Method of manufacturing cushion construction for seating unit

• US 20020125759A1
• Filed: 05/01/2002
• Published: 09/12/2002
• Est. Priority Date: 04/19/1999
• Status: Active Grant

• Current Assignee: Steelcase Incorporated
• Original Assignee: Gordon J Peterson
• Inventors: Peterson, Gordon J.
• Granted Patent: US 6,880,215 B2
• Time in Patent Office: Days
• US Class Current: 297/452.49
• CPC Class Codes: A47C 31/023 connecting upholstery to frames, e.g. by hooks, clips, snap fasteners, clamping means or the like
• CPC Class Codes: A47C 7/24 Upholstered seats A47C7/18 takes precedence
• CPC Class Codes: A47C 7/46 with special, e.g. adjustable , lumbar region support profile; "Ackerblom" profile chairs
• CPC Class Codes: Y10T 29/481 Method
• CPC Class Codes: Y10T 29/49867 of skin on frame member

Abstract

A method of manufacturing a seating unit, such as a chair, includes manufacturing a cushion made from a non-woven fibrous material, and attaching the cushion to the seating unit for comfortable support. The cushion is made by cutting a blank from non-woven fibrous sheet material, steam-forming the blank into a pre-formed cushion shaped to support a user, and attaching a stiffener panel to the pre-formed cushion to provide a stiffened cushion assembly. The cushion assembly is aesthetically covered and assembled to seating unit. Advantageously, trimmings from the fibrous material can be recycled.

Claims

1. A method comprising steps of:

cutting a blank from a sheet of non-woven fibrous material; and

forming the blank into a pre-formed cushion shaped as a back or seat on a seating unit.

2. The method defined in claim 1, including attaching a cushion stiffener to the cushion to provide additional structure to the cushion.

3. The method defined in claim 2, including providing a support panel and attaching the cushion stiffener to the support panel.

4. The method defined in claim 3, including covering the cushion with a cover assembly that forms a sock around the cushion.

5. The method defined in claim 4, wherein the cover assembly includes a fabric panel of stretch material, and including stretching the fabric panel when attaching the cover assembly and the cushion to the support panel.

6. The method defined in claim 4, wherein the support panel is shaped to support a seated user'"'"'s back, and including steps of providing a chair with a back frame and attaching the support panel to the back frame.

7. The method defined in claim 1, wherein the fibrous material includes PET material.

8. The method defined in claim 1, including covering the cushion with a cover assembly that forms a sock around the cushion.

9. The method defined in claim 8, wherein the cover assembly includes a fabric panel of stretch material, and including stretching the fabric panel when attaching the cover assembly and the cushion to the support panel.

10. The method defined in claim 9, wherein the support panel is shaped to support a seated user'"'"'s back, and including steps of providing a chair with a back frame and attaching the support panel to the back frame.

11. A method of manufacturing a seating unit comprising steps of:

providing a seat support adapted to be supported by a base;

providing a back upright adapted to be operably supported by one of the base and the seat support for movement between an upright position and an angled position;

attaching a back support to the back upright;

assembling a cushion assembly including providing a non-woven fibrous mat of cushioning material that is air-permeable, and attaching a stiffener panel to the cushion material; and

positioning the cushion assembly on at least one of the back support and the seat support.

12. The method defined in claim 11, including pre-forming the cushion material to include a feature line formed into the cushion material.

13. The method defined in claim 11, wherein the step of pre-forming the cushion material includes forming depressions in the cushion material, but with the cushion material maintaining a predetermined uniform density and an absence of flash lines or parting lines.

15. The method defined in claim 14, wherein the step of pre-forming includes heating the fibrous mat in a manner not causing a parting line on the preformed fibrous mat.

14. A method of manufacturing a seating unit comprising steps of:

providing a non-woven fibrous mat of cushioning material that is air-permeable;

trimming the fibrous mat to a predetermined shape;

pre-forming the fibrous mat by using a heating process;

attaching a stiffener panel to the cushion material; and

positioning the cushion assembly on a seating unit for comfortably supporting a seated user.