Composite foam seat cushion and method of preparation
AssigneeMilsco Manufacturing Company
InventorJames T. McEvoy
Life of this patent
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Abstract
A composite foam seat cushion is comprised of foams of different firmnesses which are bonded to adjacent foams without adhesives or glues. The cushion has a supportive bottom of one or more firm foams, a layer of soft foam on the top of and supported by the bottom layer, a protective front foam cap for the front edge of the layer of soft foam, a protective back foam cap for the back edge of the layer of soft foam and side walls of foam(s) of suitable firmness to provide support. A method of preparing the composite foam seat cushion is disclosed.
Claims12
A method of preparing a composite foam seat cushion having at least a bottom of firm supportive foam, a layer of soft foam on top of the bottom, a protective foam cap covering a back edge of the soft foam layer, and supportive foam sides, said method comprising:
- placing in the center of a suitable mold a relatively slow reacting formulation which will produce a firm supportive foam bottom of a cushion;
- placing in the front of the mold a formulation which will produce a foam of suitable properties to serve as a protective cap for the front edge of the soft layer;
- placing in the back of the mold a formulation which will produce a suitable back cap;
- placing in opposite sides of the mold formulations which will produce sides of desired properties;
- allowing all of the above-recited formulations to foam and start to rise;
- allowing such portions of the formulations in the front and rear of the mold as are in contact with the mold surface to start to gel;
- and thereafter,
- pouring through at least one of the above-recited formulations a formulation which will produce the soft layer.
A method of forming a composite foam seat cushion having a bottom of at least one layer of a firm supportive foam, a layer of a soft foam disposed on top of the bottom and at least partially enclosed thereby, protective foam caps covering front and rear edges of the soft foam layer and having firmnesses that are different from the firmness of the soft layer, and supportive foam sides each made of at least two foams forming inner and laterally outermost portions of each of the supportive foam sides, said method comprising the steps of:
- providing a suitable heated mold having a central portion and side portions disposed on opposite sides of the central portion;
- introducing, into each of the side portions of the mold, formulations which will produce foams having desired firmnesses for the outermost portions of the supportive sides of the cushion;
- introducing, into a front portion of the central portion of the mold, a formulation which will produce a foam of suitable properties to serve as the protective cap for the front edge of the soft layer;
- introducing, into a rear portion of the central portion of the mold, a formulation which will produce a foam of suitable properties to serve as the protective cap for the rear edge of the soft layer;
- introducing into the central portion of the mold, at a location thereof that is between the front and rear portions thereof, a formulation which will produce the firm foam bottom of the cushion;
- allowing all of the formulations to foam and to begin to rise;
- allowing such portions of the formulations as are in contact with the side portions of the mold and in contact with the front and rear portions of the central portion of the mold to begin to gel;
- thereafter introducing, into each of said side portions of said mold, formulations which will produce foams having desired firmnesses for the inner portions of the cushion sides, thereby displacing portions of the formulations that are to form the outermost portions of the cushion sides;
- and
- introducing, into said central portion of the mold, formulation which will produce foam having the desired firmness for the soft cushion layer, thereby causing portions of the formulation that is to form the firm bottom to form around lateral sides of the formulation for the soft layer, thereby further causing the formulations that are to form the protective front and rear caps to form around front and rear edges of the formulation for the soft layer.
Dependencies are inferred from the claim text.