Process for forming cushion articles
First Claim
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1. A process for forming cloth-covered cushion articles, comprising the steps of:
- providing a mold having the shape of the desired cushion article;
drawing a cloth covering into said mold, said cloth covering having heat fixable fibers therein;
pouring a foamable material into said mold, foaming said foamable material and curing the foam at a temperature below the heat-fixable fiber set temperature of the cloth covering to form the cushion article;
removing the cushion article from said mold; and
heating the cushion article to at least the heat-fixable fiber set temperature of the cloth covering.
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Accused Products
Abstract
A process for forming cloth-covered cushion articles. A mold is provided having the shape of the desired cushion article. In one form, a cloth covering is drawn into the mold. Foamable material is poured into the mold and cured to form the cushion article. The covered, cured article is removed from the mold and heated to at least the heat-fixable fiber set temperature of the cloth, as the cured foam acts as a male mold to hold the cloth in contour during heat setting. In another form, the foam is poured directly into the mold and cured. The cloth covering then is placed over the cured cushion and set.
26 Citations
38 Claims
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1. A process for forming cloth-covered cushion articles, comprising the steps of:
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providing a mold having the shape of the desired cushion article; drawing a cloth covering into said mold, said cloth covering having heat fixable fibers therein; pouring a foamable material into said mold, foaming said foamable material and curing the foam at a temperature below the heat-fixable fiber set temperature of the cloth covering to form the cushion article; removing the cushion article from said mold; and heating the cushion article to at least the heat-fixable fiber set temperature of the cloth covering. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A process of forming cloth-covered cushion articles, comprising the steps of:
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providing a mold having the shape of the desired cushion article; drawing a cloth covering into said mold, the cloth covering including at least a layer of nylon fabric; pouring a foamable material into said mold, foaming said foamable material and curing the foam at a temperature below the heat-fixable fiber set temperature of said nylon fabric to form the cushion article; removing the cushion article from said mold; applying a diester solution to the cloth covering; and heating the cushion article to at least the heat-fixable fiber set temperature of said nylon fabric. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A process for molding a cloth-covered seat cushion, comprising the steps of:
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providing a mold having the shape of a desired seat cushion; drawing a cloth covering into said mold, the cloth covering including at least an outer layer of standing pile fabric or the like, said cloth covering having heat fixable fibers therein; pouring cold foamable material into said mold, foaming said foamable material and curing the foam at a temperature below the heat fixable fiber set temperature of the cloth material to form the seat cushion; removing the seat cushion from said mold; and heating the seat cushion to a temperature sufficient to set the fibers of the fabric but not to alter the natural surface characteristics thereof. - View Dependent Claims (16, 17, 18, 19, 20)
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21. A process for forming a cloth-covered cushion article, comprising the steps of:
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constructing a foam cushion having the shape of the desired cushion article; placing a cloth covering over the cushion, the covering being of unfinished cloth including heat fixable fibers; heating the cloth covering while on the cushion to at least the heat-fixable fiber set temperature of the cloth covering so that the cloth will retain the three-dimensional shape of the cushion; and cooling the cloth covering while on said cushion. - View Dependent Claims (22, 23, 24, 25)
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26. A process for forming a cloth-covered cushion article, comprising the steps of:
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constructing a foam cushion having the shape of the desired cushion article; placing a cloth covering over the cushion, the covering being of unfinished cloth; and treating the cloth covering while on the cushion so that the cloth will retain the three-dimensional shape of the cushion. - View Dependent Claims (27, 28, 29, 30, 31, 32)
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33. A process for forming a cloth-covered cushion article, comprising the steps of:
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constructin a foam cushion having the shape of a desired cushion article including a contour having at least one depression; placing a cloth covering over the cushion, the cloth covering having heat fixable fibers therein; holding the cloth covering onto the cushion with portions thereof held in said depression; heating the cloth covering while held on the cushion to at least the heat-fixable fiber set temperature of the cloth covering; and cooling the cloth covering on said cushion. - View Dependent Claims (34, 35, 36, 37, 38)
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Specification