Molded cushion element and method for production thereof

There is a described a cushion element a method for producing same. Specifically, the improved cushion element includes a fastener assembly for mechanical adhesion of a trim cover to the cushion element. The fastener assembly comprises laterally spaced marginal portions which extend longitudinally along the fastener assembly. These margins are embedded in or encompassed by the foam body thereby improving the mechanical “pull-out” strength of the fastener assembly in the foam body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference to FIGS. 1 - 2 , there is illustrated a portion of a mold comprising a surface 10 . In practice, surface 10 would be a portion of the mold cavity, preferably such a mold cavity being formed by combination of a bowl (not shown) and a lid (not shown). The provision of such molds is conventional in the art. Preferably, surface 10 is that of the bowl of the mold. In a preferred environment, this surface corresponds to the A-surface of the part to be produced. As illustrated, disposed on surface 10 is a ridge 20 . As will be appreciated by those of skill in the art, ridge 20 serves to mold into the finished part a correspondingly shaped trench which, as will be discussed later, is the relatively narrow, aesthetically appealing trench to be formed in the finished foam cushion foam element. As shown, ridge 20 comprises a trench 25 disposed in the upper surface thereof. With reference to FIG. 2 , ridge 20 further comprises a magnet 30 disposed in substantial alignment with trench 25 . An initial step in the present method involves placement of a fastener assembly 35 on ridge 20 . Thus, fastener assembly 35 comprises a backing layer 40 and fastening layer 45 . Fastening layer 45 comprises a touch fastening surface 50 which comprises a plurality of hook members 55 . Hook members 55 are spaced inwardly from the combined edges of backing layer 40 and 45 . Disposed in the margin defined by this spacing is a foam seal element 60 of a type similar to that described in U.S. Pat. No. 5,766,723 &lsqb;Oborny et al.&rsqb;. The preferred seal element comprises polyurethane foam. Further, the preferred such foam seal element comprises an Indentation Force Deflection, when measured pursuant to ASTM D3574-95 (50 in 2 deflector; 20″×20″×4″ sample size), in the range of from about 10 to about 1000 pounds·force, more preferably from about 10 to about 500 pounds·force, even more preferably from about 10 to about 250 pounds·force, most preferably from about 30 to about 100 pounds·force. Sandwiched between backing layer 40 and fastening layer 45 is a magnetically attractable strip 65 . Disposed on backing layer 40 of the fastener assembly 35 are a number of loop members 70 . With reference to FIGS. 1 and 2 , fastener assembly 35 is placed on ridge 20 such that hook members 55 of fastener assembly 35 are disposed in trench 25 . When fastener assembly 35 is disposed in the vicinity of trench 25 , magnet 30 serves to attract magnetically attractable strip 65 in fastener assembly 35 . This attraction causes compression of a portion of foam seat element 60 disposed in the margins of fastener assembly 35 . This compression serves to provide an advantageous seal against ingress of foam material into trench 25 thereby fouling hook members 55 . As particularly illustrated FIG. 2 , opposed portions of foam seal element 60 , together with adjacent portions of backing layer 40 overhang ridge 20 . Thereafter, a liquid foamable composition (not shown) is dispensed in the bowl (not shown) of the mold in a conventional manner. It is preferred, that during dispensing of the liquid foamable composition, the lid and bowl of the mold are disengaged. After dispensing the liquid foamable composition, it is preferred to engage the bowl and the lid thereby defining the mold cavity. As will be appreciated by those of skill in the art, as the liquid foamable composition expands, it will encompass the overhanging portions of backing layer 40 /foam seal element 60 . During expansion of the liquid foamable composition, it is preferred that the composition penetrate the cellular matrix of foam seal element 60 thereby densifying the latter. This serves to enhance the seal formed by foam seal element 60 . With reference to FIG. 3 , there is illustrated a portion of the foam cushion member product produced from step 2 (as will be apparent to those of skill in the art), the product in FIG. 3 has been demolded and turned over). As shown in FIG. 3 , fastener assembly 35 has been mechanically adhered to a foam body 100 . Foam body 100 comprises a trench of channel 105 , at the bottom of which is mechanically adhered fastener assembly 35 . It is the width of trench or channel 105 which can be significantly reduced using the present method without significantly compromising the pull-out strength of fastener assembly 35 . This achieved by embedding or encompassing lateral marginal portions of fastener assembly 35 in foam body 100 . The cushion element illustrated in FIG. 3 may then be covered in a conventional manner with a trim cover having appropriately positioned complimentary touch fastening surfaces which will mechanically adhere the trim cover to touch fastening surface 50 . In the illustrated example, the complimentary surface of the trim cover would comprise loops which would serve to mechanically adhered the trim cover to hook members 55 of fastener assembly 35 . A preferred application of this approach is illustrated in FIG. 4 , which shows a passenger seat covered with a trim cover having incorporated therein trenches or channels ways 105 . It is along these trenches or passageways 105 that mechanical adhesion is achieved of the trim cover to the product illustrated in FIG. 3 . With reference to FIG. 5 , the adhesion of the trim cover in FIG. 4 to the product of FIG. 3 is illustrated. The theme reference numerals correspond to like elements in the previous Figures. With reference to FIG. 6 and 7 , there is illustrated an alternate embodiment of the present method and cushion element. Specifically, in the embodiment illustrated in FIGS. 6 and 7 , this is made of a so-called “taped” fastener assembly wherein a removable, impermeable cover layer 62 is used in place of foam seal element 60 referred in FIGS. 1 - 5 . The approach is otherwise very similar to that described above with respect to FIGS. 1 - 5 . As shown in FIG. 7 , once the foam cushion element has been produced (note the embedded lateral march and of fastener assembly 35 which are embedded in foam body 100 ), covering layer 62 is simply removed by tearing it away from fastener assembly 35 thereby exposing hook members 55 which are now ready to be adhered to the trim cover (not shown). While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. For example, while the present method and cushion element have been exemplified with reference to a planar or flat fastener assembly, it is equally and, in some cases, more preferable, to utilize a non-planar fastener assembly such as the one taught in U.S. Pat. Nos. 5,688,576 and 5,972,465 &lsqb;both to Ohno et al. (Ohno)&rsqb;. The Ohno faster comprises a planar fastening surface bounded by a pair of longitudinally extending margins (or wings) which are bent with respect to the planar fastening surface. Those of skill in the art will recognize that Ohno fastener may be used in accordance with the present method such that at least a portion (preferably the distal portion) of the bent “wings” or “ridges” are disposed in the mold cavity such that they are encompassed by the liquid foamable composition. In a further modification of the present method, it is possible to orient the fastener assembly such that the end marginal portions thereof (e.g., those which connect the longitudinal extending margins) are encompassed by the liquid foamable composition. For example, this may be achieved by designing ridge 20 to have a top surface area less than the surface area of the fastener assembly so that a perimeter margin portion of the fastener overhangs the ridge thereby allowing the liquid foamable composition to encompass a perimeter portion of the fastener assembly. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments. All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.