US2504874A

US2504874A - Trim panel and method of manufacture

Info

Publication number: US2504874A
Application number: US554922A
Authority: US
Inventors: Alvin W Prance
Original assignee: Briggs Manufacturing Co
Current assignee: Briggs Manufacturing Co
Priority date: 1944-09-20
Filing date: 1944-09-20
Publication date: 1950-04-18
Anticipated expiration: 1967-04-18

Description

April18, 1950 A. w. FRANCE 'nml PANEL AND mTHoD'oF uAmJFAc'rURE 3 Sheets-Sheet 1 Filed Sept. 20, 1944 INVENTOR- A 2g I April 18,1950 A. w. FRANCE 2,504,374

TRIM PANEL ma METHOD oF mul-ACTURE "Filed Sept. 20, 1944 l 3 sheets-suene 7/ I f EAL IN V EN TOR.

Patented Apr. 718,' 1950 PANEL AND METHOD Oli'v MANUFACTUR K W. France, Royal Oak, Mich., assignor to Briggs Manufacturing Company, Detroit, Mich., N a corporation of Michigan v Application September 20, 1944, Serial No. 554,922

` zo claim.. (ci. 154-106) This invention relates to the manufacture of upholstered `panels particularly, although not exclusively, adaptedrfor use as inner trim panels of various types of vehicle bodies, especially automobile bodies. The invention has for an important object thereof the provision of improved methods and means for producing upholstered panels with ornamental embossed portions or configurations and for securing the fabric material to the foundation sheet of the panel as a result of which an improved panel of ornamental or decorative character is provided.

A further object of the invention is to provide an improved upholstered panel or trim panel comprising a fabric covered foundation sheet having an interposed layer of padding material and in which an ornamental design, pattern or configuration is formed in the panel by an embossing operation through` the application of heat .and pressure whereby adherence of the fabric, padding and foundation sheet is permanently accomplished. i

Another object of the invention is to fabricate a trim panel or the like with portions of the padding and trim fabric permanenly joined together. through the medium of adhesive material incorporated in the padding and caused to effect adherence of the fabric and padding materials through the application of heat and pressure. o

' Still another object of the invention is to provide an upholstered or trim* panel `or the like, especially useful in trimming or finishing the inside of a vehicle door, and having a kick-pad or kick-panelportion and a padded upholstered portion fabricated in improved manner.

A further object of the invention is to provide an improved method and apparatus for forming the kick-pad andupholstered portions of the trim panel while also incorporating ornamentall the padding but not to the fabric at predetermined localities to be engaged by the embossing v It is also an object of the invention to impanels by eliminating previous costly operations,

simplifying the construction and enhancing the appearance of the panel. According to one aspect of the invention this may be accomplished by applying the padding to the foundation sheet and impregnating portions of the padding with an adhesive substance before superimposing the fabriccovering upon the padding. Thereafter heated dies are utilized to emboss the upholstered side of the panel in the impregnated localities to produce permanent ornamental raised and depressed portions, such as ornamental ribs with intervening grooves, and at the same time to obtain a permanent bond of the laminations of the panel in the localities engaged by the embossing die.

Another object of the invention is to fabricate a trim panel and complete the union oi' the laminations and the ornamentation of the panel under heat and pressure in a single relatively simple die operation.

vStill a further object of the invention is to unite the fabric, padding and foundation laminations of the panel through the medium of an adhesive material carried by the padding and in an embossing operation, the adhesive material serving not only as a binder but also as a means by which distinctconfigurations in the exposed face of the panel may be obtained.

Another object of the invention is to ornament the upholstered side of the panel with metal strips which may be plated or otherwise finished, such strips being formed and anchored in place in the embossing operation.

Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein 'like reference characters designate corresponding parts in the several views. Fig. 1 is a. top plan view of an upholstered panel constructed in accordance with the invention.

Fig. 2 is a sectional view of a foundation sheet utilized in the fabrication of the panel of Fig. 1.

Figs. 3 to v6 inclusive are sectional views illustrating successive vsteps in the fabrication of the upholstered panel or trim panel in accordance with one embodiment of the invention.

Fig. 7 is a view illustrating the manner in which l the padding layer of the trim panel is treated with adhesive material at predetermined localities.

Fig. s is a view similar to Fig. 6 illustrating prove the manufacture of trim or upholstered the fabric layer folded over upon the padding 3 layer after theimpregnation' of the padding layer with adhesive material in accordance with the method shown in F'ig. 7.

