Process for manufacturing a padded element using a cover preforming mandrel
First Claim
1. A process for manufacturing a padded element comprising the steps of:
- (i) placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer;
(ii) heating the trim cover, while the trim cover is on the mandrel, to a temperature sufficient to shape the thermoformable foam layer;
(iii) shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover;
(iv) transferring the shaped trim cover from the mandrel to a lower mold having a shape substantially complementary to the shaped trim cover;
(v) placing an upper mold over the lower mold to define a mold cavity;
(vi) dispensing a liquid foamable polymeric composition in the mold cavity; and
(vii) expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element.
1 Assignment
0 Petitions
Accused Products
Abstract
There is disclosed a process for manufacturing a padded element. The process comprises the steps of placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer; heating the trim cover to a temperature sufficient to shape the thermoformable foam layer; shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; transferring the shaped trim cover from the mandrel to a lower mold having shape substantially complimentary to the shaped trim cover; placing an upper mold over the lower mold to define a mold cavity; dispensing a liquid foamable polymeric composition in the mold cavity; and expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element.
49 Citations
20 Claims
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1. A process for manufacturing a padded element comprising the steps of:
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(i) placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer; (ii) heating the trim cover, while the trim cover is on the mandrel, to a temperature sufficient to shape the thermoformable foam layer; (iii) shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; (iv) transferring the shaped trim cover from the mandrel to a lower mold having a shape substantially complementary to the shaped trim cover; (v) placing an upper mold over the lower mold to define a mold cavity; (vi) dispensing a liquid foamable polymeric composition in the mold cavity; and (vii) expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A process for manufacturing a padded element comprising the steps of:
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(i) affixing a trim cover to a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable polyurethane foam layer; (ii) heating the mandrel and the trim cover, while the trim cover is on the mandrel, to a temperature sufficient to initiate shaping of the thermoformable foam layer; (iii) shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; (iv) cooling the shaped trim cover; (v) transferring the shaped trim cover from the mandrel to a lower mold having a shape substantially complementary to the shaped trim cover; (vi) placing an upper mold over the lower mold to define a mold cavity; (vii) dispensing a liquid foamable polyurethane composition in the mold cavity; and (viii) expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element.
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20. A process for manufacturing a padded element comprising the steps of:
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(i) placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprising a thermoformable foam layer; (ii) heating the trim cover to a temperature sufficient to shape the thermoformable foam layer; (iii) shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; (iv) cooling the shaped trim cover to produce a cooled trim cover which retains its shape independent of the mandrel; (v) transferring the shaped trim cover from the mandrel to a lower mold having a shape substantially complementary to the shaped trim cover; (vi) placing an upper mold over the lower mold to define a mold cavity; (vii) dispensing a liquid foamable polymeric composition in the mold cavity; and (viii) expanding the liquid foamable polymeric composition to fill substantially the mold cavity, thereby forming the padded element.
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Specification