Method for forming a cushion

• US 5,238,514 A
• Filed: 02/24/1992
• Issued: 08/24/1993
• Est. Priority Date: 02/24/1992
• Status: Expired due to Term

• Current Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Original Assignee: Roger Tornero
• Inventors: Tornero, Roger
• Primary Examiner(s): Weston, Caleb
• Application Number:
  US07/840,119
• Time in Patent Office: 547 Days
• Field of Search: 156/196, 156/216, 156/219, 156/220, 156/221, 156/245, 156/285, 264/241, 264/254, 264/257, 264/250, 264/255, 264/259, 264/263, 264/271.1
• US Class Current: 156/196
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/114 Single butt joints
• CPC Class Codes: B29C 66/12821 comprising at least two overlap joint-segments
• CPC Class Codes: B29C 66/1286 comprising at least one bevelled joint-segment
• CPC Class Codes: B29C 66/433 Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/5346 said single elements being substantially flat
• CPC Class Codes: B29C 66/61 Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/8242 Pneumatic or hydraulic drives using fluid pressure directly acting on the parts to be joined B29C66/8266
• CPC Class Codes: B29C 66/83221 cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1034 Overedge bending of lamina about edges of sheetlike base

Abstract

A process provides an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape and which eliminates unsightly underlines. A thick foam block is attached to a thin, rigid base and the assembly is placed in a mold whereby a thin foam cover is adhered to the foam block and to the outer edges of the base to produce a precisely contoured cushion which can be upholstered and fitted into a desired chair frame.

Claims

1. A method of forming a seat cushion comprising the steps of:

(a) attaching a small resilient foam block to a rigid planar base;

(b) attaching a larger resilient foam block over the small foam block, whereby ends of the larger foam block extend over said small foam block;

(c) attaching the extending foam block ends beyond the small foam block to the planar base;

(d) partially placing a thin resilient foam cover into a mold while allowing the edges of the cover to extend therefrom;

(e) thereafter placing the planar base, larger foam block and small foam block into the mold with the large foam block against the thin resilient foam cover;

(f) attaching the resilient foam cover to said large resilient foam block;

(g) urging the thin resilient foam cover against the edges of said planar base; and

(h) adhesively attaching the cover against said planar base edges to form a seat cushion.

2. The method of claim 1 and including the step of trimming the edges of the foam cover coincidentally with the edges of the planar base.

3. The method of claim 1 and including the step of applying pressure to said planar member while said large block is in contact with said foam cover.

4. A method of forming a cushion for a chair seat or the like comprising the steps of:

(a) forming a rigid planar base having thin edges;

(b) placing a smaller resilient foam block to said base whereby the outer edges of said base extend beyond said foam block;

(c) placing a larger resilient foam block atop said smaller foam block whereby the ends of said larger foam block extend beyond said smaller foam block;

(d) pressing the ends of the larger foam block against the base;

(e) attaching the ends of said larger foam block to said base to form a cushion construction;

(f) partially placing a thin resilient foam cover in a mold while allowing the edges to extend therefrom;

(g) thereafter placing said larger foam block against said foam cover within said mold;

(h) applying pressure to said planar base while attaching said cover to said large foam block;

(i) thereafter pressing said resilient cover against said planar base outer edges; and

next

(j) attaching said resilient cover to said base outer edges.

5. The method of claim 4 wherein attaching said cover to said edges comprises gluing said cover to said edges.