A foam cushion

Abstract

 The present invention relates to foam cushions, including upholstery, seats and mattresses. It discloses a foam cushion (2) comprising a body (4), within which there are a plurality of cavities defined between the limbs (6,8) from which the body is made.

Description

Field of the Invention

[0001] The present invention relates to foam cushions. In this specification, the term "cushion" shall, for the avoidance of doubt, include both upholstery seats and mattresses as well as other applications.

Background to the Invention

[0002] It is known to produce a cushion, for instance for a seat, in which the main weight bearing part of the cushion includes a plurality of helical springs surrounded by a foam material such as a polyurethane foam. Such a construction is expensive to produce and to assemble.

[0003] It is an object of the present invention to obviate or overcome disadvantages encountered with the prior art whether referred to herein or otherwise.

Summary of the Invention

[0004] According to the present invention, in a first aspect, there is provided a foam cushion comprising a body within which there are a plurality of cavities.

[0005] In this specification, the term "cavities" means those gaps or spaces having dimensions substantially greater than those of the cells of the foam forming the body of the material. "Cavity" shall be construed accordingly.

[0006] Suitably, the foam comprises a polyurethane foam.

[0007] Suitably, the body comprises at least two limbs in which the cavities are defined between the two limbs.

[0008] Suitably, the two limbs are connected.

[0009] Suitably, each limb comprises proud portions and recessed portions. conveniently, the proud and recessed portions on one limb are substantially similar, but in an opposing orientation, to those on the at least one other limb.

[0010] Suitably, at least some of the proud portions of two limbs abut against each other, whereby at least some of the recessed portions are adjacent one another to define cavities.

[0011] Suitably, at least one limb is joined to another part of the body.

[0012] Suitably, there is provided a spacing element between the first and second limbs.

[0013] Suitably, there is provided an end piece adjacent a free end of a limb to enable the limb to be joined thereto. Suitably, the end piece is connected to another limb.

[0014] Suitably, there are provided three limbs, a central limb, a first limb on one side of the central limb and a second limb on the other side of the central limb.

[0015] According to a second aspect of the present invention, there is provided a seat or mattress including a foam cushion according to the first aspect of the present invention.

[0016] According to a third aspect of the present invention, there is provided a method of manufacturing a foam cushion suitable for use as a cushion in accordance with the first aspect of the present invention, the method comprising the steps of:

providing a foam body; and

cutting or otherwise shaping the body.

Brief Description of the Drawings

[0017] The present invention will now be described, by way of example only, with reference to the drawings that follow; in which:

[0018] Figure 1 is a schematic end view of a first embodiment of a foam cushion in accordance with the present invention in its post-production configuration.

[0019] Figure 2 is a schematic elevation of the first embodiment shown in Figure 1 in its in use configuration.

[0020] Figure 3 is a schematic end elevation of a second embodiment of the present invention in its in use configuration.

[0021] Figure 4 is a schematic end elevation of the second embodiment of the present invention in a second, post production, configuration.

[0022] Figure 5 is a schematic end elevation of the second embodiment of the present invention in a third configuration between the in use and post production configuration.

[0023] Figure 6 is a schematic end elevation of a third embodiment of the present invention in its in use configuration.

[0024] Figure 7 is a schematic end elevation of the third embodiment of the present invention in its post production configuration.

[0025] Figure 8 is a schematic end elevation of a fourth embodiment of the present invention in its in use configuration.

[0026] Figure 9 is a schematic end elevation of the fourth embodiment of the present invention in its post production configuration.

[0027] Figure 10 is a schematic end elevation of a fifth embodiment of the present invention in its in use configuration.

Description of the Preferred Embodiments

[0028] Referring now to Figure 1 of the drawings that follow, there is shown a foam cushion 2 comprising a body 4 formed from a polyurethane foam material having elastomeric resilient properties.

[0029] The body 4 is shaped in cross-section, for use as a cushion. The body 4 comprises two limbs, first limb 6 and second limb 8 joined at a juncture 10.

[0030] The limbs 6, 8 are separated by a cut line 12. The cut line 12 defines a substantially castellated configuration between the two limbs 6,8. Also provided are slits 14 in the first limb 6 adjacent the juncture 10 of the two limbs 6,8.

[0031] Referring now to Figure 2 of the drawings that follow, there is shown the cushion apparatus 2 in its in use configuration.

