Patent attributes
A cushion subassembly includes a support, a cushion of non-woven polymeric (PET) or PETE fibers with a formed edge that wraps over an edge of the support, and an upholstery sock pulled onto and covering the support and the cushion. The formed edge has sufficient structure to retain the cushion in place on the support as the upholstery sock is pulled onto the support. A back support shell supports the cushion assembly, and has first fasteners that engage in a first direction and second fasteners that prevent disengagement. The cushion assembly is stressed during assembly, especially at corners, but is thermally stress-relieved after assembly to relax the polymeric fibers and the upholstery sock to a state of minimized balanced tension. The back support shell includes a shallow depression on its face. The cushion fills the depression sufficient to eliminate loose fabric but provides a same force deflection curve across its shape.
