Abstract: A process for applying a PVC heel pad to automotive carpeting to eliminate the necessity of pre-forming the heel pads before they are applied to the carpet and the products formed thereby, including the steps of applying a hot melt adhesive composition between the carpet and the back side of an unpatterned PVC sheet; positioning the composite which includes the carpet, adhesive and unpatterned PVC sheet in a metallic heel pad patterned mold; and forming in situ a pattern molding on the PVC pad simultaneously with the adhesion of the PVC pad to the carpet.

Abstract: A contoured article having three dimensional surface effects is disclosed herein, such as a headliner or floor covering for a vehicle. The contour of the article and at least one three dimensional decorative surface are incorporated into the article during molding. The three dimensional surface preferably is an exact replica of the surface of a textile product. Further, the final article may be surface decorated, if desired. A process for producing a contoured article having a three dimensional decorative surface is also disclosed and claimed herein. The process involves the provision of a master mold, the cavities of which define both the contour and the three dimensional surface design. A foamable composition is cast into one section of the master mold after which the mold sections are brought into register while the composition is fused or cured in situ, conforming to the contour and three dimensional surface cavities of the mold.

Abstract: A three dimensional, decorative material is disclosed and claimed herein, having good dimensional definition and capable of virtually unlimited design. A process for producing the three dimensional composite is also disclosed and claimed herein. The process originates with the manufacture of a master mold which can be produced with virtually any design, and preferably is made into a continuous belt. An elastomeric foam composition is then cast into the cavities of the master mold and fused in situ, whereby a three dimensional material is produced. Thereafter, a suitable adhesive is applied to the design side of the material and flock fibers or some other decorative substances are deposited thereon. After curing of the adhesive, any excess fibers are removed, and the material may be cut into suitable lengths, provided with a contact adhesive on the reverse side or the like.

Abstract: A three dimensional, decorative material is disclosed and claimed herein, having good dimensional definition and capable of virtually unlimited design. A process for producing the three dimensional composite is also disclosed and claimed herein. The process originates with the manufacture of a master mold which can be produced with virtually any design, and preferably is made into a continuous belt. An elastomeric foam composition is then cast into the cavities of the master mold and fused in situ, whereby a three dimensional material is produced. Thereafter, a suitable adhesive is applied to the design side of the material and flock fibers or some other decorative substances are deposited thereon. After curing of the adhesive, any excess fibers are removed, and the material may be cut into suitable lengths, provided with a contact adhesive on the reverse side or the like.