Method of making a vehicle seat assembly with pour-in-place foam body

• US 4,860,415 A
• Filed: 06/13/1988
• Issued: 08/29/1989
• Est. Priority Date: 06/13/1988
• Status: Expired due to Fees

• Current Assignee: Hoover Universal Incorporated (Adient plc)
• Original Assignee: Hoover Universal Incorporated (Adient plc)
• Inventors: Witzke, Duane W.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): Kuhns, Allan R.
• Application Number:
  US07/205,929
• Time in Patent Office: 442 Days
• Field of Search: 264/45.1, 264/46.6, 264/46.7, 264/46.8, 264/46.4, 29/458, 29/91.1, 29/91.5
• US Class Current: 29/91.1
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29C 44/146 Shaping the lining before foaming
• CPC Class Codes: B29C 44/148 Applying the foaming resin, moulding the lining or the like, with the lining turned inside out
• 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: Y10T 29/481 Method
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling

Abstract

A method of manufacturing a portion of a seat. A cover member is shaped to a predetermined shape and placed in a foam molding tool into which is injected an expandable liquid foaming material to mold a foam pad which is integrally bonded to the cover member. In the manufacturing of seat backs, the cover member includes a tubular envelope cover positioned on a cantilever forming tool. Once the foam pad is molded, the cover member is turned inside out to enclose the foam pad with the cover member. The cover is then telescoped over a seat frame. Alternatively, the foam pad can be molded to a shaped fabric sheet, the envelope cover formed by sewing a second cover member to the fabric sheet. A seat cushion is made by shaping a cover member, placing the cover member in a foam molding tool which also holds the seat frame and injecting an expandable liquid foaming material into the mold to mold the foam cushion, bond the cushion to the cover and embed the seat frame in the foam. The edges of the cover are then wrapped around the side of the foam pad and attached to the frame. Alternatively, a side panel can be sewn to the cover and attached to the frame.

Claims

1. A method of manufacturing at least a portion of a seat said seat including a supporting frame, a foam pad mounted on said frame, and an envelope cover member over said foam pad, said member being generally tubular in shape and having an open end and inner and outer sides and a seating load engaging portion having a predetermined shape, comprising the steps of:

a. turning said envelope cover member inside out so that said inner side is on the outside of said envelope cover member;

b. telescoping said cover member onto a forming tool;

c. shaping the load engaging portion of said envelope cover member to said predetermined shape;

d. molding said foam pad in place upon said load engaging portion of said envelope cover member by pouring-in-place an expandable liquid foaming material in such a manner that said foam pad is bonded to said load engaging portion and conformed in shape to the shape of said load engaging portion of said envelope cover;

e. manipulating said envelope cover member so that said outer side is on the outside of said envelope cover member and said foam pad is enclosed therein; and

f. telescoping said envelope cover member with said foam pad therein open end first over and onto said supporting frame.

2. The method of claim 1 wherein:

said shaping is performed by application of heat and pressure to said load engaging portion of said envelope cover member.

3. A method of forming at least a portion of a vehicle seat, said seat including a support frame, an envelope cover member of a generally tubular shape having an open end, a seating load engaging portion having a predetermined shape, a closed end, and inner and outer sides, and a foam pad molded in place onto said portion and to the inner side of said cover member, comprising the steps of:

a. turning said envelope cover member inside out so that said outer side is on the inside of said envelope cover member;

b. telescoping said cover member onto a forming tool having said predetermined shape so that said load engaging portion is against said predetermined shape of said forming tool;

c. shaping said portion to said predetermined shape;

d. positioning a foam mold over and onto said load engaging portion;

e. molding said foam pad in place onto said load engaging portion of said cover member by injecting an expandable foam into said mold so that said foam pad is bonded to said load engaging portion;

f. removing said mold from said foam pad and said cover member;

g. removing said cover member with said foam pad bonded thereto from said forming tool;

h. turning said envelope cover member outside out so that said foam pad is enclosed therein; and

i. telescoping said cover member and pad onto said supporting frame.