Importance

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Abstract

A method of manufacturing a portion of a seat. A cover member is shaped to a predetermined shape and placed in a foam molding tool into which is injected an expandable liquid foaming material to mold a foam pad which is integrally bonded to the cover member. In the manufacturing of seat backs, the cover member includes a tubular envelope cover positioned on a cantilever forming tool. Once the foam pad is molded, the cover member is turned inside out to enclose the foam pad with the cover member. The cover is then telescoped over a seat frame. Alternatively, the foam pad can be molded to a shaped fabric sheet, the envelope cover formed by sewing a second cover member to the fabric sheet. A seat cushion is made by shaping a cover member, placing the cover member in a foam molding tool which also holds the seat frame and injecting an expandable liquid foaming material into the mold to mold the foam cushion, bond the cushion to the cover and embed the seat frame in the foam. The edges of the cover are then wrapped around the side of the foam pad and attached to the frame. Alternatively, a side panel can be sewn to the cover and attached to the frame.

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First Claim