U.S. patent application number 11/580379 was filed with the patent office on 2007-02-08 for seat cushion with integral cover attachment.
Invention is credited to Lysle R. Hinkhouse, L. John Koutsky, William Tuman.
Application Number | 20070028386 11/580379 |
Document ID | / |
Family ID | 35335533 |
Filed Date | 2007-02-08 |
United States Patent
Application |
20070028386 |
Kind Code |
A1 |
Koutsky; L. John ; et
al. |
February 8, 2007 |
Seat cushion with integral cover attachment
Abstract
A seat cushion is provided having a foam cushion body with a
perimeter section. A cover is disposed over the body and has a
border that extends around the periphery of the cushion body and
juxtaposed with the perimeter section of the cushion body. An
insert is positioned within the cushion body and has an outer wall
extending along and spaced from the periphery of the cushion body
to accommodate the cushion body perimeter section. The perimeter
section has a foam density greater than that of the main cushion
body and the border of the cover is bonded directly to this
perimeter section. In addition, a support wall or pan is used
having a size and configuration to receive the covered cushion with
the border of the cover disposed within the support wall when the
seat is fully assembled. A method of forming such a seat cushion is
also disclosed.
Inventors: |
Koutsky; L. John; (Milan,
IL) ; Tuman; William; (Colona, IL) ;
Hinkhouse; Lysle R.; (Wilton, IA) |
Correspondence
Address: |
Niro, Scavone, Haller, & Niro;Suite 4600
181 W. Madison
Chicago
IL
60502
US
|
Family ID: |
35335533 |
Appl. No.: |
11/580379 |
Filed: |
October 13, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10970599 |
Oct 21, 2004 |
|
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11580379 |
Oct 13, 2006 |
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Current U.S.
Class: |
5/653 |
Current CPC
Class: |
B29C 44/0415 20130101;
B29C 44/14 20130101; B29C 44/1257 20130101 |
Class at
Publication: |
005/653 |
International
Class: |
A47C 27/14 20070101
A47C027/14 |
Claims
1. (canceled)
2. A method for fabricating a covered seat cushion comprising:
providing a seat mold cavity defined by first and second mold
parts; placing a cover within the first mold part; locating an
insert within the seat mold cavity the insert having an outer wall
extending around spaced and from the periphery of the first mold
part and cover; securing the second mold part to the first mold
part to form the mold cavity; foaming a resin material within the
cavity to form a foamed body having a first foam density and a
foamed perimeter section having a second foam density greater than
the first foam density; and said cover having a border which is
bonded to the foamed perimeter section.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to seat technology.
More specifically, the invention relates to a covered seat cushion
having an integrated cover attachment arrangement.
[0002] A very common type of seat used in cars, trucks and off the
road vehicles is one having a foam cushion body covered with a
fabric or plastic film. One of the problems associated with such
seats is how the border of the cover is to be attached to the
cushion body. Known techniques include the use of staples, clips
and a variety of other mechanical retention devices. Adhesives have
also been utilized, and some prior art teaches that the cover may
be joined to the body during the foaming and molding of the
cushion. One of the problems with this latter molding technique is
that the foam used for the cushion body may not have suitable
physical characteristics to reliably hold the cover border in place
throughout the useful life of the seat.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a seat having a cushion
body and a cover in which the cover border is bonded directly to
the cushion body while the cushion body is being foam molded. In
addition to the cushion body and cover, the seat also includes an
insert that is situated in the cushion body at the time it is
foamed and molded. The insert includes an outer wall that extends
around the periphery of the cushion body, but is spaced from it to
define a relatively small and thin perimeter section of the cushion
body between the insert and the cover. The perimeter section has a
foam density greater than that of the main cushion body and, as a
result, its physical characteristics useful for retaining the cover
border are enhanced.
[0004] The present invention is also directed to a method for
manufacturing a seat cushion having a cushion body, cover and
integrated cover attachment arrangement as just described. In
accordance with this method, a two part mold is provided which
forms a mold cavity. The cover is first placed within one of the
mold parts and the second mold part is then placed to close and
thereby define the cavity. An insert is positioned within the mold
cavity with an outer wall of the insert extending around and spaced
slightly from the periphery of the cavity. A suitable resin is then
injected or poured into the cavity and allowed to foam and thereby
fill the entire cavity. Because the space between the insert outer
wall and the periphery of the cavity is small, the foam in this
perimeter section of the cushion body has a smaller cell structure
and therefore has a greater density than the foam in the main
cushion body. As a result, the physical characteristics of the foam
in this perimeter section are better suited to hold the cover
border in place.
