US20140201921A1 - Cushion structure and construction - Google Patents
Cushion structure and construction Download PDFInfo
- Publication number
- US20140201921A1 US20140201921A1 US14/223,251 US201414223251A US2014201921A1 US 20140201921 A1 US20140201921 A1 US 20140201921A1 US 201414223251 A US201414223251 A US 201414223251A US 2014201921 A1 US2014201921 A1 US 2014201921A1
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- US
- United States
- Prior art keywords
- height
- cushion
- tufted
- assembly according
- manufactured
- 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.)
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C16/00—Stand-alone rests or supports for feet, legs, arms, back or head
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G7/00—Making upholstery
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G11/00—Finished upholstery not provided for in other classes
- B68G11/02—Finished upholstery not provided for in other classes mainly composed of fibrous materials
- B68G11/03—Finished upholstery not provided for in other classes mainly composed of fibrous materials with stitched or bonded fibre webs
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/48—Upholstered article making
- Y10T29/481—Method
Abstract
A cushion assembly includes a cover having a perimeter panel providing a perimeter height. Spaced apart cover panels extend between the perimeter panels. The perimeter and cover panels together provide a cushion cavity. A cushion includes randomly oriented fibers bonded to one another to provide a core of a batt that has opposing surfaces. In one disclosed example, the fibers are polyester and include an average length randomly oriented in three dimensions. The core has a thickness that is greater than the average length to accommodate the average length in all three dimensions. The batt includes manufactured, tufted and desired design heights. A tuft extends through the cushion to the opposing surfaces to maintain the cushion in the tufted height, which is less than the manufactured height. The cushion is provided with the desired design height with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and more than the tufted height.
Description
- This application is a continuation of prior U.S. application Ser. No. 12/605,862, filed Oct. 26, 2009, the entirety of which is herein incorporated by reference.
- This disclosure relates to a cushion structure, assembly and its construction for comfort applications, including seating and bedding utilizing polyester fiber as one filler material.
- A typical cushion assembly used in seating applications includes an aesthetic cover surrounding a soft and resilient filler material such as polyurethane foam, springs and the like. Most cushions are constructed with material which provides a desired support and comfort to the user. Polyester fiber toppers are sometimes used on top and side of the cushion assembly on which a user may sit to provide a better “hand,” which is a desired feel. An additional wrap is occasionally used to provide a desired function such as to provide improved resistance against flammability. The wrapped and/or padded core structure, usually made up of polyurethane foam is inserted into an aesthetic cover. The foam core is generally the same dimensions as the cover or very slightly larger than the cover.
- The feel of foam cushions is very customizable. This is done by changing the foam chemistry for a given density. One measurement of “feel” for a cushion is the Indentation Load Deflection, ILD, which is determined using industry guidelines. The ILD is the amount of pounds (measured as resistant force) required to compress a 4 inch thick, 15 inch×15 inch sample to 3 inches (or 25% of original height) . For example, a typical 4 inch tall polyurethane foam cushion having a density (in pounds per cubic foot, or “pcf”) of 1.0 pcf has an ILD of 30. In addition due to processing and chemistry changes this is tunable within a range of 10-40 ILD; a density of 1.2 pcf is tunable to 20-50 ILD;; and so on.
- A given foam cushion must also exhibit an acceptable comfort or “support factor,” typically in the range of 1.7-3.0. The support factor calculated by dividing the force required to compress a 4″ sample to 65% of its height by the force required to compress to 25% of its height; i.e. comfort factor=(ILD @65%)/(ILD @25%) In addition to comfort, a standard foam cushion must survive industry durability tests over several thousand cycles during which the foam cushion must substantially maintain its height and shape while maintaining the support factor. Polyurethane foam cushions are highly tunable in that a foam material can be easily selected to provide a desired density, ILD and support factor, which in turn provides the durability for a given application. For polyester fiber cushions, the ILD is very closely tied to the density and such fiber cushions are not easily tuned to provide both comfort and durability. To provide better durability fiber cushions must be made very dense but that is generally not acceptable as comfortable for the end user.
