| abstract |
The production, by either a batch process or a continuous process, of vehicle seat trim pads or like articles of cured polymer no-gel latex foam and having convex or crowned surfaces free of congealed polymer skin, is disclosed. In the process, a backing fabric is first laid on a pervious supporting surface. A no-gel latex foam is then deposited on the fabric, and an open-bottom open-top grid of a height not greater than that of the deposited mass of latex foam is placed into the latter, excess latex foam above the top plane of the grid being scraped off to impart to each pocket or island of foam a smooth and level top surface. The entire assembly is then subjected to dry heat to effect both a rapid dehydration and a curing of the latex foam. During the initial stage of this operation, the no-gel latex foam expands somewhat so that the top surface of each island thereof becomes crowned without having to be disposed in contact with a mold surface of appropriate contours. The grid is removed after curing has been completed, leaving a plurality of in situ formed channels separating the base-connected islands. An upholstery covering is then applied to the top surface of the finished pad in closely conforming relation to the crown surfaced islands, being secured to the pad by stitching through the bottoms of the channels. This abstract is not to be taken either as a complete exposition or as a limitation of the present invention, however, the full nature and extent of the invention being discernible only by reference to and from the entire disclosure. |