Patent ID: 6328266
Filing Date: 2001-12-11
Classification: A47B,B29C

Abstract:
A formable cushion produced by:providing a mold having a first cavity and second cavity in fluid communication with one another, said first cavity having a greater depth than said second cavity;depositing a first volume of foam/gel into the first and second cavities in an amount providing a level surface of foam/gel;covering the level surface of foam/gel with a formable sheet, said formable sheet covering the second cavity comprising a first continuous sheet portion and the formable sheet covering the first cavity comprising a second portion having a plurality of flat fingers joined only at one end thereof to an elongated spine extending across said second cavity, each finger being formable along a direction transverse to said spine;disposing a second volume of foam/gel onto the formable sheet; andapplying heat and pressure to the first and second volumes of foam/gel within the mold, the formable sheet providing a barrier to compression of the foam/gel deposited in said first cavity resulting in the second volume of foam/gel solidifying to a relatively firm pliable back layer, the first volume of foam/gel in said second cavity solidifying into a relatively firm pliable front layer and the first volume of foam/gel in said first cavity solidifying into an integral relatively soft compressible cushion layer.