U.S. patent application number 09/419089 was filed with the patent office on 2001-05-24 for method for forming a cushion.
Invention is credited to TORNERO, ROGER.
Application Number | 20010001515 09/419089 |
Document ID | / |
Family ID | 23115676 |
Filed Date | 2001-05-24 |
United States Patent
Application |
20010001515 |
Kind Code |
A1 |
TORNERO, ROGER |
May 24, 2001 |
METHOD FOR FORMING A CUSHION
Abstract
A seat cushion mold with an elastic member and method provide
the manufacture of an improved seat cushion for use in upholstered
chairs or the like having a smooth, uniform shape without unsightly
underlines. A thick, resilient foam block is positioned on a rigid
planer base and is urged into the mold whereby a thin foam cover
layer is adhered to the outer edges of the planar base to produce a
precisely contoured cushion which can be upholstered and fitted to
a chair frame.
Inventors: |
TORNERO, ROGER; (GREENSBORO,
NC) |
Correspondence
Address: |
WALTER L BEAVERS
326 SOUTH EUGENE STREET
GREENSBORO
NC
27401
US
|
Family ID: |
23115676 |
Appl. No.: |
09/419089 |
Filed: |
October 15, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09419089 |
Oct 15, 1999 |
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08995526 |
Dec 22, 1997 |
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08709465 |
Sep 3, 1996 |
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08545055 |
Oct 19, 1995 |
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5562873 |
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08545055 |
Oct 19, 1995 |
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08290368 |
Aug 15, 1994 |
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Current U.S.
Class: |
264/316 ;
156/212; 156/216; 156/493; 264/313; 264/321; 297/224; 425/394;
425/520 |
Current CPC
Class: |
Y10T 156/1028 20150115;
B29C 43/203 20130101; Y10T 156/1034 20150115; B29L 2031/771
20130101; B29C 63/04 20130101; B29C 43/10 20130101; B29C 2043/3652
20130101; B29D 99/0092 20130101 |
Class at
Publication: |
264/316 ;
264/313; 264/321; 156/212; 156/216; 156/493; 425/520; 425/394;
297/224 |
International
Class: |
B29C 033/40; B29C
053/04; B32B 031/12; A47C 027/15 |
Claims
I claim:
1. A cushion mold for forming a resilient seat cushion having a
crown from a compressible material comprising: a rigid frame, an
elastic member, said elastic member attached to said frame, said
elastic member deflectable from said frame, said frame comprising a
vertical inside wall, said vertical inside wall positioned to
contact said elastic member upon deflection, said inside vertical
wall to limit the deflection of said elastic member.
2. The mold of claim 1 wherein said elastic member is attached to
the periphery of said frame.
3. The mold of claim 1 wherein said frame and said elastic member
are substantially rectangular.
4. The mold of claim 1 wherein said elastic member comprises a
relatively thin, resilient rubber sheet.
5. The mold of claim 1 wherein said elastic member is downwardly
deflectable into a concave shape.
6. The mold of claim 5 wherein said frame has a height greater than
the downward deflection of said elastic member.
7. A method for forming a cushion using a mold having an elastic
member comprising the steps of: (a) placing a resilient block in
contact with a planar base; (b) positioning a cover layer over the
resilient block; (c) placing said cover layer, resilient block, and
planar base on said elastic member; (d) urging the planar base
downwardly thereby forcing the cover member, resilient block, and
planar base into said mold; and (e) deflecting the elastic member
downwardly to thereby mold the cover layer and the resilient
block.
8. The method of claim 7 and including the step of attaching the
edges of the cover layer to the edges of the planar base.
9. The method of claim 7 wherein the step of placing a resilient
block in contact with a planar base comprises the step of lacing a
plurality of resilient blocks proximate said planar base.
10. The method of claim 9 wherein the step of placing a plurality
of resilient blocks comprises the step of placing two relatively
large resilient blocks and one relatively small resilient block
proximate the planar base.
11. The method of claim 10 wherein the step of placing two large
blocks and one small block comprises the step of sandwiching the
small block between the two large blocks.
