Apparatus and method of manufacturing a seat assembly

Abstract

The subject disclosure provides for a molding assembly for manufacturing a portion of a vehicle seat assembly. The molding assembly includes a first mold half having a first inner surface and a plurality of first posts extending from the first inner surface. The molding assembly also includes a second mold half having a second inner surface and a plurality of second posts extending from the second inner surface wherein each of the second posts align with a corresponding first post of the first mold half forming a mating line between corresponding posts of the first and second mold halves. The molding assembly also includes a formed cloth having a base and disposed on at least a portion of the second inner surface of the second mold half with the formed cloth having a plurality of sealing structures wherein each of the sealing structures align with a corresponding second post of the second mold half. The sealing structures each include a flange extending from the base and a sealing end extending from the flange and wherein the sealing end engages the first post of the first mold half forming a seal about the first post with the sealing end spaced from the mating line when the second mold half closes onto the first mold half for preventing foam from entering the mating line.

Description

APPARATUS AND METHOD OF MANUFACTURING A SEAT ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all the benefits of United States Provisional Application No. 63 / 698,338, filed September 24, 2024, which is hereby incorporated by reference in its entirety.FIELD OF DISCLOSURE

[0002] The subject disclosure generally relates to an apparatus and method of manufacturing a seat assembly used in automotive applications.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

[0004] FIG. 1 is a perspective view of a vehicle seat assembly.

[0005] FIG. 2 is a partially fragmented view of a molding assembly including a first mold half spaced apart from a second mold half with a fragmented formed cloth disposed onto the second mold half.

[0006] FIG. 3 is a plan view of an interior of the second mold half.

[0007] FIG. 4 is a plan view of the second mold half with the fragmented formed cloth disposed onto the second mold half.

[0008] FIG. 4A is a cross-sectional view taken along the line 4A of FIG. 4.

[0009] FIG. 5 is a perspective view of the second mold half with the fragmented formed cloth.

[0010] FIG. 5A is an enlarged fragmented perspective view taken along the lines 5A of FIG. 5.

[0011] FIG. 6 is an enlarged perspective view of the fragmented formed cloth.

[0012] FIG. 7 is a fragmented perspective view of the fragmented formed cloth disposed onto the first mold half.

[0013] FIG. 8 is a cross-sectional view of the molding assembly with the second mold half at an angle of 15 degrees to the first mold half.

[0014] FIG. 9 is a cross-sectional view of the molding assembly with the second mold half at an angle of 3 degrees to the first mold half.1Attorney Docket No. 065837.00138

[0015] FIG. 10 is a cross-sectional view of the molding assembly with the second mold half at an angle of 1 degree to the first mold half.

[0016] FIG. 11 is a cross-sectional view of the molding assembly with the second mold half at an angle of 0.5 degrees to the first mold half.

[0017] FIG. 12 is a cross-sectional view of the molding assembly with the second mold half at an angle of 0 degrees to the first mold half.

[0018] FIG. 13 is an enlarged cross-sectional view of the molding assembly with the first and second mold halves in a closed position.SUMMARY

[0019] The subject disclosure provides for a molding assembly for manufacturing a portion of a vehicle seat assembly. The molding assembly includes a first mold half having a first inner surface and a plurality of first posts extending from the first inner surface. The molding assembly also includes a second mold half having a second inner surface and a plurality of second posts extending from the second inner surface wherein each of the second posts align with a corresponding first post of the first mold half forming a mating line between corresponding posts of the first and second mold halves. The molding assembly also includes a formed cloth having a base and disposed on at least a portion of the second inner surface of the second mold half with the formed cloth having a plurality of sealing structures wherein each of the sealing structures align with a corresponding second post of the second mold half. The sealing structures each include a flange extending from the base and a sealing end extending from the flange and wherein the sealing end engages the first post of the first mold half forming a seal about the first post with the sealing end spaced from the mating line when the second mold half closes onto the first mold half for preventing foam from entering the mating line.

