Sofa seat cushion core
An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.
1. A sofa seat cushion, comprising:
a cushion core comprising a multiplicity of pocketed springs enclosed within an upholstery foam envelope, at least one memory foam layer positioned above the upholstery foam envelope, at least one polyethylene terephthalate layer positioned above the at least one memory foam layer, an upholstery-grade polyurethane foam layer directly below the upholstery foam envelope, and at least one polyethylene terephthalate layer directly below the upholstery-grade polyurethane foam layer; and
an exterior upholstery surrounding the cushion core.
2. The sofa seat cushion of claim 1 , wherein the multiplicity of pocketed springs are positioned side by side in a spring layer arrangement, the pocketed springs being independently operable.
3. The sofa seat cushion of claim 1 , wherein each of the pocketed springs comprises a coil spring covered with a flexible wrap.
4. The sofa seat cushion of claim 3 , wherein the flexible wrap comprises a fabric or textile material.
5. The sofa seat cushion of claim 3 , wherein the coil springs are comprised of steel.
6. The sofa seat cushion of claim 1 , wherein the upholstery foam envelope comprises a bottom upholstery foam layer, a top upholstery foam layer, and a side upholstery foam layer.
7. The sofa seat cushion of claim 6 , wherein the bottom upholstery foam layer is positioned directly beneath the multiplicity of pocketed springs, and wherein the top upholstery foam layer is directly above the pocketed springs.
8. The sofa seat cushion of claim 7 , wherein the side upholstery foam layer borders a perimeter of the multiplicity of pocketed springs, the bottom upholstery foam layer, and the top upholstery foam layer.
9. The sofa seat cushion of claim 8 , wherein the side upholstery foam layer comprises a single foam piece configured to extend around the perimeter of the multiplicity of pocketed springs.
10. The sofa seat cushion of claim 8 , wherein the side upholstery foam layer comprises two or more foam pieces that are positioned end to end so as to border the perimeter of the multiplicity of pocketed springs.
11. The sofa seat cushion of claim 1 , wherein the memory foam layer comprises a material composition configured to contour a person's body in response to heat and pressure due to the person sitting on the sofa seat cushion, the memory foam layer being configured to quickly return to an original shape once the pressure and heat are removed from the sofa seat cushion.
12. The sofa seat cushion of claim 11 , wherein at least a portion of the memory foam layer is comprised of a visco-elastic memory foam.
13. The sofa seat cushion of claim 12 , wherein the at least a portion of the memory foam layer is comprised of a gel-infused visco-elastic memory foam.
14. A method for a sofa seat cushion, comprising:
arranging a multiplicity of pocketed springs into a spring layer arrangement;
enclosing the spring layer within an upholstery envelope;
positioning at least one memory foam layer within the upholstery envelope;
extending at least one friction barrier between the at least one memory foam layer and an exterior upholstery;
placing an upholstery-grade polyurethane foam layer directly beneath the upholstery foam envelope; and
extending at least one friction barrier between the upholstery-grade polyurethane foam layer and the exterior upholstery.
15. The method of claim 14 , wherein positioning comprises configuring a material composition of the memory foam layer capable of molding to a person's body in response to heat and pressure due to the person sitting on the sofa seat cushion, the material composition of the memory foam layer being configured to quickly return to an original shape once the pressure and heat are removed from the sofa seat cushion.
16. The method of claim 15 , wherein configuring comprises forming at least a portion of the memory foam layer of a visco-elastic memory foam.
17. The method of claim 15 , wherein configuring comprises forming at least a portion of the memory foam layer of a gel-infused visco-elastic memory foam.
18. The method of claim 14 , wherein extending at least one friction barrier comprises configuring at least one polyethylene terephthalate layer to discourage migration of the exterior upholstery.
19. The method of claim 14 , wherein placing the upholstery-grade polyurethane foam layer further comprises positioning at least one memory foam layer between the upholstery foam envelope and the upholstery-grade polyurethane foam layer.