US3188665A - Cushion structure - Google Patents

Description

@www

R E D Y N S M H CUSHION STRUCTURE Filed Aug. 31, 1964 u o u l l n O l b n Q l n u o n D 0 n a o o o O t C n n n l n 0 o l 0 BUI anlonoote 90.00600 llunaon Coulon-hu llutloc NVENTOR @my fw; awr@ United States Patent 3,188,665 CUSHION STRUCTURE Y Harry M. Snyder, Hickory, NAS., assignor to Snyder Paper Corporation, Hickory, N.C., a corporation of North Carolina Filed Aug. 31, 1964, Ser. No. 393,195 7 Claims. (Cl. 5--355) in furniture such as sofas and overstuffed chairs or the like must satisfy the furniture makers demand for a cushion that (l) has an attractive appearance matched to the particular style of furniture with which it is used; (2) has a proper feel or hand; (3) has sufficient firmness or body to assure comfortable seating; and (4) will not lose its shape, become matted or acquire a set within the normal life expectancy of the cushion.

The advent of latex foam rubber and of synthetic foam material such as polyurethane and synthetic latex foam rubber aided cushion manufacturers in meeting these demands by providing a material which could be used alone with a cover of ticking or the like to provide a cushion which was reasonably soft and had a requisite amount, of firmness, and which could be fabricated at a cost, which, even though varying with the quality of the foam used in the cushion, was always substantially less than the cost of using the down traditionally found in high-quality cushions.

The use of foam as a cushion material, however, has certain drawbacks. It was found, for example, that certain furniture styles, such as Early American, required that the cushion have a pronounced contour or crown which could not be easily formed with foam. In addition, it was found that even when layers of softer grades of foam were laminated onto a relatively firm foam base, the cushion did not have the hand found in cushions made of fibrous material and demanded by the more discriminating purchasers.

In an effort to eliminate these drawbacks, some prior art structures have adopted a compromise arrangement which employs an open ended cover piece or envelope comprising an outer surface of ticking and a layer of fibrous material held thereagainst by an inner layer of cheesecloth or the like sewn to the ticking, and a core piece of relatively firm foam inserted into the cover piece for enclosure thereby when the open end of the cover piece is sewn shut. Similarly, other prior art structures are formed by placing layers of fibrous material on opposite faces of a foam core piece and covering these layers with pieces of ticking glued or otherwise attached to the core element. These types of cushion structures,

however, are also difficult to form with any pronounced contour and, even more objectionalbly, the fibrous material therein tends to become matted and disarranged after a period of use causing a deterioration in the cushions appearance, comfort and hand.

The unique cushion structure of the present invention eliminates the above-noted problems of the prior art and combines the desirable qualities of foam-like materials and brous materials in a composite arrangement which provides a cushion that may be employed to exceptional advantage in furniture seating and which can be fabricated by a simple and inexpensive process that requires no sewing or special production apparatus.

Brieiiy stated, the cushion structure of the present invention is characterized by a relatively firm base element anatre? having a thickness and opposed faces proportioned in relation to the cushion structure to be formed, a filler of fibrous material disposed at'each of the opposite faces of the base element, and a cover member or layer con` sisting of relatively soft open cellular elastomeric mal.

dicated generally by the reference numeral 1t) in the drawings, comprises the previously mentioned relatively firm base element 12, with filler 14 of fibrous material disposed at each major face 16 thereof and contained thereat by a cover member or layer 18. The base element 12 is the core component of the cushion structure and is relied on to provide the requisite body and firmness therein. Preferably this base element 12 is a relatively thick and firm block of latex foam rubber in the soft to medium firmness range defined as 18 to 32 pounds Indentation or Compression Load Test value as measured by the standard ASTM Designation: D105562 or The Rubber Manufacturers Association-Buyers Specification Latex Foam. The particular firmness of the foam, the dimensions of the kopposite major faces 16, and the thickness to be employed are dictated by the specifications for the particular cushion being formed. A thickness in the order of 3 to 4 inches will be suitable for most specifications. in FIG. 2 characteristically result from the manner in which latex foam rubber is made. Although the core holes 20 appearing in the FIG. 2 section all extend from the upper face of the illustrated base element 12, it will be understood that additional bottom face core holes (not shown) are staggered therewith. One of the preferred materials would be pin core block foam of U.S. Patent No. 3,028,610. The advantage of the block foam is that filler fiber cannot work itself into the core holes.

