Foam article and method of preparation
AssigneeMilsco Manufacturing Company
InventorJames T. McEvoy
Life of this patent
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Abstract
A foam article suitable for use as a seat cushion includes a supportive bottom layer of firm high density foam, a comfortable top layer of soft low density foam and a border or side wall of foam of intermediate density. The foam article has a sag factor of about 4.5 to about 6.5, and the foam layers and the side wall are bonded together without employing adhesives. A method of preparing the foam article also is disclosed.
Claims7
A method of preparing a foam article having a top of soft foam of low density, a firm supportive bottom of foam of high density and a supportive side wall of foam of intermediate density, said method comprising:
- (a) placing a first formulation which will yield a firm foam in the center of a mold thereby partially filling said mold;
- (b) placing a second formulation which will yield a foam of intermediate density in said mold about the periphery of said first formulation thus forming a border;
- (c) permitting the first formulation to cream, foam and rise to about 10% to about 80% of its potential;
- (d) adding to the mold a third formulation which will yield a soft foam, said third formulation being liquid and having a higher specific gravity than the first formulation so that the third formulation passes through the first formulation and the first formulation will float upon the third formulation;
- and
- (e) allowing the three formulations to cream, foam, rise and cure to obtain a single foam article having a firm, foam layer, a soft foam layer and a border or side wall of foam of intermediate density, said layers and side wall being bonded and knitted together at their common boundaries during the curing process.
An article suitable for use as a cushion which includes a firm foam top layer, a soft foam bottom layer and a border or side wall of foam of intermediate density, said layers and side wall being bonded and knitted together along their common boundaries without the use of adhesives.
Dependencies are inferred from the claim text.