- Foam is generally very resilient and tunable but the chemistry is such that in its native state it is very highly flammable, further the process of making foam is considered harmful to the environment. Several attempts to replace foam with polyester fiber have resulted in different formed, thermo-bonded or loose fiber constructions, but none have been able to achieve desired comfort and performance sufficient for broad commercial viability due to the difficulty in tuning. Loose fibers or thermo-bonded fibers are sometimes used in outdoor cushion applications to provide improved long-term resiliency over foam. The fibers are loosely arranged relative to one another in an unconnected fashion, permitting the fibers to shift uninhibited within the cover. Such outdoor cushions are not very durable and as such not suitable for conventional seating and bedding applications.
- Tufting has been used to secure multiple layers to one another or provide an aesthetically pleasing exterior cover. Often, the tufts are visible through the cover. For example, tufting is used in futons to secure the multiple layers to one another and the exterior cover. The exterior cover is arranged rather loosely about the layers.
- A cushion assembly includes an aesthetic cover having a perimeter panel providing a perimeter height. Spaced apart cover panels extend between the perimeter panels. The perimeter and cover panels together provide a cushion cavity. A cushion includes randomly oriented fibers bonded to one another to provide a core of a batt that has opposing surfaces. In one disclosed example, the fibers are polyester and include an average length randomly oriented in three dimensions. The core has a thickness that is greater than the average length to accommodate the average length in all three dimensions.
- The batt includes manufactured, tufted and desired design heights. A tuft extends through the cushion to the opposing surfaces to maintain the cushion in the tufted height, which is less than the manufactured height. The cushion is provided at the desired design height with the tufted cushion arranged within the cushion cavity. The tufted height is generally less than the desired design height.
- These and other features of the disclosure can be best understood from the following specification and drawings, the following of which is a brief description.
-
FIG. 1 is a perspective view of an example cushion assembly. -
FIG. 2 is a cross-sectional view of a prior art foam cushion at a manufactured height. -
FIG. 3A is a side elevational view of a randomly oriented fiber cushion having a manufactured height for the same cushion application as the foam cushion illustrated inFIG. 2 . -
FIG. 3B is a schematic view of the randomly oriented fibers interlinked to one another with binder material. -
FIG. 4 is a cross-sectional view of the fiber cushion illustrated inFIG. 3A that has been tufted. -
FIG. 5 is a cross-sectional view of a cushion having topper layers. -
FIG. 6 is a side elevational view of an example tuft. -
FIG. 7 is a cross-sectional view of the cushion illustrated inFIG. 5 with a wrap and inserted into a cover. -
FIG. 8 is a side elevational view of a cushion assembly according to the disclosure compared to a cushion assembly using the foam illustrated inFIG. 2 for the same cushion application. - A
cushion assembly 10 is schematically illustrated inFIG. 1 . Thecushion assembly 10 includes acover 11 having aperimeter panel 12 joined to opposingcover panels 14 atedge 20. Typically, the perimeter andcover panels adjoining edges 20 using a welting. Aclosure 18, such as a zipper, edge tape or hook-and-loop fastener, is provided at aseam 16 to permit insertion of a cushion into a cavity provided within thecover 11. -
FIG. 2 schematically illustrates atypical foam cushion 22 having awidth 30 and adesign height 24. Thedesign height 24 generally corresponds to the height of theperimeter panel 12 for the cover into which thefoam cushion 22 will be inserted. Thefoam cushion 22 is generally the same dimensions as the cover into which it is inserted or very slightly larger than the cover. For example, a 4 inch, 1.4 pcf density foam cushion may be manufactured for a 4 inch finished cushion assembly height. As a result, the finished cushion assembly is virtually the identical shape and size, and perhaps slightly larger, as the manufactured dimensions of thefoam cushion 22. - A manufactured
