Patent ID: 6505570
Filing Date: 2003-01-14
Classification: B29C,B60N

Abstract:
Method for forming a foamed product integral with trim cover assembly, comprising the steps of:forming a plurality of surface cover pieces in a predetermined shape, each having ends; forming a plurality of foam padding pieces, each being small in size relative to each of said plurality of surface cover pieces and having ends; juxtaposing each of said plurality of foam padding pieces on each of said plurality of surface cover pieces; bringing said ends of said each of said plurality of foam padding pieces in alignment with said ends of said each of said plurality of surface cover pieces; then, sewing said ends of said each of said plurality of foam padding pieces with said ends of said each of said plurality of surface cover pieces, thereby forming a plurality of sewn cover sections required to form said trim cover assembly in a predetermined three-dimensional shape; thereafter, bending and sewing together end portions of said plurality of sewn cover sections, such that the thus-sewn bent end portions of said plurality of sewn cover sections face to a side where said plurality of foam padding pieces lie, thereby forming the trim cover assembly in said predetermined three-dimensional shape; injecting a liquid foaming material into inside of the thus-formed trim cover assembly where said plurality of foam padding pieces face inwardly thereof; and curing and expanding said liquid foaming material so as to create a foam cushion member filled in the trim cover assembly, whereby the foamed product integral with the trim cover assembly is formed, with said plurality of surface cover pieces stretched uniformly on and over the respective said plurality of foam padding pieces.