U.S. patent application number 11/180134 was filed with the patent office on 2005-12-08 for removable seat cushion.
This patent application is currently assigned to Total Innovative Manufacturing, LLC. Invention is credited to Assink, Kenneth, Wolters, Gary W., York, Julie L..
Application Number | 20050269850 11/180134 |
Document ID | / |
Family ID | 37067804 |
Filed Date | 2005-12-08 |
United States Patent
Application |
20050269850 |
Kind Code |
A1 |
York, Julie L. ; et
al. |
December 8, 2005 |
Removable seat cushion
Abstract
A seat cushion is disclosed that can be easily attached to, and
removed from, a chair or seat utilizing a mesh seat bottom. The
removable seat cushion includes a collection of downwardly
extending engagement members that engage the mesh upon insertion
through voids in the mesh.
Inventors: |
York, Julie L.; (Byron
Center, MI) ; Wolters, Gary W.; (Zeeland, MI)
; Assink, Kenneth; (Holland, MI) |
Correspondence
Address: |
Fay, Sharpe, Fagan, Minnich & Mckee, LLP
Seventh Floor
1100 Superior Avenue
Cleveland
OH
44114-2579
US
|
Assignee: |
Total Innovative Manufacturing,
LLC
|
Family ID: |
37067804 |
Appl. No.: |
11/180134 |
Filed: |
July 13, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11180134 |
Jul 13, 2005 |
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10463187 |
Jun 17, 2003 |
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11180134 |
Jul 13, 2005 |
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09869418 |
Jun 27, 2001 |
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09869418 |
Jun 27, 2001 |
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PCT/US00/32272 |
Nov 21, 2000 |
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60389647 |
Jun 18, 2002 |
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60167303 |
Nov 24, 1999 |
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Current U.S.
Class: |
297/258.1 |
Current CPC
Class: |
A47C 7/18 20130101; A47C
7/185 20130101; A47C 7/021 20130101; A47C 7/0213 20180801 |
Class at
Publication: |
297/258.1 |
International
Class: |
A47C 003/02 |
Claims
1. A seat cushion adapted for releasable engagement with a mesh
seat member, the seat cushion comprising: a cushion member
including a plurality of outwardly extending projections adapted to
releasably engage a mesh seat member upon insertion through voids
defined in the mesh.
2. The seat cushion of claim 1 wherein the cushion member includes:
a first face; a second face opposite said first face; and a
non-woven fibrous body disposed between said first and said second
faces, said non-woven fibrous body including (i) from about 15% to
about 60% of a fiber component dispersed throughout said body, (ii)
from about 15% to about 85% of a fire-retardant cellulose component
dispersed throughout said body, and (iii) from about 15% to about
70% of a binder component dispersed throughout said body, said body
further including a plurality of fused regions of contact defined
between adjacent portions of binder component resulting from prior
heating of said body to a temperature sufficient to cause at least
partial melting of said binder component and thereby fuse said
adjacent portions of binder component.
3. The seat cushion of claim 2 wherein said fiber component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
4. The seat cushion of claim 2 wherein said cellulose component is
a fire-retardant cellulose material treated with an agent selected
from the group consisting of boric acid, sodium polyborate, and
combinations thereof.
5. The seat cushion of claim 2 wherein said binder component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
6. The seat cushion of claim 2 wherein said fiber component
includes natural fibers selected from the group consisting of sisal
fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean
fiber, wool fiber, cotton fiber, hemp fiber, and combinations
thereof.
7. The seat cushion of claim 1 further comprising: a frame
component secured to the cushion member, the frame component
including a plurality of outwardly extending projections adapted to
releasably engage the mesh seat.
8. The seat cushion of claim 7 wherein each projection defines a
distal tip, a shaft extending between the tip and the frame
component, and at least one engagement flap extending outward from
the shaft.
9. The seat cushion of claim 8 wherein the distal tip is
tapered.
10. The seat cushion of claim 1 wherein the cushion member
includes: a first surface; a second surface opposite from said
first surface; and a non-woven fibrous body disposed between said
first surface and said second surface, said non-woven fibrous body
including (i) from about 40% to about 70% of a fire-retardant
cellulose component dispersed throughout said body, and (ii) from
about 30% to about 60% of a bi-component fiber, said bi-component
fiber having an inner portion of a first thermoplastic and an outer
portion of a second thermoplastic, said second thermoplastic having
a melting temperature less than the melting temperature of said
first thermoplastic, said body further including a plurality of
fused regions of contact defined between adjacent bi-component
fibers resulting from prior heating of said body to a temperature
greater than said melting temperature of said second
thermoplastic.
11. The seat cushion of claim 10 wherein said first thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
12. The seat cushion of claim 10 wherein said cellulose component
is a fire-retardant cellulose fiber treated with either boric acid
or sodium polyborate.
13. The seat cushion of claim 10 wherein said second thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
14. The seat cushion of claim 10 wherein said cellulose component
constitutes from about 45% to about 55% of said non-woven fibrous
body.
15. The seat cushion of claim 10 wherein said second thermoplastic
constitutes from about 20% to about 80% of said bi-component
fiber.
16. The seat cushion of claim 10 wherein said second thermoplastic
constitutes from about 40% to about 60% of said bi-component
fiber.
17. The seat cushion of claim 10 wherein said second thermoplastic
constitutes about 50% of said bi-component fiber.
18. The seat cushion of claim 10 wherein said bi-component fiber
has a diameter of from about 1.5 to about 9 denier.