Although latex foam rubber is the preferred material for the base element 12, it can be fabricated from other open cellular elastomeric material, such as polyurethane foam, if a greater tendency to set and lose shape during use is acceptable in the particular cushion structure being formed. Alternatively, any material or combination of materials which provide the requisite firmness and body could be used to form the base element 12. For example, coiled steel springs encased in a suitable cover, or rubberized horsehair are suitable materials for fabricating an adequate base element 12.

The filler 14 has a primary function of providing softf ness and hand to the cushion structure and, in the preferred embodiment, consists of a seating grade of polyester fiber which trade standards currently define by a weight of not less than 16 ounces per lineal yard of 32- inch lap. Suitable polyester fiber is manufactured under several trademarks, such as Dacron, Kodel and Fortrell.

Other fibrous materials such as acetate fiber or cotton i The base element core holes 20 shown tions 22 extending therethrough. The durability andV softness of latex foam rubber make it the preferable material for the cover members 18 although, as in the case of the base element 12, other open cellular elastomeric material, such as polyurethane, or any other material` having similar characteristics could be used.

The preferred cushion structure is formed by first cutting a base element 12 of proper size from a stock of latex foam rubber having a suitable firmness and thickness of the order previously noted. The cut base element 12 will usually have the simple shape of a substantially rectangular block, as illustrated in the drawings, with a length and breadth proportioned in relation to the cushion structure to be formed. However, it may be cut as well with a corner ear portion or portions, where such shaping is desired for end sofa cushions or for chair cushions; or the shaping may be otherwise contoured in plan to suit the ultimate cushion use intended.

Next, a mat of filler 14 is cut from a lap supply of seating grade polyester ber in a size and shape allowing it to be placed on a major base element face 16 with a peripheral surface portion 24 of the face 16 remaining exposed continuously about the ller 14 in a width of about l to 2 inches. v y

Then a pad is cut from a stock of latex foam rubber havingthe previously noted characteristicsl needed for the cover member 18. The shape and size of the cut pad in plan is made to correspond with that of the base element 12 with suitable allowance for edge joining of the cover member 18 thereto over thevfiller 14 as seen in FIG. 2. Edge joining of the cover member 18 is effected by the application of rubber cement at the cover member edges 26 and at theexposed peripheral surface portion 24 of the base element face 16 on which the filler 14 is disposed, and by placing the cover member 18 over the filler 14 and turning and pressing the edges 26 thereof on the base element peripheral portion 24-so that the tack of the previously applied cement secures the cushion structure 10 in the form illustrated by FIG. 2 after the same procedure has been carried out at both faces 16 of the base element 12. The rubber cement may be one of the many commercially available soft adhesives commonly used in the foam rubber and flexible urethane industry and may be either a solvent based type or a latex based type. v

The edge joining of the cover members 18 induces a crowned shape thereto that is yieldably supported by the fibrous fillers 14 which are captured and contained thereby, so that a pronounced contouring is provided at the seating surfaces of the cushion structure 10. The degree of-this contouring may be altered to a considerable extent by the sizing selected for the cover members 18 in relation to the base element 12, as the induced crowning is incushion structure 10 and must.

v would cause the cushion seating surfaces to lose shape a become uncomfortable, and the result is an unusually p sistent recovery of the seating surfaces to their initia formed contours after being sat upon. Additionally, t high degree of softness preferably provided in the foe cover members 18 presents an appealing feel at first cc tact with the cushion seating surfaces and combines niet with the supporting fibrous fillers 14 to approximate t seating reaction of down cushioning. Because the cov members 18 have the perforations 22 extending ther through, they are permitted to breathe readily so that t1 cushioning structure 10 yields naturally` and comfortal: to a seating load, and it is only necessary to insert ti cushion structure 10 within a decorative fabric coverii to provide furniture cushioning of extremely good quali as to both appearance and comfort as well as durability.

This invention has been described in detail above f purposes of illustration only and is notV intended to l limited by this description or otherwise except as define n the appended'clair'ns.

