Method of manufacturing cushion construction for seating unit
First Claim
Patent Images
1. A method comprising the steps of:
- cutting a blank from a sheet of non-woven fibrous material;
forming the blank into a pre-formed cushion shaped as a back for a seating unit;
attaching a cushion stiffener to the cushion to provide additional structure to the cushion;
providing a back support panel having a stiff thoracic section and a flexible lumbar section, and the cushion stiffener having a vertical length not substantially greater than the thoracic section so that the lumbar section maintains a flexibility; and
attaching the cushion stiffener to the support panel to define a back support assembly by engaging first mechanical connectors on the cushion stiffener with second mechanical connectors on the support panel, with the cushion stiffener extending across a substantial portion of the thoracic section, such that the cushion stiffener does not substantially increase the stiffness of the back support assembly in the region of the flexible lumbar section of the support panel.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of manufacturing a seating unit, such as a chair, includes manufacturing a cushion made from a non-woven fibrous material, and attaching the cushion to the seating unit for comfortable support. The cushion is made by cutting a blank from non-woven fibrous sheet material, steam-forming the blank into a pre-formed cushion shaped to support a user, and attaching a stiffener panel to the pre-formed cushion to provide a stiffened cushion assembly. The cushion assembly is aesthetically covered and assembled to seating unit. Advantageously, trimmings from the fibrous material can be recycled.
155 Citations
17 Claims
-
1. A method comprising the steps of:
-
cutting a blank from a sheet of non-woven fibrous material;
forming the blank into a pre-formed cushion shaped as a back for a seating unit;
attaching a cushion stiffener to the cushion to provide additional structure to the cushion;
providing a back support panel having a stiff thoracic section and a flexible lumbar section, and the cushion stiffener having a vertical length not substantially greater than the thoracic section so that the lumbar section maintains a flexibility; and
attaching the cushion stiffener to the support panel to define a back support assembly by engaging first mechanical connectors on the cushion stiffener with second mechanical connectors on the support panel, with the cushion stiffener extending across a substantial portion of the thoracic section, such that the cushion stiffener does not substantially increase the stiffness of the back support assembly in the region of the flexible lumbar section of the support panel. - View Dependent Claims (2, 3, 4, 5, 6)
-
-
7. A method comprising the steps of:
-
cutting a blank from a sheet of non-woven fibrous material;
forming the blank into a pre-formed cushion shaped as a back for a seating unit;
covering the cushion with a cover assembly that forms a sock around the cushion;
providing a back support panel having a stiff thoracic upper section, and a lower lumbar section having a plurality of elongated horizontal slots therein providing flexibility in the lumbar section, the support panel having a pivot connector at a lower portion to pivotably connect the back support panel to a seating unit; and
attaching a subassembly of the cushion and the cover assembly to the support panel, with both the support panel and the subassembly permitting air flow therethrough. - View Dependent Claims (8, 9)
-
-
10. A method of manufacturing a seating unit comprising the steps of:
-
providing a seat support that is air permeable and adapted to be supported by a base;
providing a back upright adapted to be operably supported by one of the base and the seat support for movement between an upright position and an angled position;
attaching a back support to the back upright, the back support being air permeable and defining a stiff upper thoracic section and a flexible lower lumbar section;
assembling a cushion assembly including providing a non-woven fibrous mat of cushioning material that is air-permeable, and attaching a stiffener panel to the cushion material; and
positioning the cushion assembly on the back support and wherein the stiffener panel does not substantially stiffen the back assembly in the region of the lower lumbar section. - View Dependent Claims (11, 12, 13)
-
-
14. A method of manufacturing a seating unit comprising the steps of:
-
providing a non-woven fibrous mat of cushioning material that is air-permeable;
trimming the fibrous mater to a predetermined shape;
pre-forming the fibrous mat by using a heating process;
attaching a stiffener panel to the cushion material to form a cushion assembly;
positioning the cushion assembly on a back support having a flexible lower lumbar portion on a seating unit for comfortably supporting a seated user; and
attaching the cushion assembly to the support by releasably engaging hooks on the stiffener panel with apertures in the support, wherein the stiffener comprises a panel that extends over an upper portion of the back support, and defines a generally horizontal lower edge above the lumbar portion of the back support. - View Dependent Claims (15)
-
-
16. A method comprising the steps of:
-
cutting a blank from a sheet of non-woven fibrous material;
forming the blank into a pre-formed cushion shaped as a back or seat on a seating unit;
attaching a cushion stiffener to the cushion to provide additional structure to the cushion;
providing a support panel and attaching the cushion stiffener to the support panel by engaging first mechanical connectors on the cushion stiffener with second mechanical connectors on the support panel;
covering the cushion with a cover assembly that forms a sock around the cushion, the cover assembly including stretchable material extending along a lower portion of the cover assembly, and a stiffening flange attached to a lower edge of the stretchable material, and wherein;
the cover assembly is attached to the support panel by connecting the stiffening flange to the support panel. - View Dependent Claims (17)
-
Specification