fiber cushion 26 is illustrated inFIG. 3A . The manufacturedfiber cushion 26 is constructed from a single layer of randomly oriented polyester staple fibers interlinked to one another using a binder material, which is elastomeric in one example. In one example, the staple fiber and binder material are the same. The manufacturedfiber cushion 26 includes a manufacturedheight 28 that is greater than a desired design finished height of thecushion 24. For example, if a finished height of 4 inches is desired, the manufacturedfiber cushion 26 may be manufactured with 1.0 pcf of polyester fibers at a 5.6 inch height. The binder material is heated to a melting temperature to secure the staple fibers to one another once the melted binder material has solidified and produce a non-layered core batt. The core is compressed during its manufacture to provide a desired density, which is also affected by the staple and binder materials selected. The interlinked randomly orientedstaple fibers 58 are shown schematically in more detail inFIG. 3B . - The
staple fibers 52 include afiber length 56 that is distributed in all three dimensions (x, y, z). In one example, theaverage fiber length 56 is approximately 2.5 inch. The manufacturedheight 28 is greater than thefiber length 56, which enables the fibers to be randomly distributed to the full extent of their fiber length in all three directions. This is contrasted with typical randomly oriented fiber manufacturing processes, such as cross lapping or air-laying, that orient the fibers in only two directions to form a relatively thin layer substantially less than the length of its staple fibers. Numerous cross lapped or air-layed layers are bonded in some fashion to one another to form a multi-layered fiber batt consisting of very thin layers. Fiber batts produced using an air-lay process do not make suitable cushions because they lose height over time to an unacceptable degree. The fiber batt formed according to this disclosure is typically an inch or greater in height, as opposed to the thin layers produced in air-lay processes, which are only fractions of an inch thick. - Referring to
FIG. 4 , the manufacturedfiber cushion 26 is reduced from the manufacturedheight 28 to a tufted height 31 using one ormore tufts 33, which may be rubber-like, for example. Thetufts 33 include a body 37 extending between opposingheads 35, as illustrated inFIG. 6 . Thetuft 33 extends through thetufted cushion 36 to opposing surfaces 32. Thewidth 30 of thetufted cushion 36 is generally the same as the width of the manufacturedfiber cushion 26. Other tufting configurations can be used. For example, a lace and felt arrangement can be used, or a button and lace arrangement can be employed. Various tufting configurations can be used separately or in combination with one another for a given cushion assembly. Thetuft 33 is not visible through thecover 11 with thecushion assembly 10 exposed and not otherwise in use. Thus, the presence of thetuft 33 is not apparent to an observer, which provides an aesthetically pleasing appearance. - The manufactured
fiber cushion 26 includes a first density that is considerably less than the desired finished density of the cushion once placed within the cover. The cushion height is reduced from the manufacturedheight 28 to the tufted height 31, at least 5%, and in one example at least 10%, which increases the density from the manufacturedfiber cushion 26 to thetufted cushion 36 at least 10%. In one example, if the desired finished height of the cushion within the cover is approximately 4 inches, the manufacturedheight 28 may be 5.6 inches, which when tufted and stuffed into a 4 inchhigh cover assembly 10 provides the comfort and resiliency of 1.4 pcf cushion that could not otherwise be provided by a 1.4 pcf cushion manufactured at a 4 inch height. Thus, the cushion will be reduced in height approximately 28%. In one example, the density is increased 40%. The example density of the manufacturedfiber cushion 26 is 1.0 pcf for the 5.6 inch manufactured height. - An example
tufted cushion 136 is illustrated inFIG. 5 . Thetufted cushion 136 includes acore 38 and topper layers 40 arranged on either side of the core 38 that are tufted together as an assembly. In one example, both thecore 38 and the topper layers 40 are manufactured of three dimensionally randomly oriented polyester fiber interlinked with one another as described above. The tufts extend through thecore 38 and the topper layers 40. Other methods of attaching thecore 38 and topper layers 40 can be used such as adhesive. The topper layers 40 may be constructed separately from thecore 38, for example. Each topper layer is compressed during its manufacture to provide a desired density, which is also affected by the staple and binder materials selected. The topper layers 40 are of a lower density and different fiber blend than the core 38 to provide a desired hand and performance. - Referring to
