Chairs and seats – Headrest
Reexamination Certificate
1999-06-03
2001-02-06
Brown, Peter R. (Department: 3636)
Chairs and seats
Headrest
C297S408000, C297S410000, C297S220000
Reexamination Certificate
active
06183045
ABSTRACT:
BACKGROUND OF THE INVENTION
1) Technical Field
The subject invention relates to a method for manufacturing an interior automotive component such as a headrest or armrest and to the interior automotive components made using the method of the present invention.
2) Description of the Prior Art
Interior automotive components, such as headrests and armrests, can be manufactured using a variety of manufacturing methods. The components generally comprise a frame structure, a foam bun and a trim cover. Foam-in-place technology has been used successfully to produce luxury headrests. Additionally, injection molded or blow molded components have been used for attachment to the frame structure. However, the interior components which incorporate the molded components still require the use of a foam bun to produce the desired shaping of the interior component.
The disadvantages of the prior art may be overcome by providing an interior component having a molded “bun” molded directly onto a frame structure to be integrated therewith and then covering the molded “bun” with a trim cover having a flexible pad.
SUMMARY OF THE INVENTION
An automotive interior component comprises a frame structure for supporting the interior component and a rigid molded contoured bun secured about a portion of the frame structure forming the desired shape of the interior component. A trim cover envelops the bun and a foam pad is secured between the trim cover and the bun for providing resilient padding to the interior component.
A method of manufacturing an automotive interior component supported on a frame structure is also provided and comprises the steps of placing the frame structure in a mold, molding a rigid bun about a portion of the frame structure to form the contoured shape of the interior component, removing the rigid bun and frame structure in a mold, molding a rigid bun about a portion of the frame structure to form the contoured shape of the interior component, removing the rigid bun and frame structure from the mold, securing a resilient foam pad onto a surface of a trim cover, and enveloping the rigid bun in the trim cover and foam pad.
The interior component is essentially foamless except for the foam attached to the trim cover.
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Johnson Richard
Marfilius Donald F.
Szalma Randall E.
Brown Peter R.
Howard & Howard
Magna Interior Systems Inc.
White Rodney B.
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