Importance

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Abstract

A soft panel has a layer formed from thermoplastic fiber clusters comprised of a very high percentage of crooked matrix fibers and a very low percentage of crooked binder fibers with a lower melt temperature and wherein the fibers have a plurality of bends that entangle the fibers together in the clusters. The fiber clusters are blown onto a first foraminous screen that defines a retainer side of the fiber layer and through which air is being drawn. A second foraminous screen is then added to compact the fiber clusters and define a skin side of the fiber layer. Hot air is then circulated through the compacted fiber clusters to melt the binder fibers to fuse the matrix fibers together where they touch to form an integral soft springy fiber cluster layer to the shape of the screens. The second screen is then removed and a layer of thermoplastic power is sprayed onto a thermoplastic veil draped over the fiber cluster layer while the latter remains on the first screen and air is drawn through this screen and the veil to retain the power layer in place. A skin and a retainer are then bonded to the fiber cluster layer.

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First Claim