Floor-supported cushion assembly and method of making same

A floor-supported cushion assembly comprising a seat pad of foam material encased in one end portion of a fabric envelope, a back pillow consisting of a pillowcase filled with shredded polyurethane foam and received in the other end portion of the envelope, and a fabric hinge formed by portions of said envelope between said end portions. A zipper is installed in the envelope in its back and extends longitudinally into both end portions. The method of making the cushion assembly is also an important aspect of the invention.

The present invention relates to cushion assemblies of the type in which 
two cushions are hingedly connected and intended to be positioned for use 
with a seat cushion resting on a floor or comparable horizontal surface, 
and a back cushion is supported in an upright position by a wall or 
similar vertical surface, and is concerned primarily with the novel 
assembly of the cushions and method of making the same. 
BACKGROUND OF THE INVENTION 
It is believed that the prior art device closest to the subject cushion 
assembly is that disclosed in U.S. Pat. No. 3,761,131. In accordance with 
this patent, two pillows are filled with chunks of polyurethane foam and 
connected by sewing the rear edge of the cushion intended to be the seat 
cushion and the lower edge of the back cushion. This so-called "sofa-like 
article of furniture" presents certain defects which are intended to be 
obviated by the present invention. 
In the first place, the seat cushion which supports the major part of a 
user's weight does not have the property of rigidity to the degree 
required to afford comfort to one sitting on it for prolonged periods. It 
is also lacking in squared corners at the forward end of the seat cushion 
which are highly desirable not only from the aspect of providing rigidity 
but also for appearance effects. 
This patented article is also lacking in an envelope or casing in which the 
seat and back cushions are received as individual elements and a 
zipper-controlled slot through which the cushions may be passed. 
This invention is founded on the concept that a seat cushion comprising a 
rectangularly shaped envelope of fabric and having spaced end portions, 
with one end portion receiving a pad of polyurethane and the other end 
portion receiving a pillow consisting of a pillowcase that is filled with 
shredded polyurethane foam with the fabric between the end portions 
forming a hinge, together with a zipper-controlled slot on the back of the 
envelope extending into both end portions, will meet with large public 
acceptance, particularly because it is susceptible of being made by 
individuals who have been properly instructed as to the method as compared 
to being manufactured in factories. 
OBJECTS OF THE INVENTION 
With the foregoing conditions in mind, the present invention has in view 
the following objectives: 
1. To provide a cushion assembly including a rectangularly shaped envelope 
having spaced end portions with a seat pad of polyurethane foam received 
in one end portion and a back pillow in the other end portion. 
2. To provide, in a cushion assembly of the type noted, a back pillow 
consisting of a pillowcase which is filled with shredded polyurethane 
foam. 
3. To provide, in a cushion assembly of the character aforesaid, a slot on 
the back of the envelope which affords access to the two end portions and 
which is controlled by a zipper. 
4. To provide, in a cushion assembly of the kind described, a hinge between 
the end portions of the envelope which is made from the fabric of the 
envelope. 
5. To provide, in a cushion assembly of the type noted, a seat end portion 
of the envelope having squared corners on its front end which snugly 
receive square corners of the seat pad. 
6. To provide a method of making a cushion assembly of the character 
aforesaid which involves the use of a pattern for forming the envelope and 
which may be included in an instruction manual. 
7. To provide, in a method of the kind described, the step of folding a 
rectangularly shaped piece of fabric of proper dimensions and having a 
decorative face on itself with the decorative face in engagement and the 
folded fabric being one-half the size of the original piece of fabric. 
8. To provide, in a method of the type noted, the step of placing pieces 
separated from the pattern over end portions of the folded fabric, marking 
places where seams are to be sewed, and cutting out a recess from end 
edges of the folded fabric of the seat end portion of the envelope. 
9. To provide, in a method of the character aforesaid, the step of sewing 
seams across end edges of the folded fabric and inwardly from each end 
seam a predetermined distance to leave space for a zipper-controlled slot. 
10. To provide, in a method of the kind described, the step of cutting the 
recess in the end edge portion of the bottom part of the envelope to leave 
a rectangular recess having two pairs of identical geometric formations at 
each corner of the recess. 
11. To provide, in a method of the character aforesaid, the step of pulling 
out the corners of the recess and folding so the matching geometric 
figures meet and sewing a seam spaced from the folded edges. 
12. To provide, in a method of the kind described, the step of installing a 
zipper in the slot provided therefor. 
13. To provide, in a method of the type noted, the steps of turning the 
envelope inside-out to bring the decorative face into exposed position; 
inserting a rectangularly shaped pad of polyurethane foam having square 
corners into the seat part of the envelope; and inserting a pillowcase 
filled with shreaded polyurethane foam into the back part of the envelope. 
14. To provide, in a method of the character aforesaid, the step of forming 
a hinge between the spaced end portions of the envelope by pressing the 
fabric back inwardly against the front face and sewing the engaging faces 
together. 
