Method for forming a cushion
AssigneeMatrex Furniture Components, Inc.
InventorRoger Tornero
Life of this patent
Estimating the term…
Abstract
A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.
Claims14
A method for forming a cushion having a smooth bottom surface using a mold having an elastic member attached along its periphery to rigid frame members having vertical inner edges, said method comprising the steps of:
- (a) placing at least one resilient block on the top surface of a flat rigid planar base having vertical edges;
- (b) positioning a cover layer, said cover layer having a width greater than the width of said planar base, atop said resilient block;
- (c) placing said cover layer, said resilient block, and said planar base onto said elastic member so that the bottom surface of said planar base is exposed and so that the vertical edges of said planar base generally oppose the vertical inner edges of said rigid frame members;
- (d) pressing said bottom surface of said planar base to force said cover layer, said resilient block and said planar base into said elastic member;
- (e) deflecting said elastic member to thereby mold said cover layer and said resilient block;
- (f) forcing said cover layer against the vertical edges of said planar base as said cover layer is pressed into said elastic member;
- (g) attaching said cover layer to the vertical edge of said planar base with the excess cover layer extending beyond the bottom surface of said planar base, to form a seat cushion;
- and
- (h) trimming the excess of said cover layer flush with the bottom surface of said planar base to provide a seat cushion having a flat smooth bottom surface.
A method of forming a seat cushion using a mold, said mold having a deflectable planar member, said planar member attached along its periphery to a rigid frame having a plurality of vertical edges, the method comprising the steps of:
- (a) placing a resilient block upon the top surface of a rigid flat planar base having vertical edges;
- (b) placing a resilient cover layer having a width greater than the width of said planar base over said resilient block with the ends of said cover layer extending beyond the bottom surface of said planar base;
- (c) placing said cover layer, said resilient block and said planar base on said planar member so that the vertical edges of said planar base generally oppose said vertical edges of said rigid frame and with the top surface of said resilient cover layer in contact with said deflectable planar member;
- (d) pressing the bottom surface of said planar base to force said cover layer, said resilient block and said planar base into said deflectable planar member;
- (e) deflecting said deflectable planar member into a concave configuration to thereby mold said resilient cover layer and said resilient block into a convex shape corresponding to the concave shape of said deflected planar member;
- (f) urging the ends of said cover layer against the vertical edges of said planar base by the deflection of said deflectable planar member;
- (g) attaching said cover layer to the vertical edges of said planar base with the excess cover layer extending beyond the bottom surface of said base to form a seat cushion;
- and
- (h) trimming the excess cover layer flush with the bottom surface of said planar base to provide a seat cushion having a flat smooth bottom surface.
A method for forming a cushion having a smooth bottom surface using a mold having an elastic member, wherein the elastic member is capable of being deflected to various depths as needed to properly form the cushion, said method comprising the steps of:
- (a) placing at least one resilient block on the top surface of a flat rigid planar base having side edges;
- (b) positioning a cover layer, said cover layer having a width greater than the width of said planar base, atop said resilient block;
- (c) placing said cover layer, said resilient block, and said planar base onto said elastic member so that the bottom surface of said planar base is exposed;
- (d) pressing said bottom surface of said planar base to force said cover layer, said resilient block, and said planar base into said elastic member to an approximate desired depth, while maintaining the perimeter of said planar base exposed;
- (e) deflecting said elastic member to thereby mold said cover layer and said resilient block;
- (f) forcing said cover layer against the side edges of said planar base as said cover layer is pressed into said elastic member by pressing the bottom surface of said planar base to a sufficient depth within the mold;
- and
- (g) attaching said cover layer to the side edge of said planar base with excess cover layer extending beyond the bottom surface of said planar base, to form a seat cushion.
Dependencies are inferred from the claim text.