Foam laminate for mold in place seating component
First Claim
1. In a method of making a cushioned component including the steps of(a) providing a cover having an exterior surface which is to present the major exterior appearance of the cushioned component;
- (b) placing the cover within a mold so that the exterior surface of the cover is facing a mold surface of the mold having a shape corresponding with the desired exterior surface shape of the cushioned component;
(c) introducing a foamable material into the mold while the cover is within the mold; and
(d) curing the foamable material as said cover is held within the mold, wherein the improvement comprises;
(e) laminating a high density foam sheet having a density of at least 4 lbs/ft3 to the interior surface of the material forming the cover prior to placing the cover into the vacuum mold, wherein the high density foam sheet has an air permeability of from 5 to 100 ft3/ft2 minute.
18 Assignments
0 Petitions
Accused Products
Abstract
A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.
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Citations
13 Claims
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1. In a method of making a cushioned component including the steps of(a) providing a cover having an exterior surface which is to present the major exterior appearance of the cushioned component;
- (b) placing the cover within a mold so that the exterior surface of the cover is facing a mold surface of the mold having a shape corresponding with the desired exterior surface shape of the cushioned component;
(c) introducing a foamable material into the mold while the cover is within the mold; and
(d) curing the foamable material as said cover is held within the mold, wherein the improvement comprises;
(e) laminating a high density foam sheet having a density of at least 4 lbs/ft3 to the interior surface of the material forming the cover prior to placing the cover into the vacuum mold, wherein the high density foam sheet has an air permeability of from 5 to 100 ft3/ft2 minute. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
- (b) placing the cover within a mold so that the exterior surface of the cover is facing a mold surface of the mold having a shape corresponding with the desired exterior surface shape of the cushioned component;
Specification