15. And finally, to provide, in a method of the type noted, the step of 
attaching ornaments, such as tassels, to the upper corners of the envelope 
which receives the pillow. 
SUMMARY OF THE INVENTION 
The foregoing objects are achieved by providing a floor-supported cushion 
assembly which comprises a rectangular envelope having a seat end portion 
and a back end portion spaced therefrom. The envelope has decorative faces 
such as a cut pile fabric. The seat portion of the envelope has squared 
front corners and received in this end portion is a seat pad of a foamed 
material having a property of rigidity to a required degree, such as 
polyurethane foam, and which pad is snugly received in the aforesaid front 
corners. 
The back portion of the envelope is filled with a pillow comprising a 
pillowcase filled with shredded foam material such as polyurethane foam. 
The back and seat portions of the envelope are connected by a fabric hinge 
formed from the fabric between these end portions which are forced into 
meeting engagement and stitched together. The back of the envelope is 
formed with a slot centrally thereof and extending into both end portions 
of the envelope with the ends of the slot being spaced from the ends of 
the envelope. A zipper is installed in this slot. 
The method of making such a cushion assembly will be described in a manual 
which includes a removable pattern. It is intended that this method be 
susceptible of being carried out by a housewife or other individual as 
compared to factory production. 
The first step of the method is to remove the pattern from the manual and 
cut it along lines inscribed thereon to separate it into a seat or bottom 
portion and a back or top portion. 
The next step is to fold a piece of rectangular fabric of required 
dimensions on itself so that the decorative faces of the fabric meet and 
the folded piece will be one-half the size of the unfolded piece of 
fabric. 
The next step is to place the two portions of the pattern over end portions 
of the folded fabric, mark lines where seams are to be formed, and cut out 
a rectangularly shaped recess from the end edge of the seat portion of the 
folded fabric centrally thereof, using the pattern part as a guide. 
The next step is to sew a seam which is spaced inwardly from a free edge of 
the folded fabric a required distance from the end edge thereof, thereby 
leaving a space between the ends of these seams. These seams are then 
pressed open and moved to the center front and a seam is sewed along the 
edges of the top and bottom portions in spaced relation with the edges 
thereof. In this position, the recess which is formed in the center of the 
front edge of the seat part presents two geometric figures such as 
identical triangular points and identical half circles at each corner. The 
corner of the envelope is then opened to bring the triangular points into 
meeting overlapping relation and the half circles into meeting overlapping 
relation. A seam is then sewed across the two plies of the fabric in a 
properly spaced relation with the edges thereof whereby the length of this 
seam is the same as the thickness of the pad. Where edges of the folded 
fabric meet, another seam is formed and trimmed. 
The envelope is now turned inside-out to bring the decorative face in 
exposed position, whereupon the zipper is inserted in the slot provided 
therefor. 
The zipper is now opened and a foam pad is inserted in the bottom seat part 
of the envelope, making sure that the corners of the pad are snugly fitted 
in the end corners of the bottom part of the envelope. 
A pillowcase is now formed from an appropriate fabric by sewing along the 
four edges of two rectangularly shaped pieces of the fabric, leaving an 
unsewn space sufficient to permit the insertion of shredded polyurethane 
foam thereinto. After the pillowcase is filled, this opening is closed by 
stitching. The pillow is stuffed into the seat or top part of the envelope 
and shaken so that it snugly fills this part of the envelope, whereupon 
the zipper slot is closed. 
The envelope with the foam pad and pillow therein is now placed on a flat 
surface, such as a floor, with the face having the zipper disposed 
downwardly. The fabric in the space between the seat and back portions of 
the envelope will form the hinge. Pressure is applied to the upper ply of 
the fabric in this position to force it downwardly against the back ply, 
whereupon the two plies are temporarily secured together by a required 
number of safety pins, after which the plies are sewn together and the 
safety pins removed. 
Finally, ornaments such as tassels are sewn to top corners of the back 
portion of the envelope.

DESCRIPTION OF A PREFERRED EMBODIMENT 
Referring now more particularly to FIGS. 1 and 21, the cushion assembly of 
this invention is shown as comprising a seat or bottom part referred to in 
its entirety at 10, and a back part designated generally 11. These two 
parts are connected by a fabric hinge shown at 12 in FIG. 21. An envelope, 
referred to in its entirety at 13, comprises a seat or bottom end portion 
14 and a back or pillow portion 15, as shown in FIG. 21. 
Referring more particularly to FIGS. 2 and 4, envelope 13 is of a fabric 
having a decorative face 16 such as one of cut pile, and a plain back 17. 
Received in the seat part 14 of envelope 13 is a pad 18 of a foam material 
having the property of rigidity to the degree required for enabling a user 
to sit hereon with comfort over prolonged periods. Polyurethane is the 
preferred foamed material. 