12. A method of forming a seat cushion using a mold having a
downwardly deflectable planar elastic member attached at its edges
to the periphery of the top of a frame, comprising the steps of:
(a) placing a first large resilient block in contact with a rigid
planar base; (b) placing a smaller resilient block over the first
large block with the ends of the first large block extending past
the ends of the small block; (c) placing a second large resilient
block over the small block with the ends of the second large block
extending past the ends of the small block; (d) placing a thin
resilient cover layer over the second large block with the ends of
the cover layer extending beyond the planar base; (e) placing said
blocks on the mold; and (f) urging the planar base downwardly to
force the resilient cover layer, resilient blocks, and the planar
base into the mold.
13. The method of claim 12 and including the step of deflecting the
elastic member of the mold downwardly into a concave configuration
to thereby mold the resilient cover and resilient blocks into a
convex shape corresponding to the concave shape of the resilient
member.
14. The method of claim 12 and including the steps of urging the
ends of the resilient cover against the edges of the planar base
and attaching the ends of the resilient cover to the edges of the
planar base to form a seat cushion.
15. The method of claim 11 and including the step of attaching the
cover layer to the planar base.
16. The method of claim 15 wherein the step of attaching the cover
layer to the edges of the planar base comprises the step of gluing
the cover layer to the edges of the planar base.
17. The method of claim 12 and including the step of trimming the
edges of the cover layer coincidentally with the edges of the
planar base.
18. The product formed by the method of claim 7.
19. The product formed by the method of claim 11.
20. A seat cushion mold having an elastic member and a means to
deflect the elastic member comprising in combination: a mold frame,
said elastic member comprising a thin sheet, said sheet attached
across said frame, said deflecting means positioned proximate said
elastic member for urging seat cushion components against said
elastic member to thereby form a seat cushion.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field Of The Invention
[0002] The present invention pertains to a mold for the formation
of seat cushions and particularly for forming a cushion for an
upholstered chair seat or the like using a mold having an elastic
sheet.
[0003] 2. Description Of The Prior Art And Objectives Of The
Invention
[0004] Polyurethane foam and other resilient materials have been
used for seat cushions for many years in the upholstered furniture
industry. Foam blocks of various dimensions and densities are cut
then covered with fabric to form seat cushions for sofas, chairs
and other furniture. Additionally, chair and sofa frames are
likewise often partially wrapped with resilient foam prior to
covering with a selected fabric to achieve the desired contours and
appearance. In the cost conscious furniture industry, it has lately
been the practice to preassemble foam covered components at various
shops which are then assembled at a central plant to expedite the
manufacturing process. For example, upholstered chair manufacturers
may contract through "outside" sources to purchase a partial chair
seat assembly consisting of a wooden base having a contoured foam
block glued thereto. The furniture maker, after receiving this
partial seat assembly, covers it with a fabric and subsequently
attaches it to a finished chair frame. A large number of such
partial seat assemblies may be kept on hand by the furniture
manufacturer so changes to the fabric type or style can be quickly
made depending on the customer's needs. While such partial seat
assemblies can be made to exact standards, concerns and uniformity
problems arise as the partial seat assembly is subject to an
individual upholsterer's ability to correctly tension and attach
the fabric cover and any additional layers prior to fixing the
fabric cover thereto. The final steps in the chair production are
subject to the particular craftsman's skills and oftentimes, by
applying too little or too much manual pressure during attachment
of the fabric covering, an unacceptable product results. This
oftentimes occurs along the upper contours and crown at the top of
the seat.
[0005] With the known disadvantages and problems associated with
the prior art seat cushion assemblies, the present invention was
conceived and one of its objectives is to provide a distortable
seat cushion mold that will allow a manufacturer to produce an
attractive, uniform and consistent seat on each chair
manufactured.
[0006] It is another objective of the present invention to provide
a seat cushion that will allow the upholsterer ease and convenience
in covering the cushion.
[0007] It is still another objective of the present invention to
provide a seat cushion that has no unsightly underlines and one
that is contoured evenly throughout.
[0008] It is yet another objective of the present invention to
provide a method for forming a seat cushion in which a plurality of
synthetic foam components are attached to a rigid base to form a
smooth, even crown.
[0009] It is still another objective of the present invention to
provide a method for forming a seat cushion whereby a distortable
seat cushion mold is used to insure uniformity in the crown.
