CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 1 19 to U S. Provisional Application No. 62/671,347, entitled“Outdoor Apparatus and Integrated Protective Cover,” and filed on May 14, 2018. The contents of that application are hereby incorporated by reference in their entirety.

FIELD

[0002] The present disclosure relates to a water resistant cushion cover.

BACKGROUND

[0003] Consumer demand for outdoor furniture is at an all-time high. Outdoor furniture is a $9 billion dollar per year business in the US and is one of the fastest growing categories in the furniture market. 92% of all new single-family homes built in the US in 2017 have a patio, porch, or deck. An“outdoor living room” is a highly requested specialty room, surpassing the home office, for the past six consecutive years according to the American Institute of Architects.

[0004] Outdoor furniture is subject to environmental conditions that are much more extreme than most other furniture. These conditions include hot and cold temperatures, cycling between extreme temperatures, humidity, extremely dry air, rain, snow, sleet and other precipitation, ice, wind, UV exposure from the sun, environmental pollutants, salt, chlorine and other swimming pool chemicals, and a myriad of other environmental contaminants. Furthermore, outdoor furniture comes in contact with all types of substances that have the potential to dirty, stain, or degrade the materials of construction, including dirt, leaves, sap, pollen, and other debris from plants, bird droppings, mold, mildew, and other fungi, bacteria, pet hair, food and beverages, natural skin oils, sunscreen, body lotion, makeup, and more. To add to the challenge, these conditions vary drastically throughout different parts of the United States, throughout different countries, and across seasons. Conventional outdoor furniture is not designed for certain geographies or seasonal periods; nevertheless, conventional outdoor furniture products are used in all conditions

[0005] To meet the requirements necessary to withstand such a wide range of harsh conditions, some conventional outdoor furniture is made from very durable materials. This durability often correlates with hard, stiff, and heavy material properties, and such materials are often high in cost. In contrast to the design of conventional furniture, customers prefer comfortable and usable products that are not too costly. Therefore, the environmental performance requirements and customer demands are often in conflict.

[0006] To balance these conflicts, conventional outdoor furniture designs are strong, sturdy, hard, and do not absorb water. For example, some conventional chairs are made entirely of aluminum, which is a strong, lightweight, non-absorbent and relatively inert (corrosion resistant) material. Aluminum chairs are durable; however, they are not comfortable. Some conventional designs use softer materials that are resistant to mold and mildew, while attempting to minimize the amount of water absorbed. For example, some conventional designs use closed cell polyurethane foam with holes drilled through for drainage. In another example, some conventional designs use open-cell Dryfast foam that allows water and air to pass through Although these materials are softer, they suffer from limitations in elasticity (i.e., either being too stiff or too soft) and durability (i.e., the materials tend to sag over time). Therefore, conventional outdoor furniture designs do not have the comfort, elasticity, and durability of indoor furniture, which does not need to be adapted to avoid temperature constraints.

[0007] Furthermore, conventional indoor materials are not suitable for outdoor applications because these materials act like a sponge absorbing and retaining water. This water absorption and retention makes them unusable for a long time after they get wet (for example, from rain) and makes them highly susceptible to bacterial and fungal growth, like mold and mildew.

SUMMARY

[0008] The various examples of the present disclosure are directed towards an outdoor cushion. The disclosed outdoor cushion includes a body portion and a cover for the body portion. The cover includes a water resistant fabric housing and a vent. The vent corresponds to a first side of the body portion.

[0009] In some examples, an area of the vent is less than an area of the first side of the body portion. For example, the first side of the body portion is an underside of the body portion.

[0010] In some examples, the water resistant fabric housing includes a panel over the vent. The panel has at least one unsecured edge, which is unattached to the water resistant fabric housing and provides an air exhaust passage. In some examples, the unsecured edge is an overlapping fabric flap.

[0011] In some examples, the water resistant fabric housing is made of a fabric with microscopic pores configured to allow passage of airflow and humidity while preventing passage of liquid water. In some examples, the water resistant fabric housing is a thin polyurethane membrane laminated to an exterior cover, which is either knit synthetic yarn or woven synthetic yarn. In some examples, the water resistant fabric housing includes a waterproof fabric. [0012] In some examples, the water resistant fabric housing includes a plurality of panels. Seams between each of the plurality of panels prevent water wicking through the seams. In some examples, the disclosed cushion includes waterproof tape covering the seams.