[0020] The subject disclosure also provides for a method of manufacturing a portion of a vehicle seat assembly using a molding assembly. The molding assembly includes a first mold half having a first inner surface and a plurality of first posts and a second mold half having a second inner surface and a plurality of second posts. The molding assembly also includes a formed cloth having a base and a plurality of sealing structures with the sealing structures each including a flange extending from the base and a sealing end extending from the flange. The method includes disposing the formed cloth on at least a portion of the second inner surface of the second mold half wherein each of the sealing structures align with a2Attorney Docket No. 065837.00138corresponding second post of the second mold half. The method also includes moving the second mold half with the formed cloth toward the first mold half such that the sealing ends of said sealing structures engage the first posts of the first mold half. The method also includes closing the second mold half onto the first mold half to form a mold chamber with each of the second posts aligning with a corresponding first post to form corresponding mating lines between corresponding first and second posts and each sealing end forms a seal about the first post with each sealing end spaced from each mating line. The method also includes injecting foam into the mold chamber wherein the foam expands within the mold chamber with the sealing structures of the formed cloth preventing foam intrusion at the mating lines between corresponding first and second posts of the first and second mold halves.DETAILED DESCRIPTION

[0021] Referring to the Figures, wherein like numerals indicate like or corresponding components throughout the several views, a vehicle seat assembly 10 is shown.

[0022] As shown in FIG. 1, a perspective view of the vehicle seat assembly 10 with a seat bottom 12, a seat back 14, and a head restraint 16 is shown. The seat bottom 12 supports the occupant's legs, while the seat back 14 supports the occupant's back, and the head restraint 16 supports the occupant's head. The vehicle seat assembly 10 shown represents a schematic seat within a vehicle and it should be appreciated to those skilled in the art that the vehicle seat assembly 10 may look different depending on the application.

[0023] A molding assembly 18 for manufacturing a portion of the vehicle seat assembly 10 is shown in FIG. 2 having a first mold half 20 and a second mold half 22. The first mold half 20 includes a first inner surface 30 and a first outer surface 32. The second mold half 22 includes a second inner surface 26 and a second outer surface 28. Additionally, the second mold half 22 includes a formed cloth 24 having a base and the formed cloth 24 is disposed on at least a portion of the second inner surface 26 of the second mold half 22. As used herein, disposed on is intended to broadly encompass arrangements in which the formed cloth 24 is positioned relative to the second mold half 22, including direct contact, partial contact, spaced configurations, or combinations thereof. As such, the formed cloth 24 may be partially disposed on (or secured to, or fastened to) the second mold half 22 while also being partially spaced from the second mold half 22 depending on the application. For example, the base of the formed cloth 24 may abut the second inner surface 26 of the second mold half 22 while the rest of the formed cloth 24 is spaced apart from the second inner surface 26 and / or the second mold half3Attorney Docket No. 065837.0013822. Additionally, the formed cloth 24 may be secured to the second mold half 22 using various attachment methods. These may include mechanical engagement, such as hooking over features of the mold; magnetic adhesion, for example using ferrous-backed stickers; or physical fastening, such as pins inserted through the formed cloth 24 and anchored to the second mold half 22. The specific method of securing may vary depending on the design requirements and manufacturing constraints of the particular application. In other words, a portion of the formed cloth 24 may be secured to the second mold half 22, while another portion remains spaced, which may help accommodate design flexibility for the particular vehicle application. The formed cloth 24 as shown in FIG. 2 is an illustrative representation of the formed cloth 24 because the formed cloth 24 preferably will be larger than depicted in FIG. 2. The details of the formed cloth 24 will be discussed further below. It should be appreciated to those skilled in the art that the first and second mold halves 20, 22 are coupled together via a hinge mechanism (not shown) or other suitable device allowing the second mold half 22 to close onto the first mold half 20 creating a mold chamber between the first inner surface 30 and the second inner surface 26. Additionally, the molding assembly 18 shown in FIG. 2 is one version of a molding assembly that may be utilized to create foam parts for the vehicle seat assembly 10, but depending on the vehicle application, the first and second mold halves 20, 22 may be shaped differently.

