Method and apparatus for forming cover for mat

Abstract

A method of manufacturing a cover for a main cushion includes at least partially assembling the cover and placing the cover in a mold. The mold may include one or more receiving slots for receiving edges, seams, and any other protruding features of the cover, enabling the mold to close as closely as possible to a panel of the cover predetermined to form the molded part. After the cover and the mold are assembled, a molded part can be formed on at least one panel of the cover. Then, the cover with the molded part formed and fixed on the cover can be removed from the mold and assembled together with the main cushion. The cover may include a pillow cover. The molded part may include an auxiliary cushion, which may be made of an elastomeric gel. A mold and a mold assembly are also disclosed.

Description

Technical Field

[0001] The present disclosure generally relates to auxiliary cushions for cushion covers and, more particularly, to methods for manufacturing auxiliary cushion components for cushion covers. More particularly, the present disclosure relates to methods for manufacturing that include molding the auxiliary cushion onto a prefabricated cushion cover. The mold used to define the auxiliary cushion on the cushion cover may include one or more recesses that receive features of the cover, such as seams, fasteners (zippers, buttonholes, and / or buttons, etc.). Background Art

[0002] U.S. patent application publication US2023 / 0142851 A1 discloses a cover for a cushion (e.g., a pillow). The cover includes a pair of stacked panels, at least a portion of their peripheries are fixed to each other. The panels define the interior of the cushion, which includes a main receiving groove for placing a main cushion (e.g., a pillow). At least one panel includes two layers, which define a pocket with a thinner auxiliary cushion in the pocket. The auxiliary cushion can be fixed to or formed on one layer of the panel. The layer can then be cut and assembled (e.g., sewn together, etc.) with the other layers of the panel and / or the rest of the cover.

[0003] The presence of auxiliary pads (more or less large and heavy) on a layer of the panel complicates the handling when assembling this layer with another layer of the panel of the cover and with the rest of the cover. In particular, the auxiliary pads increase the weight of the layer and make it difficult to move it. In addition, the size of the auxiliary pads may affect the assembly process. For example, when forming a seam near the auxiliary pad, the presser foot and the needle of the sewing machine come close to the auxiliary pad. If the presser foot or the needle comes into contact with the auxiliary pad during sewing, the seam and the auxiliary pad may be damaged. The presence of auxiliary pads on a layer that is assembled with other layers and parts of the cover of the cushion increases the manufacturing time and undesirably reduces the manufacturing yield. Summary of the Invention

[0004] A method for manufacturing a cover for a primary cushion includes assembling the cover using a mold, and then molding at least one auxiliary cushion onto the cover. The cover may be at least partially assembled before molding the at least one auxiliary cushion onto the cover. In some embodiments, the cover may be at least fully assembled before molding the at least one auxiliary cushion onto the cover. Thus, each auxiliary cushion can be molded onto a prefabricated cover.

[0005] This method may include assembling the cover with the mold, or placing the cover within the mold. The cover may include a first panel, a second panel fixed to the first panel (e.g., overlapping the first panel, etc.), and a seam fixing at least one edge of the first panel to the second panel. Each panel may include a single layer or multiple layers of material (e.g., fabric, polymer film, etc.). In embodiments where the mold includes two halves, the cover may be assembled with one half of the mold, or placed on one half of the mold or within one half of the mold. The cover may be assembled with the mold so that the first panel and the second panel lie flat on the inner surface of the mold, and at least one of the first panel and the second panel is exposed to one or more cavities of the mold (e.g., the first panel but not the second panel is exposed to the cavity of the mold, each of the first panel and the second panel is exposed to the cavity of the mold, and the second panel but not the first panel is exposed to the cavity of the mold). Assembling the cover with the mold may also include positioning the seams and any other features on the cover that may protrude beyond the flat panel of the cover (e.g., fasteners (e.g., zippers, buttons and buttonholes, touch fasteners, etc.), labels, etc.) within receiving slots in the mold (e.g., receiving slots in at least one of the two halves of the mold). Each receiving slot in the mold is capable of accommodating the seams and other protruding features of the cover, allowing the mold to completely flatten the remaining portion of the cover panel, thereby effectively sealing the one or more cavities of the mold. In the case where the mold includes two halves, the two halves of the mold can be pressed together with the cover positioned between the two halves.

