Cushion or seat structure of plastic foam with integrated cover and

Abstract

An integrated cushion structure, such as automobile or aircraft seat or seat back, an office chair, or the like and the method of making it, are disclosed. The cushion structure is comprised of fabric or other pliable cover sheet material forming an envelope constituting the exposed surface as well as defining the shape or configuration of the cushion structure. The structure includes at least one internal pliable sheet material partitioning member disposed parallel to and co-extensive area-wise with the active seat or back-forming area of the finished product. The envelope is thus divided interiorily by the partitioning member into several compartments into which a foam mix is introduced. The method of manufacture involves first peripherally bonding together an assemblage of congruent cover and internal partitioning sheets, together with one or more similarly configured annular profile strips, to form a peripherally closed envelope. The envelope is provided with an access opening which permits the envelope to be inverted on itself (i.e., turned inside-out) upon completion of the seaming operation, preliminary to introduction of plastic foam mix. Such access opening may also serve to allow introduction of reinforcing grids, attachment fittings, etc., before introducing the plastic foam mix.