Foam pad and process for production thereof

• US 6,838,155 B2
• Filed: 02/28/2002
• Issued: 01/04/2005
• Est. Priority Date: 02/28/2002
• Status: Expired due to Term

• Current Assignee: Proprietect LP
• Original Assignee: Woodbridge Foam Corporation
• Inventors: Lansue, Randall Joseph, Cappucci, Debra Marie
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): Vo, Hai
• Application Number:
  US10/084,359
• Publication Number:
  US 20030162008A1
• Time in Patent Office: 1,041 Days
• Field of Search: 428/304.4, 428/99, 428/100, 428/76, 428/68, 428/71, 428/74, 428/158, 428/159, 428/122, 428/160, 565/59, 574/0, 595/3, 573/7, 540/2, 565/3, 297/219.1, 297/226
• US Class Current: 428/158
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B60N 2/5825 by hooks, staples, clips, snap fasteners or the like
• CPC Class Codes: Y10S 5/953 Comprising structurally defined foam material or configuration
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24017 Hook or barb
• CPC Class Codes: Y10T 428/24198 Channel-shaped edge component [e.g., binding, etc.]
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/24512 Polyurethane
• CPC Class Codes: Y10T 428/24711 Plural corrugated components
• CPC Class Codes: Y10T 428/249923 Including interlaminar mechanical fastener
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A foam pad comprising a surface to which a trim cover can be secured, the surface comprising a channel having a width of up to about 15 mm. Disposed in the channel is one of a male portion or a female portion of a releasably engageable male-female trim cover attachment system. A trim cover having the other of the male or female portion attached thereto may be readily attached to the foam pad. A process and a mold for producing the foam pad are also described. The foam pad is particularly useful as a component of a vehicular seat system (e.g., seat bottom, seat back and the like).

Claims

1. A foam pad comprising:

a surface to which a trim cover can be secured, the surface comprising an open channel having a longitudinal axis and a maximum width of up to about 15 mm,

the open channel having a first section, a second section, and a third section disposed serially along the longitudinal axis, the second section;

(i) having a narrower width than the first and third sections when measured in a direction perpendicular to said longitudinal axis and (ii) having disposed therein one of a male portion or a female portion of a releasably engageable male-female trim cover attachment system.

2. The foam pad defined in claim 1, wherein the channel has a maximum width of up to about 12 mm.

3. The foam pad defined in claim 1, wherein the channel has a maximum width in the range of from about 4 to about 10 mm.

4. The foam pad defined in claim 1, wherein the channel has a maximum width in the range of from about 4 to about 8 mm.

5. The foam pad defined in claim 1, the channel having disposed therein the female portion of the releasably engageable male-female trim cover attachment system.

6. The foam pad defined in claim 5, wherein the foam pad comprises a plurality of female portions disposed in the channel.

7. The foam pad defined in claim 6, wherein the plurality of female portions are independent of one another.

8. The foam pad defined in claim 6, wherein the plurality of female portions are interconnected to one another with at least one connecting portion.

9. The foam pad defined in claim 5, wherein the female portion is constructed from a polymer.

10. The foam pad defined in claim 9, wherein the polymer is selected from the group comprising thermoset polymer and thermoplastic polymers.

11. The foam defined in claim 10, wherein the thermoplastic polymer is selected from the group consisting of polyethylene, polypropylene and mixtures thereof.

12. The foam pad defined in claim 10, wherein the thermoset polymer comprises polyurethane.

13. The foam pad defined in claim 5, wherein the female portion comprises a female attachment portion and base portion.

14. The foam pad defined in claim 13, wherein the base portion has a larger surface area than a surface area of the female attachment portion attached thereto.

15. The foam pad defined in claim 14, wherein at least a portion of the base portion is encompassed by the foam pad.

16. The foam pad defined in claim 13, wherein the female attachment portion spans the width of the channel second section.

17. The foam pad defined in claim 13, wherein the female attachment portion comprises a clip portion.

18. The foam pad defined in claim 17, wherein the clip portion comprises a substantially U-shaped cross-section.

19. The foam pad defined in claim 17, wherein U-shaped cross-section comprises a pair of generally upstanding walls defining a locking region therebetween for receiving a male portion of the male-female trim cover attachment system.

