Laminated fabric having integral raised areas formed therein and method of making same

A laminated fabric having at least one integral raised area formed therein comprising:

• a first layer of cover material having a predetermined surface area;
• a second layer of compressible material of substantial thickness adjacent said first layer, said second layer having a predetermined surface area substantially corresponding to the predetermined surface area of the cover material;
• a third layer of backing material adjacent said second layer at the surface thereof opposite said first layer;
• at least one form disposed between said first and third layers and having a predetermined shape which generally corresponds to the desired shape of a corresponding one of said raised areas, said form overlying a portion of the predetermined surface area of said second layer;
• and
• said first layer covering said form and said second layer over the predetermined surface area thereof, said first and third layers being bonded together in the region surrounding said form such that the portion of the first layer which covers said form substantially conforms to the predetermined shape of said form.

A method of forming a laminated fabric having at least one integral raised area comprising:

• disposing at least one form between a first layer of cover material and a second layer of flexible foam material of substantial thickness, each of said forms having a shape which generally corresponds to the desired shape of a corresponding one of said raised areas;
• bonding said first layer to said second layer;
• and
• forcing said first layer in the region surrounding each of said forms against the corresponding region of said second layer and causing said corresponding region of said second layer underlying said form to become compressed such that said raised areas are formed on said first layer on the side thereof opposite said forms and adjacent thereto.

A method of forming a laminated fabric with at least one integral raised area formed therein, said fabric having a first layer of cover material, a second layer of compressible foamed material and a third layer of cover material with said second layer juxtaposed between said first and third layers comprising:

• applying a film of anhydrous polyurethane foam forming materials on the contact surfaces between said first and second layers on said second and third layers;
• forming a laminate structure by bringing said first and second layers into surface contact and said second and third layers into surface contact with at least one form having a shape which corresponds to the desired shape of a corresponding one of said raised areas, being disposed between said first and third layer;
• introducing moisture to said anhydrous film sufficient to cause foaming reaction of said polyurethane materials;
• and
• applying heat and pressure to said laminate structure, said heat being sufficient to cure said polyurethane material, said pressure being in a predetermined pattern such that the first layer is bonded by said polyurethane material substantially into contact with said third layer in the region surrounding each of said forms said second layer being compressed under said form such that said raised areas are formed on said first layer on the side thereof opposite said forms and adjacent thereto.