CA1202736A - Membrane covered cushion having indented pattern and method for making same - Google Patents
Membrane covered cushion having indented pattern and method for making sameInfo
- Publication number
- CA1202736A CA1202736A CA000444374A CA444374A CA1202736A CA 1202736 A CA1202736 A CA 1202736A CA 000444374 A CA000444374 A CA 000444374A CA 444374 A CA444374 A CA 444374A CA 1202736 A CA1202736 A CA 1202736A
- Authority
- CA
- Canada
- Prior art keywords
- membrane
- cushion
- indented
- pattern
- design
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000012528 membrane Substances 0.000 title claims abstract description 91
- 238000000034 method Methods 0.000 title claims abstract description 12
- 239000000853 adhesive Substances 0.000 claims abstract description 21
- 230000001070 adhesive effect Effects 0.000 claims abstract description 21
- 239000004744 fabric Substances 0.000 claims abstract description 8
- 239000000463 material Substances 0.000 claims description 28
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 6
- 230000006835 compression Effects 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
- 239000002985 plastic film Substances 0.000 claims 2
- 229920001187 thermosetting polymer Polymers 0.000 claims 2
- 230000006837 decompression Effects 0.000 claims 1
- 238000007373 indentation Methods 0.000 abstract description 19
- 239000004033 plastic Substances 0.000 abstract description 5
- 229920003023 plastic Polymers 0.000 abstract description 5
- 229920005830 Polyurethane Foam Polymers 0.000 abstract description 3
- 239000011496 polyurethane foam Substances 0.000 abstract description 3
- 238000001816 cooling Methods 0.000 abstract 1
- 210000004379 membrane Anatomy 0.000 description 47
- 239000007788 liquid Substances 0.000 description 6
- 239000012790 adhesive layer Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 230000002950 deficient Effects 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000008258 liquid foam Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 208000003251 Pruritus Diseases 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000000740 bleeding effect Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000002844 continuous effect Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 230000007803 itching Effects 0.000 description 1
- 230000002045 lasting effect Effects 0.000 description 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/18—Seat parts having foamed material included in cushioning part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/16—Lining or labelling
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
MEMBRANE COVERED CUSHION HAVING INDENTED
PATTERN AND METHOD FOR MAKING SAME
Abstract of the Disclosure A cushion usable as a seat or back-rest in a seat for a vehicle or as an article of furniture has an indented design, which is ornamental or functional or both, formed in its outer exposed surface. The cushion comprises a resilient compressible deformable body, such as a polyurethane foam block, which has the indented design formed in a surface thereof, and further comprises a flexible stretchable membrane, either of cloth or plastic, which covers the body surface, follows the contours of the indented design and is adhesively secured thereto. The cushion is manufactured by providing a preformed body having the design indentations formed therein;
providing a flexible stretchable membrane heated and having an adhesive on one side thereof; and providing a fixture having a die cavity generally conforming in size and shape to the body but including projections which correspond in shape to but are of greater height than the design indentations in the body.
The membrane, which is heated to about 250° to 300° F, and then the body are inserted into the die cavity and the body is physically forced thereinto as by means of a weighted platten.
This causes the fixture projections and overlying membrane to penetrate deeply into the indented design in the body.
After several minutes, cooling occurs, the membrane takes a set and the adhesive cures to cause good adhesion, and the finished cushion is then removed from the die cavity.
PATTERN AND METHOD FOR MAKING SAME
Abstract of the Disclosure A cushion usable as a seat or back-rest in a seat for a vehicle or as an article of furniture has an indented design, which is ornamental or functional or both, formed in its outer exposed surface. The cushion comprises a resilient compressible deformable body, such as a polyurethane foam block, which has the indented design formed in a surface thereof, and further comprises a flexible stretchable membrane, either of cloth or plastic, which covers the body surface, follows the contours of the indented design and is adhesively secured thereto. The cushion is manufactured by providing a preformed body having the design indentations formed therein;
providing a flexible stretchable membrane heated and having an adhesive on one side thereof; and providing a fixture having a die cavity generally conforming in size and shape to the body but including projections which correspond in shape to but are of greater height than the design indentations in the body.
The membrane, which is heated to about 250° to 300° F, and then the body are inserted into the die cavity and the body is physically forced thereinto as by means of a weighted platten.
This causes the fixture projections and overlying membrane to penetrate deeply into the indented design in the body.
After several minutes, cooling occurs, the membrane takes a set and the adhesive cures to cause good adhesion, and the finished cushion is then removed from the die cavity.
Description
MEMBRANE COVERED CUSHION I~VING INDENTED
PATTERN AND METHOD FOR MAKING SAME
Background of the Invention Field of Use This invention relates generally to membrane covered compressible cushions having indented ornamental or functional designs or patterns formed in the top surface thereof.