19. A seat cushion adapted for releasable engagement with a mesh
seat member, the seat cushion comprising: a cushion member; and a
frame component secured to the cushion member, the frame component
including a plurality of downwardly extending projections adapted
to releasably engage a mesh seat member upon insertion through
voids defined in the mesh.
20. The seat cushion of claim 19 wherein the cushion member
includes: a first face; a second face opposite said first face; and
a non-woven fibrous body disposed between said first and said
second faces, said non-woven fibrous body including (i) from about
15% to about 60% of a fiber component dispersed throughout said
body, (ii) from about 15% to about 85% of a fire-retardant
cellulose component dispersed throughout said body, and (iii) from
about 15% to about 70% of a binder component dispersed throughout
said body, said body further including a plurality of fused regions
of contact defined between adjacent portions of binder component
resulting from prior heating of said body to a temperature
sufficient to cause at least partial melting of said binder
component and thereby fuse said adjacent portions of binder
component.
21. The seat cushion of claim 20 wherein said fiber component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
22. The seat cushion of claim 20 wherein said cellulose component
is a fire-retardant cellulose material treated with an agent
selected from the group consisting of boric acid, sodium
polyborate, and combinations thereof.
23. The seat cushion of claim 20 wherein said binder component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
24. The seat cushion of claim 20 wherein said fiber component
includes natural fibers selected from the group consisting of sisal
fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean
fiber, wool fiber, cotton fiber, hemp fiber, and combinations
thereof.
25. The seat cushion of claim 19 wherein each projection defines a
distal tip, a shaft extending between the tip and the frame
component, and at least one engagement flap extending outward from
the shaft.
26. The seat cushion of claim 25 wherein the distal tip is
tapered.
27. The seat cushion of claim 19 wherein the cushion member
includes: a first surface; a second surface opposite from said
first surface; and a non-woven fibrous body disposed between said
first surface and said second surface, said non-woven fibrous body
including (i) from about 40% to about 70% of a fire-retardant
cellulose component dispersed throughout said body, and (ii) from
about 30% to about 60% of a bi-component fiber, said bi-component
fiber having an inner portion of a first thermoplastic and an outer
portion of a second thermoplastic, said second thermoplastic having
a melting temperature less than the melting temperature of said
first thermoplastic, said body further including a plurality of
fused regions of contact defined between adjacent bi-component
fibers resulting from prior heating of said body to a temperature
greater than said melting temperature of said second
thermoplastic.
28. The seat cushion of claim 27 wherein said first thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
29. The seat cushion of claim 27 wherein said cellulose component
is a fire-retardant cellulose fiber treated with either boric acid
or sodium polyborate.
30. The seat cushion of claim 27 wherein said second thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
31. The seat cushion of claim 27 wherein said cellulose component
constitutes from about 45% to about 55% of said non-woven fibrous
body.
32. The seat cushion of claim 27 wherein said second thermoplastic
constitutes from about 20% to about 80% of said bi-component
fiber.
33. The seat cushion of claim 27 wherein said second thermoplastic
constitutes from about 40% to about 60% of said bi-component
fiber.
34. The seat cushion of claim 27 wherein said second thermoplastic
constitutes about 50% of said bi-component fiber.
35. The seat cushion of claim 27 wherein said bi-component fiber
has a diameter of from about 1.5 to about 9 denier.
36. A seat cushion adapted for releasable engagement with a mesh
seat member, the seat cushion comprising: a cushion member; a frame
component engaged to the cushion member; and a plurality of
engagement members extending from the frame component, the
engagement members each including a distal tip, a shaft extending
between the tip and the frame component, and at least one
engagement flap extending outward from the shaft.
37. The seat cushion of claim 36 wherein the cushion member
includes: a first face; a second face opposite said first face; and
a non-woven fibrous body disposed between said first and said
second faces, said non-woven fibrous body including (i) from about
15% to about 60% of a fiber component dispersed throughout said
body, (ii) from about 15% to about 85% of a fire-retardant
cellulose component dispersed throughout said body, and (iii) from
about 15% to about 70% of a binder component dispersed throughout
said body, said body further including a plurality of fused regions
of contact defined between adjacent portions of binder component
resulting from prior heating of said body to a temperature
sufficient to cause at least partial melting of said binder
component and thereby fuse said adjacent portions of binder
component.
38. The seat cushion of claim 37 wherein said fiber component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
39. The seat cushion of claim 37 wherein said cellulose component
is a fire-retardant cellulose material treated with an agent
selected from the group consisting of boric acid, sodium
polyborate, and combinations thereof.
40. The seat cushion of claim 37 wherein said binder component is
selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
41. The seat cushion of claim 37 wherein said fiber component
includes natural fibers selected from the group consisting of sisal
fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean
fiber, wool fiber, cotton fiber, hemp fiber, and combinations
thereof.
42. The seat cushion of claim 36 wherein the distal tip is
tapered.
43. The seat cushion of claim 36 wherein the cushion member
includes: a first surface; a second surface opposite from said
first surface; and a non-woven fibrous body disposed between said
first surface and said second surface, said non-woven fibrous body
including (i) from about 40% to about 70% of a fire-retardant
cellulose component dispersed throughout said body, and (ii) from
about 30% to about 60% of a bi-component fiber, said bi-component
fiber having an inner portion of a first thermoplastic and an outer
portion of a second thermoplastic, said second thermoplastic having
a melting temperature less than the melting temperature of said
first thermoplastic, said body further including a plurality of
fused regions of contact defined between adjacent bi-component
fibers resulting from prior heating of said body to a temperature
greater than said melting temperature of said second
thermoplastic.
