Patent Application
20060226682
The present disclosure relates in general to cushions for furniture members and more specifically to a seat cushion device and method for creating a seat cushion for a reclining chair.
Reclining chairs are chairs generally having an upright or folded position and an extended position. Reclining chairs typically provide foldable or extendable leg supports which are mechanically connected to a chair structure. Seat cushions for reclining chairs are attached to the chair structure typically using mechanical connectors such as staples to prevent their dislocation during change from the upright to the extended positions or vice versa. The seat cushions are created using a variety of materials such as leather, cloth, and/or polymeric material as an outer cover, and are generally filled with a cushioning material such as loose fiber.
Seat cushions are commonly sewn in predetermined patterns to establish a functional and visually pleasing series of sub-cushion sections. The sub-cushion sections function to retain the loose fiber material within the sub-cushion section(s), which prevents the cushion material from being forced away from user contact locations and causing a “flattened” or non-supportive condition. Specific sub-cushion sections are normally pre-defined for specific points of support such as lumbar, leg and foot areas.
As an occupant uses and/or shifts their position or weight on the seat cushion, the loose fiber fill material shifts within the cushion. Due to the loose nature of the fiber fill material, it is difficult to maintain the fiber fill within any specific region of any of the sub-sections during use. This can lead to hard or non-cushioned regions within the sub-sections. Furniture manufacturers can increase the quantity of sub-sections to control fiber fill displacement, however, this increases the manufacturing cost of the seat cushion. Increasing the quantity and/or location of stitching normally used to create the sub-sections also creates areas with little or no cushion support directly at and proximate to the stitching, which therefore is counterproductive to producing a comfortable seat cushion.
According to several embodiments of a seat cushion construction for a reclining chair of the present disclosure, a furniture member cushion includes an exterior cover having opposed walls defining an interior cavity. A cushion fill opening is created in the exterior cover. A polymeric foam cushion member is disposed through the cushion fill opening and substantially fills the interior cavity. A plurality of sewn seams are created through the opposed walls and the cushion member.
According to other embodiments of the present disclosure, a furniture member cushion includes an exterior cover having opposed walls defining an interior cavity and a cushion fill opening. A first slit is created through the cover proximate to the cushion fill opening. A foam cushion member is disposed through the cushion fill opening and substantially fills the interior cavity. A second slit is created in the cushion member, and aligned with the first slit when the cushion member is disposed in the interior cavity. A plurality of seams are sewn through the opposed walls and the cushion member, at least one aligned with the first and second slits.
According to still other embodiments, a method for creating a furniture member cushion, the cushion including opposed walls defining an interior cavity and a cushion fill opening; and a polymeric foam cushion member, includes a step for disposing the polymeric foam cushion member through the cushion fill opening to substantially fill the interior cavity. The method further includes a step for sewing a plurality of seams each extending through the opposed walls and the polymeric foam cushion member.
According to yet still other embodiments, a method for creating a cushion connectable to a furniture member, the cushion including opposed walls defining an interior cavity and a cushion fill opening; and a polymeric foam cushion member, includes disposing the polymeric foam cushion member through the cushion fill opening to substantially fill the interior cavity. The method further includes a step for sewing a plurality of seams each extending through the opposed walls and the polymeric foam cushion member. The method still further includes a step for connecting at least one strap to one of the opposed walls. The method yet still further includes a step for releasably joining the at least one strap to the furniture member to operably join the furniture member cushion to the furniture member.
A seat cushion construction for a reclining chair of the present disclosure offers several advantages. By first inserting a polymeric foam seat cushion member into a seat cushion cover and sewing through both the cover and the foam seat cushion member, the foam seat cushion member is divisible by the sewn seams into a plurality of cushion sub-sections. Because of the foam material, the foam in each of the sub-sections does not displace and cause hard or unsupported areas during use. At least one slit created in the seat cushion cover and corresponding slits created in the foam seat cushion member are aligned with each other when the foam seat cushion member is placed within the cover. The aligned slits are used to align one or more of the sewn seams. By using the prealigned slits, the cushion sub-sections are predetermined in size and location, each receiving a predetermined portion of the foam seat cushion member.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating several embodiments of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
The following description of several embodiments is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
As best seen in reference to
Cushion assembly 18 includes a back support section 20, a leg support section 22, and a foot support section 24. A right arm rest 26 and a left arm rest 28 can be fastenably connected to first side frame member 12 and second side frame member 14, respectively, or in other embodiments of the present disclosure, right and left arm rests 26, 28 are connectively attached to cushion assembly 18. A rotatable lever 30 is exemplary of a device used to rotate both leg support section 22 and foot support section 24 to or from the closed or chair-upright position shown in
Cushion assembly 18 further includes a right side sub-section 32, a left side sub-section 34 and a central support sub-section 36. A back support sub-section 38 and a head support sub-section 40 are also provided in back support section 20. A body support section 35 is also provided. At least leg support section 22 and body support section 35 are divisible into right side sub-section 32, left side sub-section 34, and central support sub-section 36. In a further embodiment (not shown) foot support section 24 is divisible into right side sub-section 32, left side sub-section 34, and central support sub-section 36. Cushion assemblies 18 of the present disclosure are not limited to the quantity or type of sub-sections identified in
Referring generally now to
As best seen in reference to
To aid in aligning subsequent sewn seams, a plurality of slits 60 are created proximate to first end 54 and spaced at predetermined intervals. The “predetermined intervals” of the present disclosure can be determined in several ways. A fixed distance between slits can be used, a distance measured to each slit from one of the first or second sealed sides 50,52 can be used, or a die with fixed slit intervals can be used. Similarly, a plurality of second slits 62 can be created proximate to an opposed wall end 63 of second wall 48. Each of the plurality of second slits 62 are aligned with individual ones of the plurality of slits 60. For example, an aligned pair of slits 60, 62 are defined by an alignment axis 64. A plurality of second end slits 66 can also be created proximate to second end 56. For clarity, second end slits 66 are shown formed only in first wall 46, but can also be formed in similar (aligned) positions at second end 56 in second wall 48. Exemplary aligned pairs of slits 60 and second slits 62 are shown as slits 60′, 62′ and 60″, 62″. The disclosure is not limited to the use of both slits 60 and second slits 62. In another embodiment, only one of the sets of slits 60 or second slits 62 is used. In still another embodiment, only a single slit is provided in cushion exterior cover 45.