FIG. 7 , thetufted cushion assembly 136 can be enclosed in awrap 50, which provides functions like desired flammability properties and/or hand, for example. Thewrap 50 is arranged around the exterior surfaces of thetufted cushion 36, including thetufts 33 and provides anactual height 48 of thetufted cushion assembly 136. Aperimeter height 42 is defined by the height of theperimeter panel 12. Theperimeter height 42 is approximately 90-98% of the actual or desireddesign height 24. Thecover panels 14 provide a desired design height 44 (which should be very close to 24 and is determined by the cushion designer) and includes a crown or apex 46. The cover gradually increases to a location central to thecover 11 to provide the apex. The desireddesign height 44 is greater than theperimeter height 42, and in one example at least approximately 120% of theperimeter height 42 at the apex 46. Thecushion assembly 10 has a crowned surface or apex 46, whereas a cushion assembly using a foam cushion has a generally flat or anominal crown surface 60, illustrated inFIG. 8 . - The disclosed cushion assembly and batt having randomly oriented staple fibers interlinked to one another using a binder material is constructed with the following specifications:
- CORE:
-
- density at manufactured height: 0.8-3.0 pcf, in one example. approximately 1.0 pcf
- manufactured thickness of 1.0 -6.0 inch
- 20-90 ILD
- TOPPER:
-
- density at manufactured height: 0.6-2.0 pcf
- manufactured thickness of 0.5-4.0 inch
- 10-55 ILD
- CUSHION ASSEMBLY (Core and at Least One Topper Layer):
-
- density at desired design height, tufted: 1.0-3.0 pcf, in one example, approximately 1.4 pcf
- support factor: ≦3, with the ILD determined using a 4 inch batt at installed height, tufted
- The performance of the batt can be increased by using more binder and a higher denier fiber. Decreasing the amount of binder and using lower denier fiber decreases performance and cost. The binder and staple fibers for each layer are selected to obtain the desired ILD for each layer in order to “tune” the overall cushion assembly. In one example, a tunable fiber cushion includes a batt of randomly oriented first polyester fibers interlinked with a first binder material. The batt has a non-layered core with a first manufactured height defined by opposing surfaces and that includes a first density. The first density is 0.8-3.0 pcf. At least one topper layer of randomly oriented second polyester fibers is interlinked with a second binder material. A topper layer includes a second manufactured height of a second density. The topper layer is arranged on a side adjacent to one opposing surface. The second density is 0.6-1.4 pcf. A tuft extends through the batt and the topper layer to provide a tufted cushion assembly having a tufted height and a third density at the tufted height that is greater than the first density or the second density. The third density is 1.0-3.0 pcf. The tufted cushion assembly at the tufted height provides a support factor of less than or equal to 3 with an ILD and is determined using a 4 inch batt sample of the batt at the tufted height.
- Although example embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.
Claims (19)
1. A cushion assembly comprising:
a cover having a perimeter panel providing a perimeter height and spaced apart cover panels extending between the perimeter panels, the perimeter and cover panels providing a cushion cavity; and
a cushion including randomly oriented fibers bonded to one another to provide a batt having opposing surfaces, the batt having manufactured, tufted and desired design heights, and a tuft extending through the cushion to the opposing surfaces maintaining the cushion in the tufted height, which is less than the manufactured height, the desired design height is provided with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and greater than the tufted height and perimeter height.
2. The cushion assembly according to claim 1 , wherein desired design height is variable, the cover panels are crowned to provide an apex at a generally central location that has a greater height than that of the desired design height between the cover panels immediately surrounding the apex.
3. The cushion assembly according to claim 2 , wherein the desired design height at the apex is at least approximately 120% the perimeter height.
4. The cushion assembly according to claim 1 , wherein the tuft is contained within the cover without being provided on an outer surface of the cover, the tuft not visible through the cover with the cushion assembly exposed.
5. The cushion assembly according to claim 1 , wherein the fibers are polyester and include an average length are randomly oriented in three dimensions, the batt having a thickness that is greater than the average length to accommodate the average length in all three dimensions.
