Cushion and Method for Manufacturing the Same
A cushion unit includes shell having a first cushion retaining portion and a second cushion retaining portion that are demarcated by a hinge-seam including a fastener portion. The fastener portion is secured to an inboard surface of the shell. According to an embodiment, the cushion unit includes a cushion member affixed to an inboard surface of the shell. According to an embodiment, the fastener portion is secured directly to an outboard surface of the cushion member and secured indirectly to an inboard an inboard surface of the shell. According to an embodiment, the fastener portion is secured directly to an inboard an inboard surface of the shell. A method for manufacturing a cushion unit is disclosed. A method for providing a cushion unit is also disclosed.
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This application is a continuation application of U.S. Ser. No. 12/829,100 filed Jul. 1, 2010, which is a divisional application of U.S. Ser. No. 11/563,778 filed on Nov. 28, 2006, now U.S. Pat. No. 7,770,248.
BACKGROUND1. Technical Field
The invention relates to a cushion unit, a method for manufacturing a cushion unit, and a method for providing a cushion unit.
2. Description of Related Art
As is known in the art, cushions are commonly provided as a separate or integral component of an article of furniture so as to increase the comfort of a person, animal, or the like that is resting or seated upon the article of furniture. Conventional cushions typically include, for example, a shell of material that encloses a collection or unit of soft material, such as, for example, foam, feathers, or the like.
As is known in the art, conventional cushion manufacturing operations typically include a plurality of steps. One conventional cushion manufacturing operation may include the steps of (a) manufacturing a shell of material into a desired shape defining a cavity volume, (b) filling the cavity volume of the shell by stuffing a soft material through an opening formed in the shell, and (c) closing-off/sealing the opening formed in the shell by way of, for example, a sewing operation.
Although conventional cushions are known in the art, structural and ornamental design improvements are continuously sought after by cushion manufacturers. Such structural and/or ornamental improvements may provide cushion customers with a cushion product that is differentiated from conventional cushions that are available in the crowded cushion marketplace.
In addition, although conventional cushion manufacturing techniques are known in the art, global competitive forces demand that material costs, manufacturing costs, shipping costs, and the like are reduced so as to provide a cushion manufacturer with a profit. As such, although the manufacturing of a cushion unit may be conducted by a skilled laborer in a low-cost national country remote from a point-of-sale national country, there is a need in the art to provide a cushion structure that is conducive to providing an improvement over conventional cushion manufacturing techniques so as to maintain profitability or return greater profits to a cushion manufacturer while also maintaining an optimal design configuration of a cushion structure that is also aesthetically pleasing.
The present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:
The Figures illustrate an exemplary embodiment of a cushion unit 10 and a partially-assembled cushion unit 100 in accordance with an embodiment of the invention. For brevity, the disclosure hereof will illustrate and describe a cushion unit 10 and a partially-assembled cushion unit that includes one or more selectively-accessible opening(s) 54a, 54b that is/are disposed proximate and along a hinge or seam 38 (i.e., a non-edge surface) of the cushion unit 10/partially-assembled cushion unit 100. Based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art.
Referring to
Even further, it will be appreciated that the cushion unit 10 may be utilized as a stand-alone unit and may not necessarily be associated with an article of furniture, F. As such, the cushion unit 10, may be shaped for any desirable, stand-alone purpose or application, such as, for example, an elongated body pillow, canine bed, or the like.
Referring to
The shell 20 is defined to include a plurality of facets 22-32 that may be defined by any combination of a width, W (
The first and second face surfaces 22, 24 are designed to include any desirable length, L, and width, W. If, for example, the cushion unit 10 is designed for application with a chair of a patio furniture set, F, the cushion unit 10 may be designed to include at least a back/lumbar support surface 11a and derriere/buttocks support surface 11b that is proportional to that of, for example, an average-sized adult, child, or the like.