[0013] In some examples, the water resistant fabric housing further includes an elastomer valve configured to allow air exhaust from the body portion when pressure is applied to the body portion. In some examples, the elastomer valve is further configured to allow intake into the body portion in response to vacuum pressure from the body portion.

[0014] In some examples, the body portion includes a foam material. In some examples, the body portion includes multi-layer foam. In some examples, the multi-layer foam includes an interior layer of memory foam and an exterior layer of curled polypropylene fiber

[0015] In some examples, the water resistant fabric housing is permanently coupled to the at least one vent. In some examples, the water resistant fabric housing is removably coupled to the at least one vent.

[0016] In some examples, the vent includes a urethane membrane. In some examples, the vent includes at least one of: a polytetrafluoroethylene coating and silicone.

[0017] In some examples, the water resistant fabric housing includes overlapping portions corresponding to the first side of the body portion. The vent extends through the overlapping portions to provide a path for air exhaust.

[0018] In some examples, the disclosed waterproof cushion includes more than one vent. For example, the waterproof cushion includes a first vent on a first side portion of the body portion and a second vent on a second side portion of the body portion. For example, the waterproof cushion includes a plurality of elastomeric purge valves alongside portions of the body portion. [0019] The above summary is not intended to represent each embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides an example of some of the novel aspects and features set forth herein. The above features and advantages, and other features and advantages of the present disclosure, will be readily apparent from the following detailed description of representative embodiments and modes for carrying out the present invention, when taken in connection with the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings exemplify the embodiments of the present invention and, together with the description, serve to explain and illustrate principles of the invention. The drawings are intended to illustrate major features of the exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of actual embodiments nor relative dimensions of the depicted elements, and are not drawn to scale.

[0021] FIG. 1A shows a top view of an exemplary cushion, according to an embodiment of the present disclosure.

[0022] FIG. 1B shows a bottom view of an exemplary cushion, according to an embodiment of the present disclosure.

[0023] FIG. 2 shows a cutaway view of an exemplary cushion, according to an embodiment of the present disclosure.

[0024] FIG. 3A shows an exemplary cushion with a panel vent, according to an embodiment of the present disclosure. [0025] FIG. 3B shows a cutaway view of the cushion of FIG. 3A, according to an embodiment of the present disclosure.

[0026] FIG. 4A shows another exemplary cushion with a panel vent, according to an embodiment of the present disclosure.

[0027] FIG. 4B shows an exemplary cushion with a scaffold, according to an embodiment of the present disclosure.

[0028] FIG. 5A shows an exemplary cushion with elastomer valves, according to an embodiment of the present disclosure.

[0029] FIG. 5B shows a cutaway view of the cushion of FIG. 5A, according to an embodiment of the present disclosure.

[0030] FIG. 6 shows a various components of an exemplary cushion, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0031] The present invention is described with reference to the attached figures, where like reference numerals are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale, and are provided merely to illustrate the instant invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the invention. One having ordinary skill in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details, or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention.

[0032] The present disclosure is directed to an outdoor cushion. The disclosed outdoor cushion includes a body portion and a cover for the body portion. The cover includes a water resistant fabric housing and a vent. The vent corresponds to a first side of the body portion. In some examples, the outdoor cushion further includes a water resistant exterior cover. In some examples, the body portion is a foam cushion, for example, made of memory foam. The disclosed outdoor cushion therefore allows air exhaust when pressure is applied to the cushion (for example, when a user sits down), but does not allow for water retention or absorption.

[0033] The present disclosure provides a vented waterproof barrier system for outdoor cushions and pillows that enables the use of materials that would have otherwise not been suitable for long term use in an outdoor environment Altogether, the disclosed cushion provides the comfort of sitting on an indoor foam cushion while providing the durability of an outdoor, water resistant cushion. Therefore, the disclosed cushion counters the sensation of sitting on a cushion of air. The disclosed water resistant fabric bag keeps out moisture by using a waterproof breathable membrane cushion cover that prevents water from penetrating the fabric.

