Note: Descriptions are shown in the official language in which they were submitted.
BP File No. 6129-069
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Title: SEAT CUSHION CONSTRUCTION
FIELD OF THE INVENTION
This invention relates to a construction for
seat cushions which may be used in chairs, sofas, love
seats and other seating devices.
BACRGROUND OF THE INVENTION
For many years, foam and springs have been used
both individually and in combination to manufacture
cushions for furniture such as chairs and couches as well
as in transportation equipment, such as car seats. Over
the years efforts have been made to improve the degree of
comfort, the amount of support and the durability of a
seat cushion without increasing, or at least unduly
increasing, the cost of constructing a seat cushion.
In some constructions, a cushion construction
comprises a resilient foam body incorporating a plurality
of springs. Each of these springs is located in an
individual cavity in the resilient foam body. Examples of
such constructions include United States Patent No.
2,882,959 (Burkart) and United States Patent No. 4,429,427
(Sklar). In some constructions, the interior of the spring
may be filled with a core material. An example of such a
construction is Canadian Patent Application No. 2,013,169
(Reinhardt). In some constructions, the springs may
incorporated in a cushion construction in a stressed state
while in others, the spring may be inserted into the
cushion in an unstressed state.
In order to increase the rigidity of a cushion
construction without the spring elements, which are used
for that purpose becoming perceptible, it has been
proposed to manufacture a support device formed from a
flexible, resilient material and having a plurality of
springs wherein the flexible resilient material and the
springs have substantially the same spring rates and the
spring elements are in an unstressed state when the
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support device is in an unloaded state. See United States
Patent No. 4,862,540 (Savenije).
United States Patent No. 3,869,739 (Klein)
discloses a cushion or mattress construction comprising an
encasing structure defining an enclosed cavity; a
plurality of coil springs and a corresponding plurality of
synthetic fabric casings. For the coil springs, the coil
springs completely filling the cavity in side-by-side
relationship; and, a thin adhesive layer bonding the top
and bottom of the casings to the encasing structure.
United States Patent No. 5,040,255 (Barber, Jr. )
discloses a construction for a cushion or mattress having
an encasing structure and a plurality of coil springs.
Each spring has a profile with the top and bottom coils of
the springs being larger in diameter than the remaining
coils of the spring. The springs are set out in a
serpentine fashion within a cavity defined by the encasing
structure.
Some of these constructions are expensive to
manufacture and are accordingly unattractive. Others have
limited durability. Another problem with prior
constructions is that they provide only a limited degree
of comfort.
SUZ~IARY OF TIC: INVENTION
In accordance with their present invention,
there is provided a cushion construction sized to seat one
individual comprising:
(a) a boxing structure having a bottom wall, a top
wall, size walls and internal walls defining a
plurality of completely enclosed cavities, each
of the walls being formed of resiliently-
flexible material, said boxing structure having
a central portion;
(b) a resiliently deformable support member
extending between the top wall and the bottom
wall at the central portion; and
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(c) spring means positioned in each of the cavities
extending in an upright position between the
bottom wall and the top wall.
The support member may be formed by the
intersection at the central portion of the plurality of
the internal walls. Preferably, the internal walls extend
outwardly from the central portion to the side walls so as
to define an internal web structure.
The number of cavities defined by the internal
walls may vary. Preferably, the internal walls define at
least three cavities . More preferably, such as in the case
of a cushion that is substantially square, there are four
cavities. The spring means may comprise a plurality of
individual springs placed in each cavity. The springs are
placed in each cavity so as to substantially fill the
cavity. Accordingly, the actual number of springs placed
in each cavity will vary depending upon the size of the
cushion, the size of the cavity and the size of the
springs. In one embodiment, the springs may be
interconnected so as to maintain the springs in an upright
position. Preferably, the springs are under compression
when the cushion construction is in an unloaded state. For
example, the springs may be encased in a fabric material
when under compression (e. g. pocketed coil springs).
When the cushion construction is utilized in
seating devices designed to seat more than one person, for
example a couch, a plurality of individual cushions each
having the cushion construction of the instant invention
may be provided. Accordingly, if a couch is designed to
seat three people, three individual cushions, each
utiiizing the cushion construction of the instant
invention, may be provided. In an alternate embodiment, a
single longitudinal extending cushion, containing a
plurality of individual cushion constructions according to
the instant invention, may be provided. The individual
cushion constructions may be separately formed and then
encased in an outer retaining means so as to form a single
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unit. Alternately, the plurality of individual cushion
constructions may be integrally formed so as to define a
single longitudinally extending cushion:
A cushion manufactured using the cushion
construction of the instant invention is surprisingly
comfortable due to the relative placement of the spring
means and the top wall, side walls, bottom wall, internal
walls and support member which are formed of a resiliently
flexible material. The cushion construction provides an
economical balance between the use of springs and
resiliently flexible material in an easily manufactured
construction.