Referring now to
By predetermining the position of the various slits and aligning predetermined ones of the slits with each other, a predetermined partial volume of foam cushion member 68 can be positioned in each of the sub-sections 32 through 40 of cushion assembly 18. Each of first end slits 70 and first end second slits 72 are positioned proximate to a cushion member first end 74. A plurality of cushion second end slits 76 can also be positioned proximate to a cushion member second end 78.
Referring next to
First and second sewn seams 80,82 further divide cushion assembly 18 into multiple sub-sections of right side sub-section 32, left side sub-section 34 and central support sub-section 36. Examples are identified as sub-sections 32′, 32″, 32′″, 34′, 34″ and 34′″. The disclosure is not limited to these examples.
According to one several process, a laser is used to illuminate a visual laser-line between individual aligned ones of slits 60,66. The appropriate sewn seam is then made by following the line indicated by the laser. A machine such as a long-arm sewing machine can be used to sew the individual sewn seams. The cross seams can also be made using a laser sighting line or visually without the laser line, with distances between proximate cross seams each having a pre-determined spacing dimension.
A plurality of straps 96 are connected to a reclining chair assembly facing side, for example second wall 48, which are subsequently used to assist in adjustably connecting cushion assembly 18 to reclining chair assembly 10. Each of the plurality of straps 96 are provided with a plurality of fastener connections 98. Fastener connections 98 can be either a plurality of hooks or a plurality of loops and thereby form half of a hook and loop assembly. A mating strap (not shown) for each of the plurality of straps 96 are positioned on the support structure of reclining chair assembly 10 and aligned to receive each of the plurality of straps 96. Straps 96 provide for adjustable connection of cushion assembly 18 to reclining chair assembly 10. One purpose for straps 96 is to aid in alignment between cushion assembly 18 and reclining chair assembly 10.
According to several embodiments of the present disclosure, a plurality of attachment members 100, 102, 104 and 106 are connected such as by sewing to cushion assembly 18. Attachment members 100, 102, 104 and 106 are provided to permanently connect cushion assembly 18 to reclining chair assembly 10. Permanent connection of cushion assembly 18 can be accomplished using a plurality of techniques, including but not limited to stapling, pinning and/or riveting through each of attachment members 100, 102, 104 and 106. Attachment members 100, 102, 104 and 106 are preferably positioned where they are out of visual sight once connected to structure of reclining chair assembly 10. For example, attachment members 104, 106 can be connected to cushion assembly 18 in locations which are subsequently visually hidden beneath left arm rest 28 and right arm rest 26 respectively.
To ensure that foam cushion member 68 is completely retained by cushion exterior cover 45, an over-extension section 108 and an over-extension section 110 of foam cushion member 68 each extend beyond cushion exterior cover 45 when the sewing operations are complete. Over-extension sections 108, 110 are generally folded over or under other material when cushion assembly 18 is connected to reclining chair assembly 10 to prevent subsequent visibility of either over-extension section 108 or 110. Each of first and second ends 54, 56 of cushion exterior cover 45 are sewn similar to the cross seams to fix foam cushion member 68 in position within cushion exterior cover 45.
A seat cushion construction for a reclining chair of the present disclosure offers several advantages. By first inserting a polymeric foam seat cushion member into a seat cushion cover and sewing through both the cover and the foam seat cushion member, the foam seat cushion member is divisible by the sewn seams into a plurality of cushion sub-sections. Because of the foam material used, the foam in each of the sub-sections does not displace and cause hard or unsupported areas during use. At least one slit created in the seat cushion cover and at least one corresponding slit created in the foam seat cushion member are aligned with each other when the foam seat cushion member is placed within the cover. The aligned slits are used to further align one or more of the sewn seams. By using the prealigned slits, the cushion sub-sections are predetermined in size and location, each receiving a predetermined volume or portion of the foam seat cushion member.
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
This application claims the benefit of U.S. Provisional Application No. 60/670,181, filed on Apr. 11, 2005. The disclosure of the above application is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60670181 | Apr 2005 | US |
