Seat cushion using vertically lapped fiber

Abstract

A seat cushion is disclosed that can be easily attached to, and removed from, a chair or seat utilizing a mesh seat bottom. The removable seat cushion includes a collection of downwardly extending engagement members that engage the mesh upon insertion through voids in the mesh. In certain applications, the seat cushion is formed from a vertically lapped fibrous batt.

1 . A furniture component comprising: 
 a frame member; and    a cushion member disposed on the frame member, the cushion member having first and second oppositely directed faces;    wherein the cushion member includes a region of vertically lapped fibers, the region extending generally across a face of the cushion member, at least a majority of the fibers in the region extending in a direction generally transverse to a face of the cushion member.    
   
   
       2 . The furniture component of  claim 1  wherein the fibers in the region of vertically lapped fibers has a size of from 0.9 to 300 denier.  
   
   
       3 . The furniture component of  claim 1  wherein the region of vertically lapped fibers is used at a thickness so as to exhibit a weight of from about 100 g/m 2  to about 2000 g/m 2 .  
   
   
       4 . The furniture component of  claim 1  wherein the region of vertically lapped fibers includes from about 10% to about 100% of the total weight of fibers in the cushion member.  
   
   
       5 . The furniture component of  claim 1  wherein the region of vertically lapped fibers comprises: 
 from about 5% to about 95% of a first fiber, and    from about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.    
   
   
       6 . The furniture component of  claim 5  wherein the first fiber has a size of from about 0.9 denier to about 300 denier.  
   
   
       7 . The furniture component of  claim 5  wherein the second fiber has a size of from about 2 denier to about 15 denier.  
   
   
       8 . The furniture component of  claim 5  wherein the interior of the cushion member has a thickness of from about 0.5 cm to about 7.6 cm.  
   
   
       9 . The furniture component of  claim 1  wherein the frame member comprises: 
 from about 30% to about 100% of a binder polymer; and    from about 70% to about 0% of a matrix fiber.    
   
   
       10 . The furniture component of  claim 1  wherein the frame member is generally planar and has a thickness of about 0.25 cm to about 0.025 cm.  
   
   
       11 . The furniture component of  claim 1  wherein the frame member includes at least one engagement member extending therefrom.  
   
   
       12 . The furniture component of  claim 11  wherein the at least one engagement member is formed from the same material as the frame member.  
   
   
       13 . The furniture component of  claim 11  wherein the at least one engagement member is formed from a moldable polymeric material selected from the group consisting of polyethylene, polypropylene, polystyrene, and combinations thereof.  
   
   
       14 . The furniture component of  claim 1  further comprising: 
 a covering layer disposed on the cushion member.    
   
   
       15 . The furniture component of  claim 1  wherein the furniture component is selected from the group consisting of seats, seat cushions, seat backs, arm pads, and combinations thereof.  
   
   
       16 . The furniture component of  claim 1  wherein the frame member has a thickness of from about 0.25 cm to about 0.025 cm.  
   
   
       17 . The furniture component of  claim 1  wherein at least one of the first and second faces of the cushion member defines a plurality of inwardly or outwardly extending geometric characters.  
   
   
       18 . The furniture component of  claim 1  wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers.  
   
   
       19 . A removable seat cushion adapted for use with a chair having a mesh seat defining a plurality of small apertures extending through the thickness of the seat, the seat cushion comprising: 
 a cushion member defining an upper surface and an oppositely directed bottom surface, the cushion member including a region of a nonwoven mat of vertically lapped fibers;    a frame component generally extending along at least one of (i) the bottom surface of the cushion member, and (ii) the outer periphery of the cushion member; and    a plurality of downwardly extending engagement members affixed to the frame component and adapted to releasably engage the mesh seat of the chair.    
   
   
       20 . The seat cushion of  claim 19  wherein the fiber of the region of vertically lapped fibers has a size of from 0.9 to 300 denier.  
   
   
       21 . The seat cushion of  claim 19  wherein the region of vertically lapped fibers comprises: 
 from about 5% to about 95% of a first fiber, and    from about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.    
   
   
       22 . The seat cushion of  claim 19  wherein the frame member comprises: 
 from about 30% to about 100% of a binder polymer; and    from about 70% to about 0% of a matrix fiber.    
   
   
       23 . The seat cushion of  claim 19  further comprising: 
 a covering layer disposed on the cushion member.    
   
   
       24 . The seat cushion of  claim 19  wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers.  
   
   
       25 . A method of forming a seat cushion having a region of vertically lapped fibers, the method comprising: 
 forming a frame component by placing a thin layer of a moldable polymeric material into a first mold, and heating to thereby form the frame;    positioning the frame in a second mold in conjunction with a plurality of fasteners adapted to be molded to or otherwise affixed to the frame, and a layer of a nonwoven batt of vertically lapped fibers, and heating the frame, fasteners, and layer to thereby form an intermediate assembly; and    positioning the intermediate assembly into a third mold in conjunction with a layer of a covering material in position to cover a face of the intermediate assembly, and heating the intermediate assembly and covering material to thereby form the seat cushion.    
   
   
       26 . The method of  claim 25  wherein the first mold includes a plurality of outwardly extending projections to thereby form a plurality of openings in the frame component.  
   
   
       27 . The method of  claim 26  wherein the fasteners, prior to molding in the second mold, are at least partially extended through corresponding openings of the plurality of openings formed in the frame component.  
   
   
       28 . The method of  claim 25  wherein prior to heating the intermediate assembly and covering material, an effective amount of an adhesive is disposed between the assembly and the covering material.  
   
   
       29 . The method of  claim 25  wherein the nonwoven batt of vertically lapped fibers contains a majority of fibers extending in a direction approximately transverse to the plane of the batt.  
   
   
       30 . The method of  claim 29  wherein of the transversely extending fibers, at least 50% of their length extends in such direction.  
   
   
       31 . The method of  claim 30  wherein of the transversely extending fibers, at least 90% of their length extends in such direction.  
   
   
       32 . The method of  claim 31  wherein of the transversely extending fibers, at least 95% of their length extends in such direction.  
   
   
       33 . The method of  claim 25  wherein the layer of nonwoven batt of vertically lapped fibers is heated by heating the second mold to a temperature of from about 150° F. to about 375° F.  
   
   
       34 . The method of  claim 25  wherein at least one of the first mold, the second mold, and the third molds are heated to a temperature of from about 150° F. to about 375° F.  
   
   
       35 . The method of  claim 34  wherein all of the first, second, and third molds are heated to a temperature of from about 150° F. to about 375° F.