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1. (WO2007008436) REMOVABLE SEAT CUSHION
Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

Claims:

1. A seat cushion adapted for releasable engagement with a mesh seat member, the seat cushion comprising:
a cushion member including a plurality of outwardly extending projections adapted to releasably engage a mesh seat member upon insertion through voids defined in the mesh.

2. The seat cushion of claim 1 wherein the cushion member includes: a first face;
a second face opposite said first face; and
a non-woven fibrous body disposed between said first and said second faces, said non-woven fibrous body including (i) from about 15% to about 60% of a fiber component dispersed throughout said body, (ii) from about 15% to about 85% of a fire-retardant cellulose component dispersed throughout said body, and (iii) from about 15% to about 70% of a binder component dispersed throughout said body, said body further including a plurality of fused regions of contact defined between adjacent portions of binder component resulting from prior heating of said body to a temperature sufficient to cause at least partial melting of said binder component and thereby fuse said adjacent portions of binder component.

3. The seat cushion of claim 2 wherein said fiber component is selected .from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

4. The seat cushion of claim 2 wherein said cellulose component is a fire-retardant cellulose material treated with an agent selected from the group consisting of boric acid, sodium polyborate, and combinations thereof.

5. The seat cushion of claim 2 wherein said binder component is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

6. The seat cushion of claim 2 wherein said fiber component includes natural fibers selected from the group consisting of sisal fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean fiber, wool fiber, cotton fiber, hemp fiber, and combinations thereof.

7. The seat cushion of claim 1 further comprising:
a frame component secured to the cushion member, the frame component including a plurality of outwardly extending projections adapted to releasably engage the mesh seat.

8. The seat cushion of claim 7 wherein each projection defines a distal tip, a shaft extending between the tip and the frame component, and at least one engagement flap extending outward from the shaft.

9. The seat cushion of claim 8 wherein the distal tip is tapered.

10. The seat cushion of claim 1 wherein the cushion member includes:
a first surface;
a second surface opposite from said first surface; and
a non-woven fibrous body disposed between said first surface and said second surface, said non-woven fibrous body including (i) from about 40% to about 70% of a fire-retardant cellulose component dispersed throughout said body, and (ii) from about 30% to about 60% of a bi-component fiber, said bi-component fiber having an inner portion of a first thermoplastic and an outer portion of a second thermoplastic, said second thermoplastic having a melting temperature less than the melting temperature of said first thermoplastic, said body further including a plurality of fused regions of contact defined between adjacent bi-component fibers resulting from prior heating of said body to a temperature greater than said melting temperature of said second thermoplastic.

11. The seat cushion of claim 10 wherein said first thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

12. The seat cushion of claim 10 wherein said cellulose component is a fire-retardant cellulose fiber treated with either boric acid or sodium polyborate.

13. The seat cushion of claim 10 wherein said second thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

14. The seat cushion of claim 10 wherein said cellulose component constitutes from about 45% to about 55% of said non-woven fibrous body.

15. The seat cushion of claim 10 wherein said second thermoplastic constitutes from about 20% to about 80% of said bi-component fiber.

16. The seat cushion of claim 10 wherein said second thermoplastic constitutes from about 40% to about 60% of said bi-component fiber.

17. The seat cushion of claim 10 wherein said second thermoplastic constitutes about 50% of said bi-component fiber.

18. The seat cushion of claim 10 wherein said bi-component fiber has a diameter of from about 1.5 to about 9 denier.

19. A seat cushion adapted for releasable engagement with a mesh seat member, the seat cushion comprising:
a cushion member; and
a frame component secured to the cushion member, the frame component including a plurality of downwardly extending projections adapted to releasably engage a mesh seat member upon insertion through voids defined in the mesh.

20. The seat cushion of claim 19 wherein the cushion member includes:
a first face;
a second face opposite said first face; and
a non-woven fibrous body disposed between said first and said second faces, said non-woven fibrous body including (i) from about 15% to about 60% of a fiber component dispersed throughout said body, (ii) from about 15% to about 85% of a fire-retardant cellulose component dispersed throughout said body, and (iii) from about 15% to about 70% of a binder component dispersed throughout said body, said body further including a plurality of fused regions of contact defined between adjacent portions of binder component resulting from prior heating of said body to a temperature sufficient to cause at least partial melting of said binder component and thereby fuse said adjacent portions of binder component.

21. The seat cushion of claim 20 wherein said fiber component is selected from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

22. The seat cushion of claim 20 wherein said cellulose component is a fire-retardant cellulose material treated with an agent selected from the group consisting of boric acid, sodium polyborate, and combinations thereof.

23. The seat cushion of claim 20 wherein said binder component is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

24. The seat cushion of claim 20 wherein said fiber component includes natural fibers selected from the group consisting of sisal fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean fiber, wool fiber, cotton fiber, hemp fiber, and combinations thereof.

25. The seat cushion of claim 19 wherein each projection defines a distal tip, a shaft extending between the tip and the frame component, and at least one engagement flap extending outward from the shaft.

26. The seat cushion of claim 25 wherein the distal tip is tapered.

27. The seat cushion of claim 19 wherein the cushion member includes:
a first surface;
a second surface opposite from said first surface; and
a non-woven fibrous body disposed between said first surface and said second surface, said non-woven fibrous body including (i) from about 40% to about 70% of a fire-retardant cellulose component dispersed throughout said body, and (ii) from about 30% to about 60% of a bi-component fiber, said bi-component fiber having an inner portion of a first thermoplastic and an outer portion of a second thermoplastic, said second thermoplastic having a melting temperature less than the melting temperature of said first thermoplastic, said body further including a plurality of fused regions of contact defined between adjacent bi-component fibers resulting from prior heating of said body to a temperature greater than said melting temperature of said second thermoplastic.

