Foamex L.p.

Michael H Panczyk

Andrew M Thompson

Paul Haslanger

Richard C Meyer

A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ftand an air permeability of 5 to 100 ft/ftminute. This high density foam may be created by felting a polyurethane foam.

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Dearborn, MI, United States of America

Michael H Panczyk