Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-09-11
2001-06-12
Aftergut, Jeff H. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S094000
Reexamination Certificate
active
06245169
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of repairing vinyl covers on vehicle seats, and more particularly to a method for patching tears, cuts, and abrasions in the outer vinyl cover of vehicle seats including the lower seat portion and the upper back seat portion.
2. Background of the Invention
Heretofore, tears or abrasions on vinyl seat covers have been repaired by using a patch material which is inserted beneath the cut or tear against the lower or inside surface of the vinyl cover. Liquid vinyl has been applied over the patch material and adjacent cover and heated to about 800 F. (800 degrees Fahrenheit) for curing of the liquid vinyl. All temperatures set forth hereinafter including the claims are expressed in numerical value or numbers with the letter F. thereafter to indicate degrees Fahrenheit. A graining pad is then pressed manually against the patch to smooth out the patched area and minimize any high spots or air pockets. Additional layers of liquid vinyl are applied and heated to about 800 F. for curing to provide the desired patch thickness over the cut area. The graining pad is applied after each layer. Then the patched area is spray painted while the patched area is hot with a paint having a color similar to the outer surface of the vinyl cover.
Oftentimes, an inner fabric layer is secured to the inner surface of the vinyl cover and may be of a substantial thickness. As a result, when the patch is inserted within the tear or cut against the backing layer of the vinyl cover, the patch is against the inner surface of the inner fabric layer secured to the outer vinyl cover and a smooth patch is oftentimes not obtained except possible with a large number of layers of liquid vinyl material applied to the patched area. Also, abrasions not involving a cut or tear in the outer vinyl cover have been difficult to repair heretofore.
It is an object of this invention to provide a method for patching a tear or cut in an outer vinyl cover for a seat in which the patch is applied to the outer surface of the vinyl cover over the cut or tear.
SUMMARY OF THE INVENTION
The present invention is directed particularly to a method of patching a tear, cut or abrasion in an outer vinyl cover of a vehicle seat by applying the patch onto the outer surface of the vinyl cover over the tear or abrasion on a lower seat portion or an upper back seat portion of the vehicle seat. The method is particularly adapted for use on vinyl seat covers for seats on school buses.
Liquid vinyl is first applied with a suitable spatula or putty knife over the cut area including the adjacent outer vinyl cover. Then, the patch material is placed against the outer surface of the vinyl cover after the liquid vinyl has been applied. Next, the liquid vinyl and patch are heated to a temperature over 1000 F. and preferably about 1400 F. for curing the liquid vinyl material. A propane heat gun or torch has been found to be effective in heating the patched area to a temperature of 1400F-1500 F. in a minimum of time. An inner foam material such as a polyurethane foam material is normally beneath the outer vinyl cover and may be replaced prior to application of the patch material and liquid vinyl if it has been torn away.
The patch comprises a mesh material which is fire resistant and is a woven fibrous material having a thickness between about 5 to 10 mils and preferably about 7 mils in thickness. After applying the patch and heating the patch and liquid vinyl, a graining pad is pressed manually against the patched area to provide a desired texture to the patch area and to smooth the patched area and remove air pockets. The vinyl material permeates the relatively thin mesh layer.
To provide additional thickness and smoothness, additional layers of liquid vinyl are applied over the patched area and heated for curing the liquid vinyl over the mesh patch. Normally, at least two additional layers of liquid vinyl are applied and cured with the graining pad pressed manually against each layer while hot. After curing of the last vinyl layer, a suitable spray paint is applied after the vinyl is cured but while the repair remains hot.
Other objects, features, and advantages of the invention will be apparent from the following specification and drawings.
REFERENCES:
patent: 2855338 (1958-10-01), Mulkey
patent: 3804685 (1974-04-01), Jacoby et al.
patent: 3887413 (1975-06-01), Speer
patent: 3975558 (1976-08-01), Speer
patent: 4013495 (1977-03-01), Golumbic
patent: 4260139 (1981-04-01), Speer
patent: 4283240 (1981-08-01), Speer
patent: 4358495 (1982-11-01), Parker
patent: 4419162 (1983-12-01), Fischer
patent: 4702956 (1987-10-01), Wilson et al.
Aftergut Jeff H.
Browning & Bushman P.C.
National Guaranteed Vinyl
Piazza Gladys
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