Method of manufacturing upholstery panels

Claim 1

A method of manufacturing an upholstered, decorative, panel having a plurality of diverse, upholstery materials which together form the decorative, upholstered surface, which comprises; (a) providing a panel base support which comprises; a core of non-woven, synthetic textile fibers; a base first layer of heat fusible, synthetic, thermoplastic textile melt fibers; a base second layer selected from the group consisting of a film of synthetic, polymeric resins and a layer of heat fusible synthetic thermoplastic textile melt fibers; said first and second layers sandwiching the core, fibers of said first layer and the core being interengaged with each other and with the second layer, said interengagement being of the character obtained by needling; (b) providing a panel intermediate layer of a synthetic, polymeric resin foam; (c) providing an outer, surface layer formed from a plurality of diverse sheets of decorative, surface upholstery materials, joined together along seam lines; (d) assembling the base (a) with the surface layer (c) so as to sandwich intermediate layer (b), leaving at least a portion of the space between base (a) and layer (c) beneath the seam lines, free of layer (b); (e) providing a mold adapted by size and configuration to receive the assembly, said mold including a means for applying heat and pressure along the seam lines of the surface layer (c) in the zones beneath the seam lines which are free of layer (b) when the assembly is received in the mold;

Claim 2

A method of manufacturing an upholstered, decorative, panel having a plurality of diverse, upholstery materials which together form the decorative, upholstered surface, which comprises; (a) providing a panel base support which comprises; a core of non-woven, synthetic textile fibers; a base first layer of heat fusible, synthetic, thermoplastic textile melt fibers; a base second layer selected from the group consisting of a film of synthetic, polymeric resins and a layer of heat fusible synthetic thermoplastic textile melt fibers; said first and second layers sandwiching the core, fibers of said first layer and the core being interengaged with each other and with the second layer, said interengagement being of the character obtained by needling; (b) providing a panel intermediate layer of a synthetic, polymeric resin foam; (c) providing an outer, surface layer formed from a plurality of diverse sheets of decorative, surface upholstery materials, joined together along seam lines; (d) assembling the base (a) with the surface layer (c) so as to sandwich intermediate layer (b), leaving at least a portion of the space between base (a) and layer (c) beneath the seam lines, free of layer (b); (e) providing a mold adapted by size and configuration to receive the assembly, said mold including a means for applying heat and pressure along the seam lines of the surface layer (c) in the zones beneath the seam lines which are free of layer (b) when the assembly is received in the mold;