Method of manufacturing a vehicle seat cover

Claim 1

A method of making an embossed, covered, polyurethane foam cushion comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, bonding a layer of covering material to said laminate overlying said first foam layer, and pressing an embossed pattern into said cover layer and the first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion of the cover layer in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cushion.

Claim 2

A method of making an embossed, covered, polyurethane foam cushion comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, bonding a layer of covering material to said laminate overlying said first foam layer, and pressing an embossed pattern into said cover layer and the first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion of the cover layer in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cushion.

Claim 3

A method of making an embossed, covered, polyurethane foam cushion comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, pressing an embossed pattern into said first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion thereof in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cushion, and thereafter bonding a cover material to the embossed surface of said laminate.

Claim 4

A method of making an embossed, covered, polyurethane foam cushion comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, pressing an embossed pattern into said first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion thereof in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cushion, and thereafter bonding a cover material to the embossed surface of said laminate.

Claim 5

A method of making an embossed, covered, polyurethane foam automotive seat cover assembly, comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, bonding a layer of covering material to said laminate overlying said first foam layer, and extending beyond said foam layer as necessary to trim an automotive seat, and pressing an embossed pattern into said cover layer and the first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion of the cover layer in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cover assembly.

Claim 6

A method of making an embossed, covered, polyurethane foam automotive seat cover assembly, comprising forming a laminate comprising two polyurethane foam layers bonded to each other, the first of said layers being composed so as to be dielectrically heatable to a fusion temperature for embossing and the second of said foam layers being composed so as to not be fused by such dielectric heating, bonding a layer of covering material to said laminate overlying said first foam layer, and extending beyond said foam layer as necessary to trim an automotive seat, and pressing an embossed pattern into said cover layer and the first polyurethane layer while dielectrically heating said first layer to fuse it and bond the depressed portion of the cover layer in the desired embossment pattern to the second foam layer without fusing and embossing the second foam layer, the initial thickness of said first layer being suitable to form the desired embossment, and the overall thickness of the two foam layers being sufficient to provide a desired cover assembly.