Description of the Prior Art Seats for vehicles, such as automobiles, motorcycles or construction machines, or for residential or commercial furniture sometimes employ resiliently compressible seat cushions or back-rest cushions which are either removable from or permanently attached to the seat structure in which they are employed. Such cushions frequently comprise a resiliently compressible body, in the form of a block or large piece of foam-like material, such as polyurethane, which is covered by a flexible membrane, such as a sheet of cloth or plastic, which is secured to one or more surfaces of the body by direct bonding, or by an adhesive, or by s~itching or stapling along the edges and corners of the membrane. In some cushions the body takes th~ form of a pre~shaped and pre-sized block of foam-like material which is then covered with the membrane which is then suitably attached to the body. In other cushions, a membrane is placed in a mold of desired size and shape and arranged to follow the shape of the mold, and then an expanded foamable liquid is poured into the mold over the membrane and allowed to expand and set~ adhering to the membrane in the process. The membrane used in both fabricatiorl methods explained above may take the form of a flexible sheet of woven or knitted cloth or plastic, such as vinyl, and may, if desired, be stretchable as well as flexible. Sometimes it is desirable, either for functional reasons or aesthetic reasons or both, to provide an indented pattern or design in the major exposed surface of the cushion. In cushions using preformed blocks of foam it is necessary to form the pattern indentations in the appropriate surface of the block and to somehow force the appropriate parts of the membrane into these indentations until the adhesive between the block and membrane sets up. In cushions wherein expandable foam is poured into a mold, it is necessary to form the pattern indentations in the mold and to make sure that the membrane closely conforms to the shape of the mold and indentations.
Heretofore, both prior art methods of making cushions with indentational designs as described above were not entirely satisfactory and numerous problems arose.
For example, improper adhesion between the block and membrane sometimes occurs in the indentation and "bridgingl' occurs, thereby resulting in a defective design in the finished cushion. Or, in the case where liquid foam is poured into a mold lined with a cloth membrane, the liquid may bleed through the relatively porous cloth resulting in a defective, unattractive, rejectable finished cushion. In addition, the tendency of the molded body to shrink in its mold as it set r caused it to pull away from the membxane and thus further reduce the likelihood of an ill-formed unsound design.
Surnmary of the Invention In accordance with the present invention there is pro-vided a method of making a cushion having an indented pattern on a side thereof comprising the s-teps of: providing a resilient compressible body having an indented pattern of predetermined depth formed in a surface of said body; providing a flexible stretchable membrane; applying adhesive material between said body surface and said membrane; providing a fixture having a wall and a projecting pattern on said wall, said projecting pa-ttern conforming to said indented pattern but projecting from said wall for a distance greater than said predetermined depth of said inden-ted pa-ttern;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretch-ing of said membrane as said projecting pattern forces said mem-brane deeply into said indented pattern in said body; allowing said adhesive material to set sufficien-tly to secure said membrane to said body; and relieving said force.
From another aspect, the inven-tion provides a cushion comprising: a body fabricated of resilient compressible deformable material, said body having a surface and an inden-ted design on said surface; a flexible stre-tchable membrane overlying said surface and con~orming to said indented design; and means for effecting con-tinuous adhesion between said membrane and said surface and said indented design, whereby portions of said surface of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively~ in the finished cushion as a resu]t of said body being cornpressed and said membrane being stretched while said means for effecting adhesion are set.
, . ~
PATTERN AND METHOD FOR MAKING SAME
Background of the Invention Field of Use This invention relates generally to membrane covered compressible cushions having indented ornamental or functional designs or patterns formed in the top surface thereof.
Description of the Prior Art Seats for vehicles, such as automobiles, motorcycles or construction machines, or for residential or commercial furniture sometimes employ resiliently compressible seat cushions or back-rest cushions which are either removable from or permanently attached to the seat structure in which they are employed. Such cushions frequently comprise a resiliently compressible body, in the form of a block or large piece of foam-like material, such as polyurethane, which is covered by a flexible membrane, such as a sheet of cloth or plastic, which is secured to one or more surfaces of the body by direct bonding, or by an adhesive, or by s~itching or stapling along the edges and corners of the membrane. In some cushions the body takes th~ form of a pre~shaped and pre-sized block of foam-like material which is then covered with the membrane which is then suitably attached to the body. In other cushions, a membrane is placed in a mold of desired size and shape and arranged to follow the shape of the mold, and then an expanded foamable liquid is poured into the mold over the membrane and allowed to expand and set~ adhering to the membrane in the process. The membrane used in both fabricatiorl methods explained above may take the form of a flexible sheet of woven or knitted cloth or plastic, such as vinyl, and may, if desired, be stretchable as well as flexible. Sometimes it is desirable, either for functional reasons or aesthetic reasons or both, to provide an indented pattern or design in the major exposed surface of the cushion. In cushions using preformed blocks of foam it is necessary to form the pattern indentations in the appropriate surface of the block and to somehow force the appropriate parts of the membrane into these indentations until the adhesive between the block and membrane sets up. In cushions wherein expandable foam is poured into a mold, it is necessary to form the pattern indentations in the mold and to make sure that the membrane closely conforms to the shape of the mold and indentations.
Heretofore, both prior art methods of making cushions with indentational designs as described above were not entirely satisfactory and numerous problems arose.
For example, improper adhesion between the block and membrane sometimes occurs in the indentation and "bridgingl' occurs, thereby resulting in a defective design in the finished cushion. Or, in the case where liquid foam is poured into a mold lined with a cloth membrane, the liquid may bleed through the relatively porous cloth resulting in a defective, unattractive, rejectable finished cushion. In addition, the tendency of the molded body to shrink in its mold as it set r caused it to pull away from the membxane and thus further reduce the likelihood of an ill-formed unsound design.
