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Seating unit with formed cushion, and manufacturing method

  • US 7,490,392 B2
  • Filed: 12/07/2005
  • Issued: 02/17/2009
  • Est. Priority Date: 12/07/2005
  • Status: Active Grant
First Claim
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1. A method for stress-relieving upholstery comprising steps of:

  • providing a furniture unit including a support having corners;

    providing a cushion of formable polymeric fibers and having formed edges;

    positioning the cushion on a front of the support with the formed edges extending rearward of the corners of the support;

    providing an upholstery cover shaped to cover the support and the cushion including the corners;

    positioning the upholstery cover on the support and the cushion to cover the support and the cushion and to form an assembly; and

    stress-relieving at least the corners of the assembly including the cushion and the upholstery cover to reduce distortions and objectionable wrinkles in the upholstery cover at the corners by applying hot gases to cause the polymeric fibers and also the upholstery cover to relax to a state of minimized balanced tension.

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