Textile Mold

This is a method of molding cloth. A special multi-layer cloth is drawn into a heated mold by means of a vacuum between the cloth and the mold. The cloth includes a fabric layer having a heat-flexible fiber, stitches of the fabric having never been thermally set, a polyurethane foam layer and a polyvinyl chloride film layer bonded together. The cloth is heated to at least the greater of the set temperatures of the fabric layer and the polyvinyl chloride film. After the cloth has conformed to the contours of the mold, the cloth is cooled in the mold.

The steps of heating the cloth in the mold and then cooling the cloth sets the stitch of the fabric to the contours of the mold. Polyurethane foam may then be poured into the mold and allowed to expand to form a seat cushion or the like.