Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-07-07
2001-03-06
Ball, Michael W. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S214000, C156S228000, C156S245000
Reexamination Certificate
active
06197140
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to cushions and, in particular, to a method of manufacturing molded cushions having skins bonded together to form a watertight seal.
BACKGROUND OF THE INVENTION
In recent years there has been new regulation of materials and processes which emit ozone and oxygen depleting substances. Previously a liquid resistant outer coating or integral skin could be made on flexible urethane foam cushions through the use of a low boiling point liquid such as CFC-11 (freon). Many such materials have been determined by the U.S. Environmental Protection Agency as being damaging to the atmosphere. The integral skin produced with these materials provided a protection to the foam core of the cushion so that the cushions could be utilized in harsh environments. At the same time as a skin was produced in the molding process it was possible to introduce mechanical devices and integrally molded shapes which facilitated the mounting of the cushion on various structures. What is desired therefore, is to adapt a process to use materials which are not deemed to be hazardous to the environment and which can perform the functions of protecting the cushion from water, chemicals, dirt, etc., while at the same time providing a non-invasive means of attaching the cushions to a supporting structure.
In order to attach skins of elastomeric material together, the prior art has used the foam fill material inside the two sheets as a seal and has molded two skins together before the elastomeric material has cured. This has proven to be unsatisfactory because without the elastomeric skins being premolded or pre-shaped, and with the elastomeric material uncured, there is movement of the fill material behind the skins which is unacceptable.
U.S. Pat. No. 3,499,065 to Haskinson et al. discloses a method of making laminated articles whereby a bond is secured between thermoplastic sheets using a powdered resin.
U.S. Pat. No. 3,736,022 to Radke discloses a molded seat cushion with a cast skin and an insert receiving recess.
U.S. Pat. No. 4,037,591 to Sarno teaches a bathtub therapeutic pad that uses a multiplicity of resilient pad elements encased in a waterproof covering.
U.S. Pat. No. 4,378,396 to Urai, et al. discloses production of a seat cushion with a surface covering.
U.S. Pat. No. 5,116,557 to Debaes et al. discloses a method of making objects having an elastomeric outer wall and a synthetic foam core, wherein elastomer is sprayed onto the surface of a mold cavity and before the elastomeric material cures, synthetic foam is injected such that the synthetic foam serves to seal two elastomeric layers.
U.S. Pat. No. 5,409,323 to Greene discloses a fastener system for attaching cushions to chairs.
U.S. Pat. No. 5,429,417 to Kim discloses a knockdown chair for children that assembles and disassembles.
U.S. Pat. No. 5,513,899 to Michaels et al. discloses a seat cushion with upper and lower elastomeric elements that are sealed at the edges.
SUMMARY OF THE INVENTION
In order to overcome problems inherent in the prior art, there has been devised by the present invention, a means of using premolded skins of elastomeric materials bonded at the seams to effect a watertight seal between two skins to form the outer cover for a cushion. In addition, portions of the elastomeric skins are reinforced to support a structural attachment means that does not penetrate the skin and which would cause a loss of integrity to the skin. This is accomplished in a first embodiment by adding a thin layer of two-part urethane elastomer at the point of connection of the elastomeric skins, so that there is an elastomeric and watertight seal between the cover and the polymeric or cushion material.
There is also provided by the present invention, a mounting means for a cushion or the like that is formed in a second embodiment with a layer of two-part urethane elastomer formed between the outer elastomeric skin and a receiving indentation in the back surface of the cushion, whereby the two-part urethane elastomer reinforces and adds integrity to the receiving indentation. The receiving indentation is formed in the back of the cushion and is adapted to fit standard button arrangements or the like on the outer surface of a receiving surface. In a third embodiment, an O-ring is placed around the receiving indentation to reinforce the receiving indentation and provide a semi-rigid mounting means to hold the cushion in place and to provide easy attachment of a cushion to a hot tub or the like. The cushion is shown attached to a hot tub for illustrative purposes, but it is to be understood that the attachment can be to any receiving surface. In a fourth embodiment, the two-part urethane elastomer is formed between the outer elastomeric skin and the receiving indentation in the back of the cushion and the O-ring is also used to reinforce the receiving indentation and to provide a semi-rigid mounting means to hold the cushion in place.
There is, therefore, provided by the present assembly and attachment for a cushion, a watertight sealing, bonding, and reinforcing means.
It is, therefore, an object and advantage of the present invention to provide a non-pollutant in manufacture, watertight seal between layers of elastomeric material.
It is another object and advantage of the present invention to provide a non-pollutant in manufacture, watertight mounting means for mounting a cushion or the like to a hot tub or spa.
It is yet another object and advantage of the present invention to provide a watertight mounting means that is reinforced and forms a semi-rigid mounting means for mounting a cushion or the like to a hot tub or spa.
It is still yet another object and advantage of the present invention to provide an elastomeric assembly and attachment that is relatively simple and inexpensive in its manufacture.
It is still yet another object and advantage of the present invention to provide an elastomeric assembly and attachment that maintains stable fill material behind the elastomeric skin.
REFERENCES:
patent: 3499065 (1970-03-01), Hoskinson et al.
patent: 3736022 (1973-05-01), Radke
patent: 4037591 (1977-07-01), Sarno
patent: 4244764 (1981-01-01), Ginsburg
patent: 4378396 (1983-03-01), Urai et al.
patent: 4447373 (1984-05-01), Chappell
patent: 4568588 (1986-02-01), Fujiki et al.
patent: 4726624 (1988-02-01), Jay
patent: 4930171 (1990-06-01), Frantz
patent: 5035758 (1991-07-01), Degler
patent: 5116557 (1992-05-01), Debaes et al.
patent: 5140713 (1992-08-01), Pesterfield
patent: 5409323 (1995-04-01), Greene
patent: 5429417 (1995-07-01), Kim
patent: 5513899 (1996-05-01), Michaels et al.
patent: 3416240 (1985-11-01), None
patent: 433636 (1991-06-01), None
Ball Michael W.
Christensen O'Connor Johnson & Kindness PLLC
Mantec Services Company
Piazza Gladys
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