Padded element, and process and mold for producing same

• US 10,252,655 B2
• Filed: 05/21/2014
• Issued: 04/09/2019
• Est. Priority Date: 05/23/2013
• Status: Active Grant

• Current Assignee: Proprietect LP
• Original Assignee: Proprietect LP
• Inventors: Rossi, Pasquale, San Miguel, Edgardo A
• Primary Examiner(s): Chen, Jose V
• Application Number:
  US14/892,670
• Publication Number:
  US 20160114712A1
• Time in Patent Office: 1,784 Days
• Field of Search: 29745248, 297DIG 1
• CPC Class Codes: A47C 27/15 consisting of two or more layers A47C27/16 takes precedence
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: A47C 7/20 with reinforcement in the foam layer
• CPC Class Codes: B29C 44/04 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
• CPC Class Codes: B29C 44/5627 by mechanical deformation, e.g. crushing, embossing, stretching
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2995/0097 Thickness
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B60N 2/5825 by hooks, staples, clips, snap fasteners or the like
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B68G 5/02 of cellular material, e.g. sponge rubber

Abstract

There is disclosed a padded element. In one embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion. The molded foam topper portion and the molded foam substrate portion have a different indentation force deflection at 25% thickness when measured pursuant to ASTM 3574-B₁. In another embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion via an interference fit.

Claims

1. A padded element comprising a molded foam topper portion and a molded foam substrate portion, wherein the molded foam topper portion and the molded foam substrate portion are molded as a unitary piece and are attached to one another by a connecting portion, the molded foam topper portion and the molded foam substrate portion having a different indentation force deflection at 25% thickness when measured pursuant to ASTM 3574 Test B1.

2. The padded element defined in claim 1, wherein the molded foam substrate portion has a greater indentation force deflection than the molded foam topper portion.

3. The padded element defined in claim 1, wherein the connecting portion is flexible, thereby permitting the molded foam topper portion and the molded foam substrate portion to pivot with respect to one another.

4. The padded element defined in claim 1, wherein the connecting portion comprises a foam element formed in situ during manufacture of the padded element.

5. The padded element defined in claim 1, wherein the connecting portion comprises a non-foam element.

6. The padded element defined in claim 1, wherein the molded foam topper portion and the molded foam substrate portion are configured to fold via the connecting portion and to secure to one another via an interference fit when folded, wherein the interference fit comprises a friction fit or interaction between the molded foam topper portion and the molded foam substrate portion.

7. The padded element defined in claim 6, wherein the interference fit comprises a plurality of male-female couplings, each of said plurality of male-female couplings comprising a male half and a female half.

8. The padded element defined in claim 7, wherein the molded foam substrate portion comprises a trim cover connection portion configured to secure a trim cover to the padded element.

9. The padded element defined in claim 8, wherein the trim cover connection portion comprises a plurality of clip portions configured to receive a rail portion comprised in the trim cover.

10. The padded element defined in claim 8, wherein the trim cover connection portion is molded in the molded foam substrate portion.

13. The padded element defined in claim 1, wherein the molded foam topper portion comprises a first internal surface and the molded foam substrate portion comprises a second internal surface opposed to the first internal surface, at least one of the first internal surface and the second internal surface comprising a textured portion.

14. The padded element defined in claim 13, wherein the first internal surface comprises a textured portion and the second internal surface is substantially untextured.

15. The padded element defined in claim 13, wherein the first internal surface is substantially untextured and the second internal surface comprises a textured portion.

16. The padded element defined in claim 13, wherein both of the first internal surface and the second internal surface comprise a textured portion.

17. A seat element comprising the padded element defined in claim 1.

18. The seat element defined in claim 17, comprising a pair of opposed side bolster portions comprising the molded foam substrate portion and a central portion interposed between the pair of opposed side bolster portions, the central portion comprising the molded foam topper portion.

19. The seat element defined in claim 18, further comprising a front bolster portion positioned between the pair of opposed side bolster portions, the front bolster portion comprising the molded foam substrate portion.

20. A vehicular seat comprising the seat element defined in claim 17.

11. A padded element comprising a molded foam topper portion and a molded foam substrate portion, wherein the molded foam topper portion and the molded foam substrate portion are molded as a unitary piece, the molded foam substrate portion being configured to fold relative to the molded foam topper portion and to secure to the molded foam topper portion via an interference fit when folded, wherein the interference fit comprises a friction fit or interaction between the molded foam topper portion and the molded foam substrate portion.

12. The padded element defined in claim 11, wherein the interference fit comprises a plurality of male-female couplings, each of said plurality of male-female couplings comprising a male half and a female half.