Skin covered foamed plastic seat with identations

• US 5,013,090 A
• Filed: 09/20/1989
• Issued: 05/07/1991
• Est. Priority Date: 10/25/1988
• Status: Expired due to Fees

• Current Assignee: Ikeda Bussan Company Limited 771 Kozono Ayase-Shi Kanagawa-Ken Japan
• Original Assignee: Ikeda Bussan Co., Ltd. (Johnson Controls International plc)
• Inventors: Matsuura, Ichiro
• Primary Examiner(s): Brown, Peter R.
• Application Number:
  US07/410,079
• Time in Patent Office: 594 Days
• Field of Search: 297/452, 297/DIG. 1, 297/DIG. 2, 264/46.4, 264/46.6, 264/46.7, 264/46.8, 264/275, 5/404, 5/471, 5/481
• US Class Current: 297/452.61
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: B29C 33/14 against the mould wall
• CPC Class Codes: B29C 44/143 Means for positioning the lining in the mould in general B29C33/12
• CPC Class Codes: B29C 44/146 Shaping the lining before foaming
• CPC Class Codes: Y10S 297/01 Foam

Abstract

A skin covered foamed plastic seat with indentations in which it is possible to obtain indentations of the desired shape at the desired location. The skin covered foamed plastic seat includes a clip for securing engagement between the sewed up portions of the skin cover and the protrusions provided on the molding surface, having a shape enabling a tight gripping of the clip on the protrusions, and having holes connecting an inner side of the clip with an outer side of the clip for allowing penetration of liquid foam resin into the inner side of the clip.

Claims

1. A skin covered foamed plastic seat, comprising:

a pad member made from liquid foam resin having at least one indentation;

a skin cover covering a surface of the skin covered foamed plastic seat and having sewed up portions located at the indentation of the pad member; and

a clip attached to the sewed up portions of the skin cover, the clip having a plurality of holes connecting an inner side of the clip with an outer side of the clip for allowing penetration of the liquid foam resin and extension of the pad member into the inner side of the clip, the clip having an approximate horseshoe shaped cross section, where in the sewed up portions are tightly gripped by, and are inserted into the inner side of the clip, said sewed up portions being pinched between opening ends of the horseshoe shaped cross section.

2. The skin covered foamed plastic seat of claim 1, wherein the horseshoe shaped cross section of the clip has an axis of symmetry and each one of the holes of the clip is located on the axis of symmetry of the clip.

3. The skin covered foamed plastic seat of claim 1, wherein the inner side of the clip and the sewed up portions have a space filled with the liquid foam resin therebetween.

4. The skin covered foamed plastic seat of claim 1, wherein the openings ends of the horseshoe shaped cross section of the clip are curled outward.

5. A method of manufacturing a skin covered foamed plastic seat with a molding surface having protrusions and with a clip having an approximate horseshoe shaped cross section and holes connecting an inner side of the clip with an outer side of the clip, comprising the steps of:

placing a skin cover having sewed up portions on the molding surface having protrusions, wherein the sewed up portions are engaged with the protrusions;

attaching the clip for securing engagement between the sewed up portions of the skin cover and the protrusions of the molding surface to the sewed up portions of the skin cover, wherein the sewed up portions are tightly gripped by the clip by being inserted into the inner side of the clip and pinched between opening ends of the horseshoe shaped cross section;

pouring liquid foam resin over the skin cover on the molding surface, to form a pad member having indentations at positions of the sewed up portions of the skin cover while the clip remains attached to the sewed up portions, the liquid foam resin being directed through said holes of said clip to allow penetration of liquid foam resin to make the pad member into the inner side of the clip; and

removing from the molding surface the skin covered foamed plastic seat made of the skin cover combined with the pad member, wherein the clip remains attached to the sewed up portions of the skin cover.

6. The method of claim 5, where in the step of pouring liquid foam resin is performed to direct the resin through each one of the holes of the clip at an axis of symmetry of the horseshoe shaped cross section.

7. The method of claim 5, wherein the step of pouring liquid foam resin is performed to direct the resin to fill a space between the inner side of the clip and the sewed up portions.

8. The method of claim 5, wherein the opening ends of the horseshoe shaped cross section of the clip are curled outward and the step of attaching the clip is performed by sliding the sewed up portions in the curled ends of the clip.