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Method of making a padded item

  • US 4,025,372 A
  • Filed: 09/09/1975
  • Issued: 05/24/1977
  • Est. Priority Date: 01/31/1973
  • Status: Expired due to Term
First Claim
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1. A method of making a resilient fabric-faced upholstered item comprising the steps of:

  • (a) shaping a laminate of a cast plasticized vinyl chloride homopolymer or copolymer sheet and a fabric by vacuum forming to the desired shape of a cover for said item by heating said vinyl chloride homo-polymer or copolymer sheet to a temperature of at least 150°

    C., said fabric being a knitted fabric having an extensibility in two directions at right angles of at least 25% under a load of 5 lb per 2 inch wide strip and being capable of increasing its surface area by at least 50% when subjected to two loads of 5 lb applied at right angles to one another to the edges of a 2 inch square of said fabric, and said vinyl chloride homopolymer or copolymer sheet containing at least 35 parts of plasticizer per 100 parts of polymer;

    (b) holding said cover to shape in a mould with said fabric outermost and said cast vinyl chloride homopolymer or copolymer sheet innermost;

    (c) placing within said cover the precursors of a resilient foam; and

    (d) allowing said precursors to foam and fill said cover to provide a resilient foam filling, said foam becoming bonded to said vinyl chloride homopolymer or copolymer sheet of said laminate cover and retaining said cover in the required shape of said upholstered item.

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