[0032] To achieve the configuration of Figure 2, the two limbs 6,8 are pulled apart, the first limb 6 is stretched away from the juncture 10 of the limbs 6, 8 to align the castellations (as shown in Figure 2). The end 16 of the body 4 distant from the juncture 10 is then glued, and each of the proud portions 18 of one limb 6, 8 are glued to the opposing proud portions of the other limb 8, 6, securing the limbs 6, 8 together.

[0033] The slits 14 allow for the stretching of the first limb 6 without substantial deformation of the remainder of the body 4. In Figure 2 the slits 14 can be seen to be expanded by the stretching the body has undergone.

[0034] In the in use configuration of Figure 2, it can be seen that the proud portions 18 of each of the castellations on the limbs 6, 8 are substantially aligned as are each of the recessed portions 20 to produce a plurality of cavities by the combination of the recessed portions 20.

[0035] It will be appreciated by those skilled in the art that the cushion 2 can readily be incorporated into a seat or mattress. In use, the inclusion of the cavities (produced by recesses 20) in the cushion 2 has, surprisingly, been found to reproduce the "spring effect" of prior art cushions. In this way, the need for polyester wrapping or other wraps found to be necessary around conventional cushions is avoided.

[0036] In relation to Figure 1 of the drawings that follow, it is noted that the two limbs can be formed from a foam block by a single cut, typically using a computer numerically controlled cutting machine of the type well known in the art.

[0037] Referring now to Figure 3 of the drawings that follow, there is shown a foam cushion 22 comprising a body 24. The material of the body 24 is substantially similar to that of the first embodiment of the present invention described in relation to Figures 1 and 2 of the drawings that follow.

[0038] The body 24 comprises a central limb 26 on one side of which is a first limb 28 and on the other side of which is a second limb 30. The central limb 26 is joined to the first limb 28 at one end at juncture 29. The central limb 26 is joined to the second limb 30 at the same end at juncture 31.

[0039] On the side of the central limb 26 facing the first limb 28, there are a series of castellations producing proud portions 32 and recessed portions 34. Similarly, on the face of the first limb 28 facing the central limb 26, castellations are also provided to produce proud portions 36 and recessed portions 38.

[0040] Between the first limb 28 and central limb 26 is provided a wedge-shaped first spacing element 40 which tapers towards the juncture 29 of the first limb 28 and central limb 26.

[0041] On the side of the central limb 26 facing the second limb 30, there are a series of castellations producing proud portions 42 and recessed portions 44. Similarly, on the face of the second limb 30 facing the central limb 26, castellations are also provided to produce proud portions 46 and recessed portions 48.

[0042] Between the second limb 30 and central limb 26 is provided a wedge-shaped second spacing element 50 which tapers towards the juncture 31 of the second limb 30 and central limb 26.

[0043] The central limb 26 and first limb 28 are spaced apart by first spacing element 40. The central limb 26 and second limb 30 are spaced apart by second spacing element 50.

[0044] At the end of the central limb 26 distant from the junctures 29 and 31, there is provided a T-shaped element 52, the arms 54 of which extend over the ends of the first and second limbs 28, 30 respectively. The limbs 28, 30 and/or spacing elements 40, 50 are adhered to the arms 54.

[0045] It is apparent from Figure 3 that the proud portions 32 of the central limb 26 are substantially aligned with the recessed portions 38 of the first limb 28 and vice versa. Similarly, the proud portions 42 of the central limb 26 are substantially aligned with the recessed portions 48 of the second limb 30 and vice versa.

[0046] It will be appreciated by those skilled in the art that the cushion 22 can readily be incorporated into a seat or mattress. In use, the inclusion of the cavities (produced by recesses 34, 38, 44 and 48) in the cushion 22 have substantially the same effect as in relation to the first embodiment. However, in this case, it has been found that the spacing elements 40, 50 enhance the "spring effect" in particular when produced in a narrowing, wedge-shape as shown in Figures 3-5.

[0047] It is noted that, in relation to this second embodiment of the present invention, it could also be formed from a foam block by a single cut, typically using a computer numerically controlled cutting machine of the type well known in the art. This is set out further below.

[0048] Referring to Figure 4 of the drawings that follow, the post-production configuration of the cushion 22 can be seen. In particular, the line of cut used to produce the body 24 is shown. It is noted that the cushion 22 can be cut out in a single cutting action with minimal waste.

[0049] In Figure 4, it can be seen that the shaped spacing elements 40 and 50 are on the outside of the first and second limbs 28, 30 respectively.