44. The seat cushion of claim 43 wherein said first thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), and combinations thereof.
45. The seat cushion of claim 43 wherein said cellulose component
is a fire-retardant cellulose fiber treated with either boric acid
or sodium polyborate.
46. The seat cushion of claim 43 wherein said second thermoplastic
is selected from the group consisting of polyester, polyethylene
terephthalate (PET), polypropylene, polyethylene, nylon,
polylactide, acrylic, and combinations thereof.
47. The seat cushion of claim 43 wherein said cellulose component
constitutes from about 45% to about 55% of said non-woven fibrous
body.
48. The seat cushion of claim 43 wherein said second thermoplastic
constitutes from about 20% to about 80% of said bi-component
fiber.
49. The seat cushion of claim 43 wherein said second thermoplastic
constitutes from about 40% to about 60% of said bi-component
fiber.
50. The seat cushion of claim 43 wherein said second thermoplastic
constitutes about 50% of said bi-component fiber.
51. The seat cushion of claim 43 wherein said bi-component fiber
has a diameter of from about 1.5 to about 9 denier.
52. A method of forming a covering for a seating surface
comprising: adding a first moldable material to a first mold and
forming a rim component; inserting the rim component into a second
mold, adding a second moldable material to the second mold over the
second mold and forming a pad component bonded to the rim
component; and inserting the bonded pad and rim components to a
third mold, covering the bonded pad and rim components with a
finish material and securing the finish material to the bonded pad
and rim components.
53. The method of claim 52 further comprising inserting a fastener
in the rim component before forming the pad component to the
component, where the fastener is in-molded in the bonded pad and
rim components between the pad and rim component.
54. The method of claim 53 wherein the fastener comprises a portion
extending from the rim component.
55. The method of claim 52 further comprising forming at least one
embossment in the finish material and the pad component.
56. A seating structure comprising: a support structure; and a pad
assembly comprising: a rim component; a pad component bonded to the
rim component; and a finish component bonded to the pad component;
wherein the pad assembly is secured to the support structure.
57. The seating structure of claim 56 wherein the support structure
has at least one opening formed therein, and further comprising at
least one fastener in-molded between the rim component and the pad
component, the fastener comprising an insert portion extending from
the rim component and secured in the at least one opening in the
support structure.
58. The seating structure of claim 57 wherein the insert portion is
a one-way fastener.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part
application from U.S. application Ser. No. 10/463,187 filed on Jun.
17, 2003; which (i) claims priority on U.S. provisional application
60/389,647 filed Jun. 18, 2002; and (ii) is a continuation-in-art
application of U.S. application Ser. No. 09/869,418 filed on Jun.
27, 2001, now abandoned, which is a .sctn.371 of PCT/US00/32272
filed Nov. 21, 2000; which claims the benefit of U.S. provisional
application 60/167,303 filed Nov. 24, 1999.
BACKGROUND OF THE INVENTION
[0002] In the office landscape environment, much of the furniture,
including chairs and seating units utilize a mesh or woven fabric
supporting member as a seat bottom. While providing good aesthetic
properties, mesh seating bottoms frequently suffer from limited
comfort and cushioning qualities. Accordingly, there is a need for
an improved seating system that can be readily used with such mesh
seating bottoms.
[0003] Removable seat cushions are known in the art. These cushions
typically include a padded member that can be placed on a seating
surface. Although satisfactory in many regards, conventional seat
cushions generally utilize a flat base member which does not
conform to contoured seat bottoms used in many of today's office
furniture. Accordingly, there is a need for a removable seat
cushion that is readily adapted for use with a contoured seat.
[0004] Provisions are known in the art for attaching a seat or seat
cushion to an underlying seat or chair. Such provisions include
straps that are attached to one another such as by buckling, or tie
downs that are secured to the underlying seat. It is often tedious
and difficult to tie or otherwise secure such tie downs or snaps,
and equally difficult to release them after use, in order to remove
the seat cushion. Accordingly, there is a need for an improved
strategy by which a removable seat cushion can readily be secured
to an underlying seat or supporting surface.
[0005] Furthermore, fire retardancy is an increasing concern for
office furniture. As efforts are underway by suppliers of office
furniture systems and seating units to increase the degree of fire
retardancy of such products, it would be desirable to also impart
fire retardant properties to components used in conjunction with
such products.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The present invention achieves all of the foregoing
objectives and provides, in a first aspect, a seat cushion adapted
for releasable engagement with a mesh seat member. The seat cushion
comprises a cushion member including a collection of outwardly
extending projections adapted to releasably engage a mesh seat
member upon insertion through voids defined in the mesh.
[0007] In another aspect, the present invention provides a seat
cushion adapted for releasable engagement with a mesh seat member.
The seat cushion comprises a cushion member and a frame component
secured to the cushion member. The frame component includes a
collection of downwardly extending projections adapted to
releasably engage a mesh seat member upon insertion through voids
defined in the mesh.
[0008] In yet another aspect, the present invention provides a seat
cushion adapted for releasable engagement with a mesh seat member.
The seat cushion comprises a cushion member, a frame component
engaged to the cushion member, a collection of engagement members
extending from the frame component. The engagement members each
include a distal tip, a shaft extending between the tip and the
frame component, and at least one engagement flap extending outward
from the shaft.
