Method for making a vehicle seat component with improved resistance to permanent deformation

The method of forming a body of a fibrous polymeric material consisting of polymeric fibers and a polymeric coating to a desired shape to form at least a portion of a vehicle seat comprising the steps of:

• a. providing a mold cavity having a shape corresponding to said desired shape;
• b. placing a predetermined quantity of said fibrous polymeric material in said cavity;
• c. providing a polymeric coating on at least some of said fibrous material, said coating having a low melting point and a known glass transition temperature;
• d. compressing said fibrous polymeric material in said cavity at an initial pressure sufficient to mold said fibrous polymeric material to a desired shape;
• e. passing a heated atmosphere through said cavity at a temperature sufficiently high to melt said polymeric coating and cause the coating to flow in quantities sufficient to bond some of said fibers to others of said fibers and thereby maintain said fibrous body in the shape of said cavity;
• f. passing a cooled atmosphere through said cavity at a temperature sufficient to cool said fibrous body to a temperature below the melting temperature of said polymeric coating but above said glass transition temperature of said polymeric coating;
• g. further compressing the molded fibrous body to safeguard the body against permanent deformation when in use in a vehicle seat;
• and
• h. thereafter passing a cooling atmosphere through said cavity at a temperature sufficiently low to cool said polymeric coating to a temperature below the glass transition temperature so as to solidify the bonds formed between the fibers.