[0024] Referring to FIGS. 3-5 A, the second mold half 22 includes a plurality of posts, which are arranged on and extend from the second inner surface 26. These posts include perimeter posts 36, a first center post 38, a first off-center post 40, a second off-center post 42, an elliptical post 44, perimeter elliptical posts 46, and a second center post 56. Collectively, the posts arranged on the second inner surface 26 may be referred to as a plurality of second posts. The perimeter posts 36, first center post 38, first off-center post 40 and second off-center post 42 are shaped as cylinders with circular open tops. Whereas the elliptical post 44 and perimeter elliptical posts 46 are shaped as elliptical cylinders with elliptical open tops. The posts help create air passageways within the finished foam part to facilitate airflow for the ventilation system to properly cool the occupant. It should be appreciated that the posts 36, 38, 40, 42, 44, 46, 56 could be in a different arrangement than the one shown in FIG. 3 including increasing or decreasing the number of posts, which could help optimize the airflow for a different vehicle application. It should also be appreciated each of the posts 36, 38, 40, 42, 44, 46, 56 may be shaped differently depending on the vehicle application. FIG. 3 also shows the second mold half 22 including a hole 34 which can be used to accommodate an additional post.4Attorney Docket No. 065837.00138

[0025] Referring to FIG. 4-5A, the formed cloth 24 as shown covers the first and second off-center posts 40, 42, the first center post 38, and the elliptical post 44 (which are seen in FIG. 3). As mentioned above, the formed cloth 24 is a fragmented portion of a larger cloth that would be used and is shown in this manner for illustrative purposes. Preferably, the formed cloth 24 will cover any post needed including all the posts 36, 38, 40, 42, 44, 46, 56, as well as the additional post, which could be disposed into the hole 34. It should be appreciated that the second mold half 22 may include additional posts not shown. If the specific part requires full B-surface cloth coverage, the formed cloth will also extend to cover the entire surface illustrated in FIG. 3.

[0026] The formed cloth 24 includes at least one, and preferably a plurality, of sealing structures that align with a corresponding second post of the second mold half 22. The sealing structures are disposed about the posts and designed to seal the corresponding posts between the first and second mold halves 20, 22. The formed cloth 24 as shown includes a first and second off-center sealing structure 50, 52 (which corresponds to the first and second off- center posts 40, 42), a center sealing structure 54 (which corresponds to the first center post 38), and an elliptical sealing structure 48 (which corresponds to the elliptical post 44). It should be appreciated that the formed cloth 24 shown may be sized differently depending on the specific application, which may include more or less sealing structures and may cover more of the second inner surface 26 of the second mold half 22 than shown. For example, the formed cloth 24 may be shaped in a way that includes covering the perimeter elliptical posts 46 as well as the perimeter posts 36 of the second mold half 22.

[0027] Each sealing structure 48, 50, 52, 54 of the formed cloth 24 includes a flange 84 extending outward from the base of the formed cloth 24. The flange 84 of each sealing structure extends along a flange height, which determines the height of each sealing structure. The height of each sealing structure may change depending in part on the respective posts of the first and second mold halves 20, 22. The sealing structures of the illustrated formed cloth 24 includes flanges 84 with associated flange heights Hl, H2, H3, H4, which can be seen in FIG. 6. A portion of these heights can also be seen in FIG. 13. Additionally, the elliptical sealing structure 48 includes a second flange height Hl’ (shown in FIG. 13), which is different from the flange height Hl due to the location of the elliptical sealing structure 48 being at the perimeter of the formed cloth 24. It should be appreciated that the flange height of each sealing structure may vary depending on the necessary height needed of each sealing structure and the location of the sealing structure on the formed cloth 24.5Attorney Docket No. 065837.00138

[0028] As best shown in FIG. 13, each sealing structure includes a sealing end 82 that extends from the flange 84 and curves backward toward the base while also extending outward from the flange 84. Each sealing end is designed to engage a corresponding post of the first mold half 20 forming a seal about each corresponding post with each sealing end being spaced apart from a mating line when the second mold half 22 closes onto the first mold half 20. This sealing effect is described in greater detail below. The sealing end 82, in one preferred embodiment, is rolled and could be known as a rolled back end 82. Thus, the term sealing end and rolled back end will be used interchangeably herein. The sealing end 82 may also be spaced apart from the second posts of the second mold half 22 while the base of the formed cloth 24 abuts the second mold half 22. Additionally, each sealing end 82 defines a distal end 86 with the distal end 86 being spaced from the flange 84 with the distal end 86 and the flange 84 being interconnected by a connector portion 83. However, it should be appreciated that the connector portion 83, as shown in FIG. 13, is illustrative and could be of different sizes and lengths including being removed altogether depending on the application. Additionally, the distal end 86 of each rolled back end 82 is continuous such that the seal and its sealing effect, which is described in more detail below, is continuous about the posts on the first mold half 20 when the first and second mold halves 20, 22 are closed.

