Abstract: A method for making a portion of a vehicle seat or back having a surface contour of predetermined shape by placing a sheet of an impermeable film against one side of a portion of a sheet of a permeable cloth fabric to make an impermeable composite portion of a fabric trim material. The composite portion is then positioned on a forming tool having a shaped upper surface complementary to the predetermined shape desired for the final product. A vacuum is then drawn between the forming tool and the impermeable composite portion so as to draw the portion into conformity with the shaped upper surface of the forming tool. A foam bun having an adhesive coated surface is then positioned against the portion on the forming tool. Heat is then applied to deteriorate the impermeable film thus enabling the adhesive to bond the cloth fabric material to the foam bun and maintain the desired shape.

Abstract: A method of manufacturing a vehicle seat cover and bonding the vehicle seat cover to a foam bun utilizing a style insert. The style insert is formed by taking a breathable cloth fabric and laminating it to a sheet of foam material. The composite so formed is then cut to a desired styled insert shape and sewn to the vehicle seat cover skirt to form a seat cover assembly.The composite, which may include an air impermeable barrier sheet or the barrier sheet may be included in the composite between the foam and fabric sheets, is positioned on a forming tool having removable style inserts, with the cloth side of the composite against the insert. An impermeable film is then positioned over the foam side of the insert composite and a vacuum drawn the forming tool and the impermeable film to draw the composite down into conformity with the style lines of the tool insert. An adhesively coated foam bun is then positioned and pressed against the composite on the forming tool.

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.