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Publication numberUS3320108 A
Publication typeGrant
Publication dateMay 16, 1967
Filing dateNov 26, 1963
Priority dateNov 26, 1963
Publication numberUS 3320108 A, US 3320108A, US-A-3320108, US3320108 A, US3320108A
InventorsBernard Z Lande
Original AssigneeBernard Z Lande
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Method of forming tufted cushion elements
US 3320108 A
Abstract  available in
Images(1)
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Claims  available in
Description  (OCR text may contain errors)

May 16, 1967 a. z. LANDE METHOD OF FORMING TUF ELEMENTS TED CUSHION Filed Nov. 26, 1965 Z7 INVENTOR. Bernard Z. Lande BY I k A? A ATTORNEY United States Patent 3,320,108 METHOD OF FORMING TUFTED CUSHION ELEMENTS Bernard Z. Lande, 161 S. Benton St., Denver, Colo. 80226 Filed Nov. 26, 1963, Ser. No. 325,847 4 Claims. (Cl. 156-219) This invention relates generically to the upholstering art wherein cushioned areas on pieces of furniture are shaped and indented to form patterns and designs. The general formation of the above areas is referred to as tufting and is accomplished in many ways such as by filling the raised portions with individual padding and stitching or tying back the indented portions.

Since the introduction of plastic foams, tufting has been attempted by thermo deformation and vulcanization of the foam padding. This method requires exceedingly expensive and complicated metal dies to withstand the necessary pressures and carry the necessary heat. Such methods are not commercially practical except for the mass production of identical pieces.

This invention relates specifically to a rapid and economical method and means for tufting cushion pieces which can be readily used in local upholstering shops and which can be quickly, easily and economically adapted to produce any desired tufted designs.

A further object is to provide an economical and highly efficient tufting method which will eliminate the stitching and tying of the earlier methods and the expensive metal dies and heating equipment of the latter methods.

Other objects and advantages reside in the detail construction of the invention, which is designed for simplicity, economy, and efficiency. These will become more apparent from the following description.

In the following detailed description of the invention, reference is made to the accompanying drawing which forms a part hereof. Like numerals refer to like parts in all views of the drawing and throughout the description.

In the drawing:

FIGS, 1-5, schematically illustrate sequential steps in this improved method which will be hereinafter described in detail;

FIGS. 6 and 7 similarly illustrate alternate steps; and

FIG. 8 illustrates a typical finished piece.

In this economical method, a mold is employed carrying the desired tufted design. The mold may be formed by gluing, or otherwise mounting, wooden pattern strips 12 upon a backboard 13 which may be an inexpensive panel of wooden plyboard. The pattern strips project uniformly upward from the backboard 13 to a height corresponding to the depth of tufting desired and follow the pattern of the desired tufted design and the outline of the finished piece. Such a mold can be quickly assembled, used and discarded, even for a single desired piece with very little expenditure of time and materials.

The selected mold is then placed upon a work table or bench and a sheet of the selected cover fabric 14 is laid over the entire mold and pressed by hand into the various pockets between the pattern strips 12 as shown in FIG. 1. To facilitate retension of the cover fabric 14 in the pockets, it is preferred to have a patch 15 of adherent material mounted on the backboard 13 in the bottom of each of the pockets.

The patches 15 may be of any type which will temporarily adhere to the cover fabric. In actual use, the patches are pieces of Velcro, a flexible fiber tape having pressure-adhesive coatings upon both its top and bottom faces and which is available upon the open market.

ice

A quick-drying transparent adhesive such as an aminoacetate plastic solution is now sprayed or brushed on the back side of the cover fabric 14 over all of the ridges formed by the upwardly extending pattern strips so as to form a relatively thick first layer of adhesive 17 conforming to the desired pattern, as shown in FIG. 2.

