Patent ID: 6120630
Filing Date: 2000-09-19
Classification: B29C,B29K,Y10T

Abstract:
A method of making a seat cushion comprising:(a) providing a film constructed of a stretchable material, a frame in which the film is secured, a seat cover fabric, an adhesive, a mold having a cavity with a contoured seat cushion-forming surface, and a foamable material for making a support core for supporting the shape of the seat cover fabric after its shape has been fixed,(b) securing the film to the frame,(c) placing the seat cover fabric on the film with the adhesive between the seat cover fabric and film and without securing the seat cover fabric to the frame,(d) orienting the seat cover fabric, adhesive, and film on a surface such that the fabric is disposed closest to the surface and the film is disposed over the fabric,(e) tacking the seat cover fabric to the film using a vacuum that urges the film toward the surface and against the fabric,(f) forming the seat cover fabric and film by drawing the seat cover fabric and film into the cavity of the mold such that the seat cover fabric is three-dimensionally contoured,(g) fixing the shape of the seat cover fabric so that it substantially conforms to the seat cushion-forming contoured surface of the mold cavity, and(h) supporting the shape of the seat cover fabric by disposing the support core, that comprises the foamable material formed in situ, in the recess in the seat cover fabric to form a seat cushion.