Fig. 9 is a sectional view illustrating the step .of embossing the upholstered side of the trim l Fig. 12 is asectional view in part similar to Fig. 9 illustrating a modified method of embossing the trim panel.

Fig. 13 is a view in part similar to Fig. 9 illustrating the method of applying a metal ilnish strip to the upholstered side of the trim panel.

Fig. 14 is a view in part similar to Fig. 8 illustrating a modified method of preparing the laminations of the trim panel preparatory to the embossing or die operation conducted in accordance with either the embodiment shown in Fig. 15 or the embodiment shown in Fig. 16.

Figs. 15 and 16 are sectional views illustrating modied methods of forming and embossing the trim panel in a single die operation.

Before explaining in detail the present invention it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried olt in various ways.

Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

In Fig. 1 there is illustrated an upholstered panel or trim panel adapted to be mounted on the inside of an automobile door immediately below the window opening thereof for the purpose of covering the inner metal door panel and providing an ornamental finish for the inside of the door. The trim panel 20 is provided with an upholstered or fabric covered padded portion 2| occupying the principal area of the panel and formedon the fabric side thereof with ornamental beading 22 which may follow any desired design or pattern and which in the -present instance is .in the form of spaced parallel ribs extending continuously in rectangular fashion and having intervening grooves or depressions between the ribs'. It will be understood that -the for the purposes of illustration since they may s vary widely in accordance with the requirements as to ornamentation and design. The upholstererl portion 2i of the panel terminates near the lower end thereof along a line 2|a and the area of the panel below this upholstered portion is formed to provided a so-called kick-pad portion 23 which in the present instance is an ornamental panel portion having no fabric covering.

The panel 20 is fabricated from various laminations or layers of material, the bottom layer or lamination being in the form of a relatively strong and rigid foundation sheet 24 which is preferably of compacted fibrous material. 'I'he foundation sheet 24 may be in the form of a board-like ymaterial in which the interlocking fibers thereof have been initially compressed and which may be impregnated with a thermoplastic or thermo-setting resinous substance. By the use of suitable solvents the resinous or plastic adhesive material may be converted into a varnish, which may be used for impregnating the fibers of the foundation sheet. Resins suitable for the purpose herein may be of the phenol-formaldehyde, ureav formaldehyde and melamine types which are -initially in the intermediate stage of reaction or polymerization and adapted to react or polymerize to their ii'nal stage under heat during the molding operations.

10 The foundation sheet should be of such character as to withstand the heat and pressure used in the molding operations. The outer surface thereof should be free from wax or oil or other contamination which would interfere with the ll laminating andA bonding operations. Furthermore, the foundation sheet should be of a weather resistent material`possessing a minimum oi hygroscopic properties.

The foundation sheet may'also comprise a zo fiber board of the zinc chloride type upon which a coating of thermosetting, thermosplastic or a 'l combination thereof, or other adhesivey material is applied capable of vproducing a bond under heat and pressure, such coating being applied by al any well known method, such as calendering,

spraying, rollcoating, etc. The outer surface of y the kick-pad or kick-panel portion 23 of the trim panel is formed by means of a sheet 25 superimposed upon the foundation sheet and adapted to provide an ornamental finish for the lower portion of the trim panel. A relatively thin alphacellulose sheet in the form of a white wood pulp paper or other fine grain cellulose material impregnated with any one of the 85 plastic materials above mentioned may be used.

25 may in some instances be in the form of a material such as a woven fabric or pigmented paper impregnated with any of the plastic materials above mentioned. In preferred practice the sheet 25 is impregnated with a thermoplastic material or a thermo-setting resin, as

above mentioned, by preparing a resin varnish and treating the sheet by a dipping, spraying or coating operation after which the sheet is allowed to dry. Where an inked pattern or design is applied to the outer surface of the sheet 25, it is preferred that a coating of plastic or resinous material be applied over the pattern or design so that the exposed surface of the panel will haveV satisfactory wear-resisting properties and also to prevent the ink of the designor pattern from flowing so as to distort or impair the fidelity of the design or pattern. Where the sheet 25 is impregnated with thermoplastic` or thermo-setting resinous material, it

00 may frequently be found possible to eliminate the coating or impregnation of the foundation sheet` since in such case the desired bond or adhesion of the sheets 25 and 26 may. be accomnlished -under heat and pressure through the medium of the plastic substance carried by the sheet 25.

