Importance

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Abstract

There is described a foam seat element comprising an isocyanate-based foam matrix having an A-surface for contact with an occupant and a B-surface for contact with a support element. An elastomeric layer is disposed on at least a portion of the B-surface for contact with the support element. This approach results in reduction in labour to produce the elastomeric layer compared with correct positioning of cloth inserts on a foam production manufacturing line. Further, since, in the preferred embodiment of the invention, the elastomeric layer is achieved by spraying a liquid elastomer-forming composition on a portion of the mold surface, the costs of achieving the elastomeric layer are significantly less than those associated with using prefabricated, pre-cut cloth inserts. Still further, the use of an elastomeric layer allows for tuning of the thickness of that layer which facilitates 'tuning' the durability of the B-surface of the foam seat element based on the specific suspension system with which it will be combined. By the use of currently available robotic spraying systems, the degree of thickness of the elastomeric layer can be controlled in an automated fashion--this further reduces the costs associated with adjusting the durability of the B-surface of the foam seat element (for example compared to producing and stocking cloth inserts of different composition and/or thickness to achieve confer different durability properties).

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First Claim