Composite blow molded article and method of making same
AssigneeCollins & Aikman Plastics, Inc.
InventorsGasper J. Palazzolo, Michael P. Leitert, W. Daniel Panter, Edward R. Terris
Life of this patent
Estimating the term…
Abstract
A head rest assembly is fabricated using a blow molding process. A skin surrounds a foam cushion and an insert is secured to the skin. The insert and the skin may be flush with each other. The skin includes a channel designed to receive the peripheral edge of the insert therein. The recess undercuts the opening periphery of the skin by 285.degree.. The insert is adhered to the skin either after the molding of the skin or, in the alternative, during the molding of the skin.
Claims22
A headrest assembly for a vehicular seat, said headrest assembly comprising:
- a rigid frame having a stem to be received by the vehicular seat;
- a foam cushion surrounding a portion of said rigid frame, said foam cushion disposed adjacent the vehicular seat;
- a skin covering all of said foam cushion, said skin including a channel extending into said skin a predetermined length;
- and
- an insert defining a peripheral edge, said insert fixedly secured over said skin wherein said peripheral edge of said insert is disposed within said channel of said skin.
A method for manufacturing a headrest assembly including a rigid frame, a foam cushion, a skin and an insert to be permanently secured to the skin, the method comprising the steps of:
- forming the skin with a channel;
- filling the skin with foam to form the foam cushion within the skin;
- and
- attaching the insert to an outer surface of the skin such that a peripheral edge of the insert is disposed within the channel whereby the insert is permanently secured to the outer surface of the skin.
A method for manufacturing a headrest assembly including a rigid frame, a foam cushion, a skin and an insert, the method comprising the steps of:
- loading the insert into an insert tool;
- securing the insert tool in a blow mold tool;
- forming the skin in the blow mold tool;
- adhering the insert to the skin inside the blow mold tool;
- and
- filling the skin with foam to form the foam cushion within the skin.
A blow mold assembly for producing a composite skin, said blow mold assembly comprising:
- a first half defining a first cavity to receive a portion of a parison therein;
- a second half defining a second cavity to receive another portion of the parison therein;
- and
- an insert tool securable to said first half completely within said first cavity to hold an insert thereon such that the insert is received by and formed into the parison as it forms within said first and second halves.
A composite blow molded article comprising:
- a foam cushion;
- a skin covering all of said foam cushion, said skin including a channel defining a recess periphery;
- and
- an insert defining a peripheral edge fixedly secured to said skin over said skin wherein said peripheral edge of said insert is disposed within said channel.
Dependencies are inferred from the claim text.