Foam laminate for mold in place seating component
First Claim
1. A laminate structure for making a cushioned component, comprising:
- a cover material having an interior surface and an exterior surfaces; and
a high density foam having an air permeability of from 5 to 100 ft3/ft2 minute bonded to the interior surface of the material to form the laminate structure;
wherein said laminate structure is insertable into a mold having a mold surface with a shape corresponding with a desired exterior surface shape of at least a portion of the cushioned component, so that the exterior surface of the material is positioned adjacent to the mold surface.
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Accused Products
Abstract
A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.
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Citations
25 Claims
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1. A laminate structure for making a cushioned component, comprising:
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a cover material having an interior surface and an exterior surfaces; and
a high density foam having an air permeability of from 5 to 100 ft3/ft2 minute bonded to the interior surface of the material to form the laminate structure;
wherein said laminate structure is insertable into a mold having a mold surface with a shape corresponding with a desired exterior surface shape of at least a portion of the cushioned component, so that the exterior surface of the material is positioned adjacent to the mold surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. In a method of making a cushioned component including the steps of (a) providing a cover having an exterior surface which is to present the major exterior appearance of the cushioned component;
- (b) placing the cover within a mold so that the exterior surface of the cover is facing a mold surface of the mold having a shape corresponding with the desired exterior surface shape of the cushioned component;
(c) introducing a foamable material into the mold while the cover is within the mold; and
(d) curing the foamable material as said cover is held within the mold, wherein the improvement comprises;
(e) laminating a high density foam sheet to the interior surface of the material forming the cover prior to placing the cover into the vacuum mold, wherein the high density foam sheet has an air permeability of from 5 to 100 ft3/ft2 minute. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
- (b) placing the cover within a mold so that the exterior surface of the cover is facing a mold surface of the mold having a shape corresponding with the desired exterior surface shape of the cushioned component;
Specification