20. The foam pad defined in claim 19, wherein a distal portion of each of the upstanding walls comprises a locking portion for engaging the attachment portion of the element to be attached.

21. The foam pad defined in claim 20, wherein the locking portion comprises a first lateral portion projecting substantially toward the locking region.

22. The foam pad defined in claim 21, wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

23. The foam pad defined in claim 20, wherein the locking portion comprising a hook-shaped portion.

24. The foam pad defined in claim 1, further comprising a trim cover attached thereto, the trim cover comprising the other of the male portion or the female portion of the releasably engageable male-female trim cover attachment system.

25. A vehicular seat comprising the foam pad defined in claim 24.

26. A foam pad comprising:

a surface to which a trim cover can be secured, the surface having molded therein an open channel having a longitudinal axis and a maximum width of up to about 5 mm,

the open channel having a first section, a second section, and a section disposed serially along the longitudinal axis, the second section;

(i) having a narrower width than the first and third sections when measured in a direction perpendicular to said longitudinal axis; and

(ii) disposed in a portion thereof at least one female portion of a releasably engageable male-female trim cover attachment system, the female portion comprising a female attachment portion and a base portion.

27. The foam pad defined in claim 26, wherein the channel has a maximum width of up to about 12 mm.

28. The foam pad defined in claim 26, wherein the channel has a maximum width in the range of from about 4 to about 10 mm.

29. The foam pad defined in claim 26, wherein the channel has a maximum width in the range of from about 4 to about 8 mm.

30. The foam pad defined in claim 26, wherein the base portion has a larger surface area than a surface area of the female attachment portion attached thereto.

31. The foam pad defined in claim 30, wherein at least a portion of the base portion is encompassed by the foam pad.

32. The foam pad defined in claim 26, wherein the female attachment portion spans the width of the channel second section.

33. The foam pad defined in claim 26, wherein the female attachment portion comprises a clip portion.

34. The foam pad defined in claim 33, wherein the clip portion comprises a substantially U-shaped cross-section.

35. The foam pad defined in claim 34, wherein U-shaped cross-section comprises a pair of generally upstanding walls defining a locking region therebetween for receiving a male portion of the male-female trim cover attachment system.

36. The foam pad defined in claim 35, wherein a distal portion of each of the upstanding walls comprises a locking portion for engaging the attachment portion of the element to be attached.

37. The foam pad defined in claim 36, wherein the locking portion comprises a first lateral portion projecting substantially toward the locking region.

38. The foam pad defined in claim 37, wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

39. The foam pad defined in claim 36, wherein the locking portion comprising a hook-shaped portion.

40. The foam pad defined in claim 26, wherein the foam pad comprises a plurality of female portions disposed in the channel.

41. The foam pad defined in claim 40, wherein the plurality of female portions are independent of one another.

42. The foam pad defined in claim 40, wherein the plurality of female portions are interconnected to one another at least one connecting portion.

43. The foam pad defined in claim 26, wherein the female portion is constructed from a polymer.

44. The foam pad defined in claim 26, further comprising a trim cover attached thereto, the trim cover comprising a male portion of the releasably engageable male-female trim cover attachment system.

45. A vehicular seat comprising the foam pad defined in claim 44.

46. A foam pad comprising:

a surface to which a trim cover can be secured, the surface having molded therein an open channel having a longitudinal axis and a maximum width of up to about 15 mm,

the open channel having a first section, a second section, and a third section disposed serially along the longitudinal axis, the second section;

(i) having a narrower width than the first and second sections when measured in a direction orthogonal to said longitudinal axis; and

(ii) having disposed in a portion thereof plurality of female portions of a releasably engageable male-female trim cover attachment system, the female portion comprising a clip portion and a base portion molded into the foam pad.

47. The foam pad defined in claim 46, further comprising a trim cover attached thereto, the trim cover comprising a male portion of the releasably engageable male-female trim cover attachment system.

48. A vehicular seat comprising the foam pad defined in claim 47.