Patent ID: 6068808
Filing Date: 2000-05-30
Classification: B29C,B29D,B29L,Y10T

Abstract:
A method for forming a cushion having a smooth bottom surface using a mold having an elastic member, wherein the elastic member is capable of being deflected to various depths as needed to properly form the cushion, said method performed in the absence of a vacuum, said method comprising the steps of:a) placing at least one resilient block on the top surface of a flat rigid planar base having side edges;b) positioning a cover atop said resilient block, said cover layer having a width greater than the width of said planar base;c) placing said cover layer, said resilient block, and said planar base onto said elastic member so that the bottom surface of said planar base is exposed;d) initially pressing said bottom surface of said planar base to force said cover layer, said resilient block, and said planar base into said elastic member to an initial desired depth, while maintaining a perimeter of said planar base exposed;e) deflecting said elastic member to thereby mold said cover layer and said resilient block;f) forcing said cover layer against the side edges of said planar base as said cover layer is pressed further into said elastic member by pressing the bottom surface of said planar base to a sufficient depth within the mold; andg) attaching said cover layer to the side edge of said planar base with excess cover layer extending beyond the bottom surface of said planar base to form a seat cushion.