[0006] After the cover and mold are assembled, the elastic gel can be introduced into one or more cavities of the mold. The elastic gel can be heated to a high temperature and introduced into the one or more cavities of the mold under high pressure (e.g., by injection molding). Therefore, when the elastic gel enters the one or more cavities of the mold and contacts the portion of the first or second panel of the cover exposed to the one or more cavities of the mold, it may be in a liquid state. While in a liquid state, the elastic gel can flow to the portion of the first or second panel of the cover exposed to the one or more cavities of the mold. In certain embodiments (e.g., embodiments in which the first or second panel comprises fabric, a porous structure, etc.), the liquid elastic gel can absorb into the portion of the first or second panel of the cover exposed to the one or more cavities of the mold, thereby impregnating such portion. The elastic gel then cools and solidifies. In embodiments in which the elastic gel has impregnated the portion of the first or second panel of the cover exposed to the one or more cavities of the mold, the elastic gel can mechanically connect to the first or second panel as it cools. Regardless of whether the elastic gel impregnates portions of the first panel or the second panel, the elastic gel, upon cooling, may adhere to portions of the first panel or the second panel that are exposed in the one or more cavities.

[0007] Once the elastic gel cools and at least partially solidifies, the cover and each newly formed auxiliary cushion can be removed from the mold. When the cover is removed from the mold, each auxiliary cushion remains on the cover. For example, the elastic gel of the auxiliary cushion can mechanically secure, adhere, or otherwise secure the auxiliary cushion to the cover.

[0008] A mold assembly for making a cushion cover includes a mold that receives a primary cushion cover. The mold is configured to form a secondary cushion on a partially or fully assembled cover having multiple panels secured together (e.g., sewn, glued, welded, bonded, etc.). Each panel may include one or more layers of material (e.g., fabric, polymer film, etc.).

[0009] The mold includes at least one cavity positionable on at least one panel of the cover. The mold also includes at least one receiving slot positionable to receive one or more features of the cover (e.g., seams, fasteners, labels, etc.) that protrude beyond the thickness of the cover. The at least one receiving slot may be disconnected from the at least one cavity, thereby preventing material that enters the at least one cavity from entering the at least one receiving slot.

[0010] In certain embodiments, a mold may include a first mold half and a second mold half. The first mold half may include a first cavity and a first receiving slot. The first receiving slot may not be in communication with the first cavity. The second mold half may include a second receiving slot. Optionally, the second mold half may further include a second cavity, which may not be in communication with the second receiving slot. The second mold half may be assembled with the first mold half (e.g., stackable). In the assembled relationship between the first and second mold halves, the first and second receiving slots may overlap, allowing the first and second receiving slots to jointly receive features protruding beyond the thickness of the cover. In embodiments where the second mold half includes a second cavity, the second cavity may be a mirror image of the first cavity; the second cavity may have the same configuration as the first cavity but be laterally offset from the first cavity when the first and second mold halves are assembled; or the second cavity may have a different configuration than the first cavity.

[0011] The shape of the mold cavity (e.g., a first cavity in the first mold half, a second cavity in the second mold half, etc.) can define the shape of the auxiliary cushion formed on the cover panel. Without limitation, the shape of the cavity can be a grid (e.g., a hexagonal grid, a square grid, a diamond grid, a triangular grid, an octagonal pattern, a circular pattern, etc.).

[0012] Optionally, the mold assembly may further include a cover.

[0013] Other aspects, features, and advantages of the disclosed subject matter will become apparent to those skilled in the art from a review of the following description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In the attached figure:

[0015] Figure 1 It is an isometric view of the cover of the cushion;

[0016] Figure 2 and Figure 3 yes Figure 1 a cross-sectional view of the illustrated cover;

[0017] Figure 4 yes Figure 1 a plan view of a first major surface (e.g., top, bottom, etc.) of the illustrated cover;

[0018] Figure 5 yes Figure 1 an isometric view of a second major surface (e.g., bottom, top, etc.) of the illustrated cover;

[0019] Figure 6 is a plan view of the inner surface of the mold half, showing the cavity and receiving groove formed in the inner surface of the mold half;

[0020] Figure 7 yes Figure 6 an end view of the mold half shown;

[0021] Figure 8 yes Figure 6 a side view of the illustrated mold half;

[0022] Figure 9 yes Figure 6 a plan view of the exterior surface of the illustrated mold half;

