The invention relates to a process for producing a motor vehicle seat cushion comprising the following steps: providing a cover with an insert, the insert having a layer of coating material and a foam sublayer; placing the cover in a mold; positioning a thermoplastic film on the sublayer; injecting a foam precursor mixture to produce a block of padding. The film used is based on polyurethane with a melting point between 40 C. and 60 C. and a melt-mass flow rate greater than 15 g/10 min. The film degrades under the action of the heat released during the formation of the foam of the block to enable an overmolding of the sublayer by the block substantially without penetration of the foam of the block into the thickness of the sublayer.

A method for forming a skin-foam architecture for a seat. The method includes loading a backing cover into a first portion of the tool. The method includes applying and curing a skin on a second portion of the tool, the skin including a first layer, and a second layer under the first layer. The method includes laminating a mesh under the skin. The method includes attaching and curing a foam layer under the mesh and the skin. The method includes mating the first and second portions of the tool. The method includes introducing foam between the mated first and second portions of the tool.

A vehicle interior panel includes a foam layer formed from a liquid foam precursor between a substrate and a visible decorative skin layer that has perforations formed therethrough. In some cases, the perforations are associated with a line of stitching sewn into and through the skin layer. A sealing film is located beneath the skin layer in the perforated region to prevent the liquid foam precursor from leaking through the perforations during foam formation. The sealing film extends beyond the perforated region and into a non-perforated region, in some cases extending substantially over the entire back side of the skin layer. In this manner, the edges of the sealing film do not cause visual blemishes on the visible surface of the decorative skin layer over time.

A seat for vehicles including a seat cushion, a seat back, and a head rest has the following arrangement to ensure that a surface member can be relatively easily but positively removed from a urethane pad if a foam molding defect is found in the urethane pad in integral molding of the urethane pad and the surface member. In the seat for vehicles, any one of the seat cushion, seat back, and head rest has a configuration where a surface of the urethane pad is covered with the surface member. The urethane pad and the surface member are partially bonded together by integral molding.

A method in which an interior trim part for a vehicle is produced. The method includes the steps of providing a block of material comprising a plurality of paper layers connected to each other by at least one resin, cutting the block into slices, wherein a cutting plane has an angle between 5 and 85 in relation to layer planes of the paper layers, providing a flexible support layer and applying at least one of the slices to the flexible support layer to obtain a flexible composite layer, and providing a rigid carrier and applying the flexible composite layer directly or indirectly to the carrier.

A vehicle interior panel includes a decorative skin layer and a backing layer. The backing layer can include a barrier material that helps prevent outgassing of a plasticizer of the decorative skin layer in a direction toward an underlying substrate of the panel. The backing layer can be formed by vacuum coating and/or formed while a slush molded layer remains on a slush molding tool surface on which it was formed. In some cases, a slush molding tool thus finds new uses in a vacuum coating process or in some other process apart from slush molding.

A vehicle seat component includes: a seat pad having a seating portion and an outer portion; and a seat cover serving as an outer cover material being bonded to the seat pad, wherein at least a part of the seat cover at which the seat cover is bonded to the outer portion, is provided with an extension part that extends from an end of the outer portion at a side opposite to the seating portion, wherein the outer portion is provided with a groove at a rear surface part of the seat pad, the groove extending along the end and having a bottom surface at a position closer to the seating portion with respect to the rear surface part, and wherein at least a part of the extension part is integrally bonded to a wall surface of the groove by the integral foam-molding.

Multilayer nonwoven fabrics for foam molding that have excellent resistance to the separation of layers, have reinforcing effects and urethane leakage prevention performance, and are producible without the occurrence of fiber dust on the surface. In the multilayer nonwoven fabric for foam molding, a reinforcing layer is stacked on at least one side of a dense layer, the dense layer includes a meltblown nonwoven fabric layer (A) and spunbonded nonwoven fabric layers (B) that are stacked on both sides of the layer (A), and the meltblown nonwoven fabric layer (A) and the spunbonded nonwoven fabric layers (B) are partially thermocompression bonded with each other.

A vehicle interior panel includes a foam layer formed from a liquid foam precursor between a substrate and a visible decorative skin layer that has perforations formed therethrough. In some cases, the perforations are associated with a line of stitching sewn into and through the skin layer. A sealing film is located beneath the skin layer in the perforated region to prevent the liquid foam precursor from leaking through the perforations during foam formation. The sealing film extends beyond the perforated region and into a non-perforated region, in some cases extending substantially over the entire back side of the skin layer. In this manner, the edges of the sealing film do not cause visual blemishes on the visible surface of the decorative skin layer over time.

A sport helmet for protecting a head of a wearer, such as a hockey, lacrosse or football player. The sport helmet has an outer shell with an internal side and an external side and an inner pad mounted to the internal side of the outer shell for absorbing shocks when the sport helmet is impacted. The inner pad has a core of polymeric cellular material with a body of expanded polymeric microspheres and a molded covering being molded onto the core of polymeric cellular material.