[0050] Referring now to Figure 5 of the drawings that follow, the second embodiment is shown in a configuration between in the in use configuration of Figure 3 and the post production configuration of Figure 4. Figure 5 shows how the body 24 can be reconfigured from the post production configuration of Figure 4 to the in use configuration of Figure 3.

[0051] After production, the first limb 28 is pulled away from the central limb 26 and the second limb 30 is also pulled away from the central limb 26.

[0052] As can be seen in Figure 5, the spacing elements 40 and 50 are connected to the first and second limbs 28, 30 respectively by hinged webs 54, 56 respectively. Using the web 54 the first spacing element 40 can be folded into the space between the central limb 26 and first limb 28 and, using the web 56, the second spacing element 50 can be folded into the space between central limb 26 and second limb 30.

[0053] The T-shaped element 50 provides an edge to which the ends of the first limb 28, second limb 30, first spacing element 40 and second spacing element 50 can be adhered. This avoids the necessity for dressing off the back edge of the cushion with a separate border of foam.

[0054] The embodiment of Figures 3-5 can be used as a reversible cushion. If a non-reversible cushion is required, only two limbs and a single spacer portion would be needed. In effect half of the cushion of the Figure 3-5 embodiment could be used.

[0055] Referring to Figure 6 of the drawings that follow, there is shown a foam cushion 60 comprising a body 62. The material of the body 62 is substantially similar to that of the first and second embodiments of the present invention, described in relation to Figures 1 and 2, and Figures 3-5 of the drawings that follow.

[0056] The body 62 comprises a central limb 64 on one side of which is a first limb 66 and on the other side of which is a second limb 68.

[0057] On the side of the central limb 64 facing the first limb 66, there are a series of castellations producing proud portions 70 and recessed portions 72. Similarly, on the face of the first limb 66 facing the central limb 64, castellations are also provided to produce proud portions 74 and recessed portions 76.

[0058] Between the first limb 66 and central limb 64 is provided a first spacing element 78 which is generally rectangular in cross section.

[0059] On the side of the central limb 64 facing the second limb 68, there are a series of castellations producing proud portions 80 and recessed portions 82. Similarly, on the face of the second limb 68 facing the central limb 64, castellations are also provided to produce proud portions 84 and recessed portions 86.

[0060] Between the second limb 68 and central limb 64 is provided a second spacing element 88 which is generally rectangular in cross-section.

[0061] The central limb 64 and first limb 66 are spaced apart by first spacing element 78. The central limb 64 and second limb 68 are spaced apart by second spacing element 88.

[0062] At either end of the central limb 64, there is provided a T-shaped element 90, the arms 92 of which extend over the ends of the first and second limbs 66, 68 respectively and over the ends of the first and second spacing elements 78, 88 respectively. The ends of the limbs 66, 68 and spacing elements 78, 88 are adhered to the arms 92 of the T-shaped element 90.

[0063] It is apparent from Figure 6 that, in use, the proud portions 70 of the central limb 64 are substantially aligned with the recessed portions 76 of the first limb 66 and vice versa. Similarly, the proud portions 80 of the central limb 64 are substantially aligned with the recessed portions 86 of the second limb 68 and vice versa.

[0064] It will be appreciated by those skilled in the art that the cushion 60 can readily be incorporated into a seat or mattress.

[0065] In use, the inclusion of the cavities (produced by recesses 72, 76, 82 and 86) in the cushion 60 have substantially the same effect as in relation to the first and second embodiments.

[0066] Referring to Figure 7 of the drawings that follow, the post production configuration of the cushion 60 can be seen. In particular, the line of cut used to produce the body 62 is shown. It is noted that in the case of this third embodiment there is substantially no waste from the cushion 60 when cut from a rectangular block. It can be cut using a single continuous cutting action.

[0067] It will be appreciated that the body 62 is transferred from its post production configuration of Figure 7 to its in use configuration of Figure 6 by stripping out and reversing the positions of the first limb 66 and first spacing element 78, and by doing the same with the second limb 68 and second spacing element 88. The ends of the limbs 66, 68 and spacing elements 78, 88 are glued to the arms 92 as explained above.

[0068] In Figure 6 it can be seen that the glued ends of the first and second limbs 66, 68 respectively narrow to where they are glued to arms 92. This is accomplished by "pinching" the ends of the limbs 66, 68.

[0069] Referring to Figures 8 and 9 of the drawings that follow, there is shown a fourth embodiment of the present invention. The fourth embodiment can be regarded as a simplified version of the second embodiment of the present invention described in relation to Figures 3 to 5. For that reason only a brief description of the fourth embodiment will be given here.