In the fabrication of the trim panel shown in the embodiments of Figs. lV to 13 inclusive the sheet 25 is first superimposed upon the foundation sheet, as shown in Fig. 2, and is then molded the flow of plastic or resinous material from one abogan 'sheet to the other. Along the upper edge of the The upholstered area'of the trim panel comprises an outer fabric layer and a padding layer interposed between the fabric and the foundation sheet. Afterv the formation of the kick-pad or kick-panel portion 23, the edge 21a of a fabric sheet 21 is cemented to the upper surface of the marginal edge portion 25a of the sheet 25, in the manner illustrated in Fig. 4. i Thereafter, a layer of padding material 28 is superimposed upon the foundation'sheet in the area above the kick-pad,

as shown in Fig. 6. the lower edge of the padiding overlapping the cemented edge 21a of the material is treated'and the remaining area is masked.' The treatment of the padding for embossing purposes is preferably accomplished by a spraying or vstriping operation, and in Fig. 'l there is illustrated a method in which the area to receive the embossing 22 is treated by a spray operation. When formed in this manner, or by mg from 200 r. to 400 F. the dxesu and u are kheated in any conventional manner to the requiredv temperatures. The lower die 33 is carried upon the bed or base of the press and the upper die 34 is carried by a heated platen 35 secured to the reciprocating ram of the press. In

a striping operation, the plastic material is carried in a liquid vehicle in the form of a varnish having the proper viscosity to permit spraying thereof. The fabric 21, as shown in Fig. 6, is

laid back to expose the upper face of the pad. ding 28 and a mask 29 s placed over the padding.

This mask has suitable `cut-away or apertured portions 38 effective to expose a narrow rectangular area corresponding substantially to the embossed area 22. The padding exposed through the cut-out portions 38 of the mask 29 is then sprayed under pressure utilizing any conventional type of spray gun 3| having a spray nozzle through which the plastic or resinous varnish is directed in a stream 32 against the padding exposed through the cut-away portions 38of the mask. The pressure of the spray should be sufcient to cause penetration of the spray solution or varnish substantially through the padding 28 so as to obtain lsufiicient impregnation of the fibers of the padding in the rectangular area 28a exposed by the mask in order to obtain a satisfactory bond of the fabric padding and foundation sheet during the embossing operation.

After treatment of the padding material in the areas 28a thereof in the manner above described and as shown in Fig. '1, the fabric layer 21 is folded back and stretched over the outer surface of the padding layer 28 to completelykcover the same, the folded position of the fabric material being shown in Fig. 8. ll'he marginal edges of the fabric are folded around the side and top edges of the foundation sheet and the fabric,

, `which isstretched over the padding, is cemented the embodiment shown in Fig. 9 the upper die 34 is rectangular in shape corresponding in shape and area to the pattern 22 to be embossed into the panel and this die is formed with spaced projecting ribs 34a extending continuously-in rectangular fashion around the area to be embossed. As the ram descends the heated ribs 34a of the upper die press grooves or depressions in the fabric and padding layers 21 and 28 leaving lntervening rounded beads or `ribs 31. The pressure of the ribs 34a of the die is suiicient to compact the padding material between the edges of the ribs 34a and the foundation sheet which is rigidly supported by the lower die 33.

The dies arevheld together for a suitable interval of time under proper lpressure in the position shown in Fig. 9 until a complete and permanent bond is obtained between the fabric 21, the pad 28 and the foundation `sheet 24 along the bottoms of the grooves 36. Where a thermo-setting resin is used in the impregnation of the padding material in the aeas 28a, the heat transmitted by the die 34 will complete the polymerization of the resin and cause it to penetrate into the fibers of the foundation sheet and the fibers of the fabric material 21. After the embossed panel has been withdrawn from the press, a permanent union, through the medium of the adhesive material in the padding layer, will be obtained between the

sheets

24, 21 and 28 along the bottoms of the embossed grooves 36. Thus, the foregoing method not only provides a means for ornamenting the upholstered side of the trim panel in a-single die operation but also a means for permanently attaching the fabric padding and foundation materials together within the ornamented regions.

