claim 19
Dependent Claim
46 words
A process as in claim 12 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, neoprene basis composition, and acrylic acid basis composition.
Claim 20
Dependent Claim
29 words
A process as in claim 1, 5 or 7 further comprising the step of casting a flexible foam layer to an elastic film to form the elastic composition layer.
Claim 21
Dependent Claim
36 words
A process as in claim 1, 5 or 7 wherein the fabric layer is formed of a polymer selected of the group consisting of polyamide, polyester, polyvinyl chloride, polyvinyl chloride copolymer, wool, cotton and combinations thereof.
Claim 22
Dependent Claim
63 words
A process as in claim 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.
Claim 23
Dependent Claim
177 words
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 heated mold, the temperature of the mold being at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; 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, including the step of transferring energy from the heated mold to the cloth; 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.
Claim 24
Dependent Claim
177 words
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 heated mold, the temperature of the mold being at least the greater of the set temperature of the fabric layer and the softening temperature of the film layer; 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, including the step of transferring energy from the heated mold to the cloth; 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.
Claim 25
Dependent Claim
47 words
A process as in claim 2, 6 or 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 composition, and acrylic acid basis composition.
Claim 26
Dependent Claim
37 words
A process as in claim 1, 5 or 17 wherein the drawing step includes the step of creating a vacuum between the cloth and the mold to thereby conform the cloth to the shape of the mold.
Claim 27
Dependent Claim
24 words
A process as in claim 1, 3, 5 or 17 further comprising the step of pouring foam into the mold after the cooling step.
Claim 28
Dependent Claim
194 words
A process for forming a cloth-covered item comprising the steps of: bonding a flexible form 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 temperature of the film layer; drawing the cloth into a heated mold, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; 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.
Claim 29
Dependent Claim
194 words
A process for forming a cloth-covered item comprising the steps of: bonding a flexible form 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 temperature of the film layer; drawing the cloth into a heated mold, the temperature of the mold being at least the greater of the set temperature of the heat-fixable fiber and the softening temperature of the 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 film layer, including the step of transferring energy from the heated mold to the cloth; 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.
References Cited (Backward Citations)
US2361371A
Cited
US3461504A
Cited
GB1325622A
Cited
DE2227143A1
Cited
US4025372A
Cited
US3954537A
Cited
US4046611A
Cited
US4089919A
Cited
US3941633A
Cited
US4114213A
Cited
US4060280A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-04-27 | 1984-10-27 | 1985-04-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-04-27 | 1988-10-27 | 1989-04-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-04-27 | 1992-10-27 | 1993-04-28 | $7700.00 | Window Closed / Lapsed |