28. The seat cushion of claim 27 wherein said first thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

29. The seat cushion of claim 27 wherein said cellulose component is a fire-retardaήt cellulose fiber treated with either boric acid or sodium polyborate.

30. The seat cushion of claim 27 wherein said second thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

31. The seat cushion of claim 27 wherein said cellulose component constitutes from about 45% to about 55% of said non-woven fibrous body.

32. The seat cushion of claim 27 wherein said second thermoplastic constitutes from about 20% to about 80% of said bi-component fiber.

33. The seat cushion of claim 27 wherein said second thermoplastic constitutes from about 40% to about 60% of said bi-component fiber.

34. The seat cushion of claim 27 wherein said second thermoplastic constitutes about 50% of said bi-component fiber.

35. The seat cushion of claim 27 wherein said bi-component fiber has a diameter of from about 1.5 to about 9 denier.

36. A seat cushion adapted for releasable engagement with a mesh seat member, the seat cushion comprising:
a cushion member;
a frame component engaged to the cushion member; and
a plurality of engagement members extending from the frame component, the engagement members each including a distal tip, a shaft extending between the tip and the frame component, and at least one engagement flap extending outward from the shaft.

37. The seat cushion of claim 36 wherein the cushion member includes:
a first face;
a second face opposite said first face; and
a non-woven fibrous body disposed between said first and said second faces, said non-woven fibrous body including (i) from about 15% to about 60% of a fiber component dispersed throughout said body, (ii) from about 15% to about 85% of a fire-retardant cellulose component dispersed throughout said body, and (iii) from about 15% to about 70% of a binder component dispersed throughout said body, said body further including a plurality of fused regions of contact defined between adjacent portions of binder component resulting from prior heating of said body to a temperature sufficient to cause at least partial melting of said binder component and thereby fuse said adjacent portions of binder component.

38. The seat cushion of claim 37 wherein said fiber component is selected from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

39. The seat cushion of claim 37 wherein said cellulose component is a fire- retardant cellulose material treated with an agent selected from the group consisting of boric acid, sodium polyborate, and combinations thereof.

40. The seat cushion of claim 37 wherein said binder component is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

41. The seat cushion of claim 37 wherein said fiber component includes natural fibers selected from the group consisting of sisal fiber, jute fiber, kena fiber, coconut fiber, corn fiber, soybean fiber, wool fiber, cotton fiber, hemp fiber, and combinations thereof.

42. The seat cushion of claim 36 wherein the distal tip is tapered.

43. The seat cushion of claim 36 wherein the cushion member includes:
a first surface;
a second surface opposite from said first surface; and
a non-woven fibrous body disposed between said first surface and said second surface, said non-woven fibrous body including (i) from about 40% to about 70% of a fire-retardant cellulose component dispersed throughout said body, and (ii) from about 30% to about 60% of a bi-component fiber, said bi-component fiber having an inner portion of a first thermoplastic and an outer portion of a second thermoplastic, said second thermoplastic having a melting temperature less than the melting temperature of said first thermoplastic, said body further including a plurality of fused regions of contact defined between adjacent bi-component fibers resulting from prior heating of said body to a temperature greater than said melting temperature of said second thermoplastic.

44. The seat cushion of claim 43 wherein said first thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), and combinations thereof.

45. The seat cushion of claim 43 wherein said cellulose component is a fire-retardant cellulose fiber treated with either boric acid or sodium polyborate.

46. The seat cushion of claim 43 wherein said second thermoplastic is selected from the group consisting of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, nylon, polylactide, acrylic, and combinations thereof.

47. The seat cushion of claim 43 wherein said cellulose component constitutes from about 45% to about 55% of said non-woven fibrous body.

48. The seat cushion of claim 43 wherein said second thermoplastic constitutes from about 20% to about 80% of said bi-component fiber.

49. The seat cushion of claim 43 wherein said second thermoplastic constitutes from about 40% to about 60% of said bi-component fiber.

50. The seat cushion of claim 43 wherein said second thermoplastic constitutes about 50% of said bi-component fiber.

51. The seat cushion of claim 43 wherein said bi-component fiber has a diameter of from about 1.5 to about 9 denier.

52. A method of forming a covering for a seating surface comprising:
adding a first moldable material to a first mold and forming a rim component;

inserting the rim component into a second mold, adding a second moldable material to the second mold over the second mold and forming a pad component bonded to the rim component; and
inserting the bonded pad and rim components to a third mold, covering the bonded pad and rim components with a finish material and securing the finish material to the bonded pad and rim components.

53. The method of claim 52 further comprising inserting a fastener in the rim component before forming the pad component to the component, where the fastener is in-molded in the bonded pad and rim components between the pad and rim component.

54. The method of claim 53 wherein the fastener comprises a portion extending from the rim component.

55. The method of claim 52 further comprising forming at least one embossment in the finish material and the pad component.

56. A seating structure comprising:
a support structure; and
a pad assembly comprising:
a rim component;
a pad component bonded to the rim component; and
a finish component bonded to the pad component;
wherein the pad assembly is secured to the support structure.

57. The seating structure of claim 56 wherein the support structure has at least one opening formed therein, and further comprising at least one fastener in-molded between the rim component and the pad component, the fastener comprising an insert portion extending from the rim component and secured in the at least one opening in the support structure.

58. The seating structure of claim 57 wherein the insert portion is a one-way fastener.