Seat cushion with integral cover attachment

• US 20060085915A1
• Filed: 10/21/2004
• Published: 04/27/2006
• Est. Priority Date: 10/21/2004
• Status: Active Grant

• Current Assignee: Sears Manufacturing Co.
• Original Assignee: Sears Manufacturing Co.
• Inventors: Koutsky, L. John, Hinkhouse, Lysle R., Tuman, William
• Granted Patent: US 7,444,700 B2
• Time in Patent Office: Days
• US Class Current: 5/653
• CPC Class Codes: B29C 44/0415 by regulating the pressure of the material during or after filling of the mould, e.g. by local venting
• CPC Class Codes: B29C 44/1257 Joining a preformed part and a lining, e.g. around the edges
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence

Abstract

A seat cushion is provided having a foam cushion body with a perimeter section. A cover is disposed over the body and has a border that extends around the periphery of the cushion body and juxtaposed with the perimeter section of the cushion body. An insert is positioned within the cushion body and has an outer wall extending along and spaced from the periphery of the cushion body to accommodate the cushion body perimeter section. The perimeter section has a foam density greater than that of the main cushion body and the border of the cover is bonded directly to this perimeter section. In addition, a support wall or pan is used having a size and configuration to receive the covered cushion with the border of the cover disposed within the support wall when the seat is fully assembled. A method of forming such a seat cushion is also disclosed.

Claims

1. A seat cushion comprising:

a foam cushion body having first foam density and a perimeter section having a second foam density higher than said first foam density.

a cover disposed over the cushion body and having a border extending around a periphery of the cushion body;

an insert molded within the cushion body and having an outer wall extending along and spaced from the periphery of the cushion body to accommodate the perimeter section of the cushion body.

the cover border being bonded to the perimeter section of the cushion body; and

a cushion support wall having a size and configuration to receive the cushion and cover, with the border of the cover disposed within the support wall.

2. A method for fabricating a covered seat cushion comprising:

providing a seat mold cavity defined by first and second mold parts;

placing a cover within the first mold part;

locating an insert within the seat mold cavity the insert having an outer wall extending around spaced and from the periphery of the first mold part and cover;

securing the second mold part to the first mold part to form the mold cavity;

foaming a resin material within the cavity to form a foamed body having a first foam density and a foamed perimeter section having a second foam density greater than the first foam density; and

said cover having a border which is bonded to the foamed perimeter section.