According to an embodiment, as shown in
Referring to the opposite, second face surface 24, the cushion unit 10 may include one or more fasteners 34, 36. As illustrated, the one or more fasteners 34, 36 may be disposed along the width, W, proximate and along the hinge-seam 38 of the cushion unit 10. The one or more fasteners 34, 36 may include any desirable fastener, such as, for example, a zipper, a plurality of hooks and loops, such as, for example, VELCRO®, or the like. Because the one or more fasteners 34, 36 is/are disposed along the width, W, and hinge-seam 38, it will be appreciated that the one or more fasteners 34, 36 are not disposed on an edge surface facet 26-32, as commonly associated with the prior art. However, it will be appreciated that, if desired, one or more fasteners 34, 36 may be disposed on the edge surface facet 26-32.
Referring to
Because the one or more fasteners 34, 36 provide the second face surface 24 with a substantially interrupted surface portion 46b that may not be aesthetically-pleasing to an observer, the second face surface 24 may positioned adjacent the article of furniture, F, so that the interrupted surface portion 46b is not in clear sight by an observer. Although the one or more fasteners 34, 36 are provided proximate to and along a width, W, of the cushion unit 10 proximate the hinge-seam 38 on the second face surface 24, it will be appreciated that the cushion unit 10 may be flipped such that the second face surface 24 may face away from the article of furniture, F, while the first face surface 22 is adjacent the article of furniture, F (i.e., the opposite positioning of the cushion unit 10 on the article of furniture, F, as shown in
Referring to
The first and second fasteners 34, 36 provide, respectively, an opening 54a, 54b (
As shown in
Referring back to
Referring now to
Referring to
According to an embodiment, as seen in
According to an alternative embodiment, as seen in
Before or after the fastener support material 40 is attached as described above proximate the hinge-seam 38, the outboard surface 62 of the cushion member 48 may also be affixed to the inboard surface 56 of the shell 20 by way of an adhesive 42 and/or a plurality of stitched-threadings 44, as shown in
In this state, the first cushion member 48 may be further defined to include and define a volume, VC1. As shown in
Referring to
Once inserted through the opening 54a, 54b the fastener 34, 36 may be moved from an opened position (
As such, it will be appreciated that the cushion-receiving volume, VC, as shown in
Thus, the cushion unit 10 provides an end-user with the ability to selectively control the cushioning effect of the cushion unit 10. For example, if an end-user chooses to reduce/increase the cushioning effect of the cushion unit 10, the end-user may move the fastener 34, 36 from a closed position (
In addition, the structure of the cushion unit 10 provides an improvement over conventional cushion manufacturing/assembling techniques so as to maintain profitability or returns greater profits to a cushion manufacturer. According to an embodiment, as shown in
In a first embodiment, as seen in
According to an embodiment, as shown in a method 300 illustrated in
According to an embodiment, as shown in
After the crate 200a of partially-assembled cushion units 100 is moved and arrives at the second, point-of-sale location, at steps S.303, S.304, the second cushion members 50a, 50b may be provided, at step S.305 for insertion, at step S.306, as shown in
As such, the manufacturer may elect to remove the costs associated with stuffing the removable cushions 50a, 50b into the shell 20 by the un/skilled laborer in the first region at step S.301 by shifting the task of the un/skilled laborer in the first region to an unskilled laborer or customer of the cushion unit 10 in the second region. Thus, when the crate 200a arrives at the point-of-sale location (i.e., at the second national country remote from the first national country having the cheaper labor force), as shown in step S.304, another laborer (e.g., the unskilled laborer or customer) may conduct the task of inserting the removable cushion 50a, 50b into the shell 20, as shown in step S.306.