[0010] It is also another objective of the present invention to
provide a seat cushion from the process as described above.
[0011] Various other objectives and advantages of the present
invention become apparent to those skilled in the art as a more
detailed presentation of the invention is set forth below.
SUMMARY OF THE INVENTION
[0012] The invention herein pertains to a seat cushion mold, a
method for using the mold to form a cushion for a chair seat or the
like and the product formed therefrom. The mold includes an elastic
sheet which is distortable downwardly into a concave shape. The
method of forming the cushion comprises contacting at least one
foam block by a rigid planar base. Next, a thin foam layer is
positioned over the foam block. The planar base, the contacted foam
block and the thin foam layer are then positioned, foam layer side
down, atop a mold with an elastic sheet and are pressed downwardly
into the elastic sheet by, for example, a hydraulic press, which
compresses the foam block into a convex mound within the now
stretched, concave elastic sheet. The thin foam layer is then urged
against the edges of the planar base while the thin foam layer is
being adhesively attached to the base. Afterwards, the extending
ends of the thin foam layer are trimmed and a seat cushion is
thereby provided which can be upholstered with a desired fabric for
later installation into a chair frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows an exploded cross-sectional view of the
invention including seat cushion components consisting of a planar
base, foam blocks and a thin foam cover layer above the seat
cushion mold;
[0014] FIG. 2 demonstrates seat cushion components of FIG. 1
compressed into the seat cushion mold with the top elastic sheet of
the mold distorted downwardly into a concave shape while the foam
blocks form an inverted convex cushion crown;
[0015] FIG. 3 illustrates the ends of the thin foam cover layer
urged against the edges of the planar base for adhesive attachment
thereto;
[0016] FIG. 4 depicts a cross-sectional view of an inverted seat
cushion of the invention after removal from the mold;
[0017] FIG. 5 shows an edge of the planar base as covered with
adhesive; and
[0018] FIG. 6 illustrates a perspective view of the mold with an
inverted seat cushion seen in cross section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The preferred process of the invention is illustrated in
FIGS. 1-6 whereby a planar base formed from one inch thick wood
having a solvent based contact cement on the outer edges is placed
next to a first relatively large, somewhat rectangular, 3/4" thick
polyurethane foam block with a density of 1.5 pounds per cubic foot
(P.C.F.) and an indentation load deflection (I.L.D.) of 35 pounds.
Planar bases can be first stacked and the edges simultaneously
sprayed with a fast drying contact cement. Positioned next to this
large foam block is a smaller, somewhat rectangular, 1" thick
polyurethane foam block with a density of 1.8 P.C.F. and an I.L.D.
of 40 pounds. Placed next to the smaller foam block is a second
large block identical to the first. Contacting the second large
block is a relatively thin, somewhat rectangular, 3/8" thick
polyurethane foam cover layer with a density of 2.0 P.C.F. and an
I.L.D. of 25 pounds. A contact cement is spread around the top
surface along the edges of the cover layer and is allowed to dry.
The seat components are then placed on a mold consisting of a 1/8"
thick planar rubber bladder fitted over a wooden frame approxiately
4" high and 24" long on each side. Pressure from a vertical ram,
such as a pneumatic cylinder press, forces the seat components into
the mold whereby the rubber bladder or sheet deflects downwardly
approximately 21/2" into a concave shape. The foam components are
thus molded into a convex, inverted crown shape corresponding to
the concave shape of the deflected rubber bladder. The free ends of
the thin foam cover layer are urged against the edges of the planar
base and the contact adhesive secures the thin foam cover layer to
the planar base edges. Excess free ends of the foam cover layer are
then trimmed and the seat cushion which results therefrom is
smooth, uniform and ready for fabric covering and attachment to a
chair frame.
