Disclosed embodiments may include methods for forming a foam product comprising forming a skin and inserting a bracket at least partially into the skin. Another embodiment method for manufacturing a foam product may comprise sealing a tube of material in a cavity of a mold, blowing air into the tube
Disclosed embodiments may include methods for forming a foam product comprising forming a skin and inserting a bracket at least partially into the skin. Another embodiment method for manufacturing a foam product may comprise sealing a tube of material in a cavity of a mold, blowing air into the tube of material to form a skin comprising an interior surrounded by a wall, cutting an incision in the skin wall, inserting a bracket through the incision and into the skin interior, filling the skin interior with foam, and curing the foam. Disclosed embodiments may further include foam product comprising a skin with an interior surrounded by a wall, a bracket within the skin interior, a foam substantially filling the skin interior and securing the bracket in place, a recessed region configured to mate with a mounting assembly on a chair, and an incision in the skin wall, the incision positioned outside of the recessed region.
대표청구항▼
1. A foam product comprising: a unitary skin wall surrounding an interior;a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture;an incision on the un
1. A foam product comprising: a unitary skin wall surrounding an interior;a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture;an incision on the underside of the skin wall, the incision separate from the mounting area;a bracket positioned within the skin interior; andfoam substantially filling the skin interior and securing the bracket in place within the skin wall;wherein the underside of the skin wall has a width; the incision has a width; the width of the mounting area is less than the width of the underside of the skin wall; the width of the incision is less than the width of the underside of the skin wall; and the width of the incision is greater than the width of the mounting area. 2. The foam product of claim 1, wherein the incision forms a closable slit in the skin wall; wherein the incision is positioned outside of the mounting area; and wherein the incision allows skin distortion to form an opening for inserting the bracket into the skin interior upon application of pressure, with the opening closing upon release of pressure. 3. The foam product of claim 1, wherein the incision is sealed shut before the interior of the skin is filled with foam. 4. The foam product of claim 1, wherein no material is removed from the skin wall to form the incision. 5. The foam product of claim 1, wherein at least a portion of the bracket is wider than the width of the mounting area. 6. The foam product of claim 1, Wherein the foam product is asymmetrical along a longitudinal plane of the foam product. 7. The foam product of claim 1, wherein the mounting area is recessed. 8. The foam product of claim 1, wherein the skin is formed from one of the following materials: polyvinyl chloride (PVC), polyvinyl acetate (PVA), polyurethane, polyethylene, polyester, leather, natural rubber, synthetic rubber, latex, or a thermoplastic elastomer(TPE). 9. The foam product of claim 1, wherein the bracket is configured and positioned within the skin interior to support a majority of the foam product, while allowing foam to occupy sufficient space between the bracket and the skin so the bracket is not readily detectible; and wherein the bracket is configured to be approximately the same shape but slightly smaller than the skin. 10. The foam product of claim 1, wherein the skin is formed of a thermoplastic elastomer, and wherein the foam is formed of one of the following materials: polyurethane, PVC, PVA, polyethylene, styrene butadiene rubber (SBR), latex, or natural rubber. 11. The foam product of claim 1, wherein the incision is sealed shut before the interior of the skin is filled with foam, and wherein no material is removed from the skin wall to form the incision. 12. The foam product of claim 11, wherein at least a portion of the bracket is wider than the width of the mounting area. 13. A foam product comprising: a unitary skin wall surrounding an interior;a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture;an incision on the underside of the skin wall, the incision separate from the mounting area;a bracket positioned within the skin interior; andfoam substantially filling the skin interior and securing the bracket in place within the skin wall;wherein the underside of the skin wall has a width; the incision has a width; the width of the mounting area is less than the width of the underside of the skin wall; the width of the incision is less than the width of the underside of the skin wall; the width of the incision is greater than the width of the mounting area; and the incision is located in a bracket insertion area, and the bracket insertion area is separate from the mounting area and is recessed. 14. The foam product of claim 13, wherein the skin is formed of cured TPE, setting the shape of the skin; wherein the incision forms a closable slit in the skin wall; wherein the incision allows skin distortion to form an opening for inserting the bracket into the skin interior upon application of pressure, with the opening closing upon release of pressure; and wherein the incision is sealed shut before the interior of the skin is filled with foam. 15. The foam product of claim 13, wherein at least a portion of the bracket is wider than the width of the mounting area. 16. A foam product comprising: a unitary skin wall surrounding an interior;a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture;an incision on the underside of the skin wall, the incision separate from. the mounting area;a bracket positioned within the skin interior; andfoam substantially filling the skin interior and securing the bracket in place within the skin wall;wherein the underside of the skin wall has a width; the incision has a width; the width of the mounting area is less than the width of the underside of the skin wall; and the width of the incision is greater than the width of the mounting area. 17. The foam product of claim 16, wherein the incision forms a closable slit in the skin wall; wherein the incision is positioned outside of the mounting area; and wherein the incision allows skin distortion to form an opening for inserting the bracket into the skin interior upon application of pressure, with the opening closing upon release of pressure. 18. The foam product of claim 16, wherein the incision is sealed shut before the interior of the skin is filled with foam, and wherein no material is removed from the skin wall to form the incision. 19. The foam product of claim 16, wherein at least a portion of the bracket is wider than the width of the mounting area. 20. The foam product of claim 16, wherein the skin is formed of cured TPE, setting the shape of the skin.
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이 특허에 인용된 특허 (20)
Magee Ted N. (Hillsborough CA), Arm cap for airplane seat or the like.
Gallagher Michael J. (Hampton NH) Nobbs Douglas (Dover NH), Method for manufacturing an automobile trim component by blow molding and injection molding.
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