[0023] Figure 10 It is along Figure 9 Cross-section of the mold half obtained through the CC line;

[0024] Figure 11 It is along Figure 9 Another cross-sectional view of the mold half obtained through line EE;

[0025] Figure 12 showing the cover of the mat positioned relative to the mold;

[0026] Figure 13 The assembly of the mold and cover is shown;

[0027] Figure 14 is a cross-sectional view showing the assembly of the mold and the cover; and

[0028] Figure 15 An article of manufacture is shown including a cover and an auxiliary cushion formed on the cover. DETAILED DESCRIPTION

[0029] Reference Figure 1-5 , describes an embodiment of a cover 10 for a cushion (not shown). The cover 10 can be configured to be used with a particular type of cushion. The cushion designed for use with the cover is referred to herein as a "primary cushion." The cover 10 can be used with a pillow (as shown), a seat cushion, a mattress, a mattress topper, or the like, without limitation. The cover 10 can be partially assembled or fully assembled. The cover 10 includes a plurality of panels 12 and 14, and seams 16 ( Figure 4 Optionally, the cover 10 may include one or more openings 18 , one or more fasteners 20 , and one or more labels 22 .

[0030] As shown, the panels 12 and 14 of the cover 10 can be stacked on top of each other, but other arrangements of the panels 12 and 14 of the cover 10 (such as adjacent panels 12 and 14, etc.) are also within the scope of the present disclosure. Each panel 12, 14 may include one or more layers of a flexible material. Suitable flexible materials include, but are not limited to, fabrics and polymer films. In more specific embodiments, each panel may include cotton or a stretchable cotton blend, such as so-called "scrim fabric."

[0031] Seam 16( Figure 4 ) can be formed in any acceptable manner depending on the type of material used for panels 12 and 14 of cover 10. For example, seam 16 can be sewn (e.g., using a suitable thread, etc.). For another example, seam 16 can include a weld. In other examples, seam 16 can be formed by an adhesive material, by bonding the materials of panels 12 and 14 together, or by any other suitable means.

[0032] An optional opening 18 of the cover 10 can be defined at a location where the peripheries of the panels 12 and 14 are not secured together by the seam 16. The opening 18 can be sized to accommodate a primary cushion designed for use with the cover 10. Thus, the opening 18 allows the cover 10 to be placed on or removed from the primary cushion. The opening 18 also allows the cover 10 to be pulled from the inside out, or to be turned with its inner surface facing outward.

[0033] In embodiments where the cover 10 includes an opening 18, a fastener 20 may also be optionally included. The fastener 20 may facilitate closing and reopening the opening 18. For example, as shown, the fastener 20 may include a zipper. Alternatively, the fastener 20 may include a touch-type fastener (e.g., Velcro or hook-and-loop fasteners; hook-and-hook fasteners, etc.), a button and corresponding buttonhole, or the like.

[0034] Alternatively, the cover 10 may include one or more labels 22. The labels 22 may include one or more brand labels 22a, care labels 22b, regulatory labels or legal markings 22c, supplier labels, or the like. Each label 22 may extend from the periphery of the cover 10 or may be affixed to the panels 12, 14 of the cover 10.

[0035] The seam 16 and any openings 18 , fasteners 20 , labels 22 , outer edges 15 of the cover 10 , or any other features that exceed the thickness of the panels 12 and 14 when laid flat, whether overlapping or not, may be referred to herein as “protruding features” of the cover 10 .

[0036] like Figure 3 As shown, barrier 30 can be positioned adjacent to and overlying panels 12, 14 of cover 10. In embodiments where panels 12, 14 are stacked, barrier 30 can be positioned between panels 12, 14. Barrier 30 can comprise a thin sheet or film of a flexible material, such as paper (e.g., wax paper), a polymer, or the like. Barrier 30 can be secured in place when cover 10 is assembled. For example, seam 16 of cover 10 can secure barrier 30 to at least one panel 12, 14. Thus, while panel 12, 14 is secured to another panel 14, 12, barrier 30 can be secured to at least one panel in the same manner. As will become more apparent from the following description, barrier 30 can comprise a material that prevents another material (e.g., an elastic gel) applied to one side of panels 12, 14 from seeping through panels 12, 14 and causing panels 12, 14 to adhere to objects on the other side of panels 12, 14 (e.g., another panel 14, 12). The barrier 30 may be removable from the panels 12 and 14; for example, from between the stacked panels 12 and 14. For example, the barrier 30 may be removed by grasping it and pulling it along the seam 16 where it may be secured to at least one of the panels 12, 14.