[0009] In another aspect, the present invention provides a method
of forming a covering for a seating surface. The method includes
adding a first moldable material to a first mold and forming a rim
component. The method also comprises inserting the rim component
into a second mold, adding a second moldable material to the second
mold over the second mold and forming a pad component bonded to the
rim component. The method also comprises inserting the bonded pad
and rim components to a third mold, covering the bonded pad and rim
components with a finish material and securing the finish material
to the bonded pad and rim components.
[0010] In still a further aspect, the present invention provides a
seating structure comprising a support structure and a pad
assembly. The pad assembly comprises a rim component, a pad
component bonded to the rim component, and a finish component
bonded to the pad component, wherein the pad assembly is secured to
the support structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will be described in detail with
several preferred embodiments and illustrated, merely by way of
example and not with intent to limit the scope thereof, in the
accompanying drawings.
[0012] FIG. 1 is a perspective view of a typical chair utilizing a
contoured mesh seat bottom.
[0013] FIG. 1A is a detailed view of a mesh material used in the
seat portion of the chair shown in FIG. 1.
[0014] FIG. 2 is a view illustrating placement of a preferred
embodiment seat cushion on the chair of FIG. 1.
[0015] FIG. 3 is an exploded view illustrating components of a
preferred embodiment seat cushion.
[0016] FIG. 4 is a cross-sectional view of a cushion member of the
seat cushion shown in FIG. 3 taken along line 4-4.
[0017] FIG. 5 is a cross-sectional view of a frame component taken
across line 5-5 in FIG. 3, illustrating a preferred embodiment
engagement member.
[0018] FIG. 6 is a view of another preferred embodiment engagement
member used in the seat cushion described herein.
[0019] FIG. 7 is a view of another preferred embodiment engagement
member.
[0020] FIG. 8 illustrates another preferred embodiment engagement
member.
[0021] FIG. 9 illustrates yet another preferred embodiment
engagement member.
[0022] FIG. 10 illustrates another preferred embodiment engagement
member.
[0023] FIG. 11 illustrates yet another preferred embodiment
engagement member.
[0024] FIG. 12 illustrates yet another preferred embodiment
engagement member.
[0025] FIG. 13 illustrates another preferred embodiment engagement
member.
[0026] FIG. 14 illustrates yet another preferred embodiment
engagement member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 1 illustrates a typical chair 100 with which the
present invention seat cushion is used in conjunction. The chair
100 typically comprises a seat back 110 and seat bottom 120
positionably coupled together by a frame assembly 115 extending
therebetween. The chair 100 also comprises first and second arm
members 130 and 132 engaged with the frame assembly 115 and/or the
seat back 110 by support members 131 and 133, respectively. The
sub-assembly of the seat back 110, seat bottom 120, frame assembly
115, and arms 130 and 132 is generally disposed and supported on a
pedestal 140 extending between the frame assembly 115 and a base
150. The base 150 can be in a variety of different forms and
arrangements, however, it is typical to utilize a plurality of
outwardly extending support members each having a caster 160 or
other rolling member disposed on their underside.
[0028] The seat bottom 120 of the chair 100 preferably utilizes a
relatively thin supporting member such as a mesh or a woven fabric.
The supporting member or mesh extends across a seat bottom frame
that imparts a contoured configuration to the mesh spanning that
frame. The term "mesh" as used herein refers to any thin planar
member having a plurality of small voids, apertures, holes, or
openings extending through the thickness of the member. In the
representative example shown in FIG. 1A, the mesh used in the seat
bottom 120 includes a collection of parallel extending fibers or
strands 122 and a second set of parallel extending fibers or
strands 124 extending at right angles with the first set of fibers
or strands 122. The sets of fibers or strands, i.e. 122 and 124,
can be bonded to each other at their locations of intersection on
contact, or remain unbonded. The resulting voids 125 defined at the
intersections of these spaced fibers or strands can be in a variety
of different shapes and sizes. However, it is typical for the shape
of a void 125 to be square or rectangular. The size of the void, or
rather span or dimension of a void, is generally somewhat variable.
The span may be significantly increased if the sets of fibers or
strands such as 122 and 124 are not bonded to one another and
forces or stresses urge the fibers apart from one another.
[0029] FIG. 2 illustrates positioning and placement of a preferred
embodiment seat cushion 200 onto the chair 100 depicted in FIG. 1.
The seat cushion 200 generally includes a cushion member 210
defining an upper surface 214 and an oppositely directed bottom
surface 212. The seat cushion 200 also comprises a frame component
220 generally extending along the underside 212 of the cushion
member 210. The frame component 220 includes a collection of
downwardly extending engagement members 230 described in greater
detail herein. The geometry and configuration of the underside of
the seat cushion 200 is preferably shaped to conform with the
geometry and configuration of the seat bottom 120 of the chair 100.
However, the present invention includes seat cushions that do not
exhibit such matching characteristics since the seat cushion 200 is
preferably flexible and can be flexed or otherwise deformed to
match the shape or contour of the seat bottom 120.