[0005] In accord with one preferred embodiment of the invention, a
seat cushion is provided having a foam cushion body with a
perimeter section. A cover is disposed over the body and has a
border that extends around the periphery of the cushion body and
juxtaposed with the perimeter section of the cushion body. An
insert is positioned within the cushion body and has an outer wall
extending along and spaced from the periphery of the cushion body
to accommodate the cushion body perimeter section. The perimeter
section has a foam density greater than that of the main cushion
body and the border of the cover is bonded directly to this
perimeter section. In addition, a support wall or pan is used
having a size and configuration to receive the covered cushion with
the border of the cover disposed within the support wall when the
seat is fully assembled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The novel features which are characteristic of the present
invention are set forth in the appended claims. However, the
invention's preferred embodiments, together with further objects
and attendant advantages, will be best understood by reference to
the following detailed description taken in connection with the
accompanying drawings in which:
[0007] FIG. 1 is a cross-sectional view showing one seat cushion
embodiment of the present invention as formed in a suitable
mold;
[0008] FIG. 2 is an enlarged cross-sectional view of the circled
portion of FIG. 1; and
[0009] FIG. 3 is a cross-sectional view showing the covered seat
cushion assembled to a support pan.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] In accordance with one preferred embodiment of the present
invention a foamed vehicle seat cushion is designated generally as
10 and includes a foam body 12, a foam body perimeter section 14, a
cover 16, an insert 18 and cushion support wall or pan 20.
[0011] The cushion body 12 is fabricated in the conventional manner
using any one of a variety of foam resins well known in the art.
Polyurethane resins are particularly preferred. Exemplary
polyurethane formulations useful in the practice of the present
invention are well known to those of the skill in the art. See,
Flexible Polyurethane Foams by Herrington and Hock, Chapter 11,
published by the Dow Chemical Company (1997). An initially liquid
resin charge 22 is poured into a mold cavity 24, formed by first
and second mold parts, 26 and 28, and allowed to foam and expand to
fill the entirety of the cavity. The second mold part 28 is
provided with vents 38 to allow air within cavity 24 to escape as
the foam expands.
[0012] The cover 16 may be fabric or polymeric film or a fabric
backed polymeric film. It is placed in the cavity of the first mold
part 26, before the resin is poured, and may be held against the
mold cavity wall by vacuum in a conventional and well known
manner.
[0013] The insert 18 is positioned within the cavity, typically by
securing it to the mold cover or second mold part 28. The insert 18
includes an outer wall 30 which extends around the periphery of the
cushion body 12. The outer wall 30 is spaced a small distance from
the mold cavity wall and cover to allow formation of a relatively
thin cushion perimeter section 14 having a smaller foam all size
and higher density than the main body of the cushion. As a result,
its cohesive strength and ability to effectively secure the border
36 cover 16 are enhanced. To achieve the desired properties for the
perimeter section when using a polyurethane foam it has been found
that the cross dimension of the perimeter section should be between
about 2.5 and 5.5 millimeters. When this cross dimension is too
small, then the resin is less likely to fill the entire space
between the insert outer wall 30 and the cover border 36. This can
result in voids which cause separation of the cover border. On the
other hand, if the cross dimension is too large, the cell structure
of the resulting foam will be too large and the physical properties
necessary for retention of the boarder 36 may be jeopardized. In
order to insure complete and uniform foaming in the cushion
perimeter section, the second mold part 28 is provided with vent
holes 39 around the mold cavity and aligned with the perimeter
section.
[0014] The insert 18 may be made from metal or plastic, although
high strength plastic is preferred. It is required to select a
material for the insert that will adhere well to the particular
polyurethane foam employed. The insert, of course, remains a part
of the finished cushion and can be used to mechanically secure the
cushion to the support pan 20 using any conventional fastening
technique. Although an angled cross-section is illustrated for the
insert 18, other configurations (i.e. bars, tubes or channels) may
prove suitable. It is, however, preferred that the cross dimension
of the perimeter section 14 remain substantially constant around
the entire periphery of the cushion body.
[0015] After the cushion body and cover are removed from the mold
cavity, the excess border may be easily trimmed and the covered
cushion may then be assembled to support pan 20.
[0016] When the covered cushion is finally assembled, the cover
border 36 is captured within the support pan 20 and the cushion is
slightly compressed to form a clamp fit and provide further
mechanical retention of the border.
[0017] It will be appreciated by those skilled in the art that
various changes and modifications can be made to the illustrated
embodiments without departing from the spirit of the present
invention. All such modifications and changes are intended to be
covered by the appended claims.
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