Trim cover assembly

• US 20040256904A1
• Filed: 03/09/2004
• Published: 12/23/2004
• Est. Priority Date: 06/19/2003
• Status: Abandoned Application

• Current Assignee: Tachi-S Company Limited
• Original Assignee: Tachi-S Company Limited
• Inventors: Takei, Yoshiyuki
• Application Number:
  US10/795,244
• Publication Number:
  US 20040256904A1
• Time in Patent Office: Days
• US Class Current: 297/452.48
• CPC Class Codes: B29C 44/1209 by impregnating a preformed part, e.g. a porous lining
• CPC Class Codes: B29C 44/145 the lining being a laminate
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for

Abstract

A trim cover assembly formed by sewing together a plurality of cover materials into a three-dimensional configuration which is to undergo a foaming process in which a liquid foaming agent is injected into the trim cover assembly and a resultant foam padding is filled therein. Each of the cover materials comprises a top cover layer and a slab foam wadding layer fixed to a reverse side of the top cover layer. The slab foam wadding layer is of a continuous cellular structure having an air permeability of from 0.2 cc/cm²/sec. to 1 cc/cm²/sec. so that, during the foaming process, the liquid foaming agent is impregnated and cured in the slab foam wadding layer at a proper rate relative to the thickness of the latter so as not to reach the top cover layer.

Claims

1. A trim cover assembly formed by sewing together a plurality of cover materials into a three-dimensional configuration which is to undergo a foaming process in which a liquid foaming agent is injected into said trim cover assembly and a resultant foam padding is filled therein, wherein each of said plurality of cover materials comprises:

a top cover layer having an outer surface side and a reverse side; and

a slab foam wadding layer integrally laminated on said reverse side of said top cover layer,

and wherein said slab foam wadding layer is of a continuous cellular structure having an air permeability of from 0.2 cc/cm²/sec. to 1 cc/cm²/sec.

2. The trim cover assembly as claimed in claim 1, where said to cover layer is of an air permeable property.

3. A foamed product using said trim cover assembly claimed in claim 1, which is formed by the foaming process comprising the steps of placing said trim cover assembly in a foaming die, injecting said liquid foaming agent into an inside of said trim cover assembly, and subjecting the trim cover assembly and said liquid foaming agent to foaming, under such a condition that a foaming pressure is set relative to a thickness of said slab foam wadding layer at a rate that allows the liquid foaming agent to be impregnated in at most half of thickness of said slab foam wadding layer.