Seat cushion with integral cover attachment

• US 7,444,700 B2
• Filed: 10/21/2004
• Issued: 11/04/2008
• 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
• Primary Examiner(s): CONLEY, FREDRICK C
• Application Number:
  US10/970,599
• Publication Number:
  US 20060085915A1
• Time in Patent Office: 1,475 Days
• Field of Search: 565/2, 565/3, 565/59, 572/7, 297/452.27
• 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 unitary foam cushion formed in a one stage foaming operation and having a body with a first foam density and a perimeter section with a second foam density higher than said first foam density, said perimeter section having an outer surface defining a periphery of the cushion;

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

an insert molded within the cushion and having an outer wall extending along, parallel to and spaced from the periphery of the cushion thereby forming a boundary between the body and perimeter section of the cushion so that the first foam density cushion body engages one side of the insert outer wall and the second foam density perimeter section engages the other side of the insert outer wall, and said outer wall thereby defining the perimeter section as having a relatively small and generally uniform cross dimension;

the cover being bonded to the periphery of the cushion; 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. The seat cushion of claim 1 wherein the outer wall of the insert comprises one leg of a generally L-shaped insert cross section.

3. The seat cushion of claim 2 wherein the other leg of the insert cross section is positioned generally parallel to a portion of the cushion support wall.