[0070] In the fourth embodiment of Figures 8 and 9, there is shown in Figure 8 a foam cushion 100 comprising a body 102 formed from a polyurethane foam material having elastomeric resilient properties.

[0071] The body 102 is shaped, in cross-section, for use as a cushion. The body 102 comprises a central limb 104 on one side of which is a first castellated limb 106, and on the other side of which is a second castellated limb 108. Between the central limb 104, and the first and second castellated limbs 106, 108 respectively are a first castellated spacing element 110 (between the first castellated limb 106 and the central limb 104) and a second castellated spacing element 112 (between the second castellated limb 108 and the central limb 104).

[0072] Proud portion of the first castellated limb 106 lie over recessed portions of the first castellated spacing element 110. Similarly, proud portions of the second castellated limb 108 lie under recessed portions of the second spacing element 112. This configuration provides, in use, the desired resilience for a comfortable cushion.

[0073] To secure the body 102 together the first and second castellated limbs 104, 108 respectively and the first and second castellated spacing elements 110, 112 respectively are adhered to a T-shaped end piece 114 of the central limb 104.

[0074] Referring to Figure 9 of the drawings that follow, the post-production (after cutting) configuration of the body 102 is shown. It will be appreciated that the first and second castellated spacing elements 110, 112 respectively are stripped out, inverted and replaced in their original positions (the other way around) to produce the configuration of Figure 8.

[0075] The fourth embodiment does not require the wedge shaped spacing element 40 of the second embodiment.

[0076] Referring now to Figure 10 of the drawings that follow, there is shown a fifth embodiment of the present invention in its in-use configuration. The fifth embodiment is, essentially, a one-sided version of the fourth embodiment of the present invention described in relation to Figures 8 and 9, and for convenience corresponding reference numerals have been used for like parts. It will be appreciated in this case that the limb 104 is not central, but serves the same purpose as for the fourth embodiment. Further, end piece 114 is not T-shaped and depends from first limb 106 as shown.

[0077] As will be apparent to a person skilled in the art, the fifth embodiment is manufactured as one side of the fourth embodiment.

[0078] It is noted that the fourth and fifth embodiments can be produced from one body by a single cut.

[0079] In the case of the second to fifth embodiments of the present invention, it is unnecessary for the proud portions of the limbs to be adhered to each other.

[0080] The third embodiment of the present invention can be used with a single set of facing castellations if a non-reversible cushion is desired, as for the second embodiment.

[0081] It will be appreciated by those skilled in the art that the proud and recessed portions need not be produced by castellations. Instead they could be produced by any non-linear cut in the foam, which is preferably repeating. For instance, a zig zag pattern, producing V-shaped cut out portions could be used.

[0082] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0083] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0084] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0085] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A foam cushion comprising a body within which there are a plurality of cavities.

2. A foam cushion according to claim 1 characterised in that the foam comprises a polyurethane foam.

3. A foam cushion according to claim 1 or claim 2 in which the body comprises at least two limbs in which the cavities are defined between the two limbs.

4. A foam cushion according to claim 3 in which at least two limbs are connected.

5. A foam cushion according to claim 3 or claim 4 in which the at least two limbs comprise proud portions and recessed portions.

6. A foam cushion according to claim 5 in which the proud and recessed portions on one limb are substantially similar, but in an opposing orientation, to those on the at least one other limb.

7. A foam cushion according to claims 5 or 6 in which some of the proud portions of two limbs abut against each other, whereby at least some of the recessed portions are adjacent to one another to define cavities.

8. A foam cushion according to any one of claims 3-7 in which at least one limb is joined to another part of the body.

9. A foam cushion according to any one of claims 3-8 comprising a spacing element between the first and second limbs.

10. A foam cushion according to claim 9 in which the spacing element comprises proud and recessed portions.

11. A foam cushion according to any one of claims 4-10 comprising an end piece adjacent a free end of a limb to enable the limb to be joined thereto.

13. A foam cushion according to claim 14 in which the end piece is connected to another limb.

14. A foam cushion according to any one of the preceding claims comprising three limbs, a central limb, a first limb on one side of the central limb and a second limb on the other side of the central limb.

15. A seat or mattress including a foam cushion as claimed in any one of the preceding claims.

16. A method of manufacturing a foam cushion as claimed in any one of the preceding claims; said method comprising the steps of:

providing a foam body; and

cutting or otherwise shaping the body.

Drawing