As such, the structure of the partially-assembled cushion unit 100 may maintain or increase the profitability of a cushion manufacturer by permitting the manufacturer to increase efficiency in the shipping step (i.e., steps S.303, S.304) by receiving a relatively large amount of partially-assembled cushion units 100 having already been processed by a skilled-laborer, less an unskilled labor step of incorporating a second cushion into the shell 20 so as to complete the assembling procedure at a later time at the second location by an unskilled laborer or customer. Thus, efficiency of a cushion manufacturing process is improved as related to the skilled-laborer manufacturing step, the shipping step, and the final unskilled laborer step by delaying any unskilled labor in the manufacturing of the cushion unit 10 until a partially-assembled cushion unit 100 arrives at a second location that is proximate the point-of-sale.
The present invention has been described with reference to certain exemplary embodiments thereof However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.
Claims
1-25. (canceled)
26. A cushion unit, comprising:
- a shell having a first cushion retaining portion and a second cushion retaining portion that are demarcated by
- a hinge-seam body that is affixed to the shell;
- a first cushion member that is non-removably affixed to an inboard surface of the shell and at least partially disposed in at least one of the first and second cushion retaining portions; and
- a fastener portion included with the hinge-seam body, wherein the hinge seam body is affixed to the shell such that it directly contacts an outboard surface of the first cushion member, and
- indirectly to an inboard surface of the shell.
27. The cushion unit according to claim 26, wherein the hinge seam body is affixed indirectly to the inboard surface of the shell by a stitched threading, wherein the indirect affixing of the hinge seam body to the inboard surface of the shell by the stitched threading permits the first cushion retaining portion to be in communication with the second cushion retaining portion and permits the first cushion member to be disposed in both of the first and second cushion retaining portions by extending the first cushion member within the shell proximate the indirect affixing of the hinge seam body to the inboard surface of the shell.
28. The cushion unit according to claim 26, wherein the fastener portion includes
- a fastener support material that supports one or more fasteners, wherein the one or more fasteners includes a first fastener and a second fastener, wherein the first fastener is disposed proximate a first opening formed by the fastener support material, wherein the second fastener is disposed proximate a second opening formed by the fastener support material, wherein the first opening permits access to the first cushion retaining portion of the shell, wherein the second opening permits access to the second cushion retaining portion of the shell, wherein the first fastener provides
- means for selectively permitting/denying access to the first cushion retaining portion of the shell by way of the first opening, wherein the second fastener provides
- means for selectively permitting/denying access to the second cushion retaining portion of the shell by way of the second opening.
29. The cushion unit according to claim 28, wherein at least one of the first and second fasteners includes
- a zipper.
30. The cushion unit according to claim 28, wherein at least one of the first and second fasteners includes
- a plurality of one or more hooks and loops.
31. The cushion unit according to claim 26, wherein the fastener portion provides selective access to at least one of the first and second cushion retaining portions of the shell.
32. A cushion unit, comprising:
- a shell having a first cushion retaining portion and a second cushion retaining portion that are demarcated by
- a hinge-seam body that is affixed to the shell;
- one or more first cushion member units that is/are non-removably affixed to an inboard surface of the shell and disposed
- proximate the hinge-seam body and
- in at least one of the first and second cushion retaining portions; and
- a fastener portion-included with the hinge seam body, wherein the hinge seam body is affixed
- directly to an inboard surface of the shell.
33. The cushion unit according to claim 32, wherein the hinge seam body is affixed directly to the inboard surface of the shell by a stitched threading, wherein the direct affixing of the hinge seam body to the inboard surface of the shell isolates the first cushion retaining portion from the second cushion retaining portion, wherein a first unit of the first cushion member is disposed within the first cushion retaining portion, wherein a second unit of the first cushion member is disposed within the second cushion retaining portion, wherein the first and second units of the first cushion member are discrete units that are not joined to one another.