A fiat pad of resilient plastic foam 18 is now placed over the patterned first adhesive layer 17 and a relatively thick second layer 19 of quick-drying transparent adhesive is applied to the back side of the plastic foam sheet, as indicated at 20 in FIG, 2. The second adhesive layer need not cover the entire area of the plastic pad but should at least provide a relatively thick adhesive plastic layer over those portions of the pad which are positioned directly above the pattern strips 12.

A backing sheet of open mesh fabric 21, such as theatrical gauze, is now spread smoothly over the second adhesive layer 19, as shown in FIG. 4, and a press plate 22 is positioned over the backing sheet 21 and forced downwardly, as shown in FIG. 5, until the pad 18 is completely flattened to a minimal thickness over the pattern strips and the adhesive is forced completely through the compressed portions of the pad to provide a continuous cross section of adhesive extending from the back of the cover sheet 14 through the pad 18 and through the backing sheet 21 over the entire areas of the tops of the pattern strips 12, The press plate 22 is left in the C0111- pressed position.until the adhesive has completely set. It is then removed and the finished piece is lifted from the mold, inverted and trimmed to form the finished tufted piece, such as shown in FIG. 8, with indentations 23 and raised portions 24, conforming in design to the pattern selected for the mold and with a border strip 27 equal in thickness to the combined thickness of the backing sheet 21, the cover sheet 14 and the completely compressed pad 18.

The essential feature of the improved tufting method resides in the fact that the pores and interstices of the foam pad, at the indentations, are completely closed and completely surrounded by solidified adhesive so that 2 cross section through the bottom of an indentation at any point will show a solid plastic cross section reinforced by the fibers of the cover sheet 14, the pad 18, and the backing sheet 21.

If it is desired to be certain that the porous structure of the pad along the design lines is completely brokendown and impregnated, an additional step may be added as shown in FIG. 6, prior to the pressing step of FIG. 5 in which the pattern lines are rolled, as indicated at 25 to pump the thick layer 17 of plastic adhesive into the interstices of the foam plastic pad before pressing the latter.

The first step of FIG. 1, if performed with care, can be accomplished without the assisting patches 15 or, i: desired, a vacuum nipple 26 can be inserted through the back board 13 into each of the pockets between the pattern strips 12, as illustrated in FIG. 7, and connected tc a vacuum source for drawing and holding the cover sheel 14 downwardly in the pockets.

The pressure plate 22 may be a relatively thick metaj plate forced downwardly by means of jackscrew or t hydraulically actuated plunger or plungers. The plate could, if only a few jobs were contemplated, be weightet with heavy weights to compress the cushion element: against the pattern strips.

While the pad 18 has been described as being formec' from sheet foamed plastic, the method is equally applicable to any resilient, compressible, fibrous or cellular material capable of being compressed-into a substantially solic state. For instance, it could be formed from a continuous sheet of wool or cotton batting, spanish moss or similai iaterial since there 'is no thermal or chemical action etween the pad and the cover and backing sheets.

While specific forms of the invention have been de- :ribed and illustrated herein, it is to be understood that 165211118 maybe varied,'within the scope of the appended laims, without departing from the spirit of the invention. Having thus described the invention, what is claimed [1d desired to be secured by Letters Patent is:

1. A method of forming tufted cushion elements comrrsmgz.

(a) mounting upstanding pattern strips upon a backing board to form open-topped pockets of uniform height upon said board;

(b) spreading a fabric cover sheet over said Pockets;

(c) depressing the cover sheet into the pockets to form upstanding ridges conforming to the desired pattern;

(d) applying a layer of adhesive along the upper crests of said ridges;

(e) placing a unitary pad of resiliently compressible material over said adhesive layer;

(f) applying a second layer of adhesive on the upper surface of said pad along and over the positions of said ridges;

(g) placing a continuous sheet of backing fabric over said second layer of adhesive;

(h) placing a flat press plate over said backing fabric and forcing said plate downwardly to compress said pad to a substantially solid state impregnated with adhesive over and along said ridges; and thence (i) maintaining said compression until said adhesive has fully set.

