# US 4,400,422 A · Laminated fabric having integral raised areas formed therein and method of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,400,422 A - Document ID: US4400422A - Status: Granted - Kind: A - Application number: 06/399,765 - Filed: 1982-07-19 - Granted: 1983-08-23 - Earliest claimed: 1980-01-14 - Assignees: Colamco, Inc. - Inventors: Thomas L. Smith - Web page: https://patentgrep.com/patent/US4400422A ## CPC - B29C 66/436: {Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats (joining through openings B29C66/304)} - B29C 65/18: using heated tools - B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)} - B29C 66/727: {being porous, e.g. foam} - B29C 66/729: {Textile or other fibrous material made from plastics} - B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)} - B68G 7/05: Covering or enveloping cores of pads {(in plastics material using a matching die B29C63/025)} - D06M 17/00: Producing multi-layer textile fabrics - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B29C 66/712: {the composition of one of the parts to be joined being different from the composition of the other part} - B29C 66/8322: {Joining or pressing tools reciprocating along one axis} - Y10T 156/1023: Surface deformation only [e.g., embossing] - Y10T 428/24479: including variation in thickness - Y10T 428/24512: Polyurethane - Y10T 428/24521: with component conforming to contour of nonplanar surface - Y10T 428/24537: Parallel ribs and/or grooves - Y10T 428/24826: Spot bonds connect components - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B68G: METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR - D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A laminated fabric having an integral raised area formed therein which simulates the appearance of a button, welt or the like, and method of making same. The laminated fabric is comprised of a layer of cloth or vinyl cover material, an intermediate layer of foam and a layer of backing material such as nylon. A form having the shape which corresponds to the desired shape of the raised area is disposed between the foam layer and the cover material. Anhydrous polyurethane foam forming materials are applied in liquid form to the form layer and cover material contact surface and the form layer and backing material contact surface. The unlaminated layers are placed over a die with each of the forms being positioned immediately above a die having protrusions which generally circumscribe the form. Moisture is introduced into the foam forming material and a heated press is applied to the backing material forcing the unlaminated layers down against the die. The resultant heat and pressure cause a foaming reaction of the foam forming materials which results in a foam bonding layer which bonds the cover material in substantial contact with the backing material in the region surrounding the form. The bonding layer also bonds the cover material and the backing material to substantially all of the remainder surface area of the foam layer. ## Claims ### Claim 1 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 foamed 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; at least one form disposed between said first and second 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; said first layer covering said form and said second layer over the predetermined surface area thereof and being bonded to said second layer 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. ### Claim 2 (depends on 1) The laminated fabric of claim 1 wherein said second layer is made of flexible foamed urethane sheet material. ### Claim 3 (depends on 2) The laminated fabric of claim 2 wherein said cover material is vinyl resin film. ### Claim 4 (depends on 2) The laminated fabric of claim 2 wherein said cover material is cloth fabric. ### Claim 5 (depends on 2) The laminated fabric of claim 2 wherein said form is a welt form. ### Claim 6 (depends on 5) The laminated fabric of claim 5 wherein said welt form is a length of flexible tubing. ### Claim 7 (depends on 2) The laminated fabric of claim 2 wherein said form is a button form. ### Claim 8 (depends on 7) The laminated fabric of claim 7 further including an anchor means which extends through said second layer for anchoring said button form to a rigid member. ### Claim 9 (depends on 8) The laminated fabric of claim 8 wherein said anchor means comprises an anchor attached to said button form and a length of flexible cord attached to said anchor and wherein the rigid member is a frame member of the object which is to be upholstered with said laminated fabric. ### Claim 10 (depends on 1) The laminated fabric of claim 1 further comprising a third layer of backing material adjacent said second layer at the surface thereof opposite said first layer. ### Claim 11 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. ### Claim 12 (depends on 11) The laminated fabric of claim 11 wherein said second layer is made of flexible foamed urethane sheet material. ### Claim 13 (depends on 11) The laminated fabric of claim 11 wherein said first layer is bonded substantially into contact with said third layer. ### Claim 14 (depends on 13) The laminated fabric of claim 13 including a bonding layer of foamed-in-place urethane plastic. ### Claim 15 (depends on 14) The laminated fabric of claim 14 wherein said bonding layer of foamed-in-place urethane plastic further bonds said first layer to said second layer and said second layer to said third layer over substantially the entire surface thereof. ### Claim 16 (depends on 13) The laminated fabric of claim 13 wherein said cover material is vinyl resin film. ### Claim 17 (depends on 13) The laminated fabric of claim 13 wherein said cover material is cloth fabric. ### Claim 18 (depends on 13) The laminated fabric of claim 13 wherein said form is a welt form. ### Claim 19 (depends on 13) The laminated fabric of claim 13 wherein said form is a button form. ### Claim 20 (depends on 19) The laminated fabric of claim 19 further including an anchor which extends through said second and third layers for anchoring said button form to a rigid member. ### Claim 21 (depends on 20) The laminated fabric of claim 20 wherein said anchor means comprises an anchor attached to said button form and a length of flexible cord attached to said anchor and wherein the rigid member is a frame member of the object which is to be upholstered with said laminated fabric. ### Claim 22 (depends on 20) The laminated fabric of claim 20 wherein said first layer is further bonded substantially into contact with said third layer in a predetermined embossed pattern. ### Claim 23 (depends on 1) The laminated fabric of claim 1 wherein said second layer is compressed in the area underlying said form. ### Claim 24 (depends on 11) The laminated fabric of claim 11 wherein said second layer is compressed in the area underlying said form. ### Claim 25 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. ### Claim 26 (depends on 25) The method of claim 25 wherein said bonding comprises the following steps: (i) applying a film of anhydrous polyurethane foam forming materials at the contact surface between said first and said second layers; (ii) introducing moisture to said anhydrous film sufficient to cause forming reaction to said polyurethane materials; and (iii) applying heat and pressure to said first and second layers, said heat being sufficient to cure said polyurethane material, said pressure being in a predetermined pattern such that said first layer is bonded to said second layer with recesses formed in said first layer in the region surrounding said form. ### Claim 27 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.