Method of making foam cushions and product formed thereby

Abstract

Abstract A METHOD OF MAKING A FOAM CUSHION FOR USE AS A SEAT, MATTRESS OR THE LIKE INCLUDING THE STEPS OF FOAMING A MATERIAL IN AN OPEN TOP MOLD TO FORM A CELLULAR PAD HAVING A DENSE UPPER CRUST, AND SUPPORTINGLY POSITIONING AN OPEN MESH FABRIC AND OVERLYING SPRING ASSEMBLY IN FLOATING RELATION ON THE FOAMING MATERIAL. THE OPEN MESH FABRIC THEREBY BECOMES ESSENTIALLY EMBEDDED IN THE CRUST OF THE INFORCE THE SAME, AND THE TERMINAL FACE PORTIONS OF THE SPRING ASSEMBLY ARE ADHERED TO THE CRUST TO INTERCONNECT THE VARIOUS COMPONENTS. TO FORM AN INNERSPRING MATTRESS, THE RESULTING STRUCTURE IS REMOVED FROM THE MOLD, INVERTED, AND POSITIONED ON ADDITIONAL FOAMING MATERIAL IN A LIKE MANNER. IN A FURTHER EMBODIMENT, THE SPRING ASSEMBLY IS POSITIONED ON THE PAD AFTER THE FOAMING PROCESS IS COMPLETED. IN THIS CASE, THE ORIGINALLY UNATTACHED FOAM PAD MAY BE EASILY STORED OR SHIPPED TO A POINT OF ASSEMBLY WHERE THE SPRING ASSEMBLY IS LATER JOINED BY HOG RINGING OR THE LIKE. IN ORDER TO DENSIFY THE FOAMING MATERIAL IN THIS LATTER EMBODIMENT, A SCREEN MEMBER HAVING A WEIGHT AND OUTLINE GENERALLY SIMILAR TO THAT OF THE SPRING ASSEMBLY MAY BE REMOVABLY POSITIONED ON THE FOAMING MATERIAL DURING THE FOAMING PROCESS.

Inventors

• 👤 C Bullock

Bibliographic Details