Method for vacuum forming composite vehicle seat

In a method of forming a portion of a vehicle seat having a surface of predetermined shape, the steps of:

• a. providing a sheet of air impermeable material which will deteriorate when heated;
• b. positioning said impermeable material on one side of a sheet of permeable cloth to form an air impermeable cloth fabric trim material;
• c. placing said trim material on a forming fixture having an upper surface complementary to said predetermined shape with the other side of said sheet of permeable cloth against said fixture;
• d. establishing a vacuum between said impermeable trim material and said fixture drawing said trim material against said surface to shape said trim material into said predetermined shape;
• e. providing a preshaped foam bun having a face of said predetermined shape;
• f. applying adhesive to said bun face;
• g. pressing said bun face against said shaped trim material on said fixture;
• and
• h. heating said trim material to deteriorate said air impermeable material to enable contact of said cloth with said adhesive such that said cloth is bonded to said bun face by said adhesive without said adhesive excessively permeating said cloth so as to impair the permeability and flexibility of the cloth.