[0037] Now go to Figure 6-11 , the figure describes the use of the cover 10 ( Figure 1-5 ) is formed on the molded part 70 ( Figure 15 ) (e.g., auxiliary cushion). The mold 40 is constructed so that it can be used to form the molded part 50 on the cover 10 using the appropriate type of molding equipment and the desired technique. In embodiments where the molded part 70 is an auxiliary cushion made of an elastic gel (e.g., an extended block copolymer (e.g., AB block copolymer, ABA triblock copolymer, etc., such as those disclosed in U.S. Patents 6,413,458, 6,797,765, and 7,964,664 (the entire disclosures of which are incorporated herein)), the mold 40 is configured so that it can be used with an injection molding machine.

[0038] Brief reference Figure 12-14 , the mold 40 may include a first mold half 50a and a second mold half 50b, and for simplicity, each mold half may be referred to as a "mold half 50."

[0039] refer to Figure 6-11 Each mold half 50 includes a body 52 having an inner surface 54 and an outer surface 56. At least one cavity 58 can be formed in the inner surface 54 of at least one mold half 50. At least one receiving groove 60 can be formed in the inner surface 54 of each mold half 40. The outer surface 56 and body 52 of each mold half 50 can include features (e.g., grooves, holes, etc.) that enable the mold half 50 to be connected and used with appropriate molding equipment (e.g., an injection molding machine, etc.).

[0040] At least one cavity 58 may be recessed in the inner surface 54 of the body 52 of at least one mold half 50. The at least one cavity 58 receives a molding medium (e.g., an elastic gel, etc.) from at least one conduit (not shown) and one or more openings (not shown) in the body 52 of the mold half 50, which in turn receive the molding medium from the molding equipment used to assemble the mold 40. The shape of the at least one cavity 58 will define the shape of the hood 10 ( Figure 1-5 ) on the molded part 70 ( Figure 15 As shown in the figure, the shape of at least one cavity 58 can be a grid (such as a hexagonal grid, a square grid, a diamond grid, a triangular grid, a circular grid, etc.) or any other suitable shape.

[0041] The mold 40 can be used to cover only the cover 10 ( Figure 1-5 ) is formed on one side of the molded part 70 ( Figure 15 In such an embodiment, at least one cavity 58 may be provided on the inner surface 54 of the body 52 of only one mold half 50 of the mold 40. Alternatively, the mold 40 may be used to form the molded parts 70 on opposite sides of the cover 10. In this embodiment, at least one cavity 58 may be provided on the inner surface 54 of the body 52 of both mold halves 50.

[0042] At least one receiving groove 60 can be recessed into the inner surface 54 of the body 52 of each mold half 50. The at least one receiving groove 60 can be positioned, shaped, and sized to receive all protruding features of the cover 10 (e.g., the seam 16, any openings 18, any fasteners 20, any labels 22, etc.). As shown, the at least one receiving groove 60 can be laterally outboard of at least one cavity 58 (if present) in the inner surface 54. When the at least one receiving groove 60 is located adjacent to the cavity 58, the at least one receiving groove 60 can be laterally isolated from the cavity 58, or the at least one receiving groove 60 can be disconnected from the cavity 58.

[0043] Reference Figure 12-15 , the figure illustrates a method for forming a molded part 70 on a cover 10. The method comprises: Figure 12 As shown, the mold 40 is opened and the cover 10 is positioned relative to the mold 40; Figure 13 and Figure 14 As shown, the mold 40 is mounted on the cover 10, or the mold 40 is closed; Figure 15 As shown, a molding medium is introduced into the mold 40 and onto the cover 10 to form the molded parts 70 ; and the mold is opened and the cover 10 and each molded part 70 on the cover 10 are removed from the mold 40 .

