Method of manufacturing a cushion article
First Claim
1. A method of making an article having a shell with a contoured cushion on a portion of a surface thereof, said method comprising the steps of:
- providing a shell having a desired shape;
providing a fabric having a size and shape suitable for covering a portion of a top surface of the shell;
providing a mold having a molding surface defining a desired contour for the cushion;
sealing the fabric to the shell at that portion of the top surface where the cushion is to be formed;
disposing the shell having the fabric sealed thereto, in the mold such that the fabric faces the molding surface;
injecting a gelable medium between the shell and the fabric in order to force the fabric away from the shell and into intimate contact with the molding surface;
contouring the cushion by allowing the gelable medium to gelate and bond with the fabric while the shell is disposed in the mold; and
removing the article having the contoured cushion from the mold.
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Accused Products
Abstract
A cushion article, such as a wrist support or the like, and a method of manufacturing same are provided. The cushion article includes a multiple density, cushioned surface bonded to a molded foam shell. The saddle includes a contoured fabric surface with an underlying layer of soft gel. The gel may be molded to form embossment or imprinting in the fabric surface. A method of the invention includes the steps of disposing the saddle shell having a fabric sealed thereto, into a mold having a molding surface defining a desired contour and/or a desired pattern of embossment to be formed in the fabric. A thermoplastic gelable liquid is injected between the shell and the fabric. The fabric is contoured and or embossed by allowing the gelable liquid to cool while the shell is disposed in mold. The shell may be made of a foam material which is compressed into a desired shape and heat treated to form a shell having firmer, more dense portions and softer, less dense portions.
34 Citations
8 Claims
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1. A method of making an article having a shell with a contoured cushion on a portion of a surface thereof, said method comprising the steps of:
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providing a shell having a desired shape; providing a fabric having a size and shape suitable for covering a portion of a top surface of the shell; providing a mold having a molding surface defining a desired contour for the cushion; sealing the fabric to the shell at that portion of the top surface where the cushion is to be formed; disposing the shell having the fabric sealed thereto, in the mold such that the fabric faces the molding surface; injecting a gelable medium between the shell and the fabric in order to force the fabric away from the shell and into intimate contact with the molding surface; contouring the cushion by allowing the gelable medium to gelate and bond with the fabric while the shell is disposed in the mold; and removing the article having the contoured cushion from the mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification