Method of making a seat cushion

Abstract

A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film. Preferably, to fix the shape of the film and fabric to that of the contoured surface of the mold cavity to enable the foam to be poured into the recess without requiring the film and fabric to be supported by the mold, the adhesive, film and fabric are heated before forming to make them pliable and cooled after forming to fix their shape to substantially conform to that of the contoured surface of the mold cavity.