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Armrest having armrest bun and method of manufactureRelated Patent Categories: Metal Working, Upholstered Article Making, MethodArmrest having armrest bun and method of manufacture description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060200960, Armrest having armrest bun and method of manufacture. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional of U.S. application Ser. No. 10/800,548 filed Mar. 15, 2004. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to armrests of the type having an armrest bun. The armrest bun inserts within the armrest for cushioning. [0004] 2. Background Art [0005] U.S. Pat. No. 6,213,538 relates to an armrest and method for manufacturing the same. The '538 patent discloses an armrest bun. The armrest bun includes a die-cut foam pad adhered to a plastic substrate. The substrate and foam are inserted within the armrest to provide cushioning thereto. [0006] Armrests are manufactured in many different sizes and shapes. Past armrests were typically rectangular in shape for ease of manufacturing. Newer armrests may include curvatures and tapers. The new shaping is more aesthetically appealing and can provide better comfort. The foam in the armrest bun must closely match the armrest shaping. [0007] Dead-spots appear on an outer surface of the armrest if the foam fails to closely match the shaping of the armrest. The dead-spots are hollows or gaps at non-cushioned portions in the armrest. The dead-spots appear as indents on the surface of the armrest. The lack of cushioning at the dead-spots interrupts the feel and texture of the armrest. [0008] The dead-spots can be limited by closely shaping the foam to match the shape of the armrest. The matched foam snugly fits into the armrest to provide proper cushioning. The snug fit cushions the outer surface of the armrest to eliminate the dead-spots. The difficulty lies in shaping the foam to match the armrest, and doing so in a cost-efficient manner. [0009] The inventors of the present invention have identified a manufacturing problem with the '538 patent. The problem relates to shaping the die-cut foam disclosed by the '538 patent to properly fit the armrest. Shaping the foam with the desired shaping, which may include curvatures and tapers, requires a number of cutting operations. Multiple workstations may also be constructed to focus on different cuts. One station may be needed to cut a blank, another station may be needed to cut a curve on the blank, and yet another station may be needed to cut a taper on the blank. [0010] It is expensive for a manufacturer to spend time performing multiple cutting steps. It is also expensive for a manufacturer to purchase and maintain the various cutting tools and workstations. Accordingly, it is desirable to provide a more cost-effective method for manufacturing the armrest buns. SUMMARY OF THE INVENTION [0011] The inventors of the present invention have developed a more cost-effective method for manufacturing an armrest bun that overcomes the above-identified deficiencies of the prior art. [0012] The present invention contemplates a number features, including an armrest bun having a support substrate and a foam layer. The foam layer adheres to the support substrate and inserts within an armrest. The bun is preferably sized and shaped to provide cushioning support to the armrest. The bun preferably supports the armrest such that dead-spots are limited and the armrest has a smooth and uninterrupted texture. [0013] In one aspect of the present invention, the foam layer is a tapered and curved to match a tapered curvature of the armrest. The foam layer preferably comprises a poured foam. The foam can be poured into a mold cavity to adhere to the support substrate. The cavity can be sized and shaped to provide the desired taper and curvature. The poured foam solidifies in the cavity to take the shape of the tapered and curved cavity. The solidified foam matches the taper and curvature of the armrest to provide a snug fit therebetween. [0014] In one aspect of the present invention, the support substrate includes a channel. The channel rides within a shoulder of a support substrate in the armrest cavity to position the support substrate thereto. The support substrate can further include a ridge. The ridge can cooperate with a lip on an outer skin of the armrest to position it thereto. The support substrate can further include a locating face proximate the lip on the outer skin. The locating face corresponds with a bottom-out position of the lip to indicate proper assembly of the outer skin to the support substrate. [0015] In one aspect of the present invention, the support substrate includes an elongated prong. The prong can extend relative to a vertical wall of the support substrate. The foam material can form on a top and/or bottom of the prong. The prong can include apertures through which the poured foam can flow for bonding. The prong can include a prong ridge to limit slippage of the foam layer. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 illustrates a door assembly in accordance with the present invention; [0017] FIG. 2 illustrates a cross-sectional view of an armrest shown in FIG. 1 along the line 2-2; [0018] FIG. 3 illustrates a perspective view of an armrest bun in accordance with first embodiment the present invention; [0019] FIG. 4 illustrates a perspective view of an armrest bun in accordance with a second embodiment of the present invention; [0020] FIG. 5 illustrates a perspective view an armrest bun in accordance with a third embodiment of the present invention; and Continue reading about Armrest having armrest bun and method of manufacture... Full patent description for Armrest having armrest bun and method of manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Armrest having armrest bun and method of manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Armrest having armrest bun and method of manufacture or other areas of interest. ### Previous Patent Application: Method and system for assembly of lighting fixtures Next Patent Application: Shaft extractor Industry Class: Metal working ### FreshPatents.com Support Thank you for viewing the Armrest having armrest bun and method of manufacture patent info. 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