Process for molding a frame onto a seat outfit for the purpose of producing a seal element

Claim 1

A process for producing a seat element from an outfit of desired shape, said outfit having at least a relatively compact plastic covering layer, a network of continuous spiral metal springs having axes parallel with the covering layer, said network of springs having intermingled turns which are substantially flush against a lower face of the covering and cover essentially the entire surface thereof, an intermediate plastic foam connecting layer between the covering layer and the network of springs adhering to the lower face of the covering layer and partially incasing the turns of the network of springs adjacent said covering layer; said process comprising the steps of: gripping a peripheral edge portion of said outfit in a cavity of an injection mold, said mold having meting jaw portions of which one said jaw portion contacts an upper face of said covering and the other jaw portion contacts the network of springs and the plastic foam connecting layer in clamping engagement, thereby sealing said cavity without interposing a sealing bead between said jaw portions; simultaneously applying a stress force to the surface of said outfit and imparting a predetermined curvature to the surface of said outfit in the region of said surface intermediate the peripheral confines of said edge portion concurrently with the gripping application of said mold to said peripheral edge portion; injecting an expandable thermoplastic material to which an expanding agent has been added into said mold cavity; allowing said expandable thermoplastic to expand and harden about said peripheral edge of said outfit and to bond therewith in said cavity of said mold while maintaining said portion of the outfit between said edge portion in contact with said curvature-imparting mold portion; and removing said seat element formed from said outfit from said mold whereby the expanded and hardened thermoplastic material engaging the peripheral edge portion of the seat element maintains the shaped curvature thereof.