In the embodiment illustrated in Fig. 10 the lower edge 21a of the fabric or trim material 21 extends underneath the marginal edge portion 25a of the sheet 25 and is held in position by adhesive material applied vto the adjacent surfaces of the foundation sheet and edge portion 25a of the sheet 25. VThe edge 21a of the fabric may also be firmly secured in position in the manner shown in Fig. 10 by the application of heat and pressure between portions oi the dies used to emboss the kick-pad resulting in creating a bond' through the medium of the plastic or resinous constituents of the foundation sheet and top sheet 25. A metal finishing strip 38 may be placed over the edge portion 25a and cemented thereto in order to provide an ornamental finishing edge along the juncture 2Ia between the upholstered and kick-pad portions of the panel. If desired the edge portion 21a of the trim fabric may be secured in position between the

sheets

25 and 24 and the metal finishing strip 38 also bonded in position in a single die operation utilizing dies similar to those shown in Fig. 15 or Fig. 16 which at the same time emboss the ornamental portion 22 of the panel and the kick-pad application of heat and .pressure through the portion 2B thereof.

In the embodiment shown in Fig. 11 the edge 21a of the trim material is placed between the foundation sheet and the kick-pad sheet 25 and is firmly united thereto thi'ough the medium of the resinous constituents of the sheets by the asogs'u in Fig. or Fig. 16. It will be understood that f these dies will be provided with portions adapted to engage and apply pressure in the area of the portion 25a of theA sheet 25 so as to effect the proper bond of the laminated materials along the lower edge 21a of the trim fabric.

In the embodiment illustrated in Fig. 12 the embossing dies are constructed to emboss both the foundation sheet and the superimposed layers of padding and trim material, thus differing from the embodiment of Fig. 9 in which the foundation sheet is maintained in a flat condi tion during the operation of embossing the fabric and padding layers. Referring to Fig. 12,the lower die 39 is provided with embossing ribs 39a which are adapted to cooperate with corresponding depressions in thebottom of the upper die 40. These depressions are formed between intervening ribs 40a adapted to form during the embossing operation spaced parallel grooves 43 in the fabric and padding layers. The upper die 40 is carried by a heated platen 4I which in turn is shifted vertically through the medium of the usual ram of the press. When the dies 40 and 39 are brought together the foundation sheet, padding and fabric layers will be embossed in the manner shown in. Fig. 12 and these layers will be intimately bonded together throughout the width of the upper die both in the bottoms ofthe grooves and in the areas of the intervening ribs 42.

In Fig. 13 there is illustrated a method of applying a metal finishing strip over the embossed area 22 in the upholstered portion of the panel. The strip 44 may be chromium plated or otherwise finished for ornamental purposes and is placed over the fabric layer 21 between the dies 33 and 34 before the press is closed. As

` these dies are brought together in the manner shown in Fig. 9, themetal finishing strip 44 will be simultaneously formed with grooves and intervening ribs, as shown in Fig. 13, and at the same time will be securely bonded to the top fabric 21 by means of the adhesive material which is forced therethrough into contact with the lower surface of the strip 44 during the embossing operation. 1

Figs. 14 and 15 illustrate the manner in which the trim panel may be formed and the various laminations thereof bonded together in a single die operation. The sheet 25 is first superimposed upon the foundation sheet 24 after which the edge portion 21a of the trim fabricis cemented to the upper edge of the sheet 25. The padding layer 28 is then placed in position on the foundation sheet and the fabric 21 is folded over upon the padding layer with the edges of the fabric folded around the side and upper edges of the foundation sheet and cemented to the back there, of. The trim panel thus assembled, as indicated 8 where :c is desired tu ehbo both the roundation sheet and the .padding and fabric layers 'in the manner shown in Fig. 12 in one operation, the panel after assembled according to Fig. 14 may be introduced between heated dies 41 and 43 which fimction to form the embossment 26 and also the embossments 39a and 43.

Thus. in the embodiments of Figs. 15 and 16 all of the formlng'or embossing operations are accomplished in a single press operation between dies such as the dies 45 and 45 of Fig. 15 or the dies 41 and 48 of Fig.`16, these dies being heated so as to complete the bonding of the laminated materials in the areas where the embossing operations take place and as previously described. It will be understood that a finishing strip 44 may be formed and secured in position in any one of the embossing operations'shown in Figs. 12, 15 and 16.

l I claim:

l. A trim panel comprising a foundation sheet, an outer fabric layer, an interposed padding layer,

and a metal nish strip superimposed upon said k fabric layer, said layers and strip having registering embossed portions and being bonded together in the region of said portions.

