Cushion structure and construction

Abstract

A cushion assembly includes a cover having a perimeter panel providing a perimeter height. Spaced apart cover panels extend between the perimeter panels. The perimeter and cover panels together provide a cushion cavity. A cushion includes randomly oriented fibers bonded to one another to provide a core of a batt that has opposing surfaces. In one disclosed example, the fibers are polyester and include an average length randomly oriented in three dimensions. The core has a thickness that is greater than the average length to accommodate the average length in all three dimensions. The batt includes manufactured, tufted and desired design heights. A tuft extends through the cushion to the opposing surfaces to maintain the cushion in the tufted height, which is less than the manufactured height. The cushion is provided with the desired design height with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and more than the tufted height.

1 . A cushion assembly comprising:
 a cover having a perimeter panel providing a perimeter height and spaced apart cover panels extending between the perimeter panels, the perimeter and cover panels providing a cushion cavity; and   a cushion including randomly oriented fibers bonded to one another to provide a batt having opposing surfaces, the batt having manufactured, tufted and desired design heights, and a tuft extending through the cushion to the opposing surfaces maintaining the cushion in the tufted height, which is less than the manufactured height, the desired design height is provided with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and greater than the tufted height and perimeter height.   
     
     
         2 . The cushion assembly according to  claim 1 , wherein desired design height is variable, the cover panels are crowned to provide an apex at a generally central location that has a greater height than that of the desired design height between the cover panels immediately surrounding the apex. 
     
     
         3 . The cushion assembly according to  claim 2 , wherein the desired design height at the apex is at least approximately 120% the perimeter height. 
     
     
         4 . The cushion assembly according to  claim 1 , wherein the tuft is contained within the cover without being provided on an outer surface of the cover, the tuft not visible through the cover with the cushion assembly exposed. 
     
     
         5 . The cushion assembly according to  claim 1 , wherein the fibers are polyester and include an average length are randomly oriented in three dimensions, the batt having a thickness that is greater than the average length to accommodate the average length in all three dimensions. 
     
     
         6 . The cushion assembly according to  claim 5 , wherein the batt includes a core constructed from the three dimensionally randomly oriented fibers, and a topper layer on each of opposite sides of the core, the topper layers providing the opposing surfaces. 
     
     
         7 . The cushion assembly according to  claim 6 , wherein the core provides at least 50-75% of the manufactured height. 
     
     
         8 . The cushion assembly according to  claim 6 , wherein a wrap substantially surrounds the batt and is arranged between the batt and the cover. 
     
     
         9 . The cushion assembly according to  claim 1 , wherein the tufted height is at least less than approximately 95% of the manufactured height. 
     
     
         10 . The cushion assembly according to  claim 9 , wherein the batt includes a first density at the manufactured height and a second density at the tufted height, the second density being at least 110% of the first density. 
     
     
         11 . The cushion assembly according to  claim 10 , wherein the perimeter height is approximately 90%-98% of the tufted height. 
     
     
         12 . A tufted cushion assembly comprising:
 a core made of first polymer fibers, the first polymer fibers being randomly oriented;   at least one topper layer made of second polymer fibers, the second polymer fibers being randomly oriented, the at least one topper layer being arranged adjacent to a surface of the core, and the at least one topper layer having a density different than the core; and   a tuft extending through the core and the at least one topper layer to provide a tufted cushion assembly.   
     
     
         13 . The assembly according to  claim 12 , wherein the tufted cushion assembly provides a support factor of less than or equal to 3. 
     
     
         14 . The assembly according to  claim 13 , wherein the support factor is determined using a 4-inch tall sample of the tufted cushion assembly at the tufted height. 
     
     
         15 . The assembly according to  claim 12 , wherein the at least one topper layer includes two topper layers arranged on opposite sides of the core. 
     
     
         16 . The assembly according to  claim 12 , further comprising multiple tufts having a length generally corresponding to the tufted height and provided by a body having opposing heads, the heads abutting opposing surfaces of the cushion to retain the cushion at the tufted height. 
     
     
         17 . The assembly according to  claim 12 , wherein the core and the at least one topper layer have different densities when at respective manufactured heights. 
     
     
         18 . The assembly according to  claim 12 , wherein the first polymer fibers are first polyester fibers. 
     
     
         19 . The assembly according to  claim 18 , wherein the second polymer fibers are second polyester fibers.