Method of making covers for foam bodies using a seam stabilizer
First Claim
1. The method of manufacturing a composite component of a seat assembly consisting of a foam body having a predetermined shape and a cover member for said body having welts secured therein, said welts having a tear away body portion connected to a tab portion, said method comprising the steps of:
- (a) shaping said cover member with said welts secured therein to said predetermined shape of said foam body;
(b) providing a mold member corresponding to said predetermined shape;
(c) molding said foam body in place upon said cover member by pouring in place an expandable liquid foaming material within said mold member in such a manner that said foam body is bonded to said cover member and conforms in shape to said predetermined shape; and
(d) removing said body portions of said welts to form said seat component.
1 Assignment
0 Petitions
Accused Products
Abstract
A tear away seam stabilizer for a vehicle seat component is provided for use with the pour-in-place molding process. The stabilizer, or welt, has an annular body attached to a notched tab portion by a tapered portion and neck portion which is sewn between covering members to form the desired shape of a component. A mold is provided within which the sewn cover, with the seam stabilizers in place, is inserted. The stabilizers maintain alignment of the seams in the cover member during the pour-in-place process and also prevent wrinkles in the cover. The end result is a vehicle seat component with the cover member tightly adhered to the foam body and conforming to a surface of predetermined shape. Once the foam pad is adhered to the cover member, the annular body of the stabilizer is readily torn off.
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Citations
8 Claims
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1. The method of manufacturing a composite component of a seat assembly consisting of a foam body having a predetermined shape and a cover member for said body having welts secured therein, said welts having a tear away body portion connected to a tab portion, said method comprising the steps of:
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(a) shaping said cover member with said welts secured therein to said predetermined shape of said foam body; (b) providing a mold member corresponding to said predetermined shape; (c) molding said foam body in place upon said cover member by pouring in place an expandable liquid foaming material within said mold member in such a manner that said foam body is bonded to said cover member and conforms in shape to said predetermined shape; and (d) removing said body portions of said welts to form said seat component. - View Dependent Claims (2, 3, 4, 5, 6)
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7. The method of forming a component portion of a vehicle seat assembly utilizing a foam pad, a component support frame, a cover including at least two members having inner and outer sides, and a welt secured between at least two of said cover members, comprising the steps of:
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(a) positioning said cover members and said welt within a first mold member having a shape complementary to a predetermined shape such that said inner side of said cover members is exposed within said first mold member, the edges of said cover members extending beyond said lower mold member; (b) mounting said component support frame to a second mold member; (c) placing said second mold member over said first mold member thereby creating a foaming cavity between said cover members, said second mold member and said component support frame; (d) injecting an expandable liquid foaming material into said foaming cavity to mold said foam pad in such a manner that said foam pad is bonded to said inner side of said cover members and encapsulating a portion of said welts and said component support frame; (e) removing said foam pad with said cover members bonded thereto and said component support frame partially encapsulated therein from said mold members; and (f) attaching said edges of said cover members to said component support frame. - View Dependent Claims (8)
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Specification