Blow mold and backfill manufacturing process
First Claim
1. A method for forming a foam product, the method comprising:
- forming a skin comprising;
a unitary skin wall surrounding an interior;
a mounting area on an underside of the skin wall, the mounting area having a width and a length;
and a bracket insertion area on the underside of the skin wall, the bracket insertion area separate from the mounting area; and
inserting a bracket at least partially into the skin interior through the bracket insertion area;
wherein the mounting area is configured to receive a mounting assembly attached to an article of furniture;
wherein the underside of the skin wall has a width;
the bracket insertion area has a width;
the width of the mounting area is less than the width of the underside of the skin wall;
the width of the bracket insertion area is less than the width of the underside of the skin wall; and
the width of the bracket insertion area is greater than the width of the mounting area.
1 Assignment
0 Petitions
Accused Products
Abstract
A method for forming a foam product comprises forming a skin and inserting a bracket at least partially into the skin. Another method for manufacturing a foam product comprises sealing a tube of material in a cavity of a mold, blowing air into the tube of material to form a skin comprising an interior surrounded by a wall, cutting an incision in the skin wall, inserting a bracket through the incision and into the skin interior, filling the skin interior with foam, and curing the foam.
A foam product comprises a skin with an interior surrounded by a wall, a bracket within the skin interior, a foam substantially filling the skin interior and securing the bracket in place, a recessed region configured to mate with a mounting assembly on a chair, and an incision in the skin wall, the incision positioned outside of the recessed region.
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Citations
19 Claims
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1. A method for forming a foam product, the method comprising:
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forming a skin comprising; a unitary skin wall surrounding an interior; a mounting area on an underside of the skin wall, the mounting area having a width and a length; and a bracket insertion area on the underside of the skin wall, the bracket insertion area separate from the mounting area; and inserting a bracket at least partially into the skin interior through the bracket insertion area;
wherein the mounting area is configured to receive a mounting assembly attached to an article of furniture;wherein the underside of the skin wall has a width;
the bracket insertion area has a width;
the width of the mounting area is less than the width of the underside of the skin wall;
the width of the bracket insertion area is less than the width of the underside of the skin wall; and
the width of the bracket insertion area is greater than the width of the mounting area. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for manufacturing a foam product, the method comprising:
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sealing a tube of material in a cavity of a mold; blowing air into the tube of material through an aperture to form a skin comprising an interior surrounded by a wall that conforms to the shape of the cavity; cutting an incision forming a closeable slit in the skin wall; inserting a bracket through the incision and into the skin interior; filling the skin interior with foam through the aperture; and curing the foam; wherein the skin comprises a recessed region on an underside of the skin wall configured to mate with a mounting assembly, the recessed region having a length and a width; and wherein the incision slit is located on the underside of the skin wall but is separate from the recessed region, the incision slit has a width, the underside of the skin wall has a width, and the incision is wider than the recessed region but less than the width of the underside of the skin wall. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
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16. A method for forming a foam product, the method comprising:
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blow molding a tube of polymeric material by blowing air through an aperture to form a skin comprising a skin wall surrounding an interior; cutting an incision into an underside of the skin wall; inserting a bracket at least partially into the skin interior through the incision without removing any material from the skin wall; filling the skin interior with foam through the aperture; and curing the foam; wherein the skin comprises a recessed region in the underside of the skin wall configured to mate with a mounting assembly, the recessed region having a length and a width; wherein a portion of the bracket is wider than the width of the recessed region; wherein the incision is located entirely on the underside of the skin wall, has a width, and is separate from the recessed region; wherein the skin wall underside has a width, and the incision is wider than the recessed region but less than the width of the underside of the skin wall; and wherein the incision allows skin distortion to form an opening for inserting the bracket upon application of pressure, with the opening closing upon release of pressure. - View Dependent Claims (17, 18, 19)
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Specification