초록 ▼

A method for three-dimensionally shaping cover materials such as woven or knitted fabrics, vinyl, leather, and the like is performed by providing a cover material (18) and a layer of foamable liquid reaction mixture such as polyurethane which changes from liquid to a viscous state (16′) at the begin

A method for three-dimensionally shaping cover materials such as woven or knitted fabrics, vinyl, leather, and the like is performed by providing a cover material (18) and a layer of foamable liquid reaction mixture such as polyurethane which changes from liquid to a viscous state (16′) at the beginning of the gas generating reaction, compressing the combined cover material and the foamed layer in a mold (21,22) having surface configurations corresponding to desired final three-dimensional shapes with the compression being performed when the foam layer has substantially completed rising, but before substantial curing thereof takes place, and then allowing the foamed layer bonded to the cover material to proceed in curing reaction. The three-dimensional cover material shaping is performed by this method without external heat or high pressure so that the cover material can retain its original appearance and high quality. By changing locally the spacings between mold halves (21,22), the resultant foam layer bonded to the cover material can be provided with portions having different local thicknesses and hardnesses.

대표청구항 ▼

A method for making a three-dimensional cover comprising: providing a flexible sheet-like cover material and a foamable liquid reaction mixture and allowing the mixture to change to a viscous liquid as a gas generation reaction begins to provide a foam that expands and provides a foam layer adjacent

A method for making a three-dimensional cover comprising: providing a flexible sheet-like cover material and a foamable liquid reaction mixture and allowing the mixture to change to a viscous liquid as a gas generation reaction begins to provide a foam that expands and provides a foam layer adjacent the cover material; positioning the cover material and the foam layer in a mold having surface contours; closing the mold after the foam layer has substantially completed its expansion and while still in its viscous liquid state to compress the foam layer and shape the cover material; allowing said foam layer to substantially cure and change to a solid state while within the mold along with the shaped cover material; and thereafter removing from the mold the shaped cover material and cured foam layer which cooperatively provide a shaped cover.