[0029] Each sealing structure 48, 50, 52, 54 of the formed cloth 24 are spaced from the corresponding posts of the second mold half 22 such that the flange 84, connector portion 83 (if present), and sealing end 82 define a cavity between the sealing structures and the corresponding first and second posts once the second mold half 22 is closed onto the first mold half 20. The cavity may be of any suitable size and is exaggerated in the figures for illustrative purposes. As discussed in greater detail below, the cavity prevents the intrusion of foam at the mating line between the mold halves, which is formed by each of the second posts aligning with a corresponding post of the first mold half 20. Each rolled back end 82 has an associated rolled back end height Rl, R2, R3, R4. The rolled back end heights may be different and depend in part on the shape of the respective posts from the first and second mold halves 20, 22. The rolled back end heights may also be different depending on the amount of sealing that is needed between each respective post of the first and second mold halves 20, 22, which may depend on the specific vehicle application.

[0030] Each flange 84 and rolled back end 82 and their associated heights function to seal the respective posts of the first and second mold halves 20, 22, which is described below. It should be appreciated that the flanges 84, the flange heights Hl, H2, H3,6Attorney Docket No. 065837.00138H4, the rolled back ends 82, and the rolled back end heights Rl, R2, R3, R4 may be different than shown depending on the specific application.

[0031] As the second mold half 22 closes onto the first mold half 20, the posts from the first mold half 20 are accepted into each sealing structure and each post penetrates into each sealing structure to meet the posts on the second mold half 22. This penetration can be seen in FIG. 7, which shows the molding assembly 18 in the closed position with the second mold half 22 removed from the view. The first and second mold halves 20, 22 are designed to fit together, which means that the two mold halves 20, 22 have corresponding posts. The first mold half 20 includes an elliptical post 70 (which corresponds to the elliptical post 44 of the second mold half 22), perimeter elliptical posts 72 (which correspond to the perimeter elliptical posts 46 of the second mold half 22), a first off-center post 74 (which corresponds to the first off-center post 40 of the second mold half 22), a second off-center post 76 (which corresponds to the second off-center post 42 of the second mold half 22), a first center post 68 (which corresponds to the first center post 38 of the second mold half 22), a second center post 66 (which corresponds to the second center post 56 of the second mold half 22), post 64 (which corresponds to the hole 34 of the second mold half 22), and a perimeter posts 58 (which correspond to the perimeter posts 36 of the second mold half 22). Collectively, the posts arranged on and extending from the first inner surface 30 may be referred to as a plurality of first posts.

[0032] As previously discussed, and shown in FIG. 4, the formed cloth 24 covers up the elliptical post 44, the first and second off-center posts 40, 42, and the first center post 38 of the second mold half 22. In other words, as the second mold half 22 closes onto the first mold half, the formed cloth 24 is in between the first and second mold halves 20, 22, which means the elliptical post 70 will correspond to the elliptical sealing structure 48, the first off- center post 74 will correspond to the first off-center sealing structure 50, the second off-center post 76 will correspond to the second off-center sealing structure 52, and the first center post 68 will correspond to the center sealing structure 54.

[0033] Referring to FIGS. 7 and 13, each post 68, 70, 76, 74 from the first mold half 20 has penetrated into each respective sealing structure 54, 48, 52, 50, which creates a distance between the flanges 84 and the mating lines of each pair of posts from the first and second mold halves 20, 22. This distance is illustrated in FIG 13 as mating heights LI and L4 and is discussed in greater detail below. This penetration helps prevent flash from the molding process because it requires the expanding foam to travel a distance prior to reaching the mating lines. The specifics of the distance and the prevention of flash forming is described in detail7Attorney Docket No. 065837.00138below. Additionally, each sealing structure 54, 48, 52, 50 define openings each having an opening diameter (shown on FIG. 5 A as W4, Wl, W3 and W2, respectively), which are sized to be smaller than a corresponding first post diameter (not shown) of the posts 68, 70, 76, 74 of the first mold half 20. The opening diameter being smaller than its corresponding first post diameter helps create a sealing effect. As each post 68, 70, 76, 74 penetrates into each sealing structure 54, 48, 52, 50, the opening of each sealing structure 54, 48, 52, 50 stretches to accommodate the larger corresponding post 68, 70, 76, 74. The stretching of each sealing structure essentially hugs each of the posts of the first mold half 20 as the second mold half 22 closes onto the first mold half 20 creating a self-sealing effect because the rolled back end 82 is continuous and the deeper the posts penetrate into each sealing structure, the tighter the sealing effect becomes. The stretching also helps accommodate the angle at which the second mold half 22 closes onto the first mold half 20. The progression of second mold half 22 closing onto the first mold half 20 is described in detail below. As mentioned above, the formed cloth 24 as shown throughout the figure drawings is generic and is represented for illustrative purposes because the formed cloth 24 would preferably be larger in size with sealing structures to accommodate all the posts in the molding assembly 18.

