Patent ID: 6365087
Filing Date: 2002-04-02
Classification: B29C,B29D,B29L,Y10T

Abstract:
A method of forming a cushion having a smooth bottom surface using an elastic member capable of being deflected to various depths as needed to properly form the cushion, said method consisting essentially of 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 layer 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) pressing said bottom surface of said planar base: i) to force said cover layer, said resilient block and said planar base into said elastic member to a desired depth while maintaining perimeter portions of the bottom surface of said planar base exposed, ii) to deflect said elastic member to form said cover layer around said resilient block while forcing said cover layer against the side edges of said planar base while within the elastic member; and e) 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 thereby form a cushion with the entirety of the bottom surface exposed.