Method for forming a molded cushion

Abstract

A method for making a molded cushion comprising positioning an object onto a bag made of a stretchable water-resistant material, wherein the bag is filled with a mixture of soft resilient pellets and a polymerizable adhesive, molding the bag and pellet/adhesive mixture around the object and allowing the adhesive to cure to conform to the shape of the object.

What is claimed and desired to be secured by Letters Patent is as follows:  
     
         1 . A method for making a molded cushion comprising: 
 mixing a plurality of soft resilient pellets with a polymerizable adhesive to form a pellet/adhesive mixture wherein said pellets do not generally absorb or react with said adhesive;    positioning an object having a seating surface onto a bag made of a stretchable water-resistant material, wherein said bag is filled with said pellet/adhesive mixture;    molding said bag and pellet/adhesive mixture around the object to reflect the details of the object's seating surface to provide cushioning around the object's seating surface; and    allowing said adhesive to cure to conform to the shape of the object.    
     
     
         2 . The method for making a molded cushion as claimed in  claim 1 , further comprising before said mixing step, the step of inserting said pellets and said adhesive into the interior of said bag, and wherein said mixing step comprises mixing said pellets and said adhesive within said bag.  
     
     
         3 . The method for making a molded cushion as claimed in  claim 1 , further comprising, after said mixing step, the step of inserting said pellet/adhesive mixture into the interior of said bag, and wherein said mixing step comprises mixing said pellets and adhesive outside of said bag.  
     
     
         4 . The method for making a molded cushion as claimed in  claim 1 , wherein said mixing step comprises mixing said pellets and said adhesive in an adhesive to pellet ratio ranging between 1:24 and 1:40 by volume.  
     
     
         5 . The method for making a molded cushion as claimed in  claim 1 , additionally comprising the following preliminary assessment steps prior to said mixing step: 
 adding a plurality of said pellets into the interior of said bag;    setting the object onto said bag;    assessing if said bag contains a sufficient number of said pellets to provide cushioning around the object's seating surface; and    removing the object off of said bag.    
     
     
         6 . The method for making a molded cushion as claimed in  claim 5 , further comprising after said assessing step, the step of adjusting the number of said pellets in said bag.  
     
     
         7 . The method for making a molded cushion as claimed in  claim 6 , further comprising after said setting step, the step of applying a vacuum to said bag.  
     
     
         8 . The method for making a molded cushion as claimed in  claim 1 , further comprising before said positioning step, the step of placing a baseboard into said bag.  
     
     
         9 . The method for making a molded cushion as claimed in  claim 8 , further comprising before said placing step, the step of affixing a support guide to said baseboard.  
     
     
         10 . The method for making a molded cushion as claimed in  claim 1 , further comprising before said positioning step, the steps of forming said bag and affixing a sleeve around an opening in said bag.  
     
     
         11 . A method for making a molded cushion comprising: 
 forming a bag from a stretchable water-resistant material, wherein said bag comprises a sleeve affixed around an opening in said bag;    inserting a plurality of soft resilient pellets into the interior of said bag through said sleeve;    sealing said sleeve to retain said pellets within said bag.    
     
     
         12 . The method for making a molded cushion as claimed in  claim 11 , further comprising after said forming step and before said sealing step, the step of inserting a polymerizable adhesive into the interior of said bag through said sleeve.  
     
     
         13 . The method for making a molded cushion as claimed in  claim 12 , further comprising after said inserting steps, the step of mixing said pellets and said adhesive  
     
     
         14 . The method for making a molded cushion as claimed in  claim 12 , further comprising before said inserting steps, the step of mixing said pellets and said adhesive.  
     
     
         15 . A method for making a molded cushion comprising: 
 inserting a plurality of soft resilient pellets and a polymerizable adhesive into the interior of a bag made of a stretchable water-resistant material;    positioning an object having a seating surface onto said bag;    molding said bag and pellet/adhesive mixture around the object to reflect the details of the object's seating surface to provide cushioning around the object's seating surface; and    allowing said adhesive to cure to conform to the shape of the object.    
     
     
         16 . The method for making a molded cushion as claimed in  claim 15 , further comprising after said molding step, the step of applying a vacuum to said bag.  
     
     
         17 . The method for making a molded cushion as claimed in  claim 15 , wherein said step of forming said bag comprises affixing a sleeve around an opening in said bag.  
     
     
         18 . The method for making a molded cushion as claimed in  claim 17 , additionally comprising the following preliminary assessment steps prior to said inserting step: 
 adding a plurality of said pellets into the interior of said bag through said sleeve;    setting the object onto said bag;    assessing if said bag contains a sufficient number of said pellets to provide cushioning around the object's seating surface;    removing the object off of said bag.    
     
     
         19 . The method for making a molded cushion as claimed in  claim 17 , further comprising after said inserting step, the step of mixing said pellets and said adhesive  
     
     
         20 . The method for making a molded cushion as claimed in  claim 17 , further comprising before said inserting step, the step of mixing said pellets and said adhesive.