DETAILED DESCRIPTION OF THE DRAWINGS AND OPERATION OF THE
INVENTION
[0020] For a more complete understanding of the invention and the
process involved, turning now to the drawings, FIG. 1 illustrates
an exploded view of a conventional chair seat cushion 30, as is
used in chairs, and seat cushion mold 17 in combination with
pressure ram 25 used to form cushion 30. Seat cushion 30 components
are shown inverted, as they are used during construction, but of
course when assembled and mounted to a completed chair frame or the
like, they would be turned over. Seat cushion 30 components include
planar base 10 comprising a relatively rigid, one inch thick member
having a desired outer configuration which may be square with
rounded corners, rectangular or having other shapes as desired and
made of plywood, composite board, or other suitable material. Below
base 10 in FIG. 1 are first large, relatively low density
polyurethane foam block 15, small, higher density polyurethane foam
block 14, second large, relatively low density polyurethane foam
block 16, and thin polyurethane foam cover layer 20. Cover layer 20
is spread with an adhesive along its top surface, near its edges,
such as with a solvent based contact cement 12 (shown in
exaggerated amounts for clarity in FIG. 1). Cement 12 is also
spread on the outer edges 11 of planar base 10, as shown in FIG.
5.
[0021] As is well known by those skilled in the chair manufacturing
art, it is usual to affix foam blocks to a planar seat base and
therefore these aspects of the invention, as illustrated in FIG. 1,
are conventional. Likewise, it is conventional in the furniture
trade to "mix" the density of foam blocks in forming cushions;
however, the following structure and steps as shown in FIGS. 1-4
and 6 are new and nonconventional and provide an improved seat
cushion. Seat cushion 30 components 10, 14, 15, 16 and 20 are
positioned above cushion mold 17, which has a generally square
frame and top elastic member 18. Two frame side members 19, 19' are
illustrated in FIGS. 1-4 and frame front member 26 is illutrated in
FIG. 6, but as would be understood, another frame member 26' (not
shown) is used to form a back frame member. Planar elastic member
18 may be composed of sheet rubber, fabric or other suitable
synthetic or natural elastic materials and is fitted over the top
of cushion mold 17 and affixed at the periphery along the outer
sides of frame members 19, 19', 26, and 26'. While mold 17 is seen
in rectangular form, other shapes could likewise be utilized.
[0022] In FIG. 2, vertical pressure ram 25 is shown compressing
and/or deflecting seat cushion components 10, 15, 14, 16 and 20
downwardly into mold 17 by driving against bottom surface 13 of
planar base 10. Pressure ram 25 may be operated by hydraulic,
pneumatic, electric or manual means as is conventional. Elastic
member 18 is stretched and deflected downwardly approximately 21/2"
into a concave shape (FIG. 2) that molds and shapes foam components
15, 14, 16 and 20 into a convex, inverted crown 29 (FIG. 6), which
corresponds to the contour of deflected elastic member 18.
[0023] FIG. 3 illustrates free ends 22, 22' of foam cover layer 20
urged against edges 11 of planar base 10 and joined thereto by
previously applied contact cement 12. As would be understood, ram
25 causes elastic members 18 to deflect downwardly and outwardly,
whereas planar vertical inside walls 28, 28' of frame member 19,
19' limit the outward or horizontal deflection. Contact cement 12
may be solvent or water based and other suitable adhesives may also
be used. As would be understood, all four ends of cover layer 20
are forced against the outer vertical edges 11 of planar base 10
and the figures herein, except for FIG. 6, show only two edges in
cross-sectional view for clarity. FIG. 6 also shows back free end
27 attached to edge 11 of planar base 10. (Front free end 27' is
not shown.) As seen in FIG. 3, free ends 26, 26' of foam cover
layer 20 are lastly trimmed by knife 24 or the like to thereby
complete the formation of seat cushion 23, as seen in FIGS. 4 and 6
with base 10 covered completely with the exception of its bottom
surface 13. FIGS. 4 and 6 also illustrate elastic sheet 18 of mold
17 having rebounded into its original planar shape upon removal of
completed seat cushion 23. Seat cushion 23, as completed, is now
available for covering with a fabric or for other treatment prior
to incorporation into a chair frame.
[0024] The mold and method as shown herein provide high production
capacity while allowing the densities of the seat cushions to be
easily varied. The outer shape of finished seat cushion 23 is
consistent from cushion to cushion due to the design of mold 17.
The method as described herein reduces operator fatigue and the
possibility of carpal tunnel syndrome of the workers.
[0025] As would be understood, other shapes and types of cushions
can likewise be formed from processes shown herein using different
materials and the illustrations and examples are used for
explanatory purposes and are not intended to limit the scope of the
appended claims.
* * * * *