[0030] FIG. 3 is an exploded view of a preferred embodiment seat
cushion 200. The seat cushion 200 includes a cushion member 210
having the noted upper surface 214 and bottom surface 212. The
upper surface 214 and bottom surface 212 are generally separated by
a laterally extending perimeter 216 extending around the perimeter
of the cushion member 210. The seat cushion 200 also comprises a
frame component 220. The frame component defines a top surface 224
and an oppositely directed under surface 222. Upon engagement of
the cushion member 210 to the frame component 220, the topside 224
of the frame component 220 is preferably in contact and immediately
adjacent to the bottom surface 212 of the cushion member 210. The
frame member also includes a plurality of downwardly extending
engagement members 230, described in greater detail herein.
[0031] FIG. 4 is a cross-section of the cushion member 210 taken
along line 4-4 in FIG. 3. The cushion member 210 includes a
deformable interior member 217 generally surrounded by an optional
protective covering 211.
[0032] The interior member 217 of the cushion member 210 is a
unified or monolithic member and preferably includes a matrix
fiber, a cellulose fiber, and a binder polymer that serves as an
adhesive to bind the components together. The interior member 217
may also include various fillers and additional materials as well.
The various components are assembled and melt-bonded together to
form a finished member.
[0033] The matrix fiber for use in the interior member provides
structure and strength characteristics to the cushion member. The
interior member provides the structure to form the cushion member
into the desired shape. The matrix fiber is preferably a high
melting point polyester, polyethylene terephthalate (PET), or
another thermoplastic. Any thermoplastic used as the matrix fiber
should preferably have a melting point higher than the temperatures
used in the molding of the interior member 217 as described below.
That is, while it is acceptable for the matrix fiber used in the
present invention to become soft during the molding process, it
should not melt to the extent of becoming a molten component or
losing its structure completely. More than one type of matrix fiber
may be used in the construction of the cushion member 210.
Alternately or in addition to the thermoplastic fiber, natural
fibers could be used such as sisal, jute, kenaf, coconut fiber or
hemp.
[0034] The cellulose fiber of the preferred embodiment cushion
member is used to provide mass and shape to the interior member as
well as contribute to its fire resistance. To increase its fire
resistance, the cellulose is treated with a fire retardant in an
amount necessary to render it nonflammable. Suitable fire
retardants include, but are not limited to, boric acid and/or
sodium polyborate. Suitable treated cellulose fiber for use in the
present invention includes NU-WOOL.RTM., available from Nu-Wool
Co., Inc. and boron cellulose available under the tradename
THERMOLOK INCIDE from Hamilton Mfg. Inc. The cellulose fiber
preferably constitutes from about 40 to about 70% by weight of the
cushion member, more preferably 45 to 55%.
[0035] The binder polymer of the interior member of the cushion
acts as an adhesive and binder to bond the matrix fiber and
cellulose fiber together and lock the fibers into position. Thus,
the binder polymer will at least partially melt during the molding
process. The binder polymer can be any recyclable fiber having this
characteristic, such as polyester, PET, polypropylene,
polyethylene, nylon, PLA and acrylic. Preferably, the binder
polymer is a polyester having a melting point of about 100.degree.
C. During the process, the binder polymer at least partially melts
and becomes flowable, penetrating between the matrix fibers and the
cellulose fibers to bond them together. Upon cooling, the binder
polymer solidifies to form the final interior member.
[0036] In one embodiment of the present invention, the matrix fiber
and the binder polymer are provided as a single bi-component
blended fiber. In this bi-component fiber, the two materials may be
arranged in co-axial arrangement, with an inner strand of higher
melting point matrix fiber surrounded by a sheath of lower melting
point binder polymer. Suitable polyester bi-component fibers for
use in the present invention are commercially available under the
trade designation "PET bi-component fiber" from various
manufacturers. Various sized bi-component fibers may be used in the
present invention seat cushion or products depending on the
particular use. Although not intended to be limiting, a typical
bi-fiber suitable for use in most applications of the present
invention has a diameter of about 5 denier or smaller. When
bi-component fiber is used, a preferred seat cushion interior
member according to the present invention will contain about 30 to
about 60% by weight bi-component fiber and about 40 to about 70% by
weight cellulose. In any event, the amount should be enough such
that the resultant member will pass ASTM E84 flame test for
building materials and UL 723 test.
[0037] Most preferably, the interior member of the cushion member
comprises from about 20% to about 40%, and most preferably about
30% of binder polymer, and from about 60% to about 80%, and most
preferably about 70'% matrix fiber. Upon formation into the
interior member, the member has a loft of about 0.500.
[0038] The covering 211 of the preferred embodiment cushion member
may be a layer made from any decorative membrane, including fiber
and non-fiber materials and woven and non-woven materials.
Additional filler materials may also be added to enhance strength
or other panel characteristics, such materials including, but not
limited to, various thermoplastics such as polyester, co-polyester,
and nylon; natural materials such as sisal, hemp, cotton and flax;
or other materials such as ceramic powder, fire-retardant
materials, or metal mesh. Specialized additives may also be added
to improve certain properties of the finished cushion member,
including but not limited to, pesticides, anti-microbial additives,
ammonia dust inhibitors, stabilizers, and water repellants.
