Process for manufacturing a trim cover assembly of a seat

• US 4,722,760 A
• Filed: 09/02/1986
• Issued: 02/02/1988
• Est. Priority Date: 10/31/1984
• Status: Expired due to Fees

• Current Assignee: Tachikawa Spring Company Limited (Tachi-S Company Limited)
• Original Assignee: Tachikawa Spring Company Limited (Tachi-S Company Limited)
• Inventors: Shimada, Makoto
• Primary Examiner(s): Dawson, Robert A.
• Assistant Examiner(s): Aftergut, Jeff H.
• Application Number:
  US06/887,949
• Time in Patent Office: 518 Days
• Field of Search: 156/228, 156/230, 156/232, 156/214, 156/212, 156/219, 156/220, 156/209, 428/159, 428/160, 428/163, 428/167, 428/173
• US Class Current: 156/214
• CPC Class Codes: A47C 27/146 on the outside surface of the mattress or cushion
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: B29C 44/10 Applying counter-pressure during expanding
• CPC Class Codes: B29C 44/56 After-treatment of articles, e.g. for altering the shape
• CPC Class Codes: B29C 63/22 using layers or sheathings having a shape adapted to the shape of the article B29C63/26 and B29C63/38 take precedence
• CPC Class Codes: B29D 99/0092 Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1041 Subsequent to lamination
• CPC Class Codes: Y10T 428/24512 : Polyurethane
• CPC Class Codes: Y10T 428/24537 : Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/2457 : Parallel ribs and/or grooves

Abstract

A process for manufacturing a trim cover assembly constituting the surface of an automotive seat or airplane seat is disclosed and comprises the step of forming a covering material and a foam wadding with a plurality of recessed grooves on the surface thereof. The process also includes the step of forming the covering material in the trim cover assembly by a thermal press or the like into a predetermined uneven configuration. Then, the thus-formed covering material is adhesively bonded to the surface of the foam wadding so that various kinds of uneven configurations are available for use as the surface of the trim cover assembly.

Claims

1. A process for manufacturing a trim cover assembly for a seat including a cover material, a foam wadding and a wadding cover, comprising the steps of:

forming a large number of suitably spaced-apart recessed grooves on the surface of said foam wadding;

placing said cover material on a lower mold having a plurality of projections corresponding to said suitably spaced-apart recessed grooves of said foam wadding;

lowering and pressing an upper mold against said cover material and said lower mold, said upper mold including a plurality of recessed cavities corresponding to respective projections of said lower mold and further having a predetermined shaped surface including curved portions between said recessed cavities so as to form said cover material into a predetermined uneven configuration including an outwardly curved configuration between spaced-apart recessed grooves whereby the thus formed cover material has arc-shaped projecting portions in cross-section;

applying an adhesive to said cover material;

placing said foam wadding on the formed cover material on said lower mold with the recessed surface of said foam wadding facing said formed cover material;

applying an adhesive to at least one of said wadding cover and said foam wadding and placing said wadding cover on said foam wadding; and

pressing said upper mold against said wadding cover, said foam wadding, and said cover material so that same are bonded into a unitary structure,

whereby, a trim cover assembly is formed having a desired uneven configuration and wherein said foam wadding is distorted in shape so as to conform to said uneven configuration of said cover material.