Method for manufacturing a separable fastener for incorporation into a seat bun

• US 5,259,905 A
• Filed: 09/03/1992
• Issued: 11/09/1993
• Est. Priority Date: 08/09/1990
• Status: Expired due to Term

• Current Assignee: Velcro Industries BV (Chartwell Industries Ltd)
• Original Assignee: Velcro Industries BV (Chartwell Industries Ltd)
• Inventors: Gilcreast, David
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): ROBEY, ROBERT
• Application Number:
  US07/939,995
• Time in Patent Office: 432 Days
• Field of Search: 156/250, 156/256, 156/297, 156/66, 156/72, 156/245, 156/298, 156/77-79, 24/444-452, 428/99, 428/100, 428/120, 428/192, 264/46.4, 264/46.5, 297/DIG. 6, 52/DIG. 13
• US Class Current: 156/250
• CPC Class Codes: B29C 33/0044 for sealing off parts of inserts projecting into the mould cavity
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29C 44/143 Means for positioning the lining in the mould in general B29C33/12
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/729 Hook and loop-type fasteners
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 24/2725 with feature facilitating, enhancing, or causing attachment of filament mounting surface to support therefor
• CPC Class Codes: Y10T 428/24017 Hook or barb

Abstract

In a device for incorporating a separable fastener in a foamed seat cushion during formation of the cushion in a mold, includes a sheet having fastener elements constituting one half of a touch fastener. A foam wall surrounds the fastening surface, the wall having a height considerably greater than the height of the fastening elements. The fastener is held on a pedestal having a predetermined height extending into the mold volume and having a predetermined cross sectional dimension generally parallel to the interior mold surface as measured at a predetermined distance from said mold surface. The foam wall defines an opening which engages the sides of said pedestal with a force sufficiently strong to resist any removal force caused by tendency of the foaming action to lift the foam wall during creation of the cushion and bonding of the forming cushion to the foam wall.

Claims

1. A method for manufacturing a device for incorporating a separable fastener in a foamed seat cushion during formation of the cushion in a mold, the fastener comprising a sheet having fastener elements constituting one half of a touch fastener, said elements being on one surface thereof, and a foam wall surrounding said fastener surface, said wall having a height considerably greater than the height of said fastener elements, comprising the steps of:

(a) cutting a slab of foam to provide an opening of predetermined size and predetermined wall height defining said opening, and (b) bonding a sheet of fastening elements to said foam slab, said fastening elements extending into said opening to form a bonded product for mounting in a mold by passing said opening over a pedestal for frictional attachment therewith.

2. The method of claim 1, wherein the fastener is attached to the foam slab by adhesive means.

3. The method of claim 1, wherein the foam slab is of a thickness at least 3 times the height of the fastener elements on the fastener.

4. A method for manufacturing a device for incorporating a separable fastener in a foamed seat cushion during formation of the cushion in a mold, the fastener comprising a sheet having fastener elements constituting one half of a touch fastener, said elements being on one surface thereof, and a foam wall surrounding said fastener surface, said wall having a height considerably greater than the height of said fastener elements, comprising the steps of:

(a) cutting a slab of foam to provide an opening of predetermined size and predetermined wall height defining said opening, and (b) bonding a sheet of fastening elements to said foam slab, said fastening elements extending into said opening to form a bonded product for mounting in a mold by passing said opening over a pedestal for frictional attachment therewith wherein the fastening elements comprise hooks, and the foam wall carries on and has bonded to its bottom surface a layer of loops which engage the hooks to attach the foam wall to the fastening sheet.

5. A method for manufacturing a device for incorporating a separable fastener into a seat bun, during the formation thereof, in a mold, the fastener comprising a base, having a face side, a back side, and fastener elements attached to the base on its face side projecting upwards from the base, the method comprising the steps of:

(a) attaching a slab of foam material to a back side of a first strip of a hook and loop fastener system to form a first laminate;

(b) cutting completely through selected areas of the first laminate to form openings of a predetermined shape;

(c) attaching a second strip of the hook and loop fastener system to a face side of the first strip to cover substantially the entire plan area of the first laminate by engaging elements of the first and second fastener strips to each other to form a second laminate;

whereby the fastener elements of the second strip are exposed through the openings in the first laminate to be in position to engage companion elements of a seat trim cover when the cover is applied to the seat bun.

6. The method of claim 5, wherein the first fastener strip comprises loops and the second fastener strip comprises hooks.

7. The method of claim 5, wherein the first fastener strip is attached to the foam slab by adhesive means.

8. The method of claim 5, wherein the foam slab is of a thickness at least 3 times the height of the fastener elements on the first fastener strip.