The seat construction can be incorporated into
a multitude of seating devices such as furnishings, e.g.
chairs, sofas, loveseats and sofa beds.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the instant
invention will be more fully and completely understood by
reference to the following drawings of a preferred
embodiment of the invention in which:
Figure 1 is a partially-cut-away, perspective
view of a cushion incorporating the cushion construction
of the instant invention;
Figure 2 is a cross-section along line 2-2 in
Figure 1;
Figure 3 is a cross-section along line 3-3 in
Figure 4;
Figure 4 is a cross-section in the same
direction as the cross-section shown in Figure 2 of an
alternate cushion incorporating the cushion construction
of the instant invention;
Figure 5 is a cross-section in the same
direction as the cross-section shown in Figure 2 of a
further alternate embodiment of the instant invention;
Figure 6 is a cross-section in the same
direction as the cross-section shown in Figure 2 of an
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additional embodiment according to the instant invention;
and,
Figure 7 is a crass-section in the direction of
line 3 - 3 of an alternate embodiment of the cushion
construction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to .Figure 1, the seat cushion
construction according to the instant invention, generally
referred to by reference number 10, comprises a boxing
structure 12, a plurality of cavities 14 and plurality of
spring means 16.
As better shown in Figures 2 and 3, boxing
structure 12 comprises bottom wall 20, top wall 22, side
walls 24 and internal walls 26. When assembled as a whole
as shown in Figure 1, bottom wall 20, top wall 22, side
walls 24 and internal walls 26 define a plurality of
fully-enclosed cavities 14. Side walls 24 encompass each
cavities 14 and accordingly define a continuous perimeter
around cavities 14. Each side wall 24 may be individually
formed and then assembled together to form the perimeter.
Alternately, side walls 24 may be integrally formed.
Bottom wall 20 has inside surface 28 and top wall.
'22 has inside surface 30. Side walls 24 extend from;
~ inside surface 28 of bottom wall 20 to inside surface
of top wall 22. Similarly, internal walls 26 extend
25 from inside surface 28 of bottom wall 20 to inside;
surface 30 of top wall 22. , .
In an alternate embodiment, top wall 22 and
bottom wall 20 extend across cushion 10 and seat within
recesses 24a of side walls 24 (see Figure 7).
30 The cushion construction also includes a
resiliently-deformable support member 32. Support member
32 extends from inside surface 28 of bottom wall 20 to
inside surface 30 of top wall 22. As shown in Figures 1
and 2, support member 32 is located at the central portion
of boxing structure 12. Support member 32 may be formed by
the intersection of internal walls 26. Preferably,
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internal walls 26 radiate outwardly from support ~
member 32 to side walls 24 so as to define an internal
web centred around support member 32.
Each of bottom wall 20, top wall 22, side walls
24, internal walls 26 and support member 32 are made from
a resiliently flexible material such as a synthetic foam
(latex foam or urethane foam). Each of side wall 24,
internal walls 26 and support member 32 may be formed as
individual members and joined together, such as by
adhesive to form a unitary construction. Alternately, side
walls 24, internal walls 26 an support member 32 may be
integrally formed.
The seat cushion 10 shown in Figures 1-3 is
sized to seat one individual. Support member 32 is
centrally positioned in boxing member 12. Accordingly,
support member 32 is placed directly under the posterior
of an individual who sits on cushion 10.
It is appreciated that a cushion constructed
using this cushion construction may be of any particular
shape. As shown in Figures 1-3, the cushion is generally
square and side walls 24 effectively define the perimeter
of the cushion, thus, support member 32 is centrally
positioned with respect not only to boxing structure 12,
but the cushion itself. It will be appreciated that
cushions of any shape may be constructed using this
construction. For example; a cushion may be rectangular
( see Figure 4 ) , oblong or f an shaped ( see Figures 5 and
6). With some of these shapes, for example, the fan shaped
cushion, it is generally intended that the person sits
toward the rear of the cushion. The rear portion, which is
generally more square, is intended to receive the
posterior of the individual. The front, fan-shaped portion
of the cushion is more for decoration as opposed to
supporting the entire weight of the individual who sits on
the cushion.
Accordingly, as shown in Figure 5, the cushion
construction of the instant invention may be utilized at
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the portion of the cushion where it is intended that the
individual sit (the "seating portion" of the cushion) and
the remainder of the cushion may be constructed of a
resiliently flexible material. Side walls 24 may extend
outwardly from cavities 14 to the edge of the cushion so
that the design features of the cushion, such as a fan-
shaped portion, are constructed of a foam material.
Alternately, side walls 24 may be of the same width and
may define the perimeter of the cushion and internal walls
26 may extend outwardly to the perimeter of the cushion
(see Figure 6).
