Method of making a foamed seat or cushion having integral fasteners

• US 4,673,542 A
• Filed: 06/14/1985
• Issued: 06/16/1987
• Est. Priority Date: 06/14/1985
• Status: Expired due to Term

• Current Assignee: Lear Corporation
• Original Assignee: General Motors Corporation (General Motors Company)
• Inventors: Wigner, Lauren R., Pandak, Zoltan I.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): TENTONI, LEO B
• Application Number:
  US06/744,760
• Time in Patent Office: 732 Days
• Field of Search: 425/3, 425/DIG. 33, 264/46.7, 264/132, 264/263, 264/275
• US Class Current: 264/46.7
• CPC Class Codes: A44B 18/0076 Adaptations for being fixed to a moulded article during moulding
• CPC Class Codes: A44D 2203/00 Fastening by use of magnets
• CPC Class Codes: B29C 33/0044 for sealing off parts of inserts projecting into the mould cavity
• CPC Class Codes: B29C 33/16 using magnetic means
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: Y10S 425/033 Magnet

Abstract

A method for integrally forming in place on an exterior side of a foam seat or backrest cushion a hook or loop strip fastener. The method includes (1) providing a mold which defines a cavity in the shape of the cushion and with its member defining the exterior of the cushion being provided with an elongated recess whose bottom overlies an elongated magnet located in the mold, (2) providing an elongated fastener strip assembly comprising a thin plastic liner, a fastener strip having integral hook or loop fasteners facing toward the liner, an elongated steel strip located on the back side of the fastener strip, and a cloth backing strip whose side edges are adhesively secured to adjacent side edges of the liner to encapsulate the fastener strip and steel strip between the cloth backing and liner, (3) placing and laying the elongated fastener strip assembly liner side down into the recess of the mold so that the steel strip overlies the magnet whereby the latter by magnetic attraction holds the fastener strip assembly in place in the mold, (4) adding foam material to the mold whereby the cloth backing strip of the fastener assembly will be integrally secured to the foam cushion during the molding operation, and (5) opening the mold to remove the foam cushion and with the fastener strip assembly being secured thereto liner side up.

Claims

1. The method of making a cushion for a seat which has a hook or loop strip fastener means molded to its exterior surface comprising the steps of:

(1) providing a mold having a pair of members which are relatively movable between open and closed positions and which together define a mold cavity and with the member defining the exterior surface of the cushion being provided with an elongated recess whose bottom lies over an elongated magnet located in the mold,

(2) providing an elongated fastener strip assembly comprising a thin plastic liner whose width is wider than the recess in the mold, a fastener strip means having a fastener strip with integral hook or loop fasteners facing toward the liner and whose width is less than the width of said recess and a backing whose width is greater than the fastener strip and approximately the same as the width of the liner and with adjacent side edge portions of the backing and liner being adhesively secured to each other and an elongated, thin steel strip located between the backing and said liner and whose width is less than the width of said recess whereby said fastener strip and said thin steel strip are sandwiched between said liner and said backing and isolated from direct contact exteriorly of said fastener strip assembly,

(3) placing and laying said fastener strip assembly liner side down into said recess of the mold so that the side edge portions of the liner and backing overlie the interior surface of the mold cavity and the steel strip overlies said magnet whereby said magnet by magnetic attraction will hold said fastener means within said recess and said fastener strip assembly in place in the mold cavity,

(4) adding foam material into the mold after it is closed to form said cushion and whereby said backing of said fastener strip assembly will be secured to said cushion,

(5) opening the mold and removing said formed cushion with the fastener strip assembly being secured to the exterior side of said cushion and with the liner facing exteriorly of said cushion.

4. The method as defined in claim 1 and including the step of stripping said liner of said fastener strip assembly from said seat cushion after it is removed from the mold to expose said hook or loops of said strip fastener.

2. The method of making a cushion for a seat which has a hook or loop strip fastener means molded to its exterior surface comprising the steps of:

(1) providing a mold having a pair of members which are relatively movable between open and closed positions and which together define a mold cavity and with the member defining the exterior surface of the cushion being provided with an elongated recess whose bottom lies over an elongated magnet located in the mold,

(2) providing an elongated fastener strip assembly comprising a thin plastic liner whose width is wider than the recess in the mold, a fastener strip means having a fastener strip with integral hook or loop fasteners facing toward the liner and whose width is less than the width of said recess and a backing whose width is greater than the fastener strip and approximately the same as the width of the liner and with adjacent side edge portions of the backing and liner being adhesively secured to each other and an elongated, thin steel strip whose width is less than the width of said recess and which is sandwiched between the backing and said fastener strip means whereby said fastener strip and said thin steel strip are isolated from direct contact exteriorly of said fastener strip assembly,

(3) placing and laying said fastener strip assembly liner side down into said recess of the mold so that the side edge portions of the liner and backing overlie the interior surface of the mold cavity and the steel strip overlies said magnet whereby said magnet by magnetic attraction will hold said fastener strip within said recess and hold said fastener strip assembly in place in the mold cavity,

(4) pouring foam material into the mold after it is closed and allowing the same to rise and set to form said cushion and whereby said backing of said fastener strip assembly will be secured to said cushion,

(5) opening the mold and removing said formed cushion with the fastener strip assembly being secured to the exterior side of said cushion and with the liner facing exteriorly of said cushion.

3. The method of making a cushion for a seat which has a hook or loop strip fastener molded to its exterior surface comprising the steps of:

(1) providing a mold having a pair of members which are relatively movable between open and closed positions and which together define a mold cavity and with the member defining the exterior surface of the cushion being provided with an elongated recess whose bottom lies over an elongated magnet located in the mold,

(2) providing an elongated fastener strip assembly comprising a thin plastic liner whose width is wider than the recess in the mold, a fastener strip means having a fastener strip with integral hook fasteners facing toward the liner and whose width is less than the width of said recess and a cloth backing whose width is greater than the fastener strip and approximately the same as the width of the liner and with adjacent side edge portions of the cloth backing and liner being adhesively secured to each other and an elongated, thin steel strip whose width is less than the width of said recess and which is sandwiched between the cloth backing and said fastener strip means whereby said fastener strip and said thin steel strip are sandwiched between said liner and said backing strip and isolated from direct contact exteriorly of said fastener strip assembly,

(3) placing and laying said fastener strip assembly liner side down into said recess of the mold so that the side edge portions of the liner and backing overlie the interior surfaces of the mold cavity adjacent the recess and the steel strip overlies said magnet whereby said magnet by magnetic attraction will hold said fastener strip means within said recess and said fastener strip assembly in place in the mold cavity,

(4) pouring foam material into the mold after it is closed and allowing the same to rise and set fo form said cushion and whereby said cloth backing of said fastener strip assembly will be secured to said cushion,

(5) opening the mold and removing said formed cushion with the fastener strip assembly being secured to the exterior side of said cushion and with the liner facing exteriorly of said cushion.

5. The method as defined in claim 3 and including the step of stripping said liner of said fastener strip assembly from said seat cushion after it is removed from the mold to expose said hooks of said strip fastener.