US5238513A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of forming a vehicle seat with a removable vacuum seal
Assignee: Hoover Universal Inc
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Filing: 1990-02-16
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Granted: 1993-08-24
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Expires: 2010-02-16
Abstract
Abstract A method of manufacturing a portion of a vehicle seat assembly utilizing a stylized forming tool and bonding a seat cover to a foam seat bun having a predetermined surface contour. The seat cover is positioned exterior side down on the stylized forming tool. A film of air impermeable material is then placed over the seat cover and a vacuum is applied between the impermeable material and the forming tool so as to draw the seat cover down into substantial conformity with style lines on the upper surface of the forming tool. The impermeable material is then removed and an adhesive coated foam seat bun is positioned and compressed against the seat cover on the forming tool. Once the seat cover and the seat bun are bonded together by the adhesive, the seat assembly is removed from the forming tool. The outer edges of the seat covers are then fastened together or to the underside of the seat bun so as to complete the assembly of the seat portion.
Inventors
- 👤 Jon R. Gill
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 20:13
CPC Classifications
B; B29; B29C; B29C63/00; B29C63/02; B29C63/025; A; A47; A47C; A47C7/00; A47C7/02; A47C7/18; B68; B68G; B68G7/00; B68G7/05; Y; Y10; Y10S; Y10S297/00; Y10S297/01; Y10S297/02; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1028; Y10T156/103; Y10T156/1039; Y10T156/1041; Y10T156/1043
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
202 words
A method of forming a vehicle seat with a surface of predetermined shape, said method comprising the steps of; a. placing a porous cover material over a surface of a forming tool being of complementary shape to said surface of predetermined shape; b. positioning an air impermeable barrier material over said cover material on said forming tool; c. applying a vacuum between said forming tool and said barrier material; d. drawing said barrier material and said cover material substantially against and into surface to surface conformity with said surface of said forming tool; e. applying adhesive to said surface of predetermined shape of a thermoplastic foam seat bun; f. removing said barrier material from substantially surface to surface conformity with said cover material and said surface of said forming tool; g. inspecting said cover material visually for discontinuities in said substantially surface to surface conformity with said surface of said forming tool; h. pressing said adhesively coated surface of said seat bun against said cover material on said forming tool after said inspecting step and allowing said surface of said seat bun to bond with said cover material; and i. removing said seat bun and bonded cover material from said forming tool.
Claim 2
Independent Claim
202 words
A method of forming a vehicle seat with a surface of predetermined shape, said method comprising the steps of; a. placing a porous cover material over a surface of a forming tool being of complementary shape to said surface of predetermined shape; b. positioning an air impermeable barrier material over said cover material on said forming tool; c. applying a vacuum between said forming tool and said barrier material; d. drawing said barrier material and said cover material substantially against and into surface to surface conformity with said surface of said forming tool; e. applying adhesive to said surface of predetermined shape of a thermoplastic foam seat bun; f. removing said barrier material from substantially surface to surface conformity with said cover material and said surface of said forming tool; g. inspecting said cover material visually for discontinuities in said substantially surface to surface conformity with said surface of said forming tool; h. pressing said adhesively coated surface of said seat bun against said cover material on said forming tool after said inspecting step and allowing said surface of said seat bun to bond with said cover material; and i. removing said seat bun and bonded cover material from said forming tool.
Claim 3
Dependent Claim
61 words
The method according to claim 1 further comprising the steps of providing a sheet of impermeable barrier material over said seat bun when said set bun is pressed against said cover material and applying a vacuum between said forming tool and said sheet of impermeable barrier material while allowing said surface of said seat bun to bond with said cover material.
Claim 4
Dependent Claim
330 words
In a method of forming a vehicle seat with predetermined contours, the steps of: a. providing a means for forming a vehicle seat including a base, a forming tool disposed centrally on said base, said forming tool having an upper surface of complementary shape to said predetermined contours, said upper surface also having vacuum ports, said vacuum ports being connected to a vacuum pump, said base also having opposingly hinged arms positioned on opposite ends thereof, a means for alternatingly lowering and raising each of said arms from a substantially vertical position to a substantially horizontal position, one of said arms providing a sheet of air impermeable latex, said other arm providing a thermoplastic foam seat bun having a surface with predetermined contours; b. positioning a seat cover member inside out on, said forming tool; c. placing said latex over said seat cover member on said forming tool; d. creating a vacuum between said upper surface of said forming tool and said latex; e. drawing said seat cover member and said latex down into substantially surface to surface contact with said upper surface of said forming tool; f. applying adhesive to said surface with predetermined contours of said thermoplastic foam seat bun; g. releasing said vacuum between said latex and said upper surface of said forming tool; h. removing said latex while retaining said seat cover member in substantially surface to surface contact with said upper surface of said forming tool; i. inspecting said seat cover member for discontinuities in said substantially surface to surface contact with said upper surface of said forming tool; j. compressing said adhesive coated surface with predetermined contours of said thermoplastic foam seat bun against said seat cover member in substantially surface to surface contact with said upper surface of said forming tool; k. allowing said thermoplastic foam seat bun and said seat cover member to bond together; and l. removing said thermoplastic foam seat bun and bonded seat cover member from said forming tool.