[0034] As mentioned above, the formed cloth 24 is made from a material that may stretch and also provides the appropriate amount of engagement and sealing against the posts while being permeable enough to allow air to escape. The formed cloth 24 may comprise of a plurality of fibers, which may include at least one chosen from polyester fibers, nylon fibers, and natural fibers. The fibers used to create the formed cloth 24 are chosen based on functionality and the properties of each type of fiber. Polyester and nylon fibers are synthetic fibers, which means they are made from chemical compounds derived from petroleum, coal, or natural gas. Natural fibers, on the other hand, come from plants or animals, such as cotton, wool, silk, or linen. For example, the plurality of fibers of the formed cloth 24 may include a nylon fiber based on the properties of nylon fibers such as strength, durability, resistance to shrinking, and moisture absorption. The plurality of fibers of the formed cloth 24 may be nonwoven. The formed cloth 24 can comprise of woven or non-woven fabrics, solid or liquid polymeric binders, optional layers such as various foams, polymeric films, metallized films, powders (e.g., carbon), encapsulated particles, and be composed of various single or blends of synthetic or natural fibers.

[0035] In addition to the formed cloth 24 creating a sealing effect as described above, the formed cloth 24 is made from a material that is permeable, which may help in avoiding imperfections in manufactured product of a portion of the vehicle seat assembly 10.8Attorney Docket No. 065837.00138This permeability allows air to travel through the formed cloth 24 throughout the molding process. For example, during the molding process when the molding assembly 18 is in the closed position, air may be present at the base of the elliptical post 44 of the second mold half 22. Without the formed cloth 24, as the foam rises within the mold chamber, trapped air could remain at the base of the elliptical post 44 and create a void in the finished foam product because the trapped air has no way of escaping. This void may comprise the functionality of the ventilated system. However, the inclusion of the formed cloth 24 allows the trapped air to move due to the permeability of the formed cloth 24. The trapped air is effectively pushed away from the base of the elliptical posts 44 and through the formed cloth 24. As well known in the industry, prior to the completion of the molding process, the air within the mold chamber escapes through vents (not shown).

[0036] During the manufacturing process, the formed cloth 24 is disposed onto the second inner surface 26 of the second mold half 22 when the second mold half 22 is in a normal position. In other words, when the molding assembly 18 is in an open position, the formed cloth 24 is disposed onto the second inner surface 26 of the second mold half 22 and then the second mold half 22 begins to close in order to create the mold chamber between the first and second mold halves 20, 22 prior to initiating the molding process. The progression of the molding assembly 18 closing is discussed in detail below.

[0037] FIGS. 8-12 show a progression of the second mold half 22 (including the disposed formed cloth 24) moving and eventually closing onto the first mold half 20 thereby creating the mold chamber between the first inner surface 30 and the second inner surface 26. Specifically, FIG. 8 shows the molding assembly 18 with the second mold half 22 at an angle of 15 degrees to the first mold half 20, FIG. 9 shows the molding assembly 18 with the second mold half 22 at an angle of 3 degrees to the first mold half 20, FIG. 10 shows the molding assembly 18 with the second mold half 22 at an angle of 1 degree to the first mold half 20, FIG. 11 shows the molding assembly 18 with the second mold half 22 at an angle of 0.5 degrees to the first mold half 20, and FIG. 12 shows the molding assembly 18 with the second mold half 22 at an angle of 0 degrees (or the closed, engaged, position) to the first mold half 20. As can be seen throughout the progression of the second mold half 22 moving and closing onto the first mold half 20, the sealing ends 82 engage the first posts on the first mold half 20 while the posts of the second mold half 22 are spaced apart from the first posts. In other words, the sealing ends 82 engage the first posts prior to the second mold half 22 fully closing onto the first mold half 20 and prior to the formation of mating lines between corresponding posts from the first and second mold halves 20, 22. The molding process begins once the molding assembly 18 is9Attorney Docket No. 065837.00138in the closed position. As previously mentioned, the first and second mold halves 20, 22 have features that correspond with one another allowing the halves 20, 22 to fit together to create foam parts for the vehicle seat assembly 10.

