Granted Patent B2

US 7,407,558 · App. 11/202,841 · Granted Aug 5, 2008

Abstract

Claims (46)

1. A method for manufacturing an article of furniture, the method comprising:

constructing a frame comprising a first area and a second area, the first area requiring a different thickness of cushioning material than the second area;

attaching a nonwoven fiber product to the frame, the nonwoven fiber product comprising:

a first nonwoven fiber batt;

a second nonwoven fiber batt; and

a separator layer attached to each of the first fiber batt and the second fiber batt, the separator layer physically separating the first fiber batt and the second fiber batt; and

separating the fiber product into a first portion comprised of the first fiber batt and the separator layer, and a second portion comprised of the second fiber batt.

2. The method of claim 1 further comprising:

attaching the first portion to the first area;

separating the second portion from the first portion; and

attaching the second portion to the second area.

3. The method of claim 2 wherein the second portion is separated from the first portion without detaching the first portion from the first area.

4. The method of claim 3 wherein the first fiber batt and the second fiber batt are high-loft nonwoven fiber batts.

5. The method of claim 4 wherein the first fiber batt is attached to the separator layer with a first strength and the separator layer is attached to the second fiber batt with a second strength, the second strength being less than the first strength so that the second fiber batt consistently separates from the first fiber batt and the separator layer.

6. A method for upholstering an article of furniture having a frame, the method comprising:

attaching a nonwoven fiber product to the frame, the nonwoven fiber product comprising:

a first nonwoven fiber batt;

a second nonwoven fiber batt; and

a separator layer attached to each of the first fiber batt and the second fiber batt, the separator layer physically separating the first fiber batt and the second fiber batt; and

separating the fiber product into a first portion and a second portion being thicker than the first portion.

7. The method of claim 6 , wherein the frame comprises a first area and a second area, the first area requiring a different thickness of cushioning than the second area, and the method further comprising:

securely attaching the first portion to the first area;

separating the second portion from the first portion; and

securely attaching the second portion to the second area.

8. The method of claim 7 wherein the second portion is separated from the first portion without detaching the first portion from the first area.

9. The method of claim 8 further comprised of attaching the first fiber batt to the separator layer with a first strength and attaching the separator layer to the second fiber batt with a second strength, the second strength being less than the first strength so that the second fiber batt consistently separates from the first fiber batt and the separator layer.

10. The method of claim 1 wherein the first fiber batt has a different thickness than the second fiber batt.

11. The method of claim 10 wherein the separator layer increases the puncture resistance of the first fiber batt.

12. The method of claim 10 further comprising upholstering the cushioned frame with fabric.

13. A method for applying cushioning to a frame comprising:

securely attaching a nonwoven fiber cushioning product to the frame;

wherein the nonwoven fiber cushioning product comprises:

a first nonwoven fiber batt;

a second nonwoven fiber batt; and

a separator layer located between and attached to each of the first fiber batt and the second fiber batt;

wherein:

the separator layer physically separates the first fiber batt and the second fiber batt;

the first fiber batt is thinner than the second fiber batt; and

the separator layer is attached less strongly to the second fiber batt than to the first fiber batt so that the second fiber batt is operable to consistently separate from the first fiber batt and the separator layer.

14. The method of claim 13 wherein if thin cushioning is desired for a portion of the frame, the first fiber batt is attached to the frame, and the second fiber batt is separated from the first fiber batt and the separator layer such that the separator layer forms the exterior of the cushioning.

15. The method of claim 13 wherein if thick cushioning is desired for a portion of the frame, the second fiber batt is not separated from the first fiber batt and the separator layer.

16. The method of claim 13 wherein if thick cushioning is desired for a portion of the frame, the second fiber batt is attached to the frame, and the first fiber batt and separator layer are jointly separated from the second fiber batt.

17. The method of claim 13 further comprising separating the nonwoven fiber cushioning product into a first portion comprised of the first fiber batt and the separator layer and a second portion comprised of the second fiber batt; wherein:

the frame comprises a first area and a second area, the first area requiring a different thickness of cushioning material than the second area;

after separation, the first portion and the second portion remain connected along an edge; and

the first portion is attached to provide cushioning for the first area, the second portion is attached to provide cushioning for the second area, and the connected edge substantially eliminates sharp discontinuities in cushioning between the first area and the second area.

Assignments (13)