US 4,040,881 A · Method of forming tufted cushion elements

Abstract

A method of forming tufted cushion elements comprising the construction of a pattern form with open cavities of various depths and wall inclinations. A piece of facing fabric is spread over the surfaces of the open cavities with its finish face toward the pattern form, and pre-cut oversize cushion elements the unconstrained geometry of which generally conforms to the cavitiesare placed into the open cavities within the facing fabric. A unitary piece of backing fabric is laid over the pattern form and attached to the facing fabric portions exposed between cushion elements along the edges of the cavity partitions, first by an adhesive and next by a sewing operaton. A unitary piece of finished backing fabric is attached on 3 sides to the edges of the backing fabric in order to provide a means of mounting the cushion element on a seat frame.

Claims12

Dependent claims

A method of forming flexible, tufted cushion elements having an array of a plurality of contiguous sections of different thicknesses, geometric forms and sizes enclosed in a continuously flexible sheet material comprising:

placing a first sheet of flexible material on a female pattern form having an array of cavities of different depths, geometric forms and sizes corresponding to said cushioned elements separated by partitions;
tucking the first flexible sheet of material into the partitioned cavities of said female pattern form to conform to the walls of the form cavities;
pre-forming bodies of resilient cushioning material of the general geometric form of said sections;
mounting the respective bodies in the respective form cavities to overlie the first flexible sheet within said cavities and expose portions of the first flexible sheet portions extending across the exposed edges of the partitions;
and
adhesively bonding a second flexible sheet on the exposed portions of the first flexible sheet.

3 more elements

Dependencies are inferred from the claim text.

Method of forming tufted cushion elements

Life of this patent

Method of forming tufted cushion elements

Life of this patent

Abstract

Claims12