Method of preparing a molded article having a rigid support and a flexible hollow member

Abstract

A method of preparing a molded article comprising (a) a rigid support, e.g., a rigid seat support ( 10 ), having a plurality of perforations, and (b) a molded flexible hollow thermoplastic member ( 20 ), e.g., a flexible thermoplastic seat cushion, fixedly attached thereto is described. During the blow molding step a portion of the thermoplastic parison precursor of the flexible hollow member (b) extends through at least some of the perforations of the rigid support (a), embedding the edges of the perforations therein. The flexible material extending through the perforations forms an attachment means, e.g., an attachment head, that serves to fixedly attach the flexible hollow member (b) to the rigid support (a).

1 . (Cancelled).  
     
     
         2 . The method of  claim 35  wherein said rigid support is fabricated from a material selected from metal, thermoset plastic material, thermoplastic material and combinations thereof.  
     
     
         3 . The method of  claim 2  wherein said rigid support is fabricated from thermoplastic material optionally reinforced with a material selected from glass fibers, carbon fibers, metal fibers, polyamide fibers and mixtures thereof.  
     
     
         4 . The method of  claim 35  wherein the thermoplastic material of said flexible member is selected from at least one of thermoplastic vulcanizates, thermoplastic polyolefins, thermoplastic polyurethanes, thermoplastic polyureas, thermoplastic polyamides, thermoplastic polyesters and thermoplastic polycarbonates.  
     
     
         5 . The method of  claim 35  wherein said flexible hollow thermoplastic member has an outer surface, and said mold has interior surfaces, said method further comprising, 
 placing a fabric insert in contact with at least a portion of the interior surfaces of said mold, and  
 said thermoplastic parison contacting and fusing with said fabric insert during said blow molding step,  
 said flexible hollow thermoplastic member thereby having a fabric covering on at least a portion of said outer surface of said flexible hollow thermoplastic member.  
 
     
     
         6 . The method of  claim 35  wherein said flexible hollow thermoplastic member has an outer surface, and said mold has interior surfaces, at least a portion of the interior surfaces of said mold having at least one surface feature selected from the group consisting of raised portions and recesses, said method further comprising, 
 contacting said thermoplastic parison with said interior surfaces of said mold, at least a portion of the outer surface of said flexible hollow thermoplastic member thereby having molded-in texture.  
 
     
     
         7 . The method of  claim 35  wherein said flexible hollow thermoplastic member has an outer surface, and said mold has interior surfaces, said method further comprising, 
 placing a film insert in contact with at least a portion of the interior surfaces of said mold, and  
 said thermoplastic parison contacting and fusing with said film insert during said blow molding step,  
 said flexible hollow thermoplastic member thereby having an integral film on at least a portion of said outer surface of said flexible hollow thermoplastic member.  
 
     
     
         8 . The method of  claim 35  wherein said flexible member is further fixedly attached to said rigid support by attachment means selected from fasteners, adhesives and combinations thereof.  
     
     
         9 . The method of  claim 35  wherein the hollow interior of said flexible member is filled with a material selected from, pressurized gas, liquid, gel, polymeric foam and combinations thereof.  
     
     
         10 . The method of  claim 35  wherein said flexible member comprises means for reversibly increasing pressure within the hollow interior of said flexible member.  
     
     
         11 . The method of  claim 10  wherein said means for reversibly increasing pressure within the hollow interior of said flexible member comprises at least one pressure regulating valve that provides fluid communication with the hollow interior of said flexible member, and one of (i) a heated liquid and (ii) a cooled liquid are reversibly introduced into the hollow interior of said flexible member through said at least one pressure regulating valve.  
     
     
         12 . The method of  claim 35  wherein said article is a seat.  
     
     
         13 . The method of  claim 12  wherein said rigid support comprises a rigid seat back support and a rigid seat bottom support, and said flexible member comprises flexible cushions fixedly attached to each of said rigid seat back support and rigid seat bottom support.  
     
     
         14 . The method of  claim 12  wherein said rigid support is a continuous unitary unit.  
     
     
         15 . The method of  claim 35  wherein at least some of said perforations have deformed edge portions, and said deformed edge portions are embedded in the plastic material of said thermoplastic parison extending therethrough during said blow molding step.  
     
     
         16 . The method of  claim 35  wherein said rigid support is a rigid hollow support having an exterior surface and a hollow interior, said flexible member is in abutting relationship with at least a portion of the exterior surface of said hollow support, at least a portion of said flexible member extends through at least some of said perforations into the hollow interior of said rigid hollow support.  
     
     
         17 . The method of  claim 35  wherein said rigid support has a plurality of anchoring extensions extending into said flexible member, each of said anchoring extensions having walls, an interior chamber and at least one wall perforation in said walls, each wall perforation having edges, a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said wall perforations into said chamber during said blow molding step, the edges of said wall perforations being embedded in the plastic material extending therethrough, thereby fixedly attaching said flexible member to said rigid support.  
     
     
         18 . The method of  claim 35  wherein said rigid support has edges, and said flexible member is further fixedly attached to said rigid support by means of portions of said thermoplastic parison wrapping around and embedding at least a portion of the edges of said rigid support during said blow molding step.  
     
     
         19 - 34 . (Cancelled).  
     
     
         35 . A method of preparing a molded article comprising a molded flexible hollow thermoplastic member fixedly attached to a rigid support, said method comprising: 
 (a) placing said rigid support in a mold, said rigid support having a plurality of perforations having edges, a first surface and a second surface; and    (b) blow molding a thermoplastic parison precursor of said flexible member against the first surface of said rigid support;    wherein a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said perforations of said rigid support, the edges of said perforations being embedded in the plastic material extending therethrough, thereby attaching fixedly said flexible member to said rigid support.    
     
     
         36 . The method of  claim 35  wherein during blow molding step (b), at least one of (i) increased gaseous pressure is provided on the interior of said thermoplastic parison, and (ii) reduced gaseous pressure is provided on the second surface of said rigid support, thereby forcing portions of said thermoplastic parison through at least some of said perforations during said blow molding step.  
     
     
         37 . The method of  claim 7  wherein said mold has an interior, said film insert has a first surface and a second surface, said first surface being opposed from said second surface, said first surface contacting at least a portion of the interior surfaces of said mold, said second surface of said film insert facing said interior of said mold and fusing with said parison during said blow molding step, said film insert having at least one member selected from the group consisting of indicia, patterns and printing on at least one of said first surface and said second surface of said film insert.