I claim:

1. A composite cushion structure 'for use in furnitui comprising a relatively firm resilient base element having thickness and opposed faces proportioned in relation 1 the cushion structure to be formed, a Afiller layer of fibrol material of substantial thickness disposed at each of sai lopposite faces of said base element,and a relatively thi cover layer consisting of a relatively soft open cellulz elastomeric material disposed over each of said fibror filler layers and secured directly and continuously to sai base element adjacent the perimeter` of each of said o; posite faces thereof to containv said fibrous filler laye thereat against disarrangement.

2. A composite cushion structure for use in furnitur comprising a resilient base element presenting oppose faces and consisting of a relativelyfirm open cellular elas tomeric material, a filler layer of fibrous material of sub stantial thickness disposed at each of said opposite basi element faces, and a relatively thin cover layer consist ing of a relatively soft open cellular material disposet over each of'said fibrous filler layers and secured directly and continuously to said base element adjacent the perime creased by increasing the plan size of the cover members 18 in relation to that of the base element 12 and the yieldable nature of the fibrous fillers 14 allow them to adjust in thickness substantially for effectively supporting the crowned cover members 18 despite a good deal of crowning variation.

The cushionstructure 10 provided according to the present invention is thus exceptionally well adapted for contouring to a particular appearance desired, while affording excellent hand and body firmness for comfortable seating as well as a very advantageous durability against loss of shape. The manner in which the fibrous fillers 14 are containedv by the cover member 18 effectively precludes any disarrangement of the filler material that ter of each of said oppositefaces thereof to contain saic fibrous filler layer thereat against disarrangement.

3. A composite cushion structure for use in furniture comprising a resilient base element consisting of a relatively thick and firm block of open cellular elastomeric material having opposed major faces proportioned in relation to the cushion structure to be formed, a filler of fibrous material disposed at each of said opposite base element faces, and a cover member consisting of a relatively thin and soft pad of open cellular elastomeric material disposed over each of said fibrous fillers with the edge surfaces thereof secured continuously along the perimeter of the adjacent base element face to contain said fibrous filler thereat against disarrangement.

4. yA composite cushion structure as defined in claim 3 and further characterized in that said base element has a thickness in the order of 3 to 4 inches and consists of latex foam rubberwithin the firmness range of 18 to 32 pounds compression.

5. A composite cushion structure as defined in claim 3 and furthercharacterized in that the edge surface joining of said cover members induces a crowned shape thereto and the fibrous filler contained thereby yieldably supports said crowned shape.

6. .A composite cushion structure as defined in claim 5 and further characterized in that said fibrous filler consists of a seating grade of polyester fiber.

7. A composite cushion structure as defined in claim 5 and further characterized in that each of said cover members has a thickness of approximately l/2 inch and consists of perforated Vlatex foam rubber.

(References on following page) l References Cited by the Examner UNITED STATES PATENTS 2,878,153 3/59 Hacklander 5-361 X 6 References Cited by the Appcant UNITED STATES PATENTS 8/35 Gerlofson et al. 7/51 Warner.

FRANK B. SHERRY, Primary Examiner.

Claims (1)

1. A COMPOSITE CUSHION STRUCTURE FOR TUSE IN FURNITURE COMPRISING A RELATIVELY FIRM RESILIENT BASE ELEMENT HAVING A THICKNESS AND OPPOSED FACES PROPORTIONED IN RELATION TO THE CUSHION STRUCTURE TO BE FORMED, A FILLER LAYER OF FIBROUS MATERIAL OF SUBSTANTIAL THICKNESS DISPOSED AT EACH OF SAID OPPOSITE FACES FO SAID BASE ELEMENT, AND A RELATIVELY THIN COVER LAYER CONSISTING OF A RELATIVELY SOFT OPEN CELLULAR ELASTOMERIC MATERIAL DISPOSED OVER EACH OF SAID FIBROUS FILLER LAYERS AND SECURED DIRECTLY AND CONTINUOUSLY TO SAID BASE ELEMENT ADJACENT THE PERIMETER OF EACH OF SAID OPPOSIT FACES THEREOF TO CONTAIN SAID FIBROUS FILLER LAYER THEREAT AGAINST DISARRANGEMENT

Images