34. The cushion unit according to claim 32, wherein the fastener portion includes
- a fastener support material that supports one or more fasteners, wherein the one or more fasteners includes a first fastener and a second fastener, wherein the first fastener is disposed proximate a first opening formed by the fastener support material, wherein the second fastener is disposed proximate a second opening formed by the fastener support material, wherein the first opening permits access to the first cushion retaining portion of the shell, wherein the second opening permits access to the second cushion retaining portion of the shell, wherein the first fastener provides
- means for selectively permitting/denying access to the first cushion retaining portion of the shell by way of the first opening, wherein the second fastener provides
- means for selectively permitting/denying access to the second cushion retaining portion of the shell by way of the second opening.
35. The cushion unit according to claim 34, wherein at least one of the first and second fasteners includes
- a zipper.
36. The cushion unit according to claim 34, wherein at least one of the first and second fasteners includes
- a plurality of one or more hooks and loops.
37. The cushion unit according to claim 32, wherein the fastener portion provides selective access to at least one of the first and second cushion retaining portions of the shell.
38. A fastener portion, comprising:
- fastener support material;
- a first fastener connected to the fastener support material; and
- a second fastener connected to the fastener support material.
39. The fastener portion according to claim 38, wherein the fastener support material includes fabric.
40. The fastener portion according to claim 38, wherein the fastener support material includes plastic.
41. The fastener portion according to claim 38, wherein an open orientation of the first fastener forms a first opening in the support material, wherein an open orientation of the second fastener forms a second opening in the support material.
42. An apparatus, comprising:
- support material including a first side and a second side, a first opening extending through the support material from the first side to the second side, and a second opening extending through the support material from the first side to the second side;
- a first zipper connected to the support material, wherein the first zipper is disposed along the first opening; and
- a second zipper connected to the support material, wherein the second zipper is disposed along the second opening.
43. The apparatus according to claim 42, wherein the support material includes fabric.
44. The apparatus according to claim 42, wherein the support material includes plastic.
45. The apparatus according to claim 42, wherein an arrangement of the first zipper in a closed orientation denies access to the first opening, wherein an arrangement of the first zipper in an open orientation permits access to the first opening, wherein an arrangement of the second zipper in a closed orientation denies access to the second opening, wherein an arrangement of the first zipper in an open orientation permits access to the first opening
46. An apparatus, comprising: wherein the first coil is connected to the first edge surface of the support material, wherein the second coil is connected to the second edge surface of the support material; and wherein the third coil is connected to the third edge surface of the support material, wherein the fourth coil is connected to the fourth edge surface of the support material.
- support material including a first opening extending through the support material, wherein the first opening is formed by a first edge surface of the support material and a second edge surface of the support material, and a second opening extending through the support material, wherein the second opening is formed by a third edge surface of the support material and a fourth edge surface of the support material;
- a first zipper connected to the support material, wherein the first zipper is disposed along the first opening, wherein the first zipper includes a first coil, a second coil, and a first tab movably-disposed upon the first coil and the second coil for selectively dis/connecting the first coil and the second coil,
- a second zipper connected to the support material, wherein the second zipper is disposed along the second opening, wherein the second zipper includes a third coil, a fourth coil, and a second tab movably-disposed upon the third coil and the fourth coil for selectively dis/connecting the third coil and the fourth coil,
47. The apparatus according to claim 46, wherein the support material includes fabric.
48. The apparatus according to claim 46, wherein the support material includes plastic.
49. The apparatus according to claim 46, wherein connection of the first coil to the second coil denies access to the first opening, wherein disconnection of the first coil to the second coil permits access to the first opening, wherein connection of the third coil to the fourth coil denies access to the second opening, wherein disconnection of the third coil to the fourth coil permits access to the first opening
Type: Application
Filed: Jul 18, 2011
Publication Date: Nov 10, 2011
Applicant: Arden Companies (Bingham Farms, MI)
Inventor: Gary J. Furlow (Rome City, IN)
Application Number: 13/185,330
International Classification: A47C 20/02 (20060101); A44B 19/12 (20060101); A44B 19/24 (20060101); A47C 16/00 (20060101); A44B 99/00 (20100101);