Skin-foam architecture for seating

1 . A method for forming a skin-foam architecture for a seating, the method comprising:

loading a backing cover into a first portion of a tool; and

applying and curing a skin on a second portion of the tool, the skin including a first layer, and a second layer under the first layer, wherein applying and curing the skin includes:

spraying the first layer directly on the second portion, and curing the first layer on the second portion, the first layer having a first thickness, and subsequent to applying and curing the first layer applying the second layer on the first layer, the second layer having a second thickness, wherein the second thickness is greater than the first thickness;

laminating a mesh under the skin and directly adjacent to the second layer of the skin subsequent to curing of the second layer, wherein the mesh is formed from a plurality of trim pieces that are not interconnected, wherein each trim piece includes conductive material, and wherein the second portion of the tool includes a plurality of channels configured to assist in holding the plurality of trim pieces in place by applying pressure on the mesh;

causing a placement of a comfort foam layer under the mesh and the skin and adjacent the mesh to bond the mesh to the skin;

mating the first portion and the second portion of the tool; and

causing a placement of foam between the mated first portion and second portion of the tool under the comfort foam layer and adjacent the comfort foam layer, wherein the comfort foam layer and the foam between the mated first portion and second portion of the tool are separate layers.

2 . The method of claim 1 , wherein the first layer is made of UV resistant A-surface polyurethane.

3 . The method of claim 1 , wherein the second layer is made of polyurethane.

4 . The method of claim 1 , wherein applying the second layer includes spraying material onto the first layer.

5 . The method of claim 1 , wherein the conductive material includes conductive fibers or conductive wires.

6 . A method for forming a skin-foam architecture for a seating, the method comprising:

loading a backing cover into a first portion of a tool;

applying and curing a skin on a second portion of the tool, the skin including a first layer, and a second layer under the first layer, wherein applying and curing the skin includes:

spraying the first layer directly on the second portion, and curing the first layer on the second portion, the first layer having a first thickness, and

subsequent to applying and curing the first layer, spraying the second layer on the first layer, the second layer having a second thickness;

laminating a mesh under the skin directly adjacent the second layer, wherein the mesh is formed from a plurality of trim pieces that are not interconnected, wherein each trim piece includes conductive material, and wherein the second portion of the tool includes a plurality of channels configured to assist in holding the plurality of trim pieces in place by applying pressure on the mesh;

causing a placement of a foam layer onto the mesh and the skin, the foam layer located under the mesh and the skin, to bond the mesh to the foam layer and to bond the foam layer to the skin;

causing, after placement of the foam layer, a placement of foam between the first portion and the second portion of the tool when mated using foam in place to place the foam between the backing cover and the foam layer, wherein the foam layer and the foam between the mated first portion and second portion of the tool are separate.

7 . The method of claim 6 , wherein the first layer is made of UV resistant A-surface polyurethane.

8 . The method of claim 6 , wherein the second layer is made of polyurethane.

9 . The method of claim 6 , wherein the foam layer comprises a comfort foam layer.

10 . The method of claim 6 , wherein causing a placement of the foam layer under the mesh and the skin comprises spraying or pouring a material onto the mesh.