[0039] The resulting cushion member such as 210, may be constructed
using a conventional carding line and cross lapper in various
arrangements. For convenience, a representative process will be
described using a polyester bi-component fiber, cellulose and a
finish layer only. As stated above, however, various other
processes may be used to make the cushion member and additional
fibers and additives may also be combined to produce the cushion
member. The bi-component fiber is introduced on a garnett or
carding machine, which straightens and parallelizes the loosened
bi-component fiber to form a web of parallel, crimped fibers. As
the bi-component fiber web exits the carding machine, the treated
cellulose fiber is spread out over the top of the web. Any
additional additives, such as pesticides, may be added at this
stage or prior to the forming of the web. The resulting cellulose
covered web is then directed through a cross lapper, to build up
the web into a batt and to integrate the cellulose with the
bi-component fiber. The resulting batt is cut to length and then
heated, in an oven to melt the outer sheath of the bi-component
fiber (the binder polymer) and cause it to intimately blend the
cellulose and the inner strand of the bi-component fiber (the
matrix fiber). This provides a "through-bonded" batt that not only
bonds the components of the member, but also seals the surface of
the batt against leakage. Any conventional carding machine and
cross lapper may be used in this process. A suitable cross lapper
is Crosslapper model CL-OC available from Technoplants.
Additionally, other known processes for forming batts may be used,
such as those disclosed in U.S. Pat. Nos. 5,974,631 and 6,276,028,
the disclosures of which are incorporated herein by reference.
[0040] The batts are heated to a point where the binder polymer
transitions from a solid state to a liquid state. Although the
temperature at which the batts are heated will therefore vary
depending on the composition of the matrix fiber and binder
polymer, a typical heating cycle using a polyester bi-component
fiber include heating the batts to about 400.degree. F. Some of the
binder polymer fibers may liquefy while others remain in a
transition or gel-like condition. Thus, the batt becomes soft and
pliable, yet can still be handled because the matrix fiber and
cellulose retain enough of the batt structure. If the batts are to
be molded into specific shapes to form a finished cushion member,
the batts are transferred by a conveyor from the oven to a bonding
press. If a finish layer is to be used in the manufacture of the
cushion member, it is transferred, from a fabric carousel or other
dispenser to the bonding press at this stage. The finish layer is
mated and aligned with the hot batt and the press is then closed,
capturing and pressing the finish layer to bond it to and embed it
in the batt.
[0041] Regardless of whether a finish layer is used, the bonding
press is closed and the batt is pressed, between the mold halves or
dies of the press. The batt, still hot from the oven, assumes the
shape of the interior of the press. The binder polymer may further
transition to a molten state at this time due to the pressure of
the press. The molten binder polymer flows throughout the mold
cavity and binds the cellulose and matrix fibers together. If a
finish layer is used, the molten material is also pressed into this
layer, so it becomes at least partially embedded in the batt.
[0042] The mold halves or dies are preferably temperature
controlled below the melting temperature of the binder polymer.
Thus the oven heats the batt and the pressure of the closed mold in
the press shapes the batt before the transfer of heat from the batt
to the dies sets the batt in a solid state.
[0043] As discussed above, the binder polymer preferably at least
partially melts to become a molten material during the heating in
the oven. However, it preferably remains viscous rather than
free-flowing. Thus, the binder polymer will only flow throughout
the mold cavity when the press closes the mold and pressure is
applied to the batt. Because of this, the final cushion member may
have localized areas of relatively higher material density, and
associated greater material toughness, where the added batt
material was originally placed in the mold.
[0044] The cushion member may be constructed using a single batt or
a combination of different batts having different compositions.
Thus, a manufacturer can make cushion members having customized
structures and properties based on a user's requirement. The
combining of different batts allows a fabricator to tailor the
characteristics of the resulting cushion member by positioning
strata of component materials within the resulting cushion member.
For example, a second batt comprised of a blend including a filler
material may be used with a first batt to introduce and position a
stratum of filler material into the resulting cushion member. The
second batt may be assembled using the same process described
above, with an exception that fibers of a filler material are
included in the blend. The first and second batts may be introduced
to each other before or after they are heated in the oven.
Preferably, the two batts are introduced prior to heating, so that
they may become at least partially bonded together during heating
by the melting and diffusion of the binder polymer between the two
batts.
[0045] As noted, it should be realized that a cushion member of the
invention may be constructed with various alternative "lay-ups" of
different fiber and filler layers and multiple batts prior to
molding in the bonding press. By selecting different components for
use in the batt or a multiple number of batts or by changing the
thickness of each batt, one may alter the stiffness, toughness,
acoustics and other characteristics of the resulting cushion
member. For example, strength and other characteristics may be
enhanced with the use of metal or ceramic fibers added to the batt.
A rigid support structure, such as a metal mesh or foil, may be
embedded in the cushion member for additional strength by including
the structure in the batt or web lay-up.
[0046] Structural characteristics of the cushion member may also be
controlled by adjustment of the material density and the mold
pressure. For a given amount of material, a defined mold cavity
volume will result in a particular material density. With a
constant mold cavity volume, increasing the amount of material in
the batt will increase the resulting density in the final cushion
member. A cushion member with a relatively higher material density
will exhibit a greater toughness that resists puncturing.
Conversely, decreasing the amount of material in the batt will
produce a cushion member with a relatively lower material density,
resulting in a lighter, less tough cushion member susceptible to
puncturing and the insertion of pins and the like. Thus, for
example, a cushion member of the invention can be made to be a
fully tackable member by reducing the resulting material density
appropriately.
[0047] The frame component is preferably formed from the same
materials as utilized for the interior member. Generally, the
materials for the frame component are selected, and used in such
proportions, that the frame component is relatively rigid. The
frame component preferably comprises from about 60% to about 80%,
and most preferably about 70% of the binder polymer, and from about
20% to about 40%, and most preferably about 30% of the matrix
fiber.