[0038] FIGS. 12 and 13 illustrate the molding assembly 18 in the closed position and foam is then injected into the mold chamber and subsequently expands. Between each respective post on the first and second mold halves, there exists mating lines. The unique formed cloth 24 of the subject invention with the sealing structures avoids flash forming in the mating lines between the respective posts. A portion of the mating lines within the molding assembly 18 are shown in FIG. 13, which shows a fragmented view of the molding assembly 18 in the closed position. The first center post 38 of the second mold half 22 and the first center post 68 of the first mold half 20 create a first mating line 78. Likewise, the elliptical post 44 of the second mold half 22 and the elliptical post 70 of the first mold half 20 creates a second mating line 80. Using these posts and mating lines as examples in FIG. 13, the relative positioning of the flange, rolled back ends, and cavity are shown. A mating height L4 is formed between the rolled back end and mating line 78. Similarly, a mating height LI is formed between rolled back end and mating line 80. Cavities are formed within the mating heights and between the posts and respective flanges. As such, the mating lines 78, 80 are disposed within the cavities.

[0039] As the foam expands within the mold chamber of the molding assembly 18, the foam pushes against the formed cloth 24 and each of the sealing structures 48, 50, 52, 54 causing the sealing structures 48, 50, 52, 54 to be displaced toward the posts of the first and second mold halves 20, 22 and thereby reducing the size of the cavity. It is to be appreciated that the cavity may become smaller and may collapse entirely or partially as the foam expands within the mold chamber. Due to the formed cloth 24 being made out of permeable material, as the sealing structures 48, 50, 52, 54 push against their respective posts 44, 40, 42, 38 of the second mold half 22, trapped air will travel along the mold chamber and escape through vents in the mold to reduce the potential for imperfections in the finished foam product. In other words, the formed cloth 24 allows air to pass through the formed cloth 24, which may include passing through each sealing structure 48, 50, 52, 54 through the cavity for preventing potential imperfections.

[0040] Each mating height LI, L4 of the sealing structure and the corresponding cavity prevent foam from reaching the mating lines 78, 80, which in turn prevent flash from forming between the mating lines 78, 80. Each rolled back end 82, which may be referred to as the sealing end 82, engages the corresponding post on the first mold half 20 and if any foam is10Attorney Docket No. 065837.00138able to enter between the rolled back end and the post, the foam is unable to travel the distance equal to the mating height LI, L4 to reach the mating lines 80, 78. Additionally, during the molding process, the foam will be expanding within the mold chamber from the first mold half 20 up to the second mold half 22. During the expansion, the foam will push each flange 84 and each rolled back end 82 toward the corresponding posts, which also helps prevent additional foam from accessing the mating lines 80, 78 and creating flash. It should be appreciated that there exists mating lines between any corresponding posts of the first and second mold halves 20, 22 and the preferred formed cloth 24 would be larger and cover the necessary additional mating lines.

[0041] An exemplary embodiment of the molding assembly 18 including the first mold half 20, the second mold half 22 and the formed cloth 24 is shown in the Figures. However, the embodiments discussed herein are not intended to be exhaustive or limit the disclosure to any particular form. The terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings and the disclosure may be practiced otherwise than as specifically described.11Attorney Docket No. 065837.00138

Claims

CLAIMSWhat is claimed is:

1. A molding assembly for manufacturing a portion of a vehicle seat assembly, said molding assembly comprising: a first mold half having a first inner surface and a plurality of first posts extending from said first inner surface; a second mold half having a second inner surface and a plurality of second posts extending from said second inner surface wherein each of said second posts align with a corresponding said first post of said first mold half forming a mating line between corresponding posts of said first and second mold halves; a formed cloth having a base and disposed on at least a portion of said second inner surface of said second mold half with said formed cloth having a plurality of sealing structures wherein each of said sealing structures align with a corresponding second post of said second mold half, said sealing structures each including: a flange extending from said base; and a sealing end extending from said flange; and wherein said sealing end engages said first post of said first mold half forming a seal about said first post with said sealing end spaced from said mating line when said second mold half closes onto said first mold half for preventing foam from entering said mating line.

