FOAM IN PLACE SEAT CUSHION USING DUAL FABRIC TRIM COVER AND FEATURELESS TOOL
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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Abstract
A method of fabricating a plurality of seat elements is provided. The plurality of seat elements are styled to have a range of styling features. The method includes a step of determining the range of styling feature by selecting characteristics of a middle ply of foam and/or the exterior ply of the trim cover and selecting a number and position of panels that are sewn to form the trim cover. The seat elements are fabricated on a common mold apparatus.
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Citations
18 Claims
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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:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. An apparatus for fabricating a plurality of seat elements, said apparatus comprising an upper mold portion and a lower mold portion, said upper mold portion being movable relative to said lower mold portion to define a mold cavity therebetween, said lower mold portion having a lower mold surface smoothly contoured to define an occupant support surface between side bolters and a ridge between said occupant support surface and each of said side bolsters.
Specification