[0034] FIGs. 1A-1B show an exemplary cushion 100, according to an embodiment of the present disclosure. FIG. 1A shows a top view 100 A, and FIG. IB shows a bottom view 100B. FIGs. 1A-1B will be discussed together to highlight various features of the disclosed cushion 100 includes a plurality of panels l02a, l02b, l02c, 102d, 102e, and 102f; a plurality of seams 104 along the edges of panels 102a, 102b, l02c, l02d, l02e, and 102f; and a vent

106. [0035] For example, cushion 100 includes a top cushion panel 102a, a botom cushion panel 102d, and a plurality of side cushion panels 102b, l02c, 102d, 102e. Therefore, cushion 100 has a rectangular prism shape. In some examples, cushion 100 includes more or fewer panels and can be in any other shape, as readily contemplated by one skilled in the art These panels 102a, 102b, 102c, 102d, 102e, and 102f yield a water resistant fabric housing

[0036] In some examples, the panels 102a, 102b, 102c, 102d, 102e, and 102f include fabric with microscopic pores configured to allow passage of airflow and humidity while preventing passage of liquid water. In some examples, the panels 102a, 102b, 102c, 102d, 102e, and l02f include a urethane membrane applied directly to a fabric cover. Natural rubber, Teflon coating, or silicone can also be used in place of the urethane membrane. In some examples, the panels l02a, 102b, 102c, 102d, 102e, and 102f include a thin polyurethane membrane laminated to an exterior cover, which is either knit synthetic yarn or woven synthetic yarn. The polyurethane membrane does not allow liquid water to pass through, but its microscopic pores are breathable allowing air to pass through and humidity to escape. The woven or knit layer makes the fabric feel soft, adds structure, and minimizes the undesirable“plastic film-like” sound creates when other materials rub against the polyurethane membrane.

[0037] In some examples, the panels 102a, 102b, 102c, 102d, 102e, and 102f include a waterproof fabric. In some examples, the panels 102a, 102b, 102c, 102d, 102e, and 102f include a woven or knit fabric layer, which is made hydrophobic through a coating, treatment, or polymer selection. In some examples of the disclosed cushion, the panels 102a, 102b, 102c, 102d, 102e, and 102f are a fibrous fabric that absorbs water causing it to expand equally and form a watertight seal.

[0038] The present disclosure further contemplates panels l02a, 102b, l02c, 102d,

102e, and 102f minimizing the unpleasant sound of fabric layers rubbing against each other. For example, panels l02a, l02b, l02c, 102d, 102e, and 102f include woven or knit fabric layer designed to dampen the“plastic film-like” sound of rubbing against a urethane membrane. In other examples, the urethane membrane is sandwiched between two layers of fabric to further reduce the“plastic film-like” rubbing sound. In some examples, the fabric used for panels 102a, 102b, 102c, 102d, l02e, and 102f includes a woven or knit layer, which does not make any sound when rubbing against other materials.

[0039] Therefore, the disclosed examples for panels 102a, 102b, 102c, 102d, 102e, and

102f provide a waterproof breathable membrane which prevents water entry into an interior section of the cushion 100. This waterproof breathable membrane is superior to conventional outdoor cushions that are made with synthetic fabric, such as olefin, acrylic or polyester. In contrast, conventional materials have a mild water repellant coating but do not prevent water from passing into an interior section of the cushion.

[0040] Additionally, the panels 102a, 102b, 102c, 102d, 102e, and 102f are sewn together along corresponding edges. These seams 104 are sewn in a particular manner to minimize water wicking through the seams, including, for example, the use of: (1) multiple stitches; (2) particular styles of stitches; (3) multiple folds of the fabric to create a circuitous path; (4) a waterproof tape over the stitched seams; or (5) any combinations of these methods.

[0041] Cushion 100 further provides a vent 106 in the bottom panel 102d. Therefore, panels 102a, 102b, 102c, 102d, 102e, and 102f completely envelope interior components of the cushion 100, except at the location of the vent 106. Vent 106 allows air to evacuate the bag when the user presses against the cushion, such as during sitting down, or, in the case of a back cushion, when the user leans back. Because the waterproof fabric of panels 102a, 102b, 102c, 102d, 102e, and 102f does not allow air to readily pass through, vent 106 prevents panels 102a, 102b, 102c, 102d, 102e, and 102f from acting as a balloon - for example, puffing out at the sides, becoming taut, and preventing the user from sinking into the cushion. This ballooning effect is common in conventionally-designed cushions and greatly impacts user comfort. The vent 106 of the present disclosure provides a highly breathable mesh, which allows air to quickly escape from cushion 100 when a user sits on the cushion.

[0042] In some examples, the vent 106 has an area less than an area of panel 102d. In some examples, the area of the vent 106 is less than half of the area of panel 102d. Vent 106 provides a large enough mesh, however, so that air rapidly escapes when a user sits down; this allows the user to nearly instantly feel the cushion material housed within an interior portion of cushion 100 (discussed further with respect to FIG. 2).

