Importance

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Abstract

A foam seating article includes an outer foam layer molded around an inner core of molded foam or expanded polystyrene that includes a lumbar support protrusion. The lumbar support protrusion has a convex outer surface disposed inside the seat back area of the outer foam layer and that is not visible on the outer contour of the seat back area. The inner core is made from polyurethane polyol and methylene diphenyl diisocyanate (MDI) and has a hardness greater than 25 Shore A and a density less than two pounds per cubic foot. The polymer material of the inner core has a hardness greater than that of the outer foam. The outer layer of molded foam is high density (HD) foam, memory foam or latex foam. A fabric covering encloses the inner core and molded outer foam layer. The foam seating article can be a chair, sofa, chaise lounge or bench.

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First Claim