[0044] Refer again Figure 12 The mold 40 can be opened by separating the two mold halves 50a and 50b of the mold 40 and spacing the mold halves 50a and 50b apart from each other. The separation between the mold halves 50a and 50b can be accomplished by a molding device (not shown). When the mold 40 is open, or the mold halves 50a and 50b are separated and spaced apart from each other, the cover 10 can be placed between the mold halves 50a and 50b. For example, the cover 10 can be placed over the inner surface 54 of the main body 52 of one mold half 50b and secured. More specifically, any protruding features of the cover 10, such as the outer edge 15, the seam 16, any openings 18, any fasteners 20, and any labels 20, can be placed within and / or completely overlap at least one receiving groove 60 in the inner surface 54 of the main body 52 of the mold half 50b. The remaining portion of each panel 12, 14 and any barrier 30 of the cover 10 can be ground flat so that the portion of each panel 12, 14 and any barrier 30 that covers at least one cavity 58 in the inner surface 54 lies substantially flat against the inner surface 54. Positioning of the cover 10 can be performed manually or automatically (e.g., using robotic tools). The mold 40 (e.g., mold half 50b) can include one or more guides (e.g., pins) that mate with corresponding features (e.g., holes) of the cover 10. Such guides ensure that the cover 10 remains consistently positioned within the mold 40 during repeated uses of the mold 40.

[0045] The cover 10 can be secured in place relative to the mold 40 (eg, mold half 50b) using suitable fasteners (not shown). The fasteners may include, but are not limited to, guides, adhesives, clamps, vacuum suction, or the like.

[0046] like Figure 13 and 14As shown, after the cover 10 is secured in position relative to the mold 40 (e.g., mold half 50b, etc.), the mold 40 can be closed around the cover 10. When the mold 40 is closed, the cover 10 can be effectively sealed therein. For example, when the mold halves 50a and 50b are assembled on the cover 10, the protruding features of the cover 10 are positioned within the at least one receiving groove 60, thereby positioning the inner surfaces 54 of the bodies 52 of the mold halves 50a and 50b as closely as possible relative to each other and effectively sealing each cavity 58 to the panels 12, 14 of the cover 10.

[0047] After the cover 10 and the mold 40 are properly assembled, a molding medium can be introduced into each cavity 58 of the mold 40 and onto the panels 12, 14 of the cover 10. As a non-limiting example, an elastic gel can be introduced into each cavity 58 of the mold 40 and onto the panels 12, 14 of the cover 10. In embodiments where one or more of the panels 12, 14 comprise a fabric (e.g., a mesh fabric, etc.), the elastic gel may absorb or penetrate the fabric. In this way, the elastic gel may be mechanically bonded to the panels 12, 14. Regardless of whether the elastic gel absorbs or penetrates the panels 12, 14, the elastic gel may adhere to the panels 12, 14.

[0048] The molding medium solidifies after cooling, forming at least one molding 70 on the cover 10. Once the molding medium is fully solidified, the mold 40 can be opened and the cover 10 and each molding 70 on the cover 10 can be removed from the mold 40. Figure 15 A cover 10 is shown having a molding 70 formed thereon. The cover may include a cover of the type described in U.S. Patent Application Publication No. US 2020 / 0390247 A1, the entire disclosure of which is hereby incorporated herein.

[0049] The cover 10 can then be turned inside out, or with its inner surface facing outward, to position the molding 70 inside the cover. Additionally, turning the cover 10 inside out can position any obstruction 30 on the outside of the cover 10. The obstruction 30 can then be removed from the cover 10. Figure 3 ) (if any). In embodiments where the barrier 30 is assembled with the cover 10, the barrier 30 can be removed by pulling it along the seam 16 of the cover 10.

[0050] The cover 10 can then be assembled with the main cushion (not shown). In embodiments where the cover 10 comprises a pillow cover, any fasteners 20 ( Figure 1 ), and then insert the main cushion into the cover 10 through the opening 18. The fasteners 20 (if any) can then be closed to secure the main cushion within the cover 10.

[0051] Once the mat is assembled, it is ready to be packaged and shipped.

[0052] Features from different embodiments of the disclosed subject matter may be used in combination. Although this disclosure provides many specific details, these details should not be construed as limiting the scope of any claim, but rather as merely providing examples of elements and features of the disclosed subject matter that fall within the scope of the claims. Other embodiments of the disclosed subject matter may be devised and fall within the scope of the claims. Therefore, the scope of each claim is limited only by its express provisions and their legal equivalents.

