Non-slip outdoor cushion

Abstract

The present invention relates to an outdoor cushion with a non-slip material that is applied to less than the entire underside of the cushion. The non-slip material may also be resistant to UV degradation. Methods of manufacturing such a cushion are also disclosed.

Description

FIELD OF THE INVENTION

[0001] This invention relates to an improved outdoor cushion and a method for manufacturing the same.

BACKGROUND OF THE INVENTION

[0002] Known cushions for outdoor furniture have several drawbacks. Resin is the material of choice for some furniture, in particular, outdoor furniture. However, resin tends to be slick, such that objects slide off the furniture with relative ease. Other materials commonly used in furniture also suffer from this problem. Fabric covered cushions are particularly susceptible to sliding off. One solution is to use ties to attach the cushion to the frame of the furniture. While fairly effective, ties prevent easy removal of the cushion from the furniture. Also, the material of the ties may degrade or tear through use. Another solution has been to include a non-slip backing on the cushion. The backing is a layer of material that is sewn to the underside of a cushion. This is effective at overcoming the limitations of the ties, but significantly increases the materials costs and manufacturing costs of the cushion because a separate layer of material is utilized and that layer of material must be sewn at least around the entire perimeter of the cushion to ensure that the non-slip layer remains in place.

[0003] Consequently, the inventor has recognized the need for a non-slip outdoor cushion that is more economical to manufacture.

SUMMARY OF THE INVENTION

[0004] The present invention relates to a cushion with a non-slip material that is applied to less than the entire underside of the cushion. The non-slip material may also be resistant to UV degradation. Methods of manufacturing such a cushion are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] In the drawings:

[0006] FIG. 1 shows, in perspective, the underside of a cushion according to the present invention with an irregular pattern of non-slip material.

[0007] FIG. 2 shows, in perspective, the underside of a cushion according to the present invention with a contiguous area of non-slip material.

DETAILED DESCRIPTION

[0008] The present invention relates to a cushion that is to be used to improve the comfort on any chair or lounge. Typically, the cushion is placed on the seat of the chair or lounge. As seen in FIGS. 1 and 2, the present invention includes a cushion 10 with a topside 12 and an underside 14 with batting or filler material between the two sides. The underside will contact a surface of a piece of outdoor furniture and is a fabric or other material suitable for construction of an outdoor cushion. The cushion 10 also includes a layer of non-slip material 16 on the underside 14, where the layer of non-slip material does not occupy the entire area of the underside. Also, the cushion may utilize a fabric or fabric coating for both the topside and undersides that is resistant to degradation from UV light.

[0009] The non-slip material is a material with a relatively high co-efficient of friction such as natural rubber, synthetic rubber, other plastic material that is tacky, or combinations thereof. In addition, when applied, the composition including the non-slip material has a viscosity that is low enough to permit the composition to be sprayed and/or screen printed on to the underside of the cushion. Any suitable curing method may be used although heat curing is preferred.

[0010] A UV stabilizer may be used to accomplish prevention of UV degradation of the fabric or fabric coating. The UV stabilizer may be a UV absorber or hindered amine light stabilizer (HALS) or any other material(s) that stabilizes against UV degradation. Preferably, the UV stabilizer is included in the non-slip material, although this is not necessarily the case.

[0011] The non-slip material may be applied either before or after construction of the cushion. For example, the non-slip material may be applied to a panel that is to become the underside when it is attached to the other components of the cushion, e.g. batting and topside. The non-slip material is preferably applied by screen printing, although other techniques, such as spraying may also be suitable.

[0012] The non-slip material may be applied to the underside in a pattern of regions of non-slip material, where the pattern covers some or the entire underside, as seen in FIG. 1. Any pattern, regular or irregular, of non-slip material may be suitable. Alternately, the non-slip material may be applied in a single contiguous area to the underside, as seen in FIG. 2. Preferably, the non-slip material covers less than 75% of the area of the underside. More preferably, the non-slip material covers less the 50% of the area of the underside. In the most preferred embodiment, the non-slip material covers less than 25% of the area of the underside.

[0013] By selectively applying the non-slip material to the underside, the minimum amount of non-slip material can be used to achieve the desired non-slip characteristics for the cushion. Minimizing the amount of non-slip material reduces material costs thus making the cushion more economical to manufacture. Furthermore, by selectively applying it, the non-slip material can be applied in the most efficient manner. For example, on some chairs/lounges, cushions with non-slip material only in the center of the underside may be needed to effectively hold the cushion in place. With other chairs, a pattern of non-slip may most effectively hold the cushion in place. With selective application, the appropriate amount and placement of non-slip material is easily and economically achieved. In addition, the option to apply the non-slip material after construction of the cushion introduces flexibility into manufacturing process, which can lead to economical customization of cushions for a customer's specific needs.

[0014] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.

Claims

1. A cushion comprising an underside that includes a non-slip material applied to less than the entire area of the underside.

2. The cushion of claim 1, wherein the area of applied non-slip material is one contiguous area.

3. The cushion of claim 1, wherein the area of applied non-slip material is a pattern of regions of non-slip material.

4. The cushion of claim 1, wherein the non-slip material is screen printed onto the underside.

5. The cushion of claim 1, wherein the non-slip material is sprayed onto the underside.

6. The cushion of claim 1, wherein the non-slip material is rubber.

7. The cushion of claim 1, wherein the non-slip material is resistant to UV degradation.

8. A method of manufacturing a cushion for furniture, comprising:

applying a non-slip material to an area of an underside of a cushion that is less than the entire area of the underside; and

curing the non-slip material.

9. The method of claim 8, wherein the applying step further includes spraying the non-slip material onto the underside.

10. The method of claim 9, wherein the spraying step includes spraying the non-slip material in one contiguous area.

11. The method of claim 9, wherein the spraying step includes spraying the non-slip material in a pattern of regions.

12. The method of claim 8, wherein the applying step further includes screen printing the non-slip material onto the underside.

13. The method of claim 12, wherein the screen printing step includes screen printing the non-slip material in one contiguous area.

14. The method of claim 12, wherein the screen printing step includes screen printing the non-slip material in a pattern of regions.

15. The method of claim 8, wherein the non-slip material is resistant to UV degradation.

16. A method of manufacturing a cushion for outdoor furniture, comprising:

screen printing a non-slip material to an area of a panel adapted to be used as an underside of a cushion, wherein the area is less than the entire area of the underside; and

curing the non-slip material.

17. The method of claim 16, wherein the non-slip material is screen printed in one contiguous area.

18. The method of claim 16, wherein the non-slip material is screen printed in a pattern of regions.

19. The method of claim 16, wherein the screen printing takes place after the underside has been incorporated into a cushion.

20. The method of claim 16, wherein the non-slip material is resistant to UV degradation.