Claim 5
Dependent Claim
330 words
In a method of forming a vehicle seat with predetermined contours, the steps of: a. providing a means for forming a vehicle seat including a base, a forming tool disposed centrally on said base, said forming tool having an upper surface of complementary shape to said predetermined contours, said upper surface also having vacuum ports, said vacuum ports being connected to a vacuum pump, said base also having opposingly hinged arms positioned on opposite ends thereof, a means for alternatingly lowering and raising each of said arms from a substantially vertical position to a substantially horizontal position, one of said arms providing a sheet of air impermeable latex, said other arm providing a thermoplastic foam seat bun having a surface with predetermined contours; b. positioning a seat cover member inside out on, said forming tool; c. placing said latex over said seat cover member on said forming tool; d. creating a vacuum between said upper surface of said forming tool and said latex; e. drawing said seat cover member and said latex down into substantially surface to surface contact with said upper surface of said forming tool; f. applying adhesive to said surface with predetermined contours of said thermoplastic foam seat bun; g. releasing said vacuum between said latex and said upper surface of said forming tool; h. removing said latex while retaining said seat cover member in substantially surface to surface contact with said upper surface of said forming tool; i. inspecting said seat cover member for discontinuities in said substantially surface to surface contact with said upper surface of said forming tool; j. compressing said adhesive coated surface with predetermined contours of said thermoplastic foam seat bun against said seat cover member in substantially surface to surface contact with said upper surface of said forming tool; k. allowing said thermoplastic foam seat bun and said seat cover member to bond together; and l. removing said thermoplastic foam seat bun and bonded seat cover member from said forming tool.
Claim 6
Dependent Claim
38 words
The method according to claim 3 further including the step of applying a vacuum between said upper surface of said forming tool and said arm providing and compressing said thermoplastic foam seat bun against said seat cover member.
Claim 7
Dependent Claim
12 words
The method according to claim 3 wherein said inspection is performed manually.
Claim 8
Dependent Claim
12 words
The method according to claim 3 wherein said inspection is performed robotically.
Claim 9
Dependent Claim
18 words
The method according to claim 3 wherein said discontinuities constitute furrows and ridges in said seat cover member.
Claim 10
Dependent Claim
296 words
In a method of forming a vehicle seat with predetermined contours, the steps of: a. providing a means for forming a vehicle seat including a base, a forming tool having a surface of complementary shape to said predetermined contours, said surface also having a vacuum ports being connected to a vacuum pump, said base having for providing a sheet of air impermeable material, and for providing a foam seat bun having a surface with predetermined contours; b. positioning a seat cover member on said forming tool; c. placing said sheet of air impermeable material over said seat cover member on said forming tool; d. creating a vacuum between said surface of said forming tool and said sheet of air impermeable material; e. drawing said seat cover member and said sheet of air impermeable material into substantially surface to surface conformity with said surface of said forming tool; f. applying adhesive to said surface of said foam seat bun having predetermined contours; g. releasing said vacuum between said sheet of air impermeable material and said surface of said forming tool; h. removing said sheet of air impermeable material while retaining said seat cover member in substantially surface to surface conformity with said surface of said forming tool; i. inspecting said seat cover member for discontinuities in said substantially surface to surface conformity with said surface of said forming tool after said removing step; j. compressing said surface of said foam seat bun coated with adhesive against said seat cover member in substantially surface to surface conformity with said surface of said forming tool after said inspecting step; k. allowing said foam seat bun and said seat cover member to bond together; and l. removing said foam seat bun and bonded seat cover member from said forming tool.
Claim 11
Dependent Claim
296 words
In a method of forming a vehicle seat with predetermined contours, the steps of: a. providing a means for forming a vehicle seat including a base, a forming tool having a surface of complementary shape to said predetermined contours, said surface also having a vacuum ports being connected to a vacuum pump, said base having for providing a sheet of air impermeable material, and for providing a foam seat bun having a surface with predetermined contours; b. positioning a seat cover member on said forming tool; c. placing said sheet of air impermeable material over said seat cover member on said forming tool; d. creating a vacuum between said surface of said forming tool and said sheet of air impermeable material; e. drawing said seat cover member and said sheet of air impermeable material into substantially surface to surface conformity with said surface of said forming tool; f. applying adhesive to said surface of said foam seat bun having predetermined contours; g. releasing said vacuum between said sheet of air impermeable material and said surface of said forming tool; h. removing said sheet of air impermeable material while retaining said seat cover member in substantially surface to surface conformity with said surface of said forming tool; i. inspecting said seat cover member for discontinuities in said substantially surface to surface conformity with said surface of said forming tool after said removing step; j. compressing said surface of said foam seat bun coated with adhesive against said seat cover member in substantially surface to surface conformity with said surface of said forming tool after said inspecting step; k. allowing said foam seat bun and said seat cover member to bond together; and l. removing said foam seat bun and bonded seat cover member from said forming tool.
Claim 12
Dependent Claim
47 words
The method according to claim 8 further including the step of applying a vacuum between said surface of said forming tool and said means providing said foam seat bun against said seat cover member to draw said foam seat bun into contact with said seat cover member.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-08-23 | 1997-02-22 | 1997-08-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-08-23 | 2001-02-22 | 2001-08-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-08-23 | 2005-02-22 | 2005-08-24 | $7700.00 | Window Closed / Lapsed |