Surnmary of the Invention In accordance with the present invention there is pro-vided a method of making a cushion having an indented pattern on a side thereof comprising the s-teps of: providing a resilient compressible body having an indented pattern of predetermined depth formed in a surface of said body; providing a flexible stretchable membrane; applying adhesive material between said body surface and said membrane; providing a fixture having a wall and a projecting pattern on said wall, said projecting pa-ttern conforming to said indented pattern but projecting from said wall for a distance greater than said predetermined depth of said inden-ted pa-ttern;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretch-ing of said membrane as said projecting pattern forces said mem-brane deeply into said indented pattern in said body; allowing said adhesive material to set sufficien-tly to secure said membrane to said body; and relieving said force.
From another aspect, the inven-tion provides a cushion comprising: a body fabricated of resilient compressible deformable material, said body having a surface and an inden-ted design on said surface; a flexible stre-tchable membrane overlying said surface and con~orming to said indented design; and means for effecting con-tinuous adhesion between said membrane and said surface and said indented design, whereby portions of said surface of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively~ in the finished cushion as a resu]t of said body being cornpressed and said membrane being stretched while said means for effecting adhesion are set.
, . ~
2'~3~
A cushion in accordance with the invention offers several advantages over the prior art. For example, the design or pattern formed -therein is well and clearly defined. The membrane adheres completely and positively to the underlying body in the indentations and at the adjacent raised portions and no undesirable bridging occurs. As a result, the finished cushion has a better appearance and is more rugged and lasting in use. Use of a preformed block instead of in-situ expanded liquid foam at the time the membrane is applied eliminates liquid leakage or bleeding through porous membranes. The equipment and steps required to carry the method in accordance with the invention are relatively few, simple and easy to employ~
Other objects and advantages will hereinafter appear.
Drawings Figure 1 is a perspective view of the front, top and one side of a vehicle seat employing a seat cushion and back-rest cushion in accordance with the present invention;
Figure 2 is a perspective view of -the fron-t, bottom and other side of the seat cushion shown in Figure l;
Figure 3 is an enlarged perspective view, partly in cross section, of a por-tion of the seat cushion of Figure 2;
Figure 4 is an exploded perspective schematic view of equipment and components employed in making the seat cushion of Figures 1 through 3;
`'``''''' 7~
Fig. 5 is an exploded view, partly in cross section, of a portion of certain manufacturing equipment and cushion components shown in Fig. 4 and showing them in pre-assembly disposition;
Fig. 6 is a view similar to Fig. 5 but showin~ the equipment and components of Fig. 5 being joined in another staye of manufacture; and Fig. 7 is a view similar to Fig. 6 but showing still another stage of manufacture where the components are joined together.
Description of Preferred Embodiments Referring to Fig. 1, the numeral 10 designates a seat which is usable in a vehicle, such as an automobile, a construction machine, tractor or the likel or which could be used as an article of domestic or commercial furniture. 5eat 10 comprises a rigid supporting frame 12, haviny an appropriate pedestal 14, and on which are mounted a seat cushion 16 and a back-rest cushion 18, each constructed and manufactured in accordance with the present invention. The cushions 16 and 18 may be removable from frame 12 or permanently secured thereto by means not shown. The cushions 16 and 18 may be assumed to be substantially identical in construction and mode of manu-facture and, therefore, only seat cushion 16 is hereinafter described in detail. Fig. 2 shows seat cushion 16 (hereinafter simply referred to as "cushion") as removed from seat frame 12 and disposed to display structural details on the underside thereof.
As Figs. l, 2 and 3 show, cushion 16 generally comprises an upper, outer or exposed surface 20, a bottom surface 22, a front surface 24, a rear surface 26 and right anc~ left side surface 28 and 30, respectively (with the terms left and right being orientated with respect to a seat occupant, not shown).
Upper surface 20 of cushion 16 is provided with a design 32, which may be ornamental or functional or both, and which comprises design indentations 34 extending inwardly into surface 20 and relatively raised portions 35 between or adjacent to the indenkations 34. The indentations 34 shown in Fig. 1 include, for example, six grooves or indentations such as 36 extending fore and aft and three grooves or inden-tations such as 38 extending laterally and transversely in intersecting relationship to the grooves 36. More or fewer indentations or other arrangements could be provided.
Figs. 2 and 3 show that cushion 16 comprises the following components, namely, a resllient compressible deform-able body 40, such as a polyurethane foam block, which has the design indentations 44 formed therein on the block surface 46 and also has a opposite rear surface 47, which body is covered at least on surface 46 by a flexible stretchable membrane 42, such as a sheet of cloth or plastic, which follows the contours of the design, and the membrane 42 is bonded or otherwise adhesively secured at least to the said one block surface 46 of the body 40 and to the design indentations 44 formed therein as by a film or layer of adhesive material 48. Membrane 42 also preferably adheres to the four sides 52 of body 40 and to portions of bottom 54 of body 40, as Figs. 2 and 3 show.
In an actual embodiment of the invention which was made and tested, body 40 was fabricated of known commercially avail-able constituents in the form of two liquids which, when mixed together, provide a mass of polyurethane foam material which then cures or dries after several minutes into a resilient compressibly deformable non-adhesive body.
Furthermore, actual embodiments were made and tested using membrane 42 in the form of commercially available stretchable vinyl sheets and in the form oE sheets of knitted stretchable 100 percent nylon fabrics, such as is available from ADELE
KNITS Company of 800 Chatham Road, Winston-Salem, North Carolina 27101, Style No. 438 in 51" widths and is 180 percent -stretchable lengthwise an~ 190 percent stretchable widthwise.
Also, in the actual embodiments made and tested, the adhesive layer 48 employed Type #3824 low viscosity liquid adhesive utilizing a base of synthetic rubber and resin, and a keytone solvent as a vehicle. This adhesive, which is well-adapted for use with either of the aforementioned mem-branes 42, is sprayable, bonds in 3 to 20 minutes depending on application, reaches 90 percent of total bonding strength in 24 hours, and is resistant to moisture, oil, plasticizers and heat. This adhesive is available from St. Clair Rubber Company, 1765 Michigan Avenue, Marysville, Michigan 48040.
The cushion 16 is manufactured in accordance with the following method and in accordance with the following steps, using the aforedescribed cushion components (namely, the pre-Eormed molded body 40, a membrane 42, and the adhesive layer 48). As Fig. 4 shows, the method uses the following manufacturing equipment, namely: a fixture 60 for receiving the body 40 and membrane 42; a frame 62 for conveniently supporting the membrane 42 for placement in a heating oven (not shown) and then in the fixture 60; an adhesive applicator-device such as a spray gun 64; a flat rigid platten 66 for appli-cation against the rear surface 47 of body 40; and force application means for platten 66, either in the form of a heavy weight 67 ~on the order of 50 pounds) embodied in or resting on platten 66 or in the form of a hydraulic ram (not shown) for applying downward force or pressure ~o platten 66~
The fixture 60 comprises an outer framework 68 in which a rigid die 70, formed of zlnc, or aluminum or some suitable metal or alloy or other material, is rigidly mounted. Die 70 defines a cavity 72 which includes a floor 74 from which design projections 76 exten~ upwardly. The cavity 72 of die 70 is exactly the same size and shape of the finished cushion 16 e~cept that the height of the design projections 76 is greater than (about double) the depth of the corresponding preformed design indentations 44 in body 40 or the design indentations 32 in finished cushion 16.
A means (not shown) is provided with means for heating the membrane 42 to about 250 to 300D F and such means comprises, for example, a heating oven (not shown),or other types of heating means (not shown) could be employed.
Frame 62 may take the form of an open rectangular metal, wood or plastic frame having releasable fasteners 84 thereon for releasably securing the membrane 42 thereon.
2~36 , .
_9_ The adhesive application device comprises the spray gun 64 which operates in a conventional manner to appl~ adhesive layer 48 in li~uid form under pressure in the form of a spray 86 from a source of liquid adhesive such as a pressurized tank 88 to membrane 42 and body 40.
Cushion 16 is manufactured as follows. Referring to Figs. 4 and 5, the membrane 42 is heated to proper temperature.
The heated membrane 42 is then sprayed or otherwise coated with a layer 48 of adhesive and placed above fixture 60. The preformed body ~0, formed to desired shape and size and having an appropriate design indentation 44 in its surface 46, is then disposed over the coated surface of the membrane 42. The, as Fig 6 shows, the body 40 is forced downwardly against the heated, coated membrane 42 and both enter the die cavity 72.
The platten 66 presses downwardly against the rear surface 47 of body 40 under appropriate force and, as this occurs, it causes the design projections 76 to bear against flexible stretchable membrane 42 and the latter penetrates deeply into the design indentations 44 in body 40 and beyond their normal depth. In practice, as Fig. 6 makes clear, a 6-inch thick body 40 was temporarily reduced to about half that thickness~ This disposition of components and application of pressure is main-tained for several minutes until good adhesive adhesion is achieved and until the membrane is cooled to a level where the adhesive layer 48 sets and the membrane 42 takes a set.
Thereafter, the platten 66 is removed, the frame 62 is detached from the membrane 42, and the cushion 16 is removed from the 73~
.
die cavity 72. At thls point any excess membrane 42 may be trimmed away or, if pre~erred, caused to adhere to other portions of body 40 as by adhesives, stitching, stapling or the like.
A cushion in accordance with the invention offers several advantages over the prior art. For example, the design or pattern formed -therein is well and clearly defined. The membrane adheres completely and positively to the underlying body in the indentations and at the adjacent raised portions and no undesirable bridging occurs. As a result, the finished cushion has a better appearance and is more rugged and lasting in use. Use of a preformed block instead of in-situ expanded liquid foam at the time the membrane is applied eliminates liquid leakage or bleeding through porous membranes. The equipment and steps required to carry the method in accordance with the invention are relatively few, simple and easy to employ~
Other objects and advantages will hereinafter appear.
Drawings Figure 1 is a perspective view of the front, top and one side of a vehicle seat employing a seat cushion and back-rest cushion in accordance with the present invention;
Figure 2 is a perspective view of -the fron-t, bottom and other side of the seat cushion shown in Figure l;
Figure 3 is an enlarged perspective view, partly in cross section, of a por-tion of the seat cushion of Figure 2;
Figure 4 is an exploded perspective schematic view of equipment and components employed in making the seat cushion of Figures 1 through 3;
`'``''''' 7~
Fig. 5 is an exploded view, partly in cross section, of a portion of certain manufacturing equipment and cushion components shown in Fig. 4 and showing them in pre-assembly disposition;
Fig. 6 is a view similar to Fig. 5 but showin~ the equipment and components of Fig. 5 being joined in another staye of manufacture; and Fig. 7 is a view similar to Fig. 6 but showing still another stage of manufacture where the components are joined together.
Description of Preferred Embodiments Referring to Fig. 1, the numeral 10 designates a seat which is usable in a vehicle, such as an automobile, a construction machine, tractor or the likel or which could be used as an article of domestic or commercial furniture. 5eat 10 comprises a rigid supporting frame 12, haviny an appropriate pedestal 14, and on which are mounted a seat cushion 16 and a back-rest cushion 18, each constructed and manufactured in accordance with the present invention. The cushions 16 and 18 may be removable from frame 12 or permanently secured thereto by means not shown. The cushions 16 and 18 may be assumed to be substantially identical in construction and mode of manu-facture and, therefore, only seat cushion 16 is hereinafter described in detail. Fig. 2 shows seat cushion 16 (hereinafter simply referred to as "cushion") as removed from seat frame 12 and disposed to display structural details on the underside thereof.
As Figs. l, 2 and 3 show, cushion 16 generally comprises an upper, outer or exposed surface 20, a bottom surface 22, a front surface 24, a rear surface 26 and right anc~ left side surface 28 and 30, respectively (with the terms left and right being orientated with respect to a seat occupant, not shown).
Upper surface 20 of cushion 16 is provided with a design 32, which may be ornamental or functional or both, and which comprises design indentations 34 extending inwardly into surface 20 and relatively raised portions 35 between or adjacent to the indenkations 34. The indentations 34 shown in Fig. 1 include, for example, six grooves or indentations such as 36 extending fore and aft and three grooves or inden-tations such as 38 extending laterally and transversely in intersecting relationship to the grooves 36. More or fewer indentations or other arrangements could be provided.
Figs. 2 and 3 show that cushion 16 comprises the following components, namely, a resllient compressible deform-able body 40, such as a polyurethane foam block, which has the design indentations 44 formed therein on the block surface 46 and also has a opposite rear surface 47, which body is covered at least on surface 46 by a flexible stretchable membrane 42, such as a sheet of cloth or plastic, which follows the contours of the design, and the membrane 42 is bonded or otherwise adhesively secured at least to the said one block surface 46 of the body 40 and to the design indentations 44 formed therein as by a film or layer of adhesive material 48. Membrane 42 also preferably adheres to the four sides 52 of body 40 and to portions of bottom 54 of body 40, as Figs. 2 and 3 show.
In an actual embodiment of the invention which was made and tested, body 40 was fabricated of known commercially avail-able constituents in the form of two liquids which, when mixed together, provide a mass of polyurethane foam material which then cures or dries after several minutes into a resilient compressibly deformable non-adhesive body.
Furthermore, actual embodiments were made and tested using membrane 42 in the form of commercially available stretchable vinyl sheets and in the form oE sheets of knitted stretchable 100 percent nylon fabrics, such as is available from ADELE
KNITS Company of 800 Chatham Road, Winston-Salem, North Carolina 27101, Style No. 438 in 51" widths and is 180 percent -stretchable lengthwise an~ 190 percent stretchable widthwise.
Also, in the actual embodiments made and tested, the adhesive layer 48 employed Type #3824 low viscosity liquid adhesive utilizing a base of synthetic rubber and resin, and a keytone solvent as a vehicle. This adhesive, which is well-adapted for use with either of the aforementioned mem-branes 42, is sprayable, bonds in 3 to 20 minutes depending on application, reaches 90 percent of total bonding strength in 24 hours, and is resistant to moisture, oil, plasticizers and heat. This adhesive is available from St. Clair Rubber Company, 1765 Michigan Avenue, Marysville, Michigan 48040.
The cushion 16 is manufactured in accordance with the following method and in accordance with the following steps, using the aforedescribed cushion components (namely, the pre-Eormed molded body 40, a membrane 42, and the adhesive layer 48). As Fig. 4 shows, the method uses the following manufacturing equipment, namely: a fixture 60 for receiving the body 40 and membrane 42; a frame 62 for conveniently supporting the membrane 42 for placement in a heating oven (not shown) and then in the fixture 60; an adhesive applicator-device such as a spray gun 64; a flat rigid platten 66 for appli-cation against the rear surface 47 of body 40; and force application means for platten 66, either in the form of a heavy weight 67 ~on the order of 50 pounds) embodied in or resting on platten 66 or in the form of a hydraulic ram (not shown) for applying downward force or pressure ~o platten 66~
The fixture 60 comprises an outer framework 68 in which a rigid die 70, formed of zlnc, or aluminum or some suitable metal or alloy or other material, is rigidly mounted. Die 70 defines a cavity 72 which includes a floor 74 from which design projections 76 exten~ upwardly. The cavity 72 of die 70 is exactly the same size and shape of the finished cushion 16 e~cept that the height of the design projections 76 is greater than (about double) the depth of the corresponding preformed design indentations 44 in body 40 or the design indentations 32 in finished cushion 16.
A means (not shown) is provided with means for heating the membrane 42 to about 250 to 300D F and such means comprises, for example, a heating oven (not shown),or other types of heating means (not shown) could be employed.
Frame 62 may take the form of an open rectangular metal, wood or plastic frame having releasable fasteners 84 thereon for releasably securing the membrane 42 thereon.
2~36 , .
_9_ The adhesive application device comprises the spray gun 64 which operates in a conventional manner to appl~ adhesive layer 48 in li~uid form under pressure in the form of a spray 86 from a source of liquid adhesive such as a pressurized tank 88 to membrane 42 and body 40.
Cushion 16 is manufactured as follows. Referring to Figs. 4 and 5, the membrane 42 is heated to proper temperature.
The heated membrane 42 is then sprayed or otherwise coated with a layer 48 of adhesive and placed above fixture 60. The preformed body ~0, formed to desired shape and size and having an appropriate design indentation 44 in its surface 46, is then disposed over the coated surface of the membrane 42. The, as Fig 6 shows, the body 40 is forced downwardly against the heated, coated membrane 42 and both enter the die cavity 72.
The platten 66 presses downwardly against the rear surface 47 of body 40 under appropriate force and, as this occurs, it causes the design projections 76 to bear against flexible stretchable membrane 42 and the latter penetrates deeply into the design indentations 44 in body 40 and beyond their normal depth. In practice, as Fig. 6 makes clear, a 6-inch thick body 40 was temporarily reduced to about half that thickness~ This disposition of components and application of pressure is main-tained for several minutes until good adhesive adhesion is achieved and until the membrane is cooled to a level where the adhesive layer 48 sets and the membrane 42 takes a set.
Thereafter, the platten 66 is removed, the frame 62 is detached from the membrane 42, and the cushion 16 is removed from the 73~
.
die cavity 72. At thls point any excess membrane 42 may be trimmed away or, if pre~erred, caused to adhere to other portions of body 40 as by adhesives, stitching, stapling or the like.
Claims (21)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A cushion comprising:
a body fabricated of resilient compressible deformable material, said body having a surface and an indented design on said surface;
a flexible stretchable membrane overlying said surface and conforming to said indented design; and means for effecting continuous adhesion between said membrane and said surface and said indented design, whereby portions of said surface of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively, in the finished cushion as a result of said body being compressed and said membrane being stretched while said means for effecting adhesion are set.
a body fabricated of resilient compressible deformable material, said body having a surface and an indented design on said surface;
a flexible stretchable membrane overlying said surface and conforming to said indented design; and means for effecting continuous adhesion between said membrane and said surface and said indented design, whereby portions of said surface of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively, in the finished cushion as a result of said body being compressed and said membrane being stretched while said means for effecting adhesion are set.
2. A cushion according to claim 1 wherein those portions of said membrane which conform to said surface and to said indented design are thermoset.
3. A cushion according to claim 2 wherein said membrane comprises woven sheet material.
4. A cushion according to claim 1, 2 or 3 wherein said material of said body comprises foraminous material.
5. A cushion comprising:
a body fabricated of resilient compressible deformable material, said body having a plurality of surfaces including a first surface with an indented design thereon and side surfaces intersecting said first surface;
a flexible stretchable membrane overlying said first surface and conforming to said indented design and overlying at least some of said side surfaces; and means for effecting continuous adhesion between said membrane and said first surface and said indented design and between said membrane and at least some of said side surfaces, whereby portions of said surfaces of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively, in the finished cushion as a result of said body being compressed and said membrane being stretched while said means for effecting adhesion are set.
a body fabricated of resilient compressible deformable material, said body having a plurality of surfaces including a first surface with an indented design thereon and side surfaces intersecting said first surface;
a flexible stretchable membrane overlying said first surface and conforming to said indented design and overlying at least some of said side surfaces; and means for effecting continuous adhesion between said membrane and said first surface and said indented design and between said membrane and at least some of said side surfaces, whereby portions of said surfaces of said body and portions of said membrane adjacent the means for effecting adhesion are under tension and stretched, respectively, in the finished cushion as a result of said body being compressed and said membrane being stretched while said means for effecting adhesion are set.
6. A cushion according to claim 5 wherein said membrane is thermoset.
7. A cushion according to claim 6 wherein said membrane comprises woven sheet material.
8. A cushion according to claim 5 or 6 or 7 wherein said body comprises foraminous material.
9. A method of making a cushion having an indented pattern on a side thereof comprising the steps of:
providing a resilient compressible body having an indented pattern of predetermined depth formed in a surface of said body;
providing a flexible stretchable membrane;
applying adhesive material between said body surface and said membrane;
providing a fixture having a wall and a projecting pattern on said wall, said projecting pattern conforming to said indented pattern but projecting from said wall for a distance greater than said predetermined depth of said indented pattern;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretching of said membrane as said projecting pattern forces said membrane deeply into said indented pattern in said body;
allowing said adhesive material to set sufficiently to secure said membrane to said body; and relieving said force.
providing a resilient compressible body having an indented pattern of predetermined depth formed in a surface of said body;
providing a flexible stretchable membrane;
applying adhesive material between said body surface and said membrane;
providing a fixture having a wall and a projecting pattern on said wall, said projecting pattern conforming to said indented pattern but projecting from said wall for a distance greater than said predetermined depth of said indented pattern;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretching of said membrane as said projecting pattern forces said membrane deeply into said indented pattern in said body;
allowing said adhesive material to set sufficiently to secure said membrane to said body; and relieving said force.
10. A method according to claim 9 including the further steps of heating said membrane before applying said force and allowing said membrane to cool and take a set before relieving said force.
11. A method of making a cushion having an indented pattern of predetermined depth on a side thereof comprising the steps of:
providing a fixture having a cavity therein generally corresponding in shape and size to a portion of said cushion, said cavity having a wall and a projecting pattern extending from said wall, said projecting pattern conforming in config-uration to said indented pattern but projecting from said wall for a distance greater than the depth of said indented pattern;
providing a resilient compressible body having an indented pattern of a second predetermined depth formed in a surface of said body;
providing a flexible stretchable membrane;
applying adhesive material between said body surface and said membrane;
inserting said membrane and said body in said cavity in said fixture;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretching of said membrane as said projecting pattern forces said membrane deeply into said indented pattern in said surface of said body;
allowing said adhesive material to set sufficiently to secure said membrane to said body;
relieving said force to enable decompression of said body;
and removing said cushion from said cavity.
providing a fixture having a cavity therein generally corresponding in shape and size to a portion of said cushion, said cavity having a wall and a projecting pattern extending from said wall, said projecting pattern conforming in config-uration to said indented pattern but projecting from said wall for a distance greater than the depth of said indented pattern;
providing a resilient compressible body having an indented pattern of a second predetermined depth formed in a surface of said body;
providing a flexible stretchable membrane;
applying adhesive material between said body surface and said membrane;
inserting said membrane and said body in said cavity in said fixture;
forcing said body against said membrane and the latter against said projecting pattern to effect compression of said body and stretching of said membrane as said projecting pattern forces said membrane deeply into said indented pattern in said surface of said body;
allowing said adhesive material to set sufficiently to secure said membrane to said body;
relieving said force to enable decompression of said body;
and removing said cushion from said cavity.
12. A method according to claim 11 including the further steps of heating said membrane before applying said force and allowing said membrane to cool and take a set before relieving said force.
13. A method according to claim 12 wherein said membrane comprises nylon stretch fabric which is heated to about 250°F
to about 300°F.
to about 300°F.
14. A cushion according to claim 2 wherein said membrane comprises knitted sheet material.
15. A cushion according to claim 2 wherein said membrane comprises crocheted sheet material.
16. A cushion according to claim 2 wherein said membrane comprises plastic sheet material.
17. A cushion according to claim 6 wherein said membrane comprises knitted sheet material.
18. A cushion according to claim 6 wherein said membrane comprises crocheted sheet material.
19. A cushion according to claim 6 wherein said membrane comprises plastic sheet material.
20. A cushion according to claim 15 or 16 wherein said material of said body comprises foraminous material.
21. A cushion according to claim 17 or 18 wherein said body comprises foraminous material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US46262083A | 1983-01-31 | 1983-01-31 | |
| US462,620 | 1983-01-31 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1202736A true CA1202736A (en) | 1986-04-01 |
