Abstract:
A cushioned support has a rigid base and a molded resilient cushion. The cushion is releasably attached to the base with a wrap-around lip or by means of a retaining member disposed along a periphery of the base. The retaining member, if used, may be conveniently manufactured as an extrusion with a first portion for attachment to the perimeter of the base and a second portion having a barbed cross-section for engaging the cushion.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to upholstery and, particularly, to a cushioned support for exercise machines, leisure furniture and the like. 
     2. Background 
     Typical seats and back rest cushions consist of sewn fabric with a soft stuffing, molded bicycle seats with a sewn fabric covering, polyurethane molded around a rigid support structure for pads on exercise equipment, and plastic-coated fabric (e.g., Naugahyde®) sewn and/or stretched over foam padding and stapled to a rigid wood backing. 
     Sewn fabric cushions absorb dust and dirt, take the support shape of the rigid surface it is sitting on, and is hard to clean without removing. 
     Molded bicycle seats are expensive to produce because of the multiple materials involved, typically an outer casing with a gel filler. 
     Polyurethane molded seats are molded onto and integrated with a rigid support structure. These can be molded into different shapes and support surfaces, but need to be integral with the rigid support in the molding process because the material does not have enough elasticity and memory to stretch over a rigid support structure after the molding process. This makes it expensive to offer color options or replacement seats because the entire seat needs to be changed out and shipping and inventory is more expensive. 
     Plastic-coated fabric seats are integrated with a rigid support structure. These can be formed into different extruding surface shapes such as a lumbar support by cutting and sewing the plastic-coated fabric around a cut shape in the foam padding, but they cannot take the form of an indent shape because the plastic-coated fabric will “pull straight” over the indent. This makes it expensive to offer color options or replacement seats because the entire seat needs to be changed out and shipping and inventory is more expensive. 
     SUMMARY OF THE INVENTION 
     The present invention provides a cushioned support having a rigid base and a molded resilient cushion. The cushion is releasably attached to the base with a wrap-around lip or by means of a retaining member disposed along a periphery of the base. The cushion may be stretched over the base or may be compressed to fit within a rim surrounding the base. The retaining member used with some embodiments may be conveniently manufactured as an extrusion with a first portion for attachment to the perimeter of the base and a second portion having a barbed cross-section for engaging the cushion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exercise machine in which the cushioned support of the present invention may be employed. 
         FIG. 2  is an exploded view of one embodiment of a cushioned support in accordance with the present invention. 
         FIG. 3A  is a partial cross-sectional view of an embodiment of the present invention. 
         FIG. 3B  is a partial cross-sectional view of a variation on the embodiment of  FIG. 3A . 
         FIG. 4  is a partial cross-sectional view of another embodiment of the present invention. 
         FIG. 5  is a cross-sectional view of yet another embodiment of the present invention. 
         FIG. 6  is a partial cross-sectional view of still another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail. 
       FIG. 1  illustrates a typical exercise machine  10  that utilizes cushioned supports  12 . The cushion supports are attached to a frame  14  of the machine and are configured to support a user performing an exercise with operable member  16 . Cushioned supports of the type described herein are suitable for use with a wide variety of exercise devices. Furthermore, cushioned supports made in accordance with the present invention may be used with lawn furniture, benches, patio swings and other types of casual furniture. 
       FIG. 2  is an exploded view of one embodiment of a cushioned support  20 . The rigid, substantially planar base  22  is made of wood or other suitable material, including metal or plastic. A resilient cushion  26  is molded of a plastic foam or similar material having “memory” so that it can be stretched over or otherwise fitted to base  22 . A retaining member  30 , versions of which will be described in greater detail below, is attached to the periphery of base  22  and includes means for engaging cushion  26  so that it becomes releasably attached to the base. The retaining member may completely encircle the base or short segments of the retaining member may be attached to the base at spaced-apart locations. 
     Cushion  26  is molded with projecting pegs  28 . Base  22  has holes or sockets  24  to receive pegs  28 . The cooperating pegs and sockets have an interference fit and help secure the cushion to the base and prevent the cushion from bulging out. Cushion  26  is also formed with a recess or well  29  to receive base  22 . This prevents lateral shifting of the cushion and also hides the edges of base  22  from view. 
       FIG. 3A  is a partial cross-sectional view of cushioned support  20 . As can be better seen in this view, retaining member  30  has a first portion  32  that secures the retaining member to base  22 . In particular, portion  32  of the retaining member is received in a channel  23  cut into the periphery of base  22 . Retaining member  30  has a second portion  34  adapted to engage cushion  26 . Portion  34  is tipped with a pair of barbs  35  that grip against the resilient material of which cushion  26  is made. Cushion  26  is formed with a channel  27  around the perimeter of the recess  29  to receive portion  34 . 
       FIG. 3B  is a partial cross-sectional view of a variation on the cushioned support  20  described above. In this case, retaining member  30   b  is secured to base  22  with nail  39  or a similar fastener, such as a staple or screw, driven through the first portion  32   b  of retaining member  30   b  and into base  22 . 
       FIG. 4  is a partial cross-sectional view of another embodiment of a cushioned support  40 . The construction is similar to that of cushioned support  20 , except that here the cushion  46  does not have a recess to receive the base  42 . Retaining member  50  is similar to retaining member  30 , except that the second portion  54  is formed with only a single barb  55 . Retaining member  50  can also be made similar to retaining member  30   b , wherein the retaining member would be attached to base  42  by means of nails or other similar mechanical fasteners. 
       FIG. 5  is a cross-sectional view of yet another embodiment of a cushioned support  60 . In this embodiment, base  62  is formed with a peripheral rim  63 . Base  62  may be conveniently formed of metal in the shape of a shallow pan. Cushion  66  is formed with a channel  67  to receive rim  63 . Cooperating lengths of hook and loop material  70  are attached to base  62  and cushion  66 , respectively, to retain the cushion on the base. 
       FIG. 6  is a partial cross-sectional view of still another embodiment of a cushioned support  80 . In this embodiment, cushion  86  is formed with a recess  89  having a lip  85  that wraps around the edge of base  82 . The lip may have cut-outs to accommodate frame members to which the base is attached. Furthermore, the lip may only partially surround the edge of base  82 , such as in the corners or at spaced-apart locations. In this embodiment, no separate retaining member is required. Cushion  86  and base  82  may have cooperating pegs and sockets as in the first described embodiment or may be secured to each other with hook and loop material as described in connection with cushioned support  60  shown in  FIG. 5 . 
     The cushions of the various embodiments may be molded in a variety of colors, textures and shapes. This allows exercise machines and other items with cushioned supports to be offered with low cost upholstery options since colors, textures and shapes may be changed by simply replacing the cushions; the rigid bases remain attached to the structure. Replacement cushions are lighter and less expensive than replacements for the entire cushioned support. 
     It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.