Method for forming a foamed product integral with trim cover assembly

Method for forming a foamed product integral with trim cover assembly, comprising the steps of:

• forming a plurality of surface cover pieces in a predetermined shape, each having ends;
• forming a plurality of foam padding pieces, each being generally equal in size to each of said plurality of surface cover pieces and having ends;
• temporarily securing local points of each of said plurality of foam padding pieces to respective local points of each of said plurality of surface cover pieces via a securing means, thereby providing a temporarily secured cover section unit;
• providing a plurality of said temporarily secured cover section units;
• thereafter, sewing together end portions of said plurality of the temporarily secured cover section units, thereby forming said trim cover assembly in a three-dimensional shape;
• injecting a liquid foaming material into inside of the thus-formed trim cover assembly;
• curing and expanding said liquid foaming material so as to create a foam cushion member filled in the trim cover assembly;
• and
• thereafter, removing said local points of each of said plurality of the cover surface pieces from the respective said local points of said each of said plurality of the foam padding pieces by overcoming a securing strength of said securing means;
• whereby the foamed product integral with the trim cover assembly is formed, in which both said plurality of surface cover pieces and said plurality of foam padding pieces are stretched uniformly.