Process for manufacturing a trim cover assembly of a seat

Claim 1

A process for manufacturing a trim cover assembly for a seat including a cover material, a foam wadding and a wadding cover, comprising the steps of: forming a large number of suitably spaced-apart recessed grooves on the surface of said foam wadding; placing said cover material on a lower mold having a plurality of projections corresponding to said suitably spaced-apart recessed grooves of said foam wadding; lowering and pressing an upper mold against said cover material and said lower mold, said upper mold including a plurality of recessed cavities corresponding to respective projections of said lower mold and further having a predetermined shaped surface including curved portions between said recessed cavities so as to form said cover material into a predetermined uneven configuration including an outwardly curved configuration between spaced-apart recessed grooves whereby the thus formed cover material has arc-shaped projecting portions in cross-section; applying an adhesive to said cover material; placing said foam wadding on the formed cover material on said lower mold with the recessed surface of said foam wadding facing said formed cover material; applying an adhesive to at least one of said wadding cover and said foam wadding and placing said wadding cover on said foam wadding; and pressing said upper mold against said wadding cover, said foam wadding, and said cover material so that same are bonded into a unitary structure, whereby, a trim cover assembly is formed having a desired uneven configuration and wherein said foam wadding is distorted in shape so as to conform to said uneven configuration of said cover material.