[0048] Although the frame component may be in a variety of
different shapes, configurations, and dimensions, preferably the
frame component is generally planar with a thickness of about 0.10
inch to about 0.010 inch thick, and most preferably about 0.050
inch thick.
[0049] After formation of the frame component, one or more of the
engagement members are preferably molded thereon. Sufficient heat
and pressure are utilized to bond the materials of the frame
component and the engagement members together. Molding or
attachment of the engagement members to the frame component can be
performed in conjunction with affixment of the frame component to
the cushion member. Optionally, the covering or cover layer of the
cushion member can then be applied. Alternately, the covering can
be applied prior to affixment of the frame component to the cushion
member.
[0050] Most preferably, the molding or attachment of the plurality
of engagement members is performed concurrently with the molding
and formation of the interior member of the cushion member. That
is, the interior member is formed and integrally molded on or about
the frame component in conjunction with molding or attaching the
engagement members to the frame component. This strategy eliminates
a secondary or additional molding operation.
[0051] The engagement members can be formed from nearly any
material. For example, the engagement members can be formed from
the same material(s) as the cushion member and/or the frame
component. Alternatively, the engagement members can be formed from
a moldable polymeric material such as for example, polyethylene,
polypropylene, polystyrene and the like.
[0052] FIG. 5 is a detailed partial cross-sectional view of the
frame component taken across line 5-5 in FIG. 3. FIG. 5 illustrates
a typical engagement member 230 extending from the under surface
222 of the frame component 220. The engagement member 230 detailed
in FIG. 5 includes a distal tip member 232 and a shaft 234
extending between the frame component 220 and the distal member
232. One or more engagement flaps or projections 235 may be
provided along the outer surface of the shaft 234. As described in
greater detail herein, the engagement flaps or projections
releasably engage a mesh material upon insertion through voids
defined in that material. The engagement member 230 may extend
through the frame component 220 and further be secured to the frame
component 220 by a head component 236 which lies along the upper
surface 224 of the frame component 220.
[0053] FIGS. 6-14 illustrate additional preferred embodiment
engagement members having various profiles. FIG. 6 illustrates a
preferred embodiment engagement member 330 having a tip 332 with a
shaft 334 extending between the tip 332 and a corresponding frame
component (not shown). The preferred embodiment engagement member
330 includes a plurality of outwardly extending projections 335
separated by a valley 336.
[0054] FIG. 7 illustrates another preferred embodiment engagement
member 430. The engagement member 430 includes a tip 432 and a
shaft 434 extending between the tip 432 and a frame component.
[0055] FIG. 8 illustrates another preferred embodiment engagement
member 530. The member 530 includes a tip 532 and a shaft extending
between the tip 532 and a corresponding frame component.
[0056] FIG. 9 illustrates another preferred embodiment engagement
member 630. The member 630 includes a tip 632 and a shaft 634
extending between the tip 632 and a frame component. The preferred
embodiment engagement member 630 is characterized by one or more
depressions or valleys 636 defined along the shaft 634.
[0057] FIG. 10 illustrates another preferred embodiment engagement
member 730. The engagement member 730 includes a tip 732 and a
shaft 734 extending between the tip 732 and a corresponding frame
component. The engagement member 730 includes one or more outwardly
extending projections 735.
[0058] FIG. 11 illustrates another preferred embodiment engagement
member 830. The member 830 includes a distal tip 832 and a shaft
834 extending between a frame component and the tip 832. The
engagement member 830 also includes one or more projections
extending outward from the shaft 834 and/or tip 832.
[0059] FIG. 12 illustrates yet another preferred embodiment
engagement member 930. The engagement member 930 includes a distal
tip 932 and a shaft 934 extending between the tip 932 and a
corresponding frame component. The engagement member 930 includes
one or more outwardly extending projections such as 935.
[0060] FIG. 13 illustrates yet another preferred embodiment
engagement member 1030. The engagement member 1030 includes a
distal tip 1032 and a shaft 1034 extending between a frame
component and the distal tip 1032. The preferred embodiment
engagement member 1030 includes a plurality of outwardly extending
projections 1035.
[0061] FIG. 14 illustrates another preferred embodiment engagement
member 1130. The engagement member 1130 includes a distal tip 1132
and a shaft 1134 extending between the tip 1132 and a corresponding
frame component. The preferred embodiment engagement member 1130
includes a projection such as 1135.
[0062] Regardless of the specific form or profile of the engagement
member, it is generally preferred that such member includes one or
more outwardly extending engagement flaps or projections such as
for example 235 shown in FIG. 5. Upon placement of the preferred
embodiment seat cushion upon a mesh seat bottom of a chair, such as
depicted in FIG. 2, one or more of the engagement members are
inserted into, and through, the mesh material forming the seat of
the chair. Specifically, the engagement members extend through
voids or openings defined in the mesh. Utilizing a tapered distal
end member such as member 232 in FIG. 5 facilitates alignment of
the fibers, strands, or other is material forming the mesh with the
engagement member such that the engagement member can readily
extend within an opening defined in the mesh. As the engagement
member is displaced into the opening and past the mesh, the
engagement flaps or projections, such as 235 in FIG. 5, preferably
contact and engage portions of adjacent mesh material. This action
is used to secure and retain the seat cushion upon the mesh seat
bottom once placed thereon. The seat cushion can be easily removed
from the seat bottom by simply displacing the cushion away from the
eat bottom. The engagement flaps or projections readily deform to
allow adjacent mesh material to pass by. although the preferred
embodiment seat cushion includes a collection of engagement members
having flaps or projections, the invention includes engagement
members free of such structures, such as the engagement member 530
shown in FIG. 8.
