Method of the manufacture of an upholstery element

Claim 1

A method of forming an upholstery element with the use of a mold closeable by a first lid to define a first closed hollow chamber and by a second lid to define a second hollow chamber, said method comprising the steps of introducing a cover to said mold in such a way as to adhere tightly to sides of said mold. closing said mold by said first lid so that the first closed hollow chamber is defined in part by the cover, clamping a border area of the cover between the mold and the first lid at the time the mold is closed by the first lid, introducing a soft foam reaction mixture into the first closed hollow chamber and reacting the same to form a soft foam body (1) filling the first closed hollow chamber and (2) adhering to the cover defining part of the first closed hollow chamber, removing the first lid from said mold and closing said mold by said second lid so that the second hollow chamber is defined in part by the soft foam body, introducing a rigid-foam reaction mixture into the second hollow chamber and reacting the same to form a rigid-foam body (1) filling the second hollow chamber and (2) adhering to the soft foam body defining part of the second closed hollow chamber so that the rigid foam body serves as a support element for the soft foam body and adhered cover of the upholstery element thus made, and introducing the border area of the cover into the second hollow chamber after removal of the first lid and prior to closing of the mold by the second lid, after which the second hollow chamber is foamed with the rigid-foam reaction mixture so that the border area is embedded in the rigid-foam body.

Claim 2

A method of forming an upholstery element with the use of a mold closeable by a first lid to define a first closed hollow chamber and by a second lid to define a second hollow chamber, said method comprising the steps of introducing a cover to said mold in such a way as to adhere tightly to sides of said mold. closing said mold by said first lid so that the first closed hollow chamber is defined in part by the cover, clamping a border area of the cover between the mold and the first lid at the time the mold is closed by the first lid, introducing a soft foam reaction mixture into the first closed hollow chamber and reacting the same to form a soft foam body (1) filling the first closed hollow chamber and (2) adhering to the cover defining part of the first closed hollow chamber, removing the first lid from said mold and closing said mold by said second lid so that the second hollow chamber is defined in part by the soft foam body, introducing a rigid-foam reaction mixture into the second hollow chamber and reacting the same to form a rigid-foam body (1) filling the second hollow chamber and (2) adhering to the soft foam body defining part of the second closed hollow chamber so that the rigid foam body serves as a support element for the soft foam body and adhered cover of the upholstery element thus made, and introducing the border area of the cover into the second hollow chamber after removal of the first lid and prior to closing of the mold by the second lid, after which the second hollow chamber is foamed with the rigid-foam reaction mixture so that the border area is embedded in the rigid-foam body.