Method of manufacturing cushion construction for seating unit
First Claim
Patent Images
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.
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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.
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Citations
15 Claims
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1. A method comprising steps of:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of manufacturing a seating unit comprising steps of:
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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. - View Dependent Claims (12, 13, 15)
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14. A method of manufacturing a seating unit comprising steps of:
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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.
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Specification