Process for manufacturing a padded element using a cover preforming mandrel

摘要

There is disclosed a process for manufacturing a padded element. The process comprises the steps of placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer; heating the trim cover to a temperature sufficient to shape the thermoformable foam layer; shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; transferring the shaped trim cover from the mandrel to a lower mold having shape substantially complimentary to the shaped trim cover; placing an upper mold over the lower mold to define a mold cavity; dispensing a liquid foamable polymeric composition in the mold cavity; and expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element.