2. The molding assembly of claim 1 , wherein said sealing ends are rolled back ends such that a distal end of each of said rolled back ends curve back toward said base of said formed cloth.

3. The molding assembly of claim 1, wherein each of said sealing structures are spaced from said corresponding second posts of second mold half such that said flange and said sealing end define a cavity between said sealing structure and said first and second posts.

4. The molding assembly of claim 1, wherein said formed cloth is partially secured to said second mold half and partially spaced from said second mold half.

5. The molding assembly of claim 1 , wherein said base of said formed cloth abuts said second inner surface of said second mold half.12Attorney Docket No. 065837.001386. The molding assembly of claim 1, wherein said sealing end defines a distal end with said distal end being continuous such that said seal is continuous about said first post.

7. The molding assembly of claim 1, wherein a portion of said formed cloth is secured to said second mold half.

8. The molding assembly of claim 1, wherein said sealing structures define openings having an opening diameter and each of said first posts of said first mold half defining a first post diameter with said opening diameter being smaller than said first post diameter.

9. The molding assembly of claim 1 , wherein said formed cloth is permeable.

10. The molding assembly of claim 1, wherein said sealing end defines a distal end with said distal end being spaced from said flange and further including a connector portion interconnecting said distal end and said flange such that said flange, said connector portion, and said distal end define a cavity between the sealing end and said first and second posts.

11. The molding assembly of claim 1, wherein said formed cloth comprises a plurality of fibers with said plurality selected from the group of polyester fibers, nylon fibers, and natural fibers.

12. A method of manufacturing a portion of a vehicle seat assembly using a molding assembly wherein said molding assembly includes a first mold half having a first inner surface and a plurality of first posts and a second mold half having a second inner surface and a plurality of second posts and a formed cloth having a base and a plurality of sealing structures with said sealing structures each including a flange extending from said base and a sealing end extending from said flange, the method comprising the steps of: disposing the formed cloth on at least a portion of the second inner surface of the second mold half wherein each of the sealing structures align with a corresponding second post of the second mold half; moving the second mold half with the formed cloth toward the first mold half such that the sealing ends of said sealing structures engage the first posts of the first mold half; closing the second mold half onto the first mold half to form a mold chamber with each of13Attorney Docket No. 065837.00138the second posts aligning with a corresponding first post to form corresponding mating lines between corresponding first and second posts and each sealing end forms a seal about the first post with each sealing end spaced from each said mating line; and injecting foam into the mold chamber wherein the foam expands within the mold chamber with the sealing structures of the formed cloth preventing foam intrusion at the mating lines between corresponding first and second posts of the first and second mold halves.

13. The method of claim 12, wherein the step of moving the second mold half toward the first mold half is further defined as the sealing ends of the sealing structures engaging the first posts of the first mold half while the second posts are spaced from the first posts.

14. The method of claim 12, wherein the step of disposing the formed cloth on at least a portion of the second inner surface of the second mold half is further defined as the sealing ends are spaced apart from the second posts of the second mold half while the base of the formed cloth abuts the second mold half.

15. The method of claim 12, wherein the formed cloth is permeable and wherein the step of injecting foam into the mold chamber is further defined by the formed cloth allowing air to pass through the formed cloth for preventing imperfections in the vehicle seat assembly.

16. The method of claim 12, wherein each of the sealing structures are spaced from the corresponding second posts of the second mold half such that the flange and sealing end define a cavity between the sealing structure and the first and second posts and the step of injecting foam into the mold chamber is further defined by the sealing structure allowing air to pass through the cavity.

17. The method of claim 12, wherein the step of injecting foam into said mold chamber is further defined by the foam displacing said flanges and said sealing ends toward said first and second posts of said first and second mold halves.

18. The method of claim 12, wherein each of the sealing structures are spaced from the corresponding second posts of the second mold half such that the flange and sealing end define a cavity between the sealing structure and the first and second posts and the step of injecting foam into the mold chamber is further defined by the cavity becoming smaller as the foam expands14Attorney Docket No. 065837.00138within the mold chamber.15Attorney Docket No. 065837.00138

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