Cushion construction and method

A cushion construction is provided whereby a resilient polymeric foam core is covered with an intermediate flexible non-woven fabric which is adhered to the foam by mechanical force with the ends of the intermediate fabric urged into slits formed in the polymeric core. A conventional decorative outer fabric is sewed or otherwise attached over the intermediate fabric to complete the cushion construction. The completed cushion is lightweight and requires no adhesives or solvents in its method of manufacture.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The invention herein pertains to furniture cushions and a method of making 
the same and particularly to a laminated cushion construction having a 
resilient core with an intermediate flexible non-woven fabric layer 
surrounding the core and covered with an outer woven fabric. 
2. Description of the Prior Art and Objectives of the Invention 
Manufacturing processes of cushions and related items have for many years 
employed synthetic polymeric foams such as polyurethane having a density 
of from one to five pounds per cubic foot to provide the necessary 
comfort, resiliency and durability required for sofas, chairs and other 
articles. More recently, cushion laminates have been utilized in which a 
resilient foam core is wrapped or covered with a protective intermediate 
layer to which a decorative outer fabric cover is applied. It is 
conventional to attach the intermediate layer which may consist of a 
relatively thin non-woven material or otherwise to the foam core by sewing 
or by the use of various solvent containing adhesives. Sewing of the 
laminate to the foam core is time consuming, expensive and is difficult to 
learn due to the different material used and the difference in sizes of 
the laminates and foam cores. During application of adhesives and during 
the drying stages, the adhesive solvents are released into the atmosphere, 
providing potential environmental damage and more recently, violations of 
certain safety and health laws and regulations. The adhesives employed 
have maintained the intermediate layer to the resilient core adequately 
and have prevented movement or slippage between the intermediate layer and 
polyurethane foam or other polymeric core. Recently, cushion manufacturers 
have had to take added precautions and sometimes have had to purchase 
solvent collecting equipment when using adhesives due to new environmental 
and safety regulations which generally increase production costs and 
diminish profits. 
With the aforesaid disadvantages of conventional cushion construction 
methods, it is one objective of the present invention to provide a new 
method of cushion construction which eliminates the need of sewing the 
laminate to the foam core and of solvent containing adhesives and special 
solvent evaporation equipment to handle the same. 
It is yet another objective of the present invention to provide a cushion 
construction and method which will tightly adhere a flexible layer to a 
resilient polymeric foam core without increasing the manufacturer's costs. 
It is yet another objective of the present invention to provide a cushion 
construction and method which employs a mechanical bond to maintain the 
integrity between an intermediate flexible layer and a resilient inner 
core as the ends of the flexible layer are frictionally held in slits 
placed in the resilient core. 
Various other objectives and attributes of the present invention will 
become apparent to those skilled in the art as more details of the 
invention unfold below. 
SUMMARY OF THE INVENTION 
The aforesaid and other objectives are realized by providing a cushion 
construction whereby a conventional resilient polymeric foam core is cut 
to size and slit with a thin blade along its ends. A flexible fabric 
intermediate layer is then placed over the resilient core and the ends of 
the fabric are inserted into the slits. The resiliency of the core causes 
the fabric filled slits to squeeze or pinch the ends of the flexible layer 
therein, thereby frictionally engaging the fabric and securely maintaining 
the flexible layer on the resilient core. After the flexible fabric layer 
has been so attached, the core and attached layer are covered with a 
suitable decorative woven outer fabric or the like to complete the cushion 
construction.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
The preferred form of the cushion construction is shown in FIG. 2 and the 
preferred method for forming the same includes cutting a polyurethane foam 
block having a density of four pounds per cubic foot with a rounded end 
and placing slits with a thin blade along the front, back and right sides 
thereof as substantially shown in FIG. 2. Next, the construction method 
includes the placement of a flexible intermediate non-woven fabric having 
side flaps over the foam core and both ends of the flexible layer are 
inserted into the right side slit as shown. The resiliency of the foam 
core causes the slit to attempt closure and tightly engage the flexible 
layer ends. Next, the side flaps of the flexible layer are tucked within 
the foam core side slits where they are likewise frictionally engaged to 
thereby complete the central cushion construction, afterwhich a decorative 
woven outer fabric or the like can be placed thereover to provide a 
durable, unique chair or sofa cushion without subjecting the employees to 
the hazards of volatile chemical solvents as are contained within many 
liquid adhesives utilized in the trade. 
