US20040026970A1 - Upholstered furniture inserts - Google Patents
Upholstered furniture inserts Download PDFInfo
- Publication number
- US20040026970A1 US20040026970A1 US10/418,096 US41809603A US2004026970A1 US 20040026970 A1 US20040026970 A1 US 20040026970A1 US 41809603 A US41809603 A US 41809603A US 2004026970 A1 US2004026970 A1 US 2004026970A1
- Authority
- US
- United States
- Prior art keywords
- insert
- rigid foam
- frame
- component
- upholstered furniture
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/54—Supports for the arms
Definitions
- This invention relates to furniture construction for upholstered furniture.
- FIGS. 1 - 3 Conventional construction techniques for upholstered furniture require substantial time and skill on the part of the workers fabricating the furniture.
- a wooden frame or skeleton 2 is constructed for a chair arm (FIG. 1). Thereafter, the frame is covered with a stiff skin 4 (FIGS. 2 - 3 ) onto which a layer of foam or padding and then upholstery material can be applied.
- a stiff skin 4 FIGS. 2 - 3
- the aforementioned wooden frame and cardboard skin are currently used. Because the wooden frame is complex and difficult to make, such a technique limits the shapes that can be made and requires much time to make.
- upholstered furniture is constructed having a wooden frame which is much simpler and requires less cross bracing parts, than a typical wooden frame.
- An insert is attached to the wooden frame to form the desired three-dimensional shape. Additionally, the upholstered material is applied to the insert. In some embodiments, a layer of soft or compressible foam or padding is arranged between the insert and the upholstered material.
- an insert for an upholstered furniture component.
- the upholstered furniture component includes a frame supporting the insert and an upholstery material covering the insert.
- the insert comprises a rigid foam material having one portion thereof shaped to conform to the frame so that the rigid foam material can be attached to the frame and another portion of the rigid foam material shaped to correspond to an outer shape of the upholstered furniture component.
- FIG. 1 is a perspective view of a conventional chair arm frame
- FIG. 2 is a perspective view of a conventional chair arm skin
- FIG. 3 is a perspective view of the chair arm skin of FIG. 2 applied to the chair arm frame of FIG. 1;
- FIG. 4 is a perspective view of a chair arm frame according to a preferred embodiment of the present invention.
- FIG. 5 is a perspective view of foam inserts according to a preferred embodiment of the present invention.
- FIG. 6 is a perspective view of the foam inserts of FIG. 5 applied to the frame of FIG. 4 according to a preferred embodiment of the present invention
- FIG. 7 is a perspective view of the foam inserts as applied to the frame of FIG. 6 and including an additional insert according to a preferred embodiment of the present invention
- FIG. 8 is a perspective view of the frame and insert combination of FIG. 7 having upholstery material applied.
- FIG. 9 is a perspective view of an alternative embodiment of the present invention.
- FIGS. 4 - 8 illustrate a chair arm comprising one embodiment of the present invention.
- a chair arm is shown and described herein, it will be appreciated by those skilled in the art that the present invention is applicable to other structural components for upholstered furniture and the like, such as the front stump.
- FIG. 4 a frame 10 according to the present invention is disclosed. While the frame 10 as depicted in FIG. 4 is made of wood, the frame 10 could also be made of metal or other suitable structural components.
- the frame 10 comprises a plurality of structural components arranged in the shape required.
- FIG. 5 illustrates rigid foam inserts 12 , 14 , 16 used to complete the desired three-dimensional shapes.
- the inserts are in the form of rigid foam components.
- the inserts are preferably formed from molded expanded polystyrene, but could be any expanded foam or any other lightweight structural or forming material such as polyethylene, polypropylene, or a copolymer material.
- the inserts can be made by any suitable process known to those of ordinary skill in the art, including molding, thermoforming, blow molding, or even carving or cutting.
- the inserts can be formed from by cutting, molding, or by thermoforming a sheet of plastic material.
- One preferred method uses expanded polystyrene molding with standard foam molding techniques and a tool customized to the desired final shape due to the consistent repeatability of the desired shape.
- the inserts 12 , 14 , 16 are rigid, i.e., substantially incompressible under normal use.
- the inserts 12 , 14 , 16 may be of a foam that, while providing significant support, does yield a little under pressure.
- One preferred type of expanded polystyrene foam has a density in the range of 0.75 to 6.0 pounds per cubic foot and a compressive stress at 10% compression (strain) of 30 to 800 kPa, more preferably has a density in the range of 1 to 3 pounds per cubic foot and a compressive stress at 10% compression (strain) of 80 to 375 kPa, and most preferably has a density in the range of 1.5 to 2.5 pounds per cubic foot and a compressive strength at 10% compression (strain) of 120 to 280 kPa.
- Such compressive stress values are determined at ambient (room) temperatures.
- One acceptable test is set forth in EN 826 .
- the inserts include two top arm components 12 , 14 and a side contour pad component 16 .