2. A trim panel comprising a single fibrous foundation sheet, a broussheet having an inked design, said fibrous sheet lcovering a portion only of the area of said foundation sheet and bonded thereto by adhesive material having the property of owing and setting under heat, a fabric material covering an adjacent portion only of the area of said foundation sheet, adjacent edge portions of said fabric material and fibrous sheet being overlapped at the upper side of the foundation sheet and bonded together.

3. A trim panel comprising a single fibrous foundation sheet, a fibrous sheet having an inked design, said fibrous sheet covering a portion only of the area of said foundation sheet and bonded thereto by adhesive material having the property of flowing and setting under heat. a fabric material covering an adjacent portion only of the area of said foundation sheet, adjacent edge portions of said fabric'material and fibrous sheet being overlapped at the upper side of the foundation sheet and bonded together, and a metal finish strip covering said overlapped portions.

4. A trim panel comprising a single relatively I stiff foundation board, one' area of said board in Fig. 14, is introduced into a press between upper and lower heated dies 45and 46, in the manner shown in Fig. 15. The [upper die 45 is provided with' embossing ribs 45a corresponding to the ribs 34a of the die 34, andthe upper and lower 'dies are also provided with cooperating portions adapted to form the embossment 26 in the kick-pad portion 23 of the panel. The operation Iof the apparatus shown in Fig. 15 is the same as that previously described only differing therefrom in that the embossing of the kickpad and the upholstered portion of the panel in the area. 22 is accomplished in a single operation through the medium of dies 45 vand 46.

being covered with a paper sheet bonded in permanent position throughout said area, the adjacent area of said foundation board being covered with a layer of padding and a superimposed fabric layer with one edge of the fabric layer adjacent the edge of said paper sheet bonded to the foundation board in a narrow area extending transversely acrossl said foundation board, and a molding strip overlying said edges of the paper sheet and fabric layer.

5. A trim panel comprising a single relatively sti foundation board, one area of said board being covered with a paper sheet bonded in permanent position throughout said area, the adjacent area of said foundation board being covered with a layer of padding and a superimposed fabric layer, adjacent transverse edge portions of said paper sheet and fabric layer being overlapped and bonded together and to said foundation board, and a molded strip overlying said edge portions and secured to the foundation board.

6. The method of making a trim panel having a foundation sheet covered over one area thereof with a layer of sheet paper material bonded thereto. including the steps of superimposing upon the foundation sheet a layer of fabric material and causingan edge portion of' said fabric material.

to overlap an edge portion of said layer of `sheet Apaper material, compressing together said overlapping edge portions and bonding them together through the medium of a resinous material, placing a layer of padding over anarea of said founwith a layer of sheet paper material bonded thereto, including the steps of superimposing upon the foundation sheet a layer of fabric material and causing an edge portion of said fabric material to overlap an edge portion of said layer of sheet paper material, compressing together said overlapping edge portions and bonding them together through the medium of a resinous material, placing a layer of padding over an area of said foundation sheet adjacent to said first named area, folding said fabric layer over upon the padding layer to cover the same, and bonding said last named layers together by the application of heat and pressure.

8. The method of making a trim panel having a single foundation sheet provided with an offset area covered over with a layer of paper material bonded thereto uniformly, an edge of said paper material extending beyond said offset area, covering the adjacent area of the foundation sheet with superimposed layers of padding and fabric material with an edge of the latter overlying said edge of the paper material, bonding said edges together through the medium of an adhesive by the application of heat and pressure, and securing together said padding and fabric layers.

9. A trim panel comprising a single foundation board, one area of said board being offset outwardly from the plane of the adjacent area and covered with a cellulosic layer permanently bonded thereto, an edge portion of said layer extending beyond said offset area, and a separate sheet covering said adjacent area of the board and having an edge portion overlying said first edge portion andbonded thereto.

10. A trim panel comprising a single foundation board, one area of said board being offset outwardly from the` plane of the adjacent area and covered with a cellulosic layer permanently bonded thereto, an edge portion of said layer extending beyond said offset area, and superimposed layers of padding and fabric material overlying said adjacent area ofthe board, the fabric layer having an edge portion overlying said first edge portion and bonded thereto.