[0043] Vent 106 is located a distance from all sides of the perimeter of panel 102d, which reduces the likelihood of water wicking from the sides of the cushion along the bottom and through the vent. The vent 106 is further configured to minimize the likelihood of water ingress through the vent For example, the vent fabric is a very fine mesh and is made from hydrophobic material to prevent water ingress through the vent.

[0044] In some examples, vent 106 is permanently coupled to panel 102d; in other examples, vent 106 is removably coupled.

[0045] In some examples, vent 106 is a polytetrafluoroethylene coating and silicone material.

[0046] Although vent 106 is shown in FIG. IB to be a breathable mesh positioned on panel 106, the present disclosure contemplates that vent 106 can be located anywhere on cushion 100. Additional examples of a vent location and type of the vent are discussed further with respect to FIGs. 3A-5B.

[0047] An interior portion of cushion 100 can be further configured to enhance user comfort. Conventional outdoor cushions use foams with limited elasticity and low resilience (i.e., flatening over time). Conventional indoor cushions use foams which have higher elasticity and higher resilience. However indoor cushions cannot be used in outdoor furniture because they have high absorption and water retention, thereby making them highly susceptible to mold, bacteria, and mildew growth. In response to the limitations of conventional indoor and outdoor cushions, the disclosed system 100 allows the use of foams with high elasticity and high resilience without allowing the foams to absorb or retain water.

[0048] FIG. 2 shows an exemplary, cutaway view of a cushion 200, according to an embodiment of the present disclosure. Cushion 200 includes interior foam 202 with first layer 202a and second layer 202b, exterior foam 204, a water resistant fabric housing 102; an exterior cover 206, and body portion 208. For example, the water resistant fabric housing 102 is the panels 102a, 102b, 102c, 102d, 102e, and 102f, the seams 104, and the vent 106 of FIG. 1A.

[0049] Cushion 200 provides an interior foam 202, which has a lower stiffness, and an exterior foam 204, which has a higher stiffness Interior foam 202 is completely enclosed by exterior foam 204. In some examples, interior foam 202 is only partially enclosed by exterior foam 204. In some examples, interior foam 202 is a memory foam and exterior foam 204 is curled polypropylene fiber. In some examples, interior foam 202 is a polymer material which provides a high resiliency support foam. In some examples, interior foam 202 comprises separate layers 202a and 202b. Although two layers are pictured, interior foam 202 can have any number of layers, and each layer can have a different stiffness. In some examples (not shown), interior foam 202 has no layers. In some examples, any elastic and/or visco-elastic material is used for interior foam 202 and exterior foam 204. Interior foam 202 and exterior foam 204 provide the body portion 208 of cushion 200.

[0050] Cushion 200 additionally includes an exterior cover 206. The exterior cover 206 is water resistant, and impairs water from wicking through the exterior cover 206 to the water resistant fabric housing 102 (or to a vent portion of the fabric housing 102). In some examples, the surface of the exterior cover 206 that contacts the fabric housing 102 is brushed to create a fuzzy layer that dampens the sound created during motion of the fabric housing 102.

[0051] In some examples of cushion 200, the cushion 200 does not have an exterior cover 206 and does not have an exterior foam 204. In some examples of cushion 200, each component fits snuggly against an adjacent component. For example, the exterior cover 206 fits snuggly around the fabric housing 102; the fabric housing 102 fits snuggly around the exterior foam 204; and the exterior foam 204 fits snuggly around the interior foam 202. In other examples, spacing is provided between each layer.

[0052] Therefore, system 200 provides for a cushion which: (1) does not absorb and retain water; (2) prevents mold, mildew, and bacterial growth in the cushion itself; (3) does not need to be covered in the event of rain or dew; (4) provides improved resilience to conventional outdoor cushions; and (5) provides improved user comfort over conventional outdoor cushions.

[0053] FIGs. 3A-3B show an exemplary cushion 300 with a panel vent, according to an embodiment of the present disclosure. FIG. 3A shows an exploded view 300 A, and FIG. 3B shows a cutaway view 300B. FIGs. 3 A and 3B will be discussed together. Cushion 300 includes similar components and labels to cushion 100 ofFIGs. 1A-1B, including the panels 102a, 102c, and the seams 104. In addition, an interior portion of cushion 300 can be the body portion 208 of FIG 2. Cushion 300 further includes a first panel 306; a second panel 308; airflow 310; vent 312; and seams 314, 316, 318, and 320.