- FIG. 6 shows the foam inserts 12 , 14 , 16 attached to the frame 10 .
- the foam inserts 12 , 14 , 16 are preferably adhered to the frame 10 by staples but could also be adhered by adhesive, nails or tape.
- FIG. 7 shows an alternate embodiment in which an additional foam insert 18 is adhered to the front of the chair arm frame 10 providing decorative ornamentation including concentric circles 20 .
- an additional foam insert 18 is adhered to the front of the chair arm frame 10 providing decorative ornamentation including concentric circles 20 .
- alternative decorative shapes can be provided. These decorative shapes can be of a more complex form than those made by traditional methods.
- FIG. 8 shows a finished chair arm having upholstery material 22 attached to the frame 10 and inserts 12 , 14 , 16 and 18 using normal furniture industry standards.
- the upholstery material 22 can be attached directly to the frame 10 and inserts 12 , 14 , 16 , and 18 .
- a layer of soft foam or other type of padding can be arranged between the inserts 12 , 14 , 16 , 18 and the upholstery material 22 .
- Such soft foam or padding is known to those of skill in the art.
- FIGS. 4 - 8 While the embodiments illustrated in the FIGS. 4 - 8 include a portion of the frame 10 extending to the edge of the inserts 12 , 14 , 16 , alternative embodiments may include foam inserts that completely cover the frame 10 such that the frame is not exposed. In such embodiments, it may not be necessary to use a layer of soft foam between the inserts and the upholstery material. In those embodiments, the inserts are preferably made of the rigid foam material, as described above.
- FIG. 9 illustrates another embodiment, wherein the frame 110 includes a top substantially planar surface 115 to which a semicylindrical insert 112 is attached.
- a second insert 114 is attached to a side surface 117 of the frame 110 .
- manufacturing can be simplified by utilizing inserts having simple or complex geometric shapes and large planar surfaces.
- Another advantage of this embodiment is that the entire upper surface of the frame 110 is covered with a single insert 112 . Accordingly, there is no wooden portion extending to the top part of the furniture component.
Abstract
An upholstered furniture component including a frame; a rigid foam insert attached to the frame; and upholstery material covering the foam insert. The rigid foam insert may be made from expanded polystyrene. And, a layer of padding may between the rigid foam insert and the upholstery material.
Description
- This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/383,876, filed on May 28, 2002, and is a continuation-in-part of U.S. patent application Ser. No. 10/360,798, filed on Feb. 10, 2003. The entire contents of both applications are incorporated herein by reference.
- This invention relates to furniture construction for upholstered furniture.
- Conventional construction techniques for upholstered furniture require substantial time and skill on the part of the workers fabricating the furniture. In one such technique, illustrated in FIGS.1-3, a wooden frame or
skeleton 2 is constructed for a chair arm (FIG. 1). Thereafter, the frame is covered with a stiff skin 4 (FIGS. 2-3) onto which a layer of foam or padding and then upholstery material can be applied. In order to obtain three-dimensional shapes the aforementioned wooden frame and cardboard skin are currently used. Because the wooden frame is complex and difficult to make, such a technique limits the shapes that can be made and requires much time to make. - In accordance with one embodiment of the present invention, upholstered furniture is constructed having a wooden frame which is much simpler and requires less cross bracing parts, than a typical wooden frame. An insert is attached to the wooden frame to form the desired three-dimensional shape. Additionally, the upholstered material is applied to the insert. In some embodiments, a layer of soft or compressible foam or padding is arranged between the insert and the upholstered material.
- According to another embodiment of the invention, an insert is provided for an upholstered furniture component. The upholstered furniture component includes a frame supporting the insert and an upholstery material covering the insert. The insert comprises a rigid foam material having one portion thereof shaped to conform to the frame so that the rigid foam material can be attached to the frame and another portion of the rigid foam material shaped to correspond to an outer shape of the upholstered furniture component.
- Other features of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
- FIG. 1 is a perspective view of a conventional chair arm frame;
- FIG. 2 is a perspective view of a conventional chair arm skin;
- FIG. 3 is a perspective view of the chair arm skin of FIG. 2 applied to the chair arm frame of FIG. 1;
- FIG. 4 is a perspective view of a chair arm frame according to a preferred embodiment of the present invention;
- FIG. 5 is a perspective view of foam inserts according to a preferred embodiment of the present invention;
- FIG. 6 is a perspective view of the foam inserts of FIG. 5 applied to the frame of FIG. 4 according to a preferred embodiment of the present invention;
- FIG. 7 is a perspective view of the foam inserts as applied to the frame of FIG. 6 and including an additional insert according to a preferred embodiment of the present invention;
- FIG. 8 is a perspective view of the frame and insert combination of FIG. 7 having upholstery material applied; and
- FIG. 9 is a perspective view of an alternative embodiment of the present invention.
- Reference is made to FIGS.4-8 which illustrate a chair arm comprising one embodiment of the present invention. Although a chair arm is shown and described herein, it will be appreciated by those skