CA2132918C - Seat cushion construction - Google Patents

Seat cushion construction Download PDF

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Publication number
CA2132918C
CA2132918C CA 2132918 CA2132918A CA2132918C CA 2132918 C CA2132918 C CA 2132918C CA 2132918 CA2132918 CA 2132918 CA 2132918 A CA2132918 A CA 2132918A CA 2132918 C CA2132918 C CA 2132918C
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CA
Canada
Prior art keywords
cavities
individual
cushion construction
cushion
top wall
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 - Lifetime
Application number
CA 2132918
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French (fr)
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CA2132918A1 (en
Inventor
R. Michael Stewart
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SSH Bedding Canada Co
Original Assignee
Simmons Canada Inc
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Filing date
Publication date
Application filed by Simmons Canada Inc filed Critical Simmons Canada Inc
Priority to CA 2132918 priority Critical patent/CA2132918C/en
Publication of CA2132918A1 publication Critical patent/CA2132918A1/en
Application granted granted Critical
Publication of CA2132918C publication Critical patent/CA2132918C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06Spring inlays
    • A47C27/063Spring inlays wrapped or otherwise protected
    • A47C27/064Pocketed springs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/34Seat parts with springs in compression, e.g. coiled

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  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Vehicle Step Arrangements And Article Storage (AREA)
  • Buffer Packaging (AREA)

Abstract

A cushion construction comprises a boxing structure having a bottom wall, a top wall, side walls and internal walls defining a plurality of completely enclosed cavities. Each of the walls is formed of a resiliently flexible material. The boxing structure has a central portion. A resiliently deformable support member which extends between the top wall and the bottom wall at the central portion is also provided. Springs are positioned in each of the cavities and extend in an upright position between the bottom wall and the top wall.

Description

BP File No. 6129-069 - .1 -Title: SEAT CUSHION CONSTRUCTION
FIELD OF THE INVENTION
This invention relates to a construction for seat cushions which may be used in chairs, sofas, love seats and other seating devices.
BACRGROUND OF THE INVENTION
For many years, foam and springs have been used both individually and in combination to manufacture cushions for furniture such as chairs and couches as well as in transportation equipment, such as car seats. Over the years efforts have been made to improve the degree of comfort, the amount of support and the durability of a seat cushion without increasing, or at least unduly increasing, the cost of constructing a seat cushion.
In some constructions, a cushion construction comprises a resilient foam body incorporating a plurality of springs. Each of these springs is located in an individual cavity in the resilient foam body. Examples of such constructions include United States Patent No.
2,882,959 (Burkart) and United States Patent No. 4,429,427 (Sklar). In some constructions, the interior of the spring may be filled with a core material. An example of such a construction is Canadian Patent Application No. 2,013,169 (Reinhardt). In some constructions, the springs may incorporated in a cushion construction in a stressed state while in others, the spring may be inserted into the cushion in an unstressed state.
In order to increase the rigidity of a cushion construction without the spring elements, which are used for that purpose becoming perceptible, it has been proposed to manufacture a support device formed from a flexible, resilient material and having a plurality of springs wherein the flexible resilient material and the springs have substantially the same spring rates and the spring elements are in an unstressed state when the support device is in an unloaded state. See United States Patent No. 4,862,540 (Savenije).
United States Patent No. 3,869,739 (Klein) discloses a cushion or mattress construction comprising an encasing structure defining an enclosed cavity; a plurality of coil springs and a corresponding plurality of synthetic fabric casings. For the coil springs, the coil springs completely filling the cavity in side-by-side relationship; and, a thin adhesive layer bonding the top and bottom of the casings to the encasing structure.
United States Patent No. 5,040,255 (Barber, Jr. ) discloses a construction for a cushion or mattress having an encasing structure and a plurality of coil springs.
Each spring has a profile with the top and bottom coils of the springs being larger in diameter than the remaining coils of the spring. The springs are set out in a serpentine fashion within a cavity defined by the encasing structure.
Some of these constructions are expensive to manufacture and are accordingly unattractive. Others have limited durability. Another problem with prior constructions is that they provide only a limited degree of comfort.
SUZ~IARY OF TIC: INVENTION
In accordance with their present invention, there is provided a cushion construction sized to seat one individual comprising:
(a) a boxing structure having a bottom wall, a top wall, size walls and internal walls defining a plurality of completely enclosed cavities, each of the walls being formed of resiliently-flexible material, said boxing structure having a central portion;
(b) a resiliently deformable support member extending between the top wall and the bottom wall at the central portion; and (c) spring means positioned in each of the cavities extending in an upright position between the bottom wall and the top wall.
The support member may be formed by the intersection at the central portion of the plurality of the internal walls. Preferably, the internal walls extend outwardly from the central portion to the side walls so as to define an internal web structure.
The number of cavities defined by the internal walls may vary. Preferably, the internal walls define at least three cavities . More preferably, such as in the case of a cushion that is substantially square, there are four cavities. The spring means may comprise a plurality of individual springs placed in each cavity. The springs are placed in each cavity so as to substantially fill the cavity. Accordingly, the actual number of springs placed in each cavity will vary depending upon the size of the cushion, the size of the cavity and the size of the springs. In one embodiment, the springs may be interconnected so as to maintain the springs in an upright position. Preferably, the springs are under compression when the cushion construction is in an unloaded state. For example, the springs may be encased in a fabric material when under compression (e. g. pocketed coil springs).
When the cushion construction is utilized in seating devices designed to seat more than one person, for example a couch, a plurality of individual cushions each having the cushion construction of the instant invention may be provided. Accordingly, if a couch is designed to seat three people, three individual cushions, each utiiizing the cushion construction of the instant invention, may be provided. In an alternate embodiment, a single longitudinal extending cushion, containing a plurality of individual cushion constructions according to the instant invention, may be provided. The individual cushion constructions may be separately formed and then encased in an outer retaining means so as to form a single unit. Alternately, the plurality of individual cushion constructions may be integrally formed so as to define a single longitudinally extending cushion:
A cushion manufactured using the cushion construction of the instant invention is surprisingly comfortable due to the relative placement of the spring means and the top wall, side walls, bottom wall, internal walls and support member which are formed of a resiliently flexible material. The cushion construction provides an economical balance between the use of springs and resiliently flexible material in an easily manufactured construction.
The seat construction can be incorporated into a multitude of seating devices such as furnishings, e.g.
chairs, sofas, loveseats and sofa beds.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the instant invention will be more fully and completely understood by reference to the following drawings of a preferred embodiment of the invention in which:
Figure 1 is a partially-cut-away, perspective view of a cushion incorporating the cushion construction of the instant invention;
Figure 2 is a cross-section along line 2-2 in Figure 1;
Figure 3 is a cross-section along line 3-3 in Figure 4;
Figure 4 is a cross-section in the same direction as the cross-section shown in Figure 2 of an alternate cushion incorporating the cushion construction of the instant invention;
Figure 5 is a cross-section in the same direction as the cross-section shown in Figure 2 of a further alternate embodiment of the instant invention;
Figure 6 is a cross-section in the same direction as the cross-section shown in Figure 2 of an additional embodiment according to the instant invention;
and, Figure 7 is a crass-section in the direction of line 3 - 3 of an alternate embodiment of the cushion construction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to .Figure 1, the seat cushion construction according to the instant invention, generally referred to by reference number 10, comprises a boxing structure 12, a plurality of cavities 14 and plurality of spring means 16.
As better shown in Figures 2 and 3, boxing structure 12 comprises bottom wall 20, top wall 22, side walls 24 and internal walls 26. When assembled as a whole as shown in Figure 1, bottom wall 20, top wall 22, side walls 24 and internal walls 26 define a plurality of fully-enclosed cavities 14. Side walls 24 encompass each cavities 14 and accordingly define a continuous perimeter around cavities 14. Each side wall 24 may be individually formed and then assembled together to form the perimeter.
Alternately, side walls 24 may be integrally formed.
Bottom wall 20 has inside surface 28 and top wall.
'22 has inside surface 30. Side walls 24 extend from;
~ inside surface 28 of bottom wall 20 to inside surface of top wall 22. Similarly, internal walls 26 extend 25 from inside surface 28 of bottom wall 20 to inside;
surface 30 of top wall 22. , .
In an alternate embodiment, top wall 22 and bottom wall 20 extend across cushion 10 and seat within recesses 24a of side walls 24 (see Figure 7).
30 The cushion construction also includes a resiliently-deformable support member 32. Support member 32 extends from inside surface 28 of bottom wall 20 to inside surface 30 of top wall 22. As shown in Figures 1 and 2, support member 32 is located at the central portion of boxing structure 12. Support member 32 may be formed by the intersection of internal walls 26. Preferably, internal walls 26 radiate outwardly from support ~
member 32 to side walls 24 so as to define an internal web centred around support member 32.
Each of bottom wall 20, top wall 22, side walls 24, internal walls 26 and support member 32 are made from a resiliently flexible material such as a synthetic foam (latex foam or urethane foam). Each of side wall 24, internal walls 26 and support member 32 may be formed as individual members and joined together, such as by adhesive to form a unitary construction. Alternately, side walls 24, internal walls 26 an support member 32 may be integrally formed.
The seat cushion 10 shown in Figures 1-3 is sized to seat one individual. Support member 32 is centrally positioned in boxing member 12. Accordingly, support member 32 is placed directly under the posterior of an individual who sits on cushion 10.
It is appreciated that a cushion constructed using this cushion construction may be of any particular shape. As shown in Figures 1-3, the cushion is generally square and side walls 24 effectively define the perimeter of the cushion, thus, support member 32 is centrally positioned with respect not only to boxing structure 12, but the cushion itself. It will be appreciated that cushions of any shape may be constructed using this construction. For example; a cushion may be rectangular ( see Figure 4 ) , oblong or f an shaped ( see Figures 5 and 6). With some of these shapes, for example, the fan shaped cushion, it is generally intended that the person sits toward the rear of the cushion. The rear portion, which is generally more square, is intended to receive the posterior of the individual. The front, fan-shaped portion of the cushion is more for decoration as opposed to supporting the entire weight of the individual who sits on the cushion.
Accordingly, as shown in Figure 5, the cushion construction of the instant invention may be utilized at the portion of the cushion where it is intended that the individual sit (the "seating portion" of the cushion) and the remainder of the cushion may be constructed of a resiliently flexible material. Side walls 24 may extend outwardly from cavities 14 to the edge of the cushion so that the design features of the cushion, such as a fan-shaped portion, are constructed of a foam material.
Alternately, side walls 24 may be of the same width and may define the perimeter of the cushion and internal walls 26 may extend outwardly to the perimeter of the cushion (see Figure 6).
Internal walls 26 define a plurality of cavities surrounding support member 32. As shown in Figures 2, 5, and 6, four cavities are shown. However, a cushion construction may comprise at least three cavities and, preferably, comprise four cavities. It will be appreciated that the actual shape of the cavities will depend upon the number of cavities present and the shape of the perimeter formed by side walls 24. For example, referring to Figure 5, although the cushion represented therein is fan-shaped, four cavities are utilized and each cavity is generally square. In the alternate construction shown in Figure 6, while there are still four cavities, the two forward cavities in the fan-shaped portion of the cushion are irregular in shape. Preferably, the number of cavities and the shape of the perimeter are chosen so that the cavities have a square or rectangular shape.
Each cavity contains spring means 16. The spring means may comprise a plurality of springs. For example, as shown in Figure 2 each cavity contains four springs. If the cavities vary in shape, then the number of springs in each cavity may vary. For example, referring to Figure 6, the two forward cavities contain five springs. It will also be appreciated that, by varying the size of each spring, the number of springs in each cavity may be varied, and in the same cushion, cavities of the same size may, accordingly, have different numbers of springs.

_8_ Spring means 16 are selected so as to essentially fill each cavity 14. Spring means 16 extend vertically between bottom wall 20 and top wall 22 and, preferable, are dimensioned such that, when the cushion is in an unloaded state, spring means 16 are in contact with inside wall 28 of bottom 20 and inside wall 30 of top wall 22. Since spring means 16 essentially fill cavity 14, the loading of the cushion, for example, by a person sitting thereon, causes spring means 16 to compress as opposed to deflecting outwardly into side walls 24 and inner walls 26.
Preferably, spring means 16 are under compression when the cushion construction is in an unloaded state. For example, each spring means 16 may be a pocketed coil spring as is shown in Figure 1.
Preferably, the spring means 16 are bound together so as to maintain them in an upright position even when the cushion construction is in a loaded state.
If an open coil is utilized, ie. a coil which is not surrounded by any fabric, then the coils may be joined together at their top and bottom by any means known in the art such as rings. Alternately, if the spring means are pocketed coils, then the individual pockets may connected together. Generally, pocketed coils are longitudinally extending rows. The longitudinally extending rows are cut to the desired length for a particular application. In the embodiment shown in Figure 2, two rows, each of which contains two pocketed coil springs, are utilized. Coils 16a and 16b comprise one row and coils 16c and 16d comprise the second row. Coils 16a and 16b are connected together by the pocket material extending between the two coils. Similarly, coil 16c and 16d are connected together.
In an alternate embodiment, coils 16a and 16c, as well as coils 16b and 16d, may be joined together such as by bonding the fabric together where the coils attach (not shown).

_ g _ It will be appreciated that the cushion construction described so far may be utilized to prepare a cushion to seat one individual. The cushion construction of the instant invention may be utilized to construct a cushion which is sized to seat more than one person. For example, a plurality of individual cushion construction units as shown in Figure 2 may be placed in a longitudinally extending row so as to define a cushion for use in, for example, a couch. If the couch is designed to seat three people, then three box structures 12 may be placed side by side. Preferably, the boxing structures are connected together so as to form a unitary construction.
For example, the individual units may be fixed together such as by adhesive. Alternately,.or in addition, the individual units may be encased in an outer perimeter of flexible resilient material (not shown). In a further alternate embodiment, as shown in Figure 4, the individual boxing structures may be integrally formed as a whole:
Thus, a cushion construction may comprise three individual boxing structures 34, 36 and 38. Dashed lines 40 and 42 are used to demonstrate the notional end of each individual unit. Each individual construction comprises a plurality of side walls 24 and internal walls 26 defining a plurality of .cavities 14. Each cavity 14 includes spring means 16 to fill the cavity. Each boxing structure 34, 36 and 38 may be as described above.
The cushion construction may be manufactured by providing a boxing structure 12 having side walls 24, internal walls 26 and a plurality of cavities 14. Spring means may then be placed in each cavity 14. Bottom and top walls 20 and 22 may then be placed around boxing structure 12 fully enclosing cavities 14. Referring to Figure 1, additional padding material 44 may be placed on top of the exterior side of top wall 22. Optionally, additional padding may also be placed against the external wall of bottom wall 20. Fabric covering 46 may then be placed around the entire construction.

213~~18 Alternately the cushion may be constructed by providing boxing structure l2 and then placing boxing structure 12 on either bottom wall 20 or top wall 22.
After insertion of the spring means, the other of bottom wall 20 and top wall 22 may be placed in position and the unit finished as described above.

Claims (28)

1. A cushion construction sized to seat one individual comprising:
a) a boxing structure having a bottom wall, a top wall, side walls and internal walls defining a plurality of completely enclosed cavities, each of said walls being formed of resiliently flexible material, said internal walls extend outwardly from a central portion so as to define an internal web structure;
b) a resiliently deformable support member extending between said top wall and said bottom wall at said central portion; and c) spring means positioned in each of said cavities extending in an upright position between said bottom wall and said top wall.
2. A cushion construction as claimed in claim 1 wherein said internal walls intersect to define said central portion, and said resiliently deformable support member comprises a portion of at least one of said internal walls.
3. A cushion construction as claimed in claim 1 wherein, said resiliently deformable support member is contiguous with the internal walls which extend outwardly from the central portion.
4. A cushion construction as claimed in claim 1 wherein said walls define at least three cavities.
5. A cushion construction as claimed in claim 1 wherein said walls define four cavities.
6. A cushion construction as claimed in claim 1 wherein each of said spring means comprise a plurality of springs.
7. A cushion construction as claimed in claim 6 wherein said springs are interconnected so as to maintain the said springs in said upright position.
8. A cushion construction as claimed in claim 1, 6 or 7 wherein said spring means are under compression when said cushion construction is in an unloaded state.
9. A cushion construction as claimed in claim 6 wherein said springs are pocketed springs.
10. A cushion construction as claimed in claim 5 wherein each of said cavities is generally rectangular.
11. A cushion construction as claimed in claim 5 wherein each of said cavities is generally square.
12. A cushion construction as claimed in claim 1 wherein said walls are integrally formed.
13. A cushion construction sized to seat a plurality of individuals comprising:
a) a plurality of individual boxing structures sized to seat an individual, each of said individual boxing structures having a bottom wall, a top wall, side walls and internal walls defining a plurality of completely enclosed cavities, each of said walls being formed of resiliently flexible material, each of said individual boxing structures having a central portion;
b) a resiliently deformable support member extending between said top wall and said bottom wall at each of said central portions;
and c) spring means positioned in each of said cavities extending in an upright position between said bottom wall and said top wall.
14. A cushion construction as claimed in claim 13 wherein in an individual boxing structure, at least some of the internal walls intersect to form the resiliently deformable support member.
15. A cushion construction as claimed in claim 13 wherein said internal walls of a particular individual boxing structure extend outwardly from the central portion of the particular individual boxing structure to said side walls so as to define an internal web structure for the particular individual boxing structure.
16. A cushion construction as claimed in claim 13 wherein said walls define at least three cavities for each of said individual boxing structures.
17. A cushion construction as claimed in claim 13 wherein said walls define four cavities for each of said individual boxing structures.
18. A cushion construction as claimed in claim 13 wherein each of said spring means comprise a plurality of springs.
19. A cushion construction as claimed in claim 18 wherein said springs are interconnected so as to maintain said springs in said upright position.
20. A cushion construction as claimed in claim 13, 18 or 19 wherein said spring means are under compression when said cushion construction is in an unloaded state.
21. A cushion construction as claimed in claim 18 wherein said springs are pocketed springs.
22. A cushion construction as claimed in claim 17 wherein each of said cavities is generally rectangular.
23. A cushion construction as claimed in claim 17 wherein each of said cavities is generally square.
24. A cushion construction as claimed in claims 13 wherein said side walls, said top wall and said bottom wall are each integrally formed.
25. A cushion construction as claimed in claim 13 wherein said top wall and said bottom wall are each integrally formed and said respective side walls for each of said individual boxing structures are integrally formed.
26. A method of constructing a support structure for a cushion comprising the steps of:
(a) providing a least one individual boxing structure sized to seat an individual, each of said at least one individual boxing structure having side walls and internal walls defining a plurality of cavities, each of said walls being formed of resiliently flexible material, each of said at least one individual boxing structure having a central portion and a resiliently deformable support member at each of said central portions;
(b) providing spring means in each of said cavities; and, (c) providing a top wall and a bottom waif formed of resiliently flexible material and positioning said at least one individual boxing structure between said top wall and said bottom wall so as to completely enclose said cavities, each of said spring means extending between said bottom wall and said top wall, and each of said resiliently deformable support members extending between said top wall and said bottom wall.
27. A method of constructing a support structure for a cushion comprising the steps of:
(a) providing at least one individual boxing structure sized to seat an individual, each of said at least one individual boxing structure having side walls and internal walls defining a plurality of cavities, each of said walls being formed of resiliently flexible material, each of said at least one individual boxing structure having a central portion and a resiliently deformable support member at each of said central portion;
then (b) providing a bottom wall formed of resiliently flexible material and positioning said at least one individual boxing structure upon said bottom wall; then (c) providing spring means in each of said cavities; and then (d) providing a top wall formed of resiliently flexible material and positioning said top wall so as to completely enclose said cavities, each of said spring means extending between said bottom wall and said top wall, and each of said resiliently deformable support member s extending between said top wall and said bottom wall.
28. A method of constructing a support structure for a cushion comprising the steps of:
(a) providing at least one individual boxing structure sized to seat an individual, each of said at least one individual boxing structure having side walls and internal walls defining a plurality of cavities, each of said walls being formed of resiliently flexible material, each of said at least one individual boxing structure having a central portion and a resiliently deformable support member at each of said central portion;
then (b) providing a top wall formed of resiliently flexible material and positioning said at least one individual boxing structure upon said bottom wall; then (c) providing spring means in each of said cavities; and then (d) providing a bottom wall formed of resiliently flexible material and positioning said top wall so as to completely enclose said cavities, each of said spring means extending between said bottom wall and said top wall, and each of said resiliently deformable support members extending between said top wall and said bottom wall.
CA 2132918 1994-09-26 1994-09-26 Seat cushion construction Expired - Lifetime CA2132918C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA 2132918 CA2132918C (en) 1994-09-26 1994-09-26 Seat cushion construction

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA 2132918 CA2132918C (en) 1994-09-26 1994-09-26 Seat cushion construction

Publications (2)

Publication Number Publication Date
CA2132918A1 CA2132918A1 (en) 1996-03-27
CA2132918C true CA2132918C (en) 2005-04-26

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2132918 Expired - Lifetime CA2132918C (en) 1994-09-26 1994-09-26 Seat cushion construction

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CA2132918A1 (en) 1996-03-27

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Effective date: 20140926