DETAILED DESCRIPTION OF THE DRAWINGS AND EXPLANATION OF THE INVENTION 
For a better understanding of the invention, turning now to the drawings, 
FIG. 1 demonstrates cushion construction 10 having a conventional core 
consisting of a polyurethane foam block 11. As shown, resilient 
polyurethane block 11 may be for example, eighteen inches long, eighteen 
inches wide with a thickness of two to eight inches and a density of one 
to five pounds per cubic foot. Along sides 12, 12' thin slits 13, 13' have 
been placed with a blade within foam block 11 and may extend inwardly for 
approximately three to four inches. Slits 13, 13' are openable as shown in 
FIG. 1 to allow the insertion of the ends of non-woven intermediate 
flexible layers 14 and 15 which cover the top and bottom respectively of 
foam block 11. Flexible layers 14 and 15 may comprise a non-woven fabric 
formed from Dacron or other synthetic fibers and may have a thickness of 
three-quarter to two and one-half inches. Layers 14 and 15 and are 
compressible for easy insertion into slits 13, 13' where layers 14 and 15 
are tightly, frictionally engaged. As would be understood by those skilled 
in the art, cushion construction 10 requires no adhesives and therefore 
does not pollute the environment with gaseous, harmful solvents which now 
may require special expensive equipment for handling and disposal. A 
conventional woven fabric 16 forms the outer layer or covering of cushion 
construction 10 and can be sewed or otherwise attached. Vinyl or leather 
may also be used as an outer covering in place of fabric 16. As shown, 
cushion construction 10 is lightweight, durable, easy and safe to assemble 
and will withstand long periods of use without losing its form or 
resiliency. 
Another embodiment of a cushion is shown in FIG. 2 whereby cushion 
construction 20 shown therein comprises a substantially rectangular foam 
core 21 cut from a large polyurethane block or mass, but unlike foam block 
11, foam core 21 has a rounded side 22 and is slit only along side 23. 
Flexible layer 24 is wrapped around side 22 and both ends of intermediate 
flexible non-woven layer 24 are tightly inserted into slit 25. As further 
shown in FIG. 2, outer cover 24 has a pair of front flaps 26, 26' which 
are inserted into front side slit 27. As understood, a rear side slit 28 
shown in phantom lines is also available for receiving similar rear flaps 
29, 29' (not shown). 
In FIG. 3, foam block 30 is shown having a rounded right side 31, a front 
side 32 with slits 33 and a left side 34 with slits 35. Foam block 30 
having pairs of slits as shown provides convenience in assembly, depending 
on the particular flexible layer employed. For example, when a thicker, 
intermediate flexible non-woven layer is used, left side slits 35 each may 
accommodate one end of the flexible layer and provide less bulk than as 
shown in FIG. 2 whereby a pair of flexible layer ends are inserted into 
single slit 25. 
In FIG. 4, cushion construction 40 comprises a substantially rectangular 
shaped polyurethane foam core 41. Foam block 41 defines single, individual 
slits along each of its four sides 42, 43, 44 and 45. Separate flexible 
top layer 47 and bottom layer 48 are attached thereto by insertion of the 
flap ends into the provided slits on sides 42, 43, 44 and 45. 
FIG. 5 illustrates round polyurethane foam block or core 50 with top 
flexible member 51 and bottom flexible member 52 removed therefrom. Flaps 
53 and 54 are insertable within side slits 55 to maintain intermediate 
non-woven flexible members 51, 52 suitably attached to block 50. 
The construction herein allows for easy disassembly and separation of the 
foam or core and flexible member when use of the cushion is finished so 
the core and flexible member can be easily recycled. 
As would be understood, the cushion construction as shown herein utilizes a 
foam block or core cut or formed from a large polyurethane block or mass 
having a density of approximately one to five pounds per cubic foot and a 
thickness of approximately three inches. However, depending on the 
particular structural characteristics desired, the core can be formed from 
other materials, densities, resiliencies, polymeric materials or 
thicknesses. Likewise, the intermediate flexible layer which engages and 
surrounds the resilient core can likewise be made of a variety of 
materials as can the outer covering and the examples and illustrations 
herein are merely for explanatory purposes and are not intended to limit 
the scope of the appended claims.