Method of manufacturing a seat using adhesive

• US 5,372,667 A
• Filed: 08/04/1992
• Issued: 12/13/1994
• Est. Priority Date: 08/09/1991
• Status: Expired due to Term

• Current Assignee: TOYO Seat Company Limited
• Original Assignee: TOYO Seat Company Limited
• Inventors: Hashiguchi, Shuichi, Miyota, Akihiro
• Primary Examiner(s): Ball, Michael
• Assistant Examiner(s): YODER, MICHELE
• Application Number:
  US07/924,517
• Time in Patent Office: 861 Days
• Field of Search: 156/212, 156/213, 156/390, 156/285, 156/290, 156/245, 156/311, 156/220, 156/221, 156/214, 156/285, 264/321, 297/DIG. 1, 297/DIG. 2
• US Class Current: 156/213
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: B29C 63/0065 Heat treatment
• 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 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/484 Moisture curing adhesives
• CPC Class Codes: B29C 65/4845 Radiation curing adhesives, e.g. UV light curing adhesives
• CPC Class Codes: B29C 66/5326 said single elements being substantially flat
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: Y10S 297/01 Foam
• CPC Class Codes: Y10S 297/02 Molded
• CPC Class Codes: Y10T 156/103 Encasing or enveloping the configured lamina
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly

Abstract

In a method of manufacturing a seat by using adhesives in which an air permeable skin material and a cushioning pad are bonded to each other by means of reactive hot-melt adhesives, the method comprises a step of coating adhesives to the cushioning pad, a step of provisionally assembling the skin material to the cushioning pad from the side of the adhesive coating surface, a step of setting the provisionally assembled cushioning pad and skin material to an attaching die, a step of applying heating by a heating die to the skin material and the cushioning pad attached in the attaching die assembling step from the side of the skin material and a step of applying cooling under pressure by a cooling die from the surface of the skin material subsequent to the heating step. A seat comprising a skin material and a cushioning pad can be molded with a seat frame by this method. It enables easy positioning, bonding of the skin material even to a deep recess of the cushioning pad, shortening the molding cycle, and keeping the raised skin material intact.

Claims

1. A method of manufacturing a seat comprising an air permeable skin material, a cushioning pad and a frame by using adhesives in which said skin material and said cushioning pad are bonded to each other by means of reactive hot-melt adhesives, wherein the method comprises the following steps:

coating adhesives to one side of said cushioning pad,

assembling said frame to an attaching die,

attaching said cushioning pad to said frame which has been assembled to said attaching die, and attaching said one side of said skin material to the cushioning pad,

heating with a heating die said frame, said cushioning pad and said skin material from a second side of said skin material, and

applying cooling under pressure with a cooling die from said second side of said skin material subsequent to said heating step, and wherein the attaching die comprises a frame receiving jig mounted on a support substrate and a rotational shaft mounted to one end of said support substrate said shaft including bracket set pins attached to opposite ends of said shaft, said frame formed with two lower sides in which holes are formed, said bracket set pins receivable in said holes so that said frame, said cushioning pad and said skin can be rotated down toward the side of said frame receiving jig so that said heating and cooling steps can be done.

2. A seat manufacturing method as defined in claim 1, wherein the cushioning pad is covered with said skin material and said skin is formed into a bag-shaped member and said skin material in the form of the bag is assembled to the frame which has been previously attached to the attaching die.