Family
ID=23837115
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000444374A Expired CA1202736A (en) | 1983-01-31 | 1983-12-29 | Membrane covered cushion having indented pattern and method for making same |
Country Status (7)
| Country | Link |
|---|---|
| JP (1) | JPS59144475A (en) |
| CA (1) | CA1202736A (en) |
| DE (1) | DE3403106A1 (en) |
| FR (1) | FR2540091A1 (en) |
| GB (1) | GB2133980B (en) |
| IT (1) | IT1177514B (en) |
| SE (1) | SE8400257L (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006102751A1 (en) * | 2005-03-30 | 2006-10-05 | Woodbridge Foam Corporation | Foam seat element, mold for the production thereof and method to manufacture the mold |
Families Citing this family (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS61131785A (en) * | 1984-11-30 | 1986-06-19 | 株式会社タチエス | Production of seat |
| JPS61176387A (en) * | 1985-01-31 | 1986-08-08 | 株式会社タチエス | Production of seat |
| JPS62168298A (en) * | 1986-01-20 | 1987-07-24 | 株式会社川島織物 | Chair upholstering sample mounting apparatus |
| GB2191689B (en) * | 1986-06-23 | 1989-12-13 | Tachi S Co | Method of forming an interior assembly for a vehicle |
| DE3641472A1 (en) * | 1986-12-04 | 1988-06-09 | Metzeler Schaum Gmbh | Cushion with covering for vehicle seats and process for the production thereof |
| AU605480B2 (en) * | 1987-04-18 | 1991-01-17 | Tachi-S Co., Ltd. | Apparatus for manufacturing a seat |
| DE3834607C2 (en) * | 1988-10-11 | 1997-12-11 | Alkor Gmbh | Process for the production of objects from thermoformable plastic films |
| FR2724130B1 (en) * | 1994-09-07 | 1996-12-06 | Plastic Omnium Cie | METHOD FOR PRODUCING PLASTIC MATERIALS COMPRISING AN OVER-MOLDED COATING |
| US7481637B2 (en) * | 2004-05-12 | 2009-01-27 | Woodbridge Foam Corporation | Vented mold and method for producing molded article |
| US7413698B2 (en) * | 2004-06-01 | 2008-08-19 | Novo Foam Products Llc | Method of molding load-bearing articles from compressible cores and heat malleable coverings |
| DE102009012956B4 (en) * | 2008-03-14 | 2012-04-19 | Lear Corporation | Method for producing a vehicle seat |
| WO2012029822A1 (en) * | 2010-08-31 | 2012-03-08 | 積水化成品工業株式会社 | Molded foam |
| JP7272081B2 (en) * | 2019-04-17 | 2023-05-12 | トヨタ紡織株式会社 | Skin material manufacturing method |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH394536A (en) * | 1959-11-04 | 1965-06-30 | Miller Herman Inc | Curvable, flat base for upholstery with at least approximately the same wall thickness everywhere |
| GB988449A (en) * | 1962-03-01 | 1965-04-07 | Parker Knoll Ltd | Method of forming upholstery covers |
| GB1057312A (en) * | 1963-09-09 | 1967-02-01 | Fritzmeier Kg Georg | Upholstered seat cup for tractors and method for its production |
| US3331089A (en) * | 1965-04-14 | 1967-07-18 | Int Harvester Co | Seat construction |
| GB1138216A (en) * | 1966-06-21 | 1968-12-27 | Bostrom Mfg Company Ltd | Improvements in and relating to the construction of seats |
| GB1318696A (en) * | 1969-10-02 | 1973-05-31 | Hille Int Ltd | Upholstering of chairs |
| BE794953A (en) * | 1972-02-04 | 1973-05-29 | Hairlok Ltd | LAMINATED TEXTILE MATERIALS |
| US3879245A (en) * | 1972-06-27 | 1975-04-22 | Composite Structures Corp | Method of making composite cored structures |
| ES405044A1 (en) * | 1972-07-21 | 1976-01-01 | Hicks & Otis Prints Nc | Mattress including laminated foam fabrics and their production |
| JPS5940037B2 (en) * | 1979-10-31 | 1984-09-27 | 立川スプリング株式会社 | Seat body manufacturing method |
| JPS6018434B2 (en) * | 1979-11-13 | 1985-05-10 | 立川スプリング株式会社 | integrally molded seat body |
| GB2067460B (en) * | 1980-01-23 | 1984-01-25 | Nichiei Ind | Shaping foam slabs |
| DE3009885C2 (en) * | 1980-03-14 | 1982-03-04 | Metzeler Schaum Gmbh, 8940 Memmingen | Process for the production of cushion covers, mold for carrying out the process and cushion cover produced with the process |
| JPS5746838A (en) * | 1980-05-31 | 1982-03-17 | Tokyo Seat Kk | Welding method of facing member into seat or the like |
| GB2114509B (en) * | 1982-01-18 | 1985-05-09 | Textile Bonding Limited | Article incorporating fire-resistant fabric |
-
1983
- 1983-12-29 CA CA000444374A patent/CA1202736A/en not_active Expired
-
1984
- 1984-01-11 GB GB08400660A patent/GB2133980B/en not_active Expired
- 1984-01-19 SE SE8400257A patent/SE8400257L/en not_active Application Discontinuation
- 1984-01-27 FR FR8401319A patent/FR2540091A1/en active Pending
- 1984-01-27 IT IT47604/84A patent/IT1177514B/en active
- 1984-01-30 DE DE19843403106 patent/DE3403106A1/en not_active Withdrawn
- 1984-01-31 JP JP59014565A patent/JPS59144475A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006102751A1 (en) * | 2005-03-30 | 2006-10-05 | Woodbridge Foam Corporation | Foam seat element, mold for the production thereof and method to manufacture the mold |
| US8821777B2 (en) | 2005-03-30 | 2014-09-02 | Proprietect L.P. | Foam seat element, mold for the production thereof and method to manufacture the mold |
| US10492612B2 (en) | 2005-03-30 | 2019-12-03 | Proprietect L.P. | Foam seat element, mold for the production thereof and method to manufacture the mold |
Also Published As
| Publication number | Publication date |
|---|---|
| FR2540091A1 (en) | 1984-08-03 |
| JPS59144475A (en) | 1984-08-18 |
| DE3403106A1 (en) | 1984-08-02 |
| IT1177514B (en) | 1987-08-26 |
| GB2133980A (en) | 1984-08-08 |
| GB8400660D0 (en) | 1984-02-15 |
| SE8400257D0 (en) | 1984-01-19 |
| GB2133980B (en) | 1986-05-29 |
| IT8447604A0 (en) | 1984-01-27 |
| SE8400257L (en) | 1984-08-01 |
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Legal Events
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| MKEX | Expiry |