Cushion with aesthetic exterior

Abstract

An aesthetic cushion assembly includes an aesthetic layer and a fiber cushion bonded to the aesthetic layer. In one example, the aesthetic layer extends beyond a periphery of the fiber cushion to provide flaps that can be used to secure the aesthetic cushion assembly to a commercial product, such as a chair. The flaps can also be used to form a finished product such as a mattress. The aesthetic cushion assembly can be manufactured using a variety of methods. In one example, the fiber is blown onto the aesthetic layer and the fiber and aesthetic layer are heated together. In another example, the fiber is blown into a cavity and separately heated or a simple batt is generated by non-woven manufacturing methods. The fibers are molded into a desired article shape to form a fiber cushion. The fiber cushion and/or aesthetic layer are then trimmed, if necessary, to provide a finished article shape. The aesthetic cushion can then be shipped to a customer and only requires installation onto a commercial product. A machine used to form a mattress according to the inventive method is also disclosed.

Dependencies are inferred from the claim text.