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Method of making a covered article

  • US 3,971,112 A
  • Filed: 09/22/1975
  • Issued: 07/27/1976
  • Est. Priority Date: 09/22/1975
  • Status: Expired due to Term
First Claim
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1. A method of making a covered article which comprises the steps of:

  • forming at least a pair of covering members of a covering material, said covering material being impervious to a foam material which is formed from a foamable composition;

    sewing said covering members together along at least one sew line to form a cover having a peripheral edge portion therearound and an interior volume, said sewing operation placing openings through said cover which permit the passage of said foam material through said cover;

    forming a locating member having both an inner peripheral edge portion therearound defining a central opening and locating portions between said inner peripheral edge portion and an outer peripheral edge portion, said locating member'"'"'s inner peripheral edge portion having the same general configuration as said peripheral edge portion of said cover;

    joining said peripheral edge portion of said cover to said inner peripheral edge portion of said locating member;

    sealing said opening along said sew lines joining said covering members together so that said foam material produced upon foaming of said foamable composition cannot flow through said openings;

    locating said cover and joined locating member in a foaming mold having a mold portion containing a die surface upon which a vacuum can be drawn and an openable cover portion, said locating portions of said locating member being aligned with locating positions on said foaming mold to align accurately said cover with said die surface of said foaming mold;

    drawing a vacuum on said die surface of said foaming mold thereby to draw a facing surface of said cover into contact with said die surface;

    placing a charge of said foamable composition into said interior volume of said cover defined between an inner surface of said cover and its peripheral edge when said cover is held in contact with said die surface by vacuum;

    closing said cover portion of said foaming mold;

    reacting said foamable composition to fill said interior volume of said cover with said foam material;

    opening said foaming mold;

    removing said cover, foam material and locating member from said foaming mold;

    removing said locating member from said cover having said foam material therein thereby to form a covered article.

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