2. A method as described in claim 1 including temporarily attaching the depressed cover sheet to the bottoms of said pockets before applying adhesive along the upper crests of said ridges.

3. A method as described in claim 1 including applying a rolling pressure to said pad along the tops of said ridges before applying said backing fabric thereover.

4. A method as described in claim 1 including creating a partial vacuum in the bottoms of said pockets to retain said fabric cover sheet in said pockets before applying adhesive along the upper crests of said ridges.

References Cited by the Examiner UNITED STATES PATENTS 2,618,581 11/1952 Lyijynen 156290 X 2,670,501 3/1954 Michiels 156210 X 2,946,713 7/1960 Dusina et a1 156219 XR 3,012,926 12/1961 Wintermute et al. 156290 X 3,072,520 1/1963 Groth 156--292 X 3,116,569 1/1964 Kramer 156292 X 3,257,263 6/1966 Miller 1611 19 EARL M. BERGERT, Primary Examiner.

P. DIER, Assistant Examiner.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US2618581 *Dec 9, 1948Nov 18, 1952Briggs Mfg CoTrim panel and method of making the same
US2670501 *Aug 24, 1951Mar 2, 1954Us Rubber CoMethod of forming plastic material
US2946713 *Oct 6, 1955Jul 26, 1960Gen Motors CorpProcess for embossing decorative articles
US3012926 *Oct 17, 1957Dec 12, 1961Arvin Ind IncMethod of making quilted padded articles
US3072520 *Jan 20, 1959Jan 8, 1963Fred A GrothVacuum-forming of a laminated article having a resilient central layer
US3116569 *May 29, 1962Jan 7, 1964Norman S KramerQuilted headboard and method of fabrication thereof
US3257263 *Dec 24, 1962Jun 21, 1966Hicks & Otis Prints IncContoured ornamentation of laminated resilient materials and product
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3446685 *Aug 13, 1965May 27, 1969Allen IndTrim panel and method of making same
US3833439 *Jul 24, 1972Sep 3, 1974Gen Motors CorpMethod of dielectrically embossing risers in a trim assembly
US3856907 *Oct 4, 1972Dec 24, 1974PirelliProcess for manufacturing toothed belts
US4040881 *Mar 22, 1976Aug 9, 1977General Engineering & Manufacturing CorporationMethod of forming tufted cushion elements
US4692199 *Dec 13, 1985Sep 8, 1987Lear Siegler, Inc.Method and apparatus for bonding fabric to a foam pad
US4765045 *Jun 22, 1987Aug 23, 1988Hoover Universal, Inc.Method of manufacturing trimmed seat
US4996092 *Feb 5, 1990Feb 26, 1991Minnesota Mining And Manufacturing CompanyCold welding a flat foam web along parallel lines; masking purposes in vehicle body shops
US5494725 *Jul 26, 1993Feb 27, 1996Nippon Steel CorporationLoad bearing pad
US6793998Jun 7, 1995Sep 21, 2004Jean SilvestreMasking method and masking means
US6818251Jul 21, 2003Nov 16, 20043M Innovative Properties CompanyMasking materials and method of use
US7462311 *Jul 14, 2003Dec 9, 2008Webasto Vehicle Systems International GmbhProcess for producing a compound motor vehicle component
EP0354737A1 *Aug 4, 1989Feb 14, 1990Hoover Universal, Inc.Contoured foam article and method of making contoured foam articles
EP0727301A1 *Jan 18, 1996Aug 21, 1996REYDEL Société AnonymeProcess for making a multilayered article
Classifications
U.S. Classification156/219, 156/290, 264/321, 428/170, 297/452.61, 264/257, 428/172, 297/452.62
International ClassificationB29C44/56, A47C27/14
Cooperative ClassificationB29L2031/751, B29K2105/255, A47C27/146, B29C44/569
European ClassificationA47C27/14C4, B29C44/56H