Trim cover assembly

Abstract

A trim cover assembly formed by sewing together a plurality of cover materials into a three-dimensional configuration which is to undergo a foaming process in which a liquid foaming agent is injected into the trim cover assembly and a resultant foam padding is filled therein. Each of the cover materials comprises a top cover layer and a slab foam wadding layer fixed to a reverse side of the top cover layer. The slab foam wadding layer is of a continuous cellular structure having an air permeability of from 0.2 cc/cm 2 /sec. to 1 cc/cm 2 /sec. so that, during the foaming process, the liquid foaming agent is impregnated and cured in the slab foam wadding layer at a proper rate relative to the thickness of the latter so as not to reach the top cover layer.

What is claimed is:  
     
         1 . A trim cover assembly formed by sewing together a plurality of cover materials into a three-dimensional configuration which is to undergo a foaming process in which a liquid foaming agent is injected into said trim cover assembly and a resultant foam padding is filled therein, wherein each of said plurality of cover materials comprises: 
 a top cover layer having an outer surface side and a reverse side; and    a slab foam wadding layer integrally laminated on said reverse side of said top cover layer,    and wherein said slab foam wadding layer is of a continuous cellular structure having an air permeability of from 0.2 cc/cm 2 /sec. to 1 cc/cm 2 /sec.    
     
     
         2 . The trim cover assembly as claimed in  claim 1 , where said to cover layer is of an air permeable property.  
     
     
         3 . A foamed product using said trim cover assembly claimed in  claim 1 , which is formed by the foaming process comprising the steps of placing said trim cover assembly in a foaming die, injecting said liquid foaming agent into an inside of said trim cover assembly, and subjecting the trim cover assembly and said liquid foaming agent to foaming, under such a condition that a foaming pressure is set relative to a thickness of said slab foam wadding layer at a rate that allows the liquid foaming agent to be impregnated in at most half of thickness of said slab foam wadding layer.