Process for molding cloth including a fabric layer by heating to at least the greater of the set or softening temperature the stitches thereof having never been set, and molding a cloth covered foam filled product

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, stitches of the fabric having never been thermally set, and an elastic composition layer bonded to the fabric layer, the elastic composition 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 film layer;
• and
• cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.

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, stitches of the fabric having never been thermally set, 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 heat-fixable fiber and the softening temperature of said film layer;
• and
• cooling the cloth, the process heat-fixing the heat-fixable fiber and the film layer to the shape of the mold.

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, stitches of the fabric having never been thermally set, and an elastic composition layer bonded to the fabric layer;
• heating the cloth to at least the heat-fixable fiber set temperature during the drawing step;
• and
• cooling the cloth, the process heat-fixing that heat-fixable fiber of the cloth to the shape of the mold.

A process for molding cloth comprising the steps of:

• preheating the cloth, the cloth including a fabric layer having a heat-fixable fiber, stitches of the fabric having never been thermally set, 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 set temperature of the heat-fixable fiber and the softening 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.

A process for forming a cloth covered item comprising the steps of:

• drawing the cloth into a mold, the cloth including a fabric layer having a heat-fixable fiber, stitches of the fabric having never been thermally set, and an elastic composition layer bonded to the fabric layer;
• heating the cloth to at least the heat-fixable fiber set temperature during the drawing step;
• 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.

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, stitches of the fabric having never been thermally set, the cloth comprising the foam layer, film layer and fabric layer;
• drawing the cloth into a mold;
• heating the cloth 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.

A process for forming a cloth-covered foam filled 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 stitches of the fabric having never been thermally set, the cloth comprising the foam layer, 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 mold;
• 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;
• 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.