[0054] Cushion 300 provides a fabric housing 102 which further includes a first panel

306 and a second panel 308. In some examples, a vent 312 is located under panel 306. In other examples, first panel 306 and second panel 308 provide the vent 312. First panel 306 is affixed to fabric housing 102 by seams 314, 320, and 318. An upper seam 316 is unsecured to first panel 306. In some examples, there is a gap between first panel 306 and upper seam 320. Second panel 306 is affixed to fabric housing 102 by seams 314, 316, and 318. In other words, a lower seam 320 is unsecured to second panel 306. Therefore, according to the disclosed seams, airflow 310 can exit from an interior portion 208 of the cushion 300 by passing through a top portion of first panel 306 and under a bottom portion of panel 308. This airflow path 310 provides a tortuous path for water, so that water cannot easily enter interior portion 208 of the cushion 300; however, airflow 310 can easily escape.

[0055] FIG. 4A shows another exemplary cushion 400A with a panel vent, according to another embodiment of the present disclosure. Cushion 400A includes similar components and labels to cushion 300 of FIGs. 3A-3B. Cushion 400A further includes a first panel 412, a second panel 414, an opening 416, and airflow 418.

[0056] A first panel 412 is configured to partially overlap with a second panel 414 to yield a vent. In some examples, these panels 412 and 414 are on a bottom portion of fabric housing 102. The partial overlap between first panel 412 and second panel 414 yields an opening 416. Airflow 418 from an interior portion 208 of the cushion 400A exits through the opening 416 when force is applied (e ., by a user sitting on cushion 400A). Cushion 400A further provides protection against water intrusion into the interior portion 208 because water cannot easily ingress through the opening 416 due to the overlapping portions of first panel 412 and second panel 414.

[0057] FIG. 4B shows a cutaway view of another exemplary cushion 400B, according to another embodiment of the present disclosure. Cushion 400B includes similar components and identical labels to cushion 400A of FIG. 4A. In addition, cushion 400B further includes a scaffold 422. Scaffold 422 provides a structural support to opening 416 to allow ease of air exhaust 418. In some examples (not shown), scaffold 422 includes elastomer valves on either end of the scaffold 422. In some examples (not shown), scaffold 422 is inclined to prevent water ingress into interior portion 208.

[0058] FIGs. 5A-5B show an exemplary cushion 500 with a panel vent, according to an embodiment of the present disclosure. FIG. 5A shows a top view 500A, and FIG. 5B shows a cutaway view 500B. FIGs. 5A and 5B will be discussed together. Cushion 500 includes similar components and labels to cushion 100 of FIGs. 1A-1B, and cushion 200 of FIG. 2. Cushion 500 further includes valves 530.

[0059] Valves 530 provide ventilation for cushion 500. In some examples, the valves

530 are elastomer valves 530, which are made from silicone. The valves 530 are sealed when no pressure is applied, and opened to allow air to pass through when pressure is applied (i.e. when user presses against cushion 500). The valves 530 open due to a vacuum resulting from the interior portion 208 rebounding after a user stopped pressing against cushion 500 (e.g. the user stands up) In some examples, the valves 530 are a flap or a silicone membrane with a X cut in it. In some examples, the valves 530 are perforations in the fabric housing 102. In some examples, these perforations are strengthened with a laminate or grommet.

[0060] FIG. 5A shows how the valves 530 can be positioned alongside panels 102b and

102c of the fabric housing 102. Although three valves 530 are shown, the side panels 102a and 102c can include any number of valves 530. In some examples (shown in FIG. 5B), opposing side panels each include one valve 530a and 530b.

[0061] FIG. 6 shows a various components of an exemplary cushion 600, according to an embodiment of the present disclosure. Cushion 600 includes an eco-friendly performance fabric 602, a waterproof shell 604, a polypropylene batting 606, a visco elastic memory foam 608, a high resiliency support foam 610, and a polypropylene batting 612. These cushions can be in sequential vertical or horizontal layers Although pictured in a particular order and combination, the layers can be in any orientation and/or combination. For example, some examples of the exemplary cushion include more or fewer layers.

[0062] While various examples of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed examples can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described examples. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.

[0063] Although the invention has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.

[0064] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting of the invention. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, to the extent that the terms "including," "includes," "having," "has," "with," or variants thereof, are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising." [0065] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Furthermore, terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.