6. The cushion assembly according to claim 5 , wherein the batt includes a core constructed from the three dimensionally randomly oriented fibers, and a topper layer on each of opposite sides of the core, the topper layers providing the opposing surfaces.
7. The cushion assembly according to claim 6 , wherein the core provides at least 50-75% of the manufactured height.
8. The cushion assembly according to claim 6 , wherein a wrap substantially surrounds the batt and is arranged between the batt and the cover.
9. The cushion assembly according to claim 1 , wherein the tufted height is at least less than approximately 95% of the manufactured height.
10. The cushion assembly according to claim 9 , wherein the batt includes a first density at the manufactured height and a second density at the tufted height, the second density being at least 110% of the first density.
11. The cushion assembly according to claim 10 , wherein the perimeter height is approximately 90%-98% of the tufted height.
12. A tufted cushion assembly comprising:
a core made of first polymer fibers, the first polymer fibers being randomly oriented;
at least one topper layer made of second polymer fibers, the second polymer fibers being randomly oriented, the at least one topper layer being arranged adjacent to a surface of the core, and the at least one topper layer having a density different than the core; and
a tuft extending through the core and the at least one topper layer to provide a tufted cushion assembly.
13. The assembly according to claim 12 , wherein the tufted cushion assembly provides a support factor of less than or equal to 3.
14. The assembly according to claim 13 , wherein the support factor is determined using a 4-inch tall sample of the tufted cushion assembly at the tufted height.
15. The assembly according to claim 12 , wherein the at least one topper layer includes two topper layers arranged on opposite sides of the core.
16. The assembly according to claim 12 , further comprising multiple tufts having a length generally corresponding to the tufted height and provided by a body having opposing heads, the heads abutting opposing surfaces of the cushion to retain the cushion at the tufted height.
17. The assembly according to claim 12 , wherein the core and the at least one topper layer have different densities when at respective manufactured heights.
18. The assembly according to claim 12 , wherein the first polymer fibers are first polyester fibers.
19. The assembly according to claim 18 , wherein the second polymer fibers are second polyester fibers.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/223,251 US20140201921A1 (en) | 2009-10-26 | 2014-03-24 | Cushion structure and construction |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/605,862 US8689378B2 (en) | 2009-10-26 | 2009-10-26 | Cushion structure and construction |
US14/223,251 US20140201921A1 (en) | 2009-10-26 | 2014-03-24 | Cushion structure and construction |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/605,862 Continuation US8689378B2 (en) | 2009-10-26 | 2009-10-26 | Cushion structure and construction |
Publications (1)
Publication Number | Publication Date |
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US20140201921A1 true US20140201921A1 (en) | 2014-07-24 |
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Family Applications (2)
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US12/605,862 Active 2032-04-14 US8689378B2 (en) | 2009-10-26 | 2009-10-26 | Cushion structure and construction |
US14/223,251 Abandoned US20140201921A1 (en) | 2009-10-26 | 2014-03-24 | Cushion structure and construction |
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US12/605,862 Active 2032-04-14 US8689378B2 (en) | 2009-10-26 | 2009-10-26 | Cushion structure and construction |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20220281210A1 (en) * | 2021-03-03 | 2022-09-08 | D.C. Humphrys Co. Inc. | Floor and wall mat and method of making the same |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160015185A1 (en) * | 2014-06-30 | 2016-01-21 | Indratech Llc | Mattress with customized density |
KR102606769B1 (en) * | 2021-02-19 | 2023-11-29 | 김성수 | Multi core cushion and method of manufacturing the same |
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US20120284926A1 (en) * | 2011-05-12 | 2012-11-15 | Tyree Steven | Low shear mattress topper constructions |
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Publication number | Priority date | Publication date | Assignee | Title |
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US20220281210A1 (en) * | 2021-03-03 | 2022-09-08 | D.C. Humphrys Co. Inc. | Floor and wall mat and method of making the same |
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US8689378B2 (en) | 2014-04-08 |
US20110094038A1 (en) | 2011-04-28 |
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