Claims

1. A method of making a cushion cover, comprising: securing a cover between two halves of a mold, the cover comprising a first panel, a second panel secured to the first panel, and a seam securing at least one edge of the first panel to the second panel, including positioning the seam within a receiving slot of at least one of the two halves of the mold, with at least one of the first panel and the second panel exposed in a cavity of the mold; and An elastic gel is introduced into the cavity of the mold and into the first or second panel of the cover. 2 . The method of claim 1 , wherein securing the cover comprises securing a prefabricated cover between two halves of a mold.

3. The method of claim 1 , wherein securing the cover comprises securing the cover including a zipper between two halves of the mold, the zipper being located between the first panel and the second panel, the zipper being received by a receiving slot in at least one of the two halves of the mold.

4. The method of claim 1, wherein the receiving groove is not in communication with the cavity when the two halves of the mold are aligned and abutted against each other.

5. The method according to claim 1, wherein: Securing the cover includes securing the cover between two halves of a mold, the cavity of the mold including a first cavity located in a first half of the two halves and a second cavity located in a second half of the two halves; as well as Introducing the elastic gel into the cavity involves: introducing an elastic gel into the first cavity and onto the first panel of the cover; as well as An elastic gel is introduced into the second cavity and onto the second panel of the cover.

6. The method of claim 1, wherein introducing the elastic gel into the cavity of the mold comprises defining a grid formed by the elastic gel on the first panel or the second panel of the mask.

7. The method according to claim 1, further comprising: allowing the elastic material to at least partially solidify within the cavity of the mold; Once the elastic material has at least partially solidified, the two halves of the mold are separated; as well as After the two halves of the mold are separated, the cover is removed from between the two halves of the mold, leaving the elastic gel on the first or second panel of the cover.

8. A mold for manufacturing a cushion cover, comprising: a first mold half including a first cavity and a first receiving slot that is not in communication with the first cavity, the first receiving slot being positioned to receive a seam of the cover of the cushion when the first panel of the cushion is abutted against the first mold half; as well as A second mold half is stackable with the first mold half, the second mold half being abuttable against the first mold half to define a seam within the first receiving channel and to define a cover between the first mold half and the second mold half.

9. The mold of claim 8, wherein the first receiving slot of the first mold half is further positioned to receive a zipper of a cover of the cushion, and the second mold half is positionable against the first mold half to confine the zipper within the first receiving slot.

10. The mold of claim 8, wherein the second mold half includes a second receiving groove that can overlap with the first receiving groove of the first mold half, and the second mold half can abut against the first mold half to define a seam within the first receiving groove and the second receiving groove.

11. The mold of claim 8, wherein the first cavity of the first mold half comprises a grid cavity that opens to the first panel of the cushion cover when the first and second mold halves are assembled with the cushion cover and with each other.

12. The mold of claim 8, wherein the second mold half includes a second cavity.

13. The mold according to claim 12, wherein When the first mold half and the second mold half are in assembled relationship, the second cavity is a mirror image of the first cavity.

14. The mold according to claim 12, wherein When the first mold half and the second mold half are in assembled relationship, the second cavity is offset from the first cavity.

15. A mold assembly for making a cushion cover, comprising: a first mold half comprising a first cavity and a first receiving groove, wherein the first cavity and the first receiving groove are not in communication with each other; as well as The second mold half includes a second cavity and a second receiving slot, the second cavity and the second receiving slot are not in communication, the second mold half is superimposed on the first mold half in an assembled relationship, the second receiving slot is superimposed on the first receiving slot when the first mold half and the second mold half are placed in the assembled relationship, and the first receiving slot and the second receiving slot are superimposed to receive the seam of the cover of the cushion when the cover is located between the first mold half and the second mold half.

16. The mold assembly of claim 15, wherein at least one of the first receiving slot of the first mold half and the second receiving slot of the second mold half is positioned to receive a zipper of the cushion cover when the cover is positioned between the first mold half and the second mold half.

17. The mold assembly of claim 15, wherein at least one of the first cavity of the first mold half and the second cavity of the second mold half comprises cavities for defining a grid on a panel of a cover of the cushion.

18. The mold assembly according to claim 15, wherein: When the first mold half and the second mold half are in assembled relationship, the first cavity and the second cavity are mirror images of each other.

19. The mold assembly according to claim 15, wherein: When the first mold half and the second mold half are in assembled relationship, the second cavity is offset from the first cavity.

20. The mold assembly of claim 15, further comprising: Cushion cover.

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