[0063] In one embodiment, and referring to FIGS. 2-3, a thin seat
cushion or pad 200 is secured over one or both of the seat and back
seating structure. Preferably, the thin pad is a molded batt or
panel material, as disclosed for example in US Patent Application
Publication US 2004/0028958 A1 (U.S. application Ser. No.
10/463,187), PCT Application PCT/US01/10262 (Publication No. WO
01/74583 A1), U.S. Provisional Application No. 60/193,196, U.S.
Provisional Application No. 60/389,647, U.S. Application
09/869,418, PCT Application PCT/US00/32272 and U.S. Provisional
Application No. 60/167,303, all of which are hereby incorporated
herein by reference. In particular, the pad includes a layer of
moldable material 217 and a finish material 211, such as a fabric,
secured or disposed along one side of the moldable material.
[0064] The thin pad can be formed in a three-dimensional shape to
mate with and conform to the upper, body-facing surface of a
seating structure, whether it be the back or seat. As previously
noted, in one embodiment, the moldable material is made of a
non-woven material, and can include without limitation
thermoplastics, polyester, co-polyester, polypropylene, nylon,
polyethylene, or combinations thereof. For example, one suitable
non-woven material is available from western Nonwovens, Los
Angeles, Calif. The finish, e.g. fabric, is bonded to the moldable
material substrate with an adhesive, for example and without
limitation a powder adhesive, including for example, and without
limitation a co-polyester resin available from EMS-Griltech, S.C.
Alternatively, the fabric is simply embedded into the moldable
material substrate. In certain embodiments, the overall pad
preferably has a thickness of 0.10 inches to about 0.75 inches, and
in one embodiment is about 0.25 inches when covering the back and
about 0.50 inches when covering the seat. The pad is relatively
thin, such that it is flexible and can flex and conform to the
underlying seating structure.
[0065] Referring to FIGS. 3-5, a seat pad assembly 200 is shown as
including a frame or rim component 220, a pad component 217 and a
fabric covering component 211, or finish material. The rim
component 220 is formed by placing a polyester material into a
first mold. The mold compresses the polyester material and creates
a rigid rim in the shape of the perimeter of the seat or back. The
mold further forms a plurality of openings spaced around the rim
component. The rim component is then placed in a second mold.
Fasteners 230, such as Christmas tree fasteners include a one-way
insert portion such as distal member 232 in FIG. 5, that are
inserted in the openings of the rim. The term "one-way" insert
portion means the fastener can be easily inserted in one direction,
but cannot be easily removed in the other, opposite direction.
[0066] Additional polyester material is placed in the second mold
on top of the rim. The pad component 217 is formed and bonded to
the rim component 220 with heat. The fasteners 230, can include a
top flange component 236, are trapped or secured/in-molded between
the rim component and pad component. The second mold further trims
or cuts the perimeter of the pad component. By making the rim
component 220 separately from the pad component 217, the rim
component can be made more rigid such that it can support the
fasteners 230.
[0067] Next, the bonded rim and pad components 220, 217 are
inserted into a third mold. A powder adhesive is added to the top
of the pad component and a fabric covering is placed over the top
of the pad component. The mold heat cures the fabric 211 onto the
pad component 217. The mold further forms the shape of the pad
around the edge thereof, for example by forming a radius or curve
to the edge. The mold can further form embossments resembling a
plurality of dimples, in the top of the pad assembly. In one
embodiment, the dimples are formed by using pins.
[0068] After the pad assembly is removed from the third mold, the
fabric 211 is trimmed and wrapped around the bottom of the assembly
where it is secured with adhesive. The pad can be secured to an
underlying support member by placing the support member in a die,
which stamps or forms a plurality of openings shaped and
dimensioned to receive the one-way insert portion of the fasteners.
the pad assembly 200 is then secured to the support member by
inserting the fasteners into the openings with a one-way attachment
and pressing the pad assembly and seat support together.
[0069] Rather than the exemplary dimples, other markings, signage
or indicia can be embossed into the chair seat and/or back,
including for example and without limitation the name of a
business, department or individual, or other designs.
[0070] In alternative embodiments, the pad assembly is secured to
the seating structure with adhesives, mechanical fasteners such as
screws and the like, or combinations thereof. In one embodiment, an
anchor member, such as a screw or the insert portion of the
"Christmas tree" fastener is in-molded with the attachment portion
extending from a rear or bottom side thereof. The attachment
portion is received in mating holes (not shown) formed in the
seating structure, for example with a snap-fit or by threading a
nut thereon, so as to secure the pad to the seating structure.
[0071] Although the preferred embodiment seat cushions can be used
in conjunction with nearly any mesh material forming a seat bottom,
the preferred seat cushions of the invention are particularly
adapted to be used in association with the chairs having a mesh
seat bottom described and shown in one or more of the following
patents or publications: U.S. Pat. Nos. 6,035,901; 6,702,390;
6,722,741; 6,726,286; 2004/0189073; and 2004/0155503; all of which
are hereby incorporated by reference.
[0072] The invention has been described with reference to the
preferred embodiments. Obviously, modifications and alterations
will occur to others upon a reading and understanding of this
specification. The invention is intended to include all such
modifications and alterations.
* * * * *