BLOW MOLD AND BACKFILL MANUFACTURING PROCESS
First Claim
1. A foam product comprising:
- a unitary skin wall surrounding an interior;
a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture;
an incision on the underside of the skin wall, the incision separate from the mounting area;
a bracket positioned within the skin interior; and
foam substantially filling the skin interior and securing the bracket in place within the skin wall;
wherein the underside of the skin wall has a width;
the incision has a width;
the width of the mounting area is less than the width of the underside of the skin wall;
the width of the incision is less than the width of the underside of the skin wall; and
the width of the incision is greater than the width of the mounting area.
1 Assignment
0 Petitions
Accused Products
Abstract
Disclosed embodiments may include methods for forming a foam product comprising forming a skin and inserting a bracket at least partially into the skin. Another embodiment method for manufacturing a foam product may comprise sealing a tube of material in a cavity of a mold, blowing air into the tube of material to form a skin comprising an interior surrounded by a wall, cutting an incision in the skin wall, inserting a bracket through the incision and into the skin interior, filling the skin interior with foam, and curing the foam. Disclosed embodiments may further include foam product comprising a skin with an interior surrounded by a wall, a bracket within the skin interior, a foam substantially filling the skin interior and securing the bracket in place, a recessed region configured to mate with a mounting assembly on a chair, and an incision in the skin wall, the incision positioned outside of the recessed region.
25 Citations
20 Claims
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1. A foam product comprising:
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a unitary skin wall surrounding an interior; a mounting area on an underside of the skin wall, the mounting area having a width and a length, and the mounting area being configured to mate with a mounting assembly attached to an article of furniture; an incision on the underside of the skin wall, the incision separate from the mounting area; a bracket positioned within the skin interior; and foam substantially filling the skin interior and securing the bracket in place within the skin wall; wherein the underside of the skin wall has a width;
the incision has a width;
the width of the mounting area is less than the width of the underside of the skin wall;
the width of the incision is less than the width of the underside of the skin wall; and
the width of the incision is greater than the width of the mounting area. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for forming a foam product, the method comprising:
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forming a skin comprising; a unitary skin wall surrounding an interior; a mounting area on an underside of the skin wall, the mounting area having a width and a length; and an incision on the underside of the skin wall, the incision separate from the mounting area; and inserting a bracket at least partially into the skin interior through the incision;
wherein the mounting area is configured to receive a mounting assembly attached to an article of furniture; andwherein the underside of the skin wall has a width;
the incision has a width;
the width of the mounting area is less than the width of the underside of the skin wall;
the width of the incision is no greater than the width of the underside of the skin wall; and
the width of the incision is no less than the width of the mounting area. - View Dependent Claims (9, 10, 11, 12, 13)
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14. A method for forming a foam product, the method comprising:
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forming a skin comprising; a unitary skin wall surrounding an interior; a mounting area on an underside of the skin wall, the mounting area having a width and a length; and an incision on the underside of the skin wall, the incision separate from the mounting area; and inserting a bracket at least partially into the skin interior through the incision;
wherein the mounting area is configured to receive a mounting assembly attached to an article of furniture. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification