Patent ID: 7560060
Filing Date: 2009-07-14
Classification: B60N,Y10T

Abstract:
1. A method of making a safety seat shell unitarily molded in a configuration for seating of only a single occupant to be adapted for use as a driver's seat in a racing automobile, and wherein the safety seat shell comprises a laminate having an inner layer, an outer layer and a core positioned therebetween, the method comprising the steps of: providing a mold of the shell, including configuring the mold to define the shell to have a seat back and a seat bottom defining a seating surface for a single occupant, wings projecting forwardly from opposite lateral sides of the seat back for constraining lateral movement of an occupant's shoulders, and sides projecting upwardly from opposite lateral sides of the seat bottom for constraining lateral movement of an occupant's legs; forming the outer layer by adhering a plurality of attachment plates to the inner surface of the outer layer at predetermined locations thereon; placing the core on the inner surface of the formed outer layer; forming the inner layer on the core material by layering a plurality of sheets of woven carbon fibers and at least one sheet of the resilient fiber material upon a side of the core material opposite the outer layer; closing the mold such that the outer layer, attachment plates, core material and inner layer are enclosed within the mold; enclosing the mold in a bag; establishing a vacuum within the bag; inserting the bag into the autoclave; maintaining the autoclave at a predetermined pressure and a defined temperature profile; removing the bag from the autoclave; removing the mold from bag; and releasing the shell from the mold.