11. A trim panel comprising a single foundation board, one area of said board being offset outwardly from the plane of the adjacent area and covered with a cellulosic layer permanently bonded thereto, an edge portion of said layer extending beyond said offset area, and'a separate sheet covering said adjacent area of the board and having an edge portion overlying said first edge por- `tion and bonded thereto, said bonded together edge portions lying in a, relatively narrow area extending the width of the foundation board and below the plane `of the outer surface of said offset area.

12. A trim panel comprising a single foundation board, one area of said board being o'set outwardly from the plane of the adjacent area and 10 covered with a cellulosic layer permanently bonded thereto,.an edge portion of said layer extending beyond said offset area, and a separate sheet covering said adjacent area of the board and havingv an edge portionV overlying said first edge portion and bonded thereto and lying in a relatively narrow area extending transversely of the foundation board belowthe plane of offset area.

13. A trim panel comprising a single foundation board, one area of said board being offset outwardly from the plane of the adjacent area and covered with a cellulosic layer permanently bonded thereto, a separate sheet covering said adjacent area of the board and having an edge portion secured thereto along an edge of said offset portion below the plane of the outer surface of said offset area, and a molding strip covering said edge portion and secured in position along said edge of said offset portion.

14. In the method of making a trim panel having a foundation layer, the steps of bonding a layer of brous material to a portion of the area of said foundation layer, overlapping an edge of said fibrous material by an edge of a fabric layer the outer surface of said and bonding said lapping edges together, placing a layer of fibrous material to a portion of the area of said foundation layer, overlapping an edge of said fibrous material by an edge of a fabric layer and bonding said lapping edges together, placing a padding layer on said foundation layer with an edge of the padding layer adjacent the lapping edges of the fibrous and fabric layers, treating certain regions of said padding layer with an adhesive, extending the fabric layer over upon the padding layer. and embossing said layers under heat and pressure at said regions to effect a bond therebetween through the medium of said adhesive substance.

16. In the method of making a trim panel having a foundation layer, the steps of bonding a layer of fibrous material to a portion of the 4area of said foundation layer, placing a fabric layer over the fibrous layer with edge portions of said layers lapping each other, bonding said lapping edges together through the medium of an adhesive substance, placing a padding layer on said foundation layer with an edge of the padding layer overlapping said lappingedges, folding the fabric layer back on itself along said lapping edges to overlie said. padding layer, and bonding said fabric, padding and foundation layers together at selected regions through the medium of an adhesive substance.

17. In the method of making a trim panel having a unitary foundation layer for a kickpanel area and an adjacent upholstered area, the steps of superimposing a fibrous layer on the kick-panel area of the foundation, arranging a.

fabric layer on said foundation withv edge portions of said fibrous and fabric layers lapping each other at the juncture of the kick-panel and A ll ing certain regions cf said padding layer with a resinous material, extending the fabric layer over upon the padding layer, and embossing said layers under heat and pressure at said regions to effect a bond therebetween through the medium of said resinous material.

18. In a trim panel having a unitary foundation layer for a kick-panel area and an adjacent upholstered area, a fibrous layer overlying the kick-panel area of the foundation and bonded thereto, a fabric layer overlying the upholstered y area and having an edge portion lapping an l ing the upholstered area of said foundation. ad-

jacent edges of said fabric and brous layers being overlapped and bonded together at the juncture of the kick-panel and upholstered areas.

20. In a. trim panel having a unitary foundal2 tion layer for a kick-panel area and an adjacent upholstered area, a sheet of paper material bonded to said foundation over the kick-panel area, a layer of fabric material overlying the upholstered area of said foundation and having an edge portion overlapping and bonded to the edge of the paper -layer lalong the juncture of the aforesaid two areas, a padding layer interposed between said foundation and fabric layer, said fabric and padding layers being embossed and bonded together and to said foundation at selected regions.

ALVIN W. PRANCE.

REFERENCES CITED The following references are of record in the ille of this patent:

UNITED STATES PATENTS Number Name Date 1,838,102 McGovern Dec. 29, 1931 1,997,358 Cochrane Apr. 9, 1935 1,999,385 Woodall Apr. 30, 1935 2,099,989 Osborn Nov. 23, 1937 2,215,973 Osborn Sept. 24, 1940 2,227,212 Beck Dec. 31, 1940 2,287,159 Zinser June23, 1942 2,291,935 Woodall Aug. 4, 1942 2,322,226 Cunnington June 26, 1943