Abstract: A method for making contoured covers for vehicle seats is disclosed. A cover member is attached to a foam sheet which has an adhesive layer covering the face opposite from the cover member. The adhesive layer is in turn covered with a backing material. Portions of the cover member are pressed into the foam sheet, contacting the adhesive. The adhesive bonds the cover member to the backing material forming the contours in the cover. Alternatively the adhesive layer may be omitted if a thermally sensitive backing material is used. In this case the portion of backing material pressed into contact with the cover is partially melted to bond the backing material to the cover.

Abstract: A method of manufacturing a portion of a seat. A cover member is shaped to a predetermined shape and placed in a foam molding tool into which is injected an expandable liquid foaming material to mold a foam pad which is integrally bonded to the cover member. In the manufacturing of seat backs, the cover member includes a tubular envelope cover positioned on a cantilever forming tool. Once the foam pad is molded, the cover member is turned inside out to enclose the foam pad with the cover member. The cover is then telescoped over a seat frame. Alternatively, the foam pad can be molded to a shaped fabric sheet, the envelope cover formed by sewing a second cover member to the fabric sheet. A seat cushion is made by shaping a cover member, placing the cover member in a foam molding tool which also holds the seat frame and injecting an expandable liquid foaming material into the mold to mold the foam cushion, bond the cushion to the cover and embed the seat frame in the foam.

Abstract: The method and apparatus for forming at least a portion of a seat wherein an envelope cover comprising a generally tubular shape fabric member having an open end and inner and outer sides is positioned on a cantilever supported forming tool so as to shape at least a portion of the outer side to a desired shape. A foam pad which has been molded to a shape conforming to the predetermined shape of the cover is then positioned in firm surface-to-surface engagement with the shaped cover portion and secured by glue thereto. The envelope can then be removed from the cantilever supported forming tool with the foamed pad adhered thereto and then turned inside out and assembled with a seat frame to provide a desired portion of a seat. This eliminates the need for fasteners or hard plastic back panels in the seat portion.

Abstract: A vehicle seat assembly consisting of a main frame, a fibrous matrix supported in a generally horizontal position on the frame and a foam body molded in place on the frame so as to encapsulate the matrix in the body in a position forming a support for a load-carrying portion of the body.

Abstract: A vehicle seat assembly which includes a frame having side rails with upright webs and upper flanges and a load carrying pre-stretched web mounted on and extending between the side rails. A plurality of J-clips are provided for mounting the web on the side rails so as to maintain the web in its pre-stretched condition.