Internal walls 26 define a plurality of cavities
surrounding support member 32. As shown in Figures 2, 5,
and 6, four cavities are shown. However, a cushion
construction may comprise at least three cavities and,
preferably, comprise four cavities. It will be appreciated
that the actual shape of the cavities will depend upon the
number of cavities present and the shape of the perimeter
formed by side walls 24. For example, referring to Figure
5, although the cushion represented therein is fan-shaped,
four cavities are utilized and each cavity is generally
square. In the alternate construction shown in Figure 6,
while there are still four cavities, the two forward
cavities in the fan-shaped portion of the cushion are
irregular in shape. Preferably, the number of cavities and
the shape of the perimeter are chosen so that the cavities
have a square or rectangular shape.
Each cavity contains spring means 16. The spring
means may comprise a plurality of springs. For example, as
shown in Figure 2 each cavity contains four springs. If
the cavities vary in shape, then the number of springs in
each cavity may vary. For example, referring to Figure 6,
the two forward cavities contain five springs. It will
also be appreciated that, by varying the size of each
spring, the number of springs in each cavity may be
varied, and in the same cushion, cavities of the same size
may, accordingly, have different numbers of springs.
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Spring means 16 are selected so as to
essentially fill each cavity 14. Spring means 16 extend
vertically between bottom wall 20 and top wall 22 and,
preferable, are dimensioned such that, when the cushion is
in an unloaded state, spring means 16 are in contact with
inside wall 28 of bottom 20 and inside wall 30 of top wall
22. Since spring means 16 essentially fill cavity 14, the
loading of the cushion, for example, by a person sitting
thereon, causes spring means 16 to compress as opposed to
deflecting outwardly into side walls 24 and inner walls
26.
Preferably, spring means 16 are under
compression when the cushion construction is in an
unloaded state. For example, each spring means 16 may be
a pocketed coil spring as is shown in Figure 1.
Preferably, the spring means 16 are bound
together so as to maintain them in an upright position
even when the cushion construction is in a loaded state.
If an open coil is utilized, ie. a coil which is not
surrounded by any fabric, then the coils may be joined
together at their top and bottom by any means known in the
art such as rings. Alternately, if the spring means are
pocketed coils, then the individual pockets may connected
together. Generally, pocketed coils are longitudinally
extending rows. The longitudinally extending rows are cut
to the desired length for a particular application. In the
embodiment shown in Figure 2, two rows, each of which
contains two pocketed coil springs, are utilized. Coils
16a and 16b comprise one row and coils 16c and 16d
comprise the second row. Coils 16a and 16b are connected
together by the pocket material extending between the two
coils. Similarly, coil 16c and 16d are connected together.
In an alternate embodiment, coils 16a and 16c, as well as
coils 16b and 16d, may be joined together such as by
bonding the fabric together where the coils attach (not
shown).
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It will be appreciated that the cushion
construction described so far may be utilized to prepare
a cushion to seat one individual. The cushion construction
of the instant invention may be utilized to construct a
cushion which is sized to seat more than one person. For
example, a plurality of individual cushion construction
units as shown in Figure 2 may be placed in a
longitudinally extending row so as to define a cushion for
use in, for example, a couch. If the couch is designed to
seat three people, then three box structures 12 may be
placed side by side. Preferably, the boxing structures are
connected together so as to form a unitary construction.
For example, the individual units may be fixed together
such as by adhesive. Alternately,.or in addition, the
individual units may be encased in an outer perimeter of
flexible resilient material (not shown). In a further
alternate embodiment, as shown in Figure 4, the individual
boxing structures may be integrally formed as a whole:
Thus, a cushion construction may comprise three individual
boxing structures 34, 36 and 38. Dashed lines 40 and 42
are used to demonstrate the notional end of each
individual unit. Each individual construction comprises a
plurality of side walls 24 and internal walls 26 defining
a plurality of .cavities 14. Each cavity 14 includes spring
means 16 to fill the cavity. Each boxing structure 34, 36
and 38 may be as described above.
The cushion construction may be manufactured by
providing a boxing structure 12 having side walls 24,
internal walls 26 and a plurality of cavities 14. Spring
means may then be placed in each cavity 14. Bottom and top
walls 20 and 22 may then be placed around boxing structure
12 fully enclosing cavities 14. Referring to Figure 1,
additional padding material 44 may be placed on top of the
exterior side of top wall 22. Optionally, additional
padding may also be placed against the external wall of
bottom wall 20. Fabric covering 46 may then be placed
around the entire construction.
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Alternately the cushion may be constructed by
providing boxing structure l2 and then placing boxing
structure 12 on either bottom wall 20 or top wall 22.
After insertion of the spring means, the other of bottom
wall 20 and top wall 22 may be placed in position and the
unit finished as described above.
