Method of forming a vehicle seat with a stylized seating surface

• US 4,975,135 A
• Filed: 05/01/1989
• Issued: 12/04/1990
• Est. Priority Date: 05/01/1989
• Status: Expired due to Term

• Current Assignee: Hoover Universal Incorporated (Adient plc)
• Original Assignee: Hoover Universal Incorporated (Adient plc)
• Inventors: Lowe, Michael E.
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): YODER, MICHELE
• Application Number:
  US07/345,789
• Time in Patent Office: 582 Days
• Field of Search: 156/221, 156/155, 156/309.6, 156/182, 156/214, 156/245, 156/285, 156/222, 156/256, 297/DIG. 1, 297/DIG. 2, 29/91.1, 5/451, 425/388
• US Class Current: 156/155
• CPC Class Codes: B29C 44/569 Shaping and joining components with different densities or hardness
• 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: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: Y10S 297/01 Foam
• CPC Class Codes: Y10S 297/02 Molded
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1062 Prior to assembly

Abstract

A method of manufacturing a vehicle seat cover and bonding the vehicle seat cover to a foam bun utilizing a style insert. The style insert is formed by taking a breathable cloth fabric and laminating it to a sheet of foam material. The composite so formed is then cut to a desired styled insert shape and sewn to the vehicle seat cover skirt to form a seat cover assembly.

The composite, which may include an air impermeable barrier sheet or the barrier sheet may be included in the composite between the foam and fabric sheets, is positioned on a forming tool having removable style inserts, with the cloth side of the composite against the insert. An impermeable film is then positioned over the foam side of the insert composite and a vacuum drawn the forming tool and the impermeable film to draw the composite down into conformity with the style lines of the tool insert. An adhesively coated foam bun is then positioned and pressed against the composite on the forming tool. Heat is applied to the forming tool to evaporate the film, allowing the adhesive to bond the cover assembly to the foam bun and release the composite from the forming tool allowing removal of the seat assembly from the forming tool. The edges of the skirt are then fastened together or to the underside of the foam bun so as to at least partially enclose the bun.

Claims

1. In a method of forming a portion of a vehicle seat having a surface of predetermined shape, the steps of:

a. providing a sheet of air impermeable material which will substantially evaporate when heated;

b. laminating a sheet of plastic foam to one side of a sheet of permeable trim material to form a composite having a trim side and a foam side;

c. positioning said impermeable material on said foam side of said composite to form a sandwich having an air impermeable surface;

d. placing said sandwich on a forming tool having an upper surface complementary to said predetermined shape, with the trim side of said composite against said upper surface of said tool;

e. establishing a vacuum between said air impermeable surface of said sandwich and said forming tool drawing said sandwich against said upper surface to shape said composite into said predetermined shape;

f. applying adhesive to a foam bun having a face;

g. pressing said bun face against said impermeable material on said forming tool; and

h. heating said sandwich to substantially evaporate said air impermeable material to enable contact of said foam side of said composite with said adhesive to bond said composite to said bun face.

2. The method according to claim 1 wherein said air impermeable material is a polyolefin material.

3. The method according to claim 1 further comprising the steps of:

a. cutting said composite to a predetermined size; and

b. sewing a portion of said composite to a skirt portion.

4. In a method of forming a portion of a vehicle seat having a surface of predetermined shape, the steps of:

a. providing a sheet of air impermeable material which will deteriorate when heated;

b. laminating a sheet of plastic foam to one side of a sheet of permeable cloth fabric to form a composite having a cloth side and a foam side;

c. cutting said composite to a predetermined size;

d. sewing said composite to a vehicle trim cover member having an aperture therein of said predetermined size so as to close said aperture;

e. positioning said sheet of air impermeable material on said foam side of said composite to form an air impermeable trim material;

f. placing said trim material on a forming fixture having an insert therein, said insert having an upper surface complementary to said predetermined shape, with the cloth side of said composite against said upper surface of said insert;

g. establishing a vacuum between said trim material and said fixture drawing said material against said surface to shape said material into said predetermined shape;

h. placing a foam bun having a face adjacent said material;

i. applying adhesive to said bun face;

j. pressing said bun face against said material on said fixture;

k. heating said material to deteriorate said air impermeable film to enable contact of said foam side of said composite with said adhesive to bond said composite to said bun face and release said bun and said trim material from said fixture;

l. removing said bun and trim material attached thereto from said fixture; and

m. securing said said trim cover member to said bun so as to cover said face and at least partially enclose said bun.