As shown in FIG. 21, back part 15 of the envelope is filled with a pillow 
19 which, as shown in FIG. 23, comprises a fabric pillowcase 20 that is 
filled with shredded polyurethane foam 21. Pillow 19 is formed by leaving 
a slot 22 therein of sufficient extent to permit of the shredded foam 
being inserted therethrough after which the slot 22 is closed by stitching 
23. 
Envelope 13 is formed from a rectangular piece of fabric having a 
decorative face 16 and back 17. While the dimensions of this piece of 
fabric may vary, by way of example it is noted that it is 60 inches long 
and 54 inches wide. When folded along a longitudinal center line, such as 
indicated at 24 in FIG. 2, the folded piece will present two plies each 27 
inches wide. These two plies are pressed together to form the hinge shown 
at 12 in FIGS. 20 and 21. 
It is evident that seat cushion 10 may be placed on a floor or a comparable 
horizontal surface, and back 11 against a wall or similar support. 
As shown in FIG. 22, an ornament such as a tassel 25 may be attached to 
each upper corner of back 11. 
THE METHOD 
It is contemplated that the above-described cushion assembly be susceptible 
of production by a housewife or other individual and, to enable her to do 
so, a manual of instructions will be distributed and this manual will 
include a pattern which may be detached from the manual and separated to 
provide two parts--one for the seat or bottom, and one for the back or 
top. The pattern before being so separated is not illustrated; however, as 
shown in FIG. 2, it provides a back or pillow part 26 and a bottom or seat 
part 27. 
The first step of the method is to fold the piece of fabric into the 
position of FIG. 2 in which the cut pile faces of the two plies are in 
meeting engagement. The top or pillow pattern part 26 is placed over one 
end portion, and the back or seat part 27 over the other end portion. In 
this position, a generally rectangularly shaped recess 28 is cut in both 
plies at the end edge 29 of seat part 27. This recess 28 is clearly shown 
in detail in FIG. 3. It is defined by side edges 30 and 31 and a bottom 
edge 32. These edges provide corners 33 and 34. Two identical formations 
of the same geometric design extend into recess 28 from the side edge 30 
and end edge 32 at corner 33 and preferably take the form of the partial 
circles 35. Similarly, formations of identical geometric design, but 
different from the partial circles 35, such as points 36, extend into 
recess 28 from side edge and end edge 32 at corner 34. 
Both plies of the folded fabric have an end edge remote from edge 29, as 
shown at 37. As illustrated in FIG. 5, a seam 38 is sewn inwardly from end 
edge 37. This seam is spaced from free edges 39 of both plies an 
appropriate distance, such as one inch for the dimensions of the present 
embodiment. A similar seam 40 extends inwardly from end edge 29. These 
seams 38 and 40 extend inwardly of the folded fabric sufficient to leave a 
slot 41 of a required length for the purpose of receiving a zipper. 
The next step of the method is to open these seams 38 and 40 and adjust the 
fabric into the position of FIG. 7 in which the seams 38 and 40 are 
located centrally of the folded piece. In this position, the recess 28 of 
each ply provides a corner formation which is more clearly illustrated in 
FIG. 8. A seam 42 is now sewn adjacent to end edge 37 and another seam 43 
adjacent to end edge 29. 
As shown in FIG. 7, those portions of the free edges 39 between seams 38 
and 40 provide the slot 41. The slot 41 is shown in transverse section in 
FIG. 10. The seam 40 is illustrated in FIG. 11 and seam 43 in FIG. 12. 
Each corner with the recess 28 therein is opened into the position of FIG. 
13, whereupon the corner is closed into the position of FIG. 14 in which 
the partial circles 35 and triangular points 36 overlap, whereby insuring 
accurate positioning of the plies of the fabric. Another seam is now sewn 
along line 44 as illustrated in FIG. 14. This seam at 44 is spaced 
one-half inch from the adjacent portion of end edges 29. 
The next step in the method is to turn the envelope inside-out to bring the 
cut pile face 16 to exposed position. A zipper 45 is then positioned in 
slot 41 and firmly secured by sewing, this being shown in FIG. 17. 
A portion of the foam pad 18 is illustrated in FIG. 16 and presents two 
corners, one of which is shown at 46 at its front end. These corners fit 
into front end corners of the seat part 14 of envelope 13. 
After zipper 45 is positioned, it is opened and seat pad 18 is inserted 
into envelope part 14, as shown in FIG. 18. Pillow 19 is then inserted 
through the open slot into back part 11, as shown in FIG. 19. 
The next step in the method is to form hinge 12 by pressing the two plies 
of the fabric together, as shown in FIG. 20. These plies may then be 
temporarily secured together as by an appropriate number of safety pins, 
such as four pins, after which they are sewn together by strong stitches 
and the safety pins removed. 
The final step is to attach the tassels 25 to the upper corners of back 
part 11, as shown in FIGS. 1 and 22. 
While a preferred specific embodiment of the invention is hereinbefore set 
forth, it is to be clearly understood that the invention is not to be 
limited to the exact construction, materials and steps illustrated and 
described because various modifications of these details may be provided 
in putting the invention into practice.