BLOW MOLD AND BACKFILL MANUFACTURING PROCESS

• US 20070166529A1
• Filed: 10/03/2006
• Published: 07/19/2007
• Est. Priority Date: 10/03/2005
• Status: Active Grant

• Current Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Original Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Inventors: Hsu, James
• Granted Patent: US 7,922,944 B2
• Time in Patent Office: Days
• US Class Current: 428/304.400
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 2793/00 Shaping techniques involving a cutting or machining operation
• CPC Class Codes: B29C 2793/0036 Slitting
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 35/0288 Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process controlling or regulating chemical, physical or physico- chemical processes in general B01J19/0006
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/18 Filling preformed cavities B29C44/1204 takes precedence
• CPC Class Codes: B29C 49/04 Extrusion blow-moulding
• CPC Class Codes: B29C 49/60 Blow-needles
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/3026 Arm-rests
• CPC Class Codes: B29L 2031/443 Chairs
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/24314 Slit or elongated
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A method for forming a foam product comprises forming a skin and inserting a bracket at least partially into the skin. Another method for manufacturing a foam product comprises sealing a tube of material in a cavity of a mold, blowing air into the tube of material to form a skin comprising an interior surrounded by a wall, cutting an incision in the skin wall, inserting a bracket through the incision and into the skin interior, filling the skin interior with foam, and curing the foam. A foam product comprises a skin with an interior surrounded by a wall, a bracket within the skin interior, a foam substantially filling the skin interior and securing the bracket in place, a recessed region configured to mate with a mounting assembly on a chair, and an incision in the skin wall, the incision positioned outside of the recessed region.

Claims

1. A method for forming a foam product, the method comprising:

forming a skin comprising;

a mounting area, and

a bracket insertion area separate from the mounting area; and

inserting a bracket at least partially into the skin through the bracket insertion area;

wherein the mounting area is configured to receive a mounting assembly attached to an article of furniture.

2. The method of claim 1 further comprising:

filling the skin with foam.

3. The method of claim 1 further comprising:

sealing the bracket insertion area after inserting the bracket.

4. The method of claim 1 wherein at least a portion of the bracket is wider than the mounting area.

5. The method of claim 1 wherein the foam product is asymmetrical.

6. The method of claim 1 wherein no material is removed from the skin to insert the bracket into the skin.

7. The method of claim 1 wherein the skin is formed without using a liquid skin material.

8. A method for manufacturing a foam product, the method comprising:

sealing a tube of material in a cavity of a mold;

blowing air into the tube of material to form a skin comprising an interior surrounded by a wall that conforms to the shape of the cavity;

cutting an incision in the skin wall;

inserting a bracket through the incision and into the skin interior;

filling the skin interior with foam; and

curing the foam.

9. The method of claim 8 further comprising:

removing the skin from the mold and trimming excess material from the skin.

10. The method of claim 8 further comprising:

sealing the incision.

11. The method of claim 8 wherein the bracket is inserted without removing any material from the skin wall.

12. The method of claim 8 wherein the skin comprises a recessed region configured to mate with a mounting assembly.

13. The method of claim 12 wherein the bracket is wider than the recessed region.

14. The method of claim 12 wherein the skin further comprises:

a bracket insertion area located outside of the recessed area; and

wherein the incision is located in the bracket insertion area.

15. The method of claim 8 wherein the foam product is an asymmetrical foam product.

16. A foam product comprising:

a skin comprising an interior surrounded by a wall;

a bracket positioned within the skin interior;

a foam substantially filling the skin interior and securing the bracket in place within the skin wall;

a recessed region formed in the underside of the foam product, the recessed region configured to mate with a mounting assembly on a chair; and

an incision in the skin wall, the incision positioned outside of the recessed region.

17. The foam product of claim 16 wherein the incision is located in a bracket insertion area positioned outside of the recessed region.

18. The foam product of claim 16 wherein the incision is wider than the recessed region.

19. The foam product of claim 16 wherein the incision does not remove any material from the skin.

20. The foam product of claim 16 wherein the foam product is asymmetrical.