Method for vacuum forming composite vehicle seat

• US 5,000,805 A
• Filed: 04/28/1989
• Issued: 03/19/1991
• Est. Priority Date: 04/28/1989
• 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): Barry, Chester T.
• Application Number:
  US07/344,765
• Time in Patent Office: 690 Days
• Field of Search: 156/286, 156/155, 156/90, 156/214, 156/285, 428/308.4, 264/46.8
• US Class Current: 156/90
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 63/025 applied by a die matching with the profile of the surface of resilient articles, e.g. cushions, seat pads
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/301 Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/436 Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats joining through openings B29C66/304
• CPC Class Codes: B29C 66/5326 said single elements being substantially flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29K 2023/00 Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/771 Seats

Abstract

A method for making a portion of a vehicle seat or back having a surface contour of predetermined shape by placing a sheet of an impermeable film against one side of a portion of a sheet of a permeable cloth fabric to make an impermeable composite portion of a fabric trim material. The composite portion is then positioned on a forming tool having a shaped upper surface complementary to the predetermined shape desired for the final product. A vacuum is then drawn between the forming tool and the impermeable composite portion so as to draw the portion into conformity with the shaped upper surface of the forming tool. A foam bun having an adhesive coated surface is then positioned against the portion on the forming tool. Heat is then applied to deteriorate the impermeable film thus enabling the adhesive to bond the cloth fabric material to the foam bun and maintain the desired shape.

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 deteriorate when heated;

b. positioning said impermeable material on one side of a sheet of permeable cloth to form an air impermeable cloth fabric trim material;

c. placing said trim material on a forming fixture having an upper surface complementary to said predetermined shape with the other side of said sheet of permeable cloth against said fixture;

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

e. providing a preshaped foam bun having a face of said predetermined shape;

f. applying adhesive to said bun face;

g. pressing said bun face against said shaped trim material on said fixture; and

h. heating said trim material to deteriorate said air impermeable material to enable contact of said cloth with said adhesive such that said cloth is bonded to said bun face by said adhesive without said adhesive excessively permeating said cloth so as to impair the permeability and flexibility of the cloth.

2. The method according to claim 1 wherein said vacuum between said trim material and said fixture is established by providing vacuum passages in said fixture.

3. The method according to claim 2 wherein said trim material is heated by directing hot material through said vacuum passages into contact with said trim material after said vacuum has been released.