Seat assembly and method of making same

Abstract

A molded seat assembly comprises an insert having an upper and a lower surface, a peripheral edge, and a ridge disposed adjacent to the peripheral edge. A seat portion comprised of a plastic material is molded directly to the insert whereby the ridge is adapted to prevent the flow of the plastic material beyond the ridge. The plastic material contacts the ridge and melts or softens the ridge. The ridge is then deformed forming both a cohesive bond and a locking engagement between the seat portion and the insert.

What is claimed is:  
     
         1 . A molded seat assembly comprising: 
 an insert having an upper and a lower surface, a peripheral edge, and a ridge disposed adjacent to said peripheral edge; and    a seat portion comprised of a plastic material molded directly to said insert whereby said ridge is adapted to prevent the flow of the plastic material beyond said ridge.    
     
     
         2 . A molded seat assembly as set forth in    claim 1   , wherein said ridge extends upwardly from said surface of said insert.  
     
     
         3 . A molded seat assembly as set forth in    claim 2   , wherein said ridge continuously extends about said insert.  
     
     
         4 . A molded seat assembly as set forth in    claim 1   , wherein said peripheral edge is partially embedded in said seat portion.  
     
     
         5 . A molded seat assembly as set forth in    claim 4   , wherein said peripheral edge is partially cohesive with said seat portion.  
     
     
         6 . A molded seat assembly as set forth in    claim 4   , wherein said peripheral edge is partially deformed by and is partially embedded in the plastic material to provide locking engagement between said insert and said seat portion.  
     
     
         7 . A molded seat assembly as set forth in    claim 1   , wherein said insert comprises an injection molded plastic material.  
     
     
         8 . A molded seat assembly as set forth in    claim 7   , wherein the plastic material comprising said insert is polyethylene.  
     
     
         9 . A molded seat assembly as set forth in    claim 1   , wherein the plastic material comprising said seat portion is polyethylene.  
     
     
         10 . A molded seat assembly as set forth in    claim 9   , wherein the plastic material comprising said seat portion is linear polyethylene.  
     
     
         11 . A molded seat assembly as set forth in    claim 1    wherein said insert further includes at least one aperture through said top surface.  
     
     
         12 . A molded seat assembly as set forth in    claim 11   , wherein said at least one aperture includes a ridge, said ridge continuously extending about said aperture.  
     
     
         13 . A molded seat assembly as set forth in    claim 12   , wherein said ridge extends upwardly from said top surface of said insert.  
     
     
         14 . A molded seat assembly as set forth in    claim 11   , wherein said aperture includes an internal edge, said internal edge being partially embedded in said seat portion.  
     
     
         15 . A molded seat assembly as set forth in    claim 14   , wherein said internal edge is partially cohesive with said seat portion.  
     
     
         16 . A molded seat assembly as set forth in    claim 14   , wherein said internal edge is partially deformed by and is partially embedded in the plastic material to provide locking engagement between said insert and said seat portion.  
     
     
         17 . A method of making a molded seat assembly, said method comprising the steps of: 
 a) disposing an insert into an orifice of a mold, the mold having an inner surface defining an outer surface of a seat body, wherein said insert includes a peripheral edge which is adapted to be partially embedded in the outer surface of the seat body and wherein said insert includes a ridge disposed adjacent to said peripheral edge;    b) disposing a plastic material into said mold; and    c) molding said plastic material by simultaneously forcing said material against said mold inner surface and said insert, thereby forming said seat body, said plastic material engulfing said peripheral edge and forming a locking engagement between said seat body and said peripheral edge, said ridge limiting the flow of plastic material to a area adjacent to said peripheral edge.    
     
     
         18 . A method as set forth in    claim 17   , wherein said molding step includes forming a seat body having a seat bottom portion and a seat back portion.  
     
     
         19 . A method as set forth in    claim 17   , wherein said molding step includes partially cohesively bonding said peripheral edge with said outer surface of the seat body.  
     
     
         20 . A method as set forth in    claim 19    further including the step of deforming said peripheral edge to provide locking engagement between said insert and said seat.  
     
     
         21 . A method as set forth in    claim 17   , wherein said plastic material comprises polyethylene.  
     
     
         22 . A method as set forth in    claim 17   , wherein said insert comprises an injection molded plastic material.  
     
     
         23 . A method as set forth in    claim 22   , wherein said plastic material comprises polyethylene.  
     
     
         24 . A method as set forth in    claim 17   , wherein said insert includes an aperture with an internal edge, said internal edge limiting the flow of the plastic material from extending beyond said internal edge.  
     
     
         25 . The method as set forth in    claim 17    further including the step of cooling the formed seat assembly.  
     
     
         26 . The method as set forth in    claim 25    further including the step of straightening the fixture prior to cooling the formed seat assembly.