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FOAM IN PLACE SEAT CUSHION USING DUAL FABRIC TRIM COVER AND FEATURELESS TOOL

  • US 20080036110A1
  • Filed: 08/14/2007
  • Published: 02/14/2008
  • Est. Priority Date: 08/14/2006
  • Status: Abandoned Application
First Claim
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1. A method of fabricating a plurality of seat elements with a common mold assembly comprising an upper mold portion and a lower mold portion, the method comprising the steps of:

  • providing a lower mold portion having a lower mold surface contoured to define an occupant support surface between side bolters;

    providing a trim cover having a plurality of panels sewn together, at least one of said panels comprising at least two plies of material including an exterior ply and a middle ply of foam;

    positioning the trim cover onto the lower mold surface;

    applying an imperforate film on the trim cover;

    closing the mold assembly to define a mold cavity therebetween and retain the trim cover relative to said lower mold portion;

    applying a negative pressure between the lower mold surface and the imperforate film so as to conform the trim cover to the lower mold surface;

    pouring a charge of foam substrate into the mold cavity and allowing the charge to cure and form a foam body and activate bond at least a portion of the trim cover to the foam body; and

    removing the foam body with the trim cover bonded thereto from the mold cavity,whereby said plurality of seat elements are styled to have a range of styling features and said method includes a step of determining said range of styling feature by selecting characteristics of said exterior ply and said middle ply of foam and selecting a number and position of said plurality of panels.

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