Cushion forming apparatus and method of use

• US 20050161151A1
• Filed: 11/01/2004
• Published: 07/28/2005
• Est. Priority Date: 10/31/2003
• Status: Active Grant

• Current Assignee: Ohio Foam Corporation
• Original Assignee: Tiger Sales, Inc.
• Inventors: Cabraja, Mark S.
• Granted Patent: US 7,320,737 B2
• Time in Patent Office: Days
• US Class Current: 156/212
• CPC Class Codes: B29D 99/0092 Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B68G 7/05 Covering or enveloping cores of pads in plastics material using a matching die B29C63/025
• CPC Class Codes: Y10T 156/1011 Overedge bending or overedge folding
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1034 Overedge bending of lamina about edges of sheetlike base
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1046 Bending of one lamina only
• CPC Class Codes: Y10T 156/1744 Means bringing discrete articles into assembled relationship

Abstract

A cushion forming apparatus includes a frame with a pivoted hold down member and a pneumatic bladder below the hold down member. The bladder is alternately connectable with a source of pressure and to atmosphere through control valve. The components of a cushion sub-assembly are loaded onto the deflated bladder, the hold down member is lowered to the locked position, the bladder is inflated to force a cover around foam blocks and adjacent a base, the cover is attached to the side edges of the base, the bladder is deflated, the hold down member released and the assembled structure removed.

Claims

1. A cushion forming apparatus comprising:

a frame for securing the apparatus to a work surface;

a hold down member moveably attached to the frame and moveable between an open position for loading and unloading of the apparatus ad a closed operative position; and

a bladder below the hold down member, wherein the bladder is configured to receive components of a cushion thereon wherein the bladder is selectively inflated and deflated when the hold down member is in the closed position and the components of the cushion are on the bladder for forming and assembly of the cushion.

2. The apparatus of claim 1 further including a source of air pressure and a control valve, wherein the bladder is a pneumatic bladder alternately connectable with a source of pressure and to atmosphere through the control valve.

3. The apparatus of claim 2 further including a latch on the hold down member that selectively engages with the frame when the hold down member is pivoted to the closed position.

4. The apparatus of claim 3 further including a controller coupled to the control valve wherein the controller prevents inflation of the bladder unless the latch on the hold down member is engaged with the frame.

5. The apparatus of claim 3 further including a controller coupled to the control valve wherein the controller prevents disengagement of the latch on the hold down member from the frame unless the bladder is sufficiently deflated.

6. The apparatus of claim 3 further including a controller coupled to the control valve wherein the controller prevents inflation of the bladder unless the operator has both hands on the controller.

7. The apparatus of claim 2 further including a controller coupled to the control valve wherein the controller includes a timer which will deflate the bladder a predetermined time after full inflation of the bladder.

8. The apparatus of claim 7 wherein the predetermined time is set by the operator from between a maximum and a minimum.

9. A method of forming a cushion having components thereof including a rigid base, at least one foam block and a cover, said method comprising the steps of:

placing the components of the cushion onto a deflated bladder with a hold down member in an open loading position;

lowering the hold down member to a closed, locked position with a latch thereon engaging a base frame;

inflating the bladder to force the cover around the foam blocks of the cushion to a position adjacent the rigid base;

attaching the cover to the rigid base;

deflating the bladder;

releasing the latch and raising the hold down member to an unloading position; and

removing the cushion.

10. The method of claim 9 wherein the cover of the cushion is a foam cover and the cushion is a cushion sub-assembly.

11. The method of claim 10 wherein a plurality of blocks are provided in the cushion subassembly.

12. The method of claim 11 wherein the attaching of the cover to the rigid base is though adhesives and further including the step of trimming excess portions of the cover after the assembled cushion is removed.

13. The method of claim 12 further including the step of providing a curing time following the attaching of the cover to the rigid base prior to the deflation of the bladder.

14. The method of claim 13 wherein the cover is attached to the side edges of the rigid base.

15. The method of claim 14 further including the step of detecting the locked position of the hold down member prior to inflation of the bladder.

16. The method of claim 15 further including the step of detecting proper operator position prior to inflation of the bladder.

17. The method of claim 16 further including the step of detecting the appropriate deflation of the bladder prior to releasing the latch.

18. The method of claim 17 wherein the trimming of the cover is manual.

19. The method of claim 18 wherein the rigid base is a frame with a webbing central portion.

20. An apparatus for forming a cushion having components thereof including a rigid base, at least one foam block and a cover, said apparatus comprising:

Means for placing the components of the cushion onto a deflated bladder with a hold down member in an open loading position;

Means for lowering the hold down member to a closed, locked position with a latch thereon engaging a base frame;

Means for inflating the bladder to force the cover around the foam blocks of the cushion to a position adjacent the rigid base;

Means for attaching the cover to the rigid base;

Means for deflating the bladder;

Means for releasing the latch and raising the hold down member to an unloading position; and

Means for removing the cushion.