Abstract A plastic cushion product comprising a flexible polyvinyl chloride skin and a closed-cell polyurethane core which is preferably directly bonded to the polyvinyl chloride skin. A preferred method of making the plastic cushion products comprising: molding and curing the vinyl chloride at temperatures above about 255* F. for a time sufficient to produce an open polyvinyl chloride shell of desired thickness and just sufficient to cure the polyvinyl chloride to its gild or gel stage; molding polyurethane foam at a temperature of at least 350* F. into a shape substantially conforming to the polyvinyl chloride shell; curing a second amount of vinyl chloride at the temperature and time conditions previously described to form a polyvinyl chloride cover such that the polyvinyl chloride shell and cover mate to form a completely enclosed structure; heating the completely enclosed polyvinyl chloride structure containing the polyurethane foam to a temperature of at least 350* F. to completely cure the polyvinyl chloride. The final cure bonds the polyvinyl chloride shell and cover into a substantially continuous skin and bonds the polyvinyl chloride shell and cover to the polyurethane foam to form an essentially unitary cushion product.
The method of claim 1 wherein said polyurethane foam core is preshaped to substantially conform to the inner dimensions of said skin by heating polyurethane foam in a mold at a temperature of 350* F.
Claim 2
Dependent Claim
19 words
The method of claim 1 wherein said polyurethane foam core is foamed in place in said polyvinyl chloride skin.
Claim 3
Dependent Claim
28 words
The method of claim 1 wherein said polyurethane foam core is foamed in place in said polyvinyl chloride skin after said further heating of said polyvinyl chloride skin.
Claim 4
Dependent Claim
20 words
The method of claim 1 wherein said vinyl chloride is heated to a temperature of at least about 255* F.
Claim 5
Independent Claim
144 words
A method for making polyvinyl chloride-polyurethane foam cushion products comprising: heating liquid vinyl chloride (at a temperature of at least 255* F.) in a mold for a time sufficient to produce gelled polyvinyl chloride sheets having a desired thickness, said gelled polyvinyl chloride sheets capable of being formed into a continuous closed skin; heating closed-cell polyurethane foam at a temperature of at least 350* F. in the substantial absence of oxygen for a time sufficient to mold said polyurethane foam into a configuration having substantially the same dimensions as the interior of said skin; heating said gelled polyvinyl chloride sheets, associated to form said closed skin and containing therein said polyurethane foam, to a temperature of at least 350* F. to completely cure said gelled polyvinyl chloride sheets and to bond said gelled polyvinyl chloride sheets to each other and to said polyurethane foam.
Claim 6
Dependent Claim
23 words
The method of claim 6 wherein said liquid vinyl chloride is heated to a temperature between about 255* F. and about 285* F.
Claim 7
Dependent Claim
21 words
The method of claim 6 wherein said gelled polyvinyl chloride sheets are between about 60 percent to about 70 percent cured.
Claim 8
Dependent Claim
22 words
The method of claim 6 wherein said polyurethane foam is heated to a temperature between about 350* F. and about 400* F.
Claim 9
Dependent Claim
20 words
The method of claim 6 wherein said polyurethane foam has a density between about 1.75 lb./cu.ft. and about 2.0 lb./cu.ft.
Claim 10
Dependent Claim
17 words
The method of claim 6 wherein said thickness of said gelled polyvinyl chloride is about 0.125 in.
Claim 11
Dependent Claim
90 words
The method of claim 6 wherein an anchor member is positioned within said cushion products, said member comprising the further steps of: bonding a layer of gelled polyvinyl chloride to a metallic sheet to form said anchor member; inserting said anchor member between said polyurethane foam and said gelled polyvinyl chloride of said skin prior to completely curing said polyvinyl chloride, whereby, after completely curing said polyvinyl chloride skin, said anchor member is bonded to said skin and to said polyurethane foam to be securely positioned in said cushion products.