FOAM LAMINATE FOR MOLD IN PLACE SEATING COMPONENT

摘要

A laminate structure (20) for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam (26) bonded to an interior surface of a seat cover material (28). After the laminate structure (20) is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold (10) having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam (26) of the laminate structure (20) preferably has a density of at least 4 lbs/ft<3> (64 kg/m<3>) and an air permeability of 5 to 100 ft<3>/ft<2> minute (1.52 m<3>/m<2> minute to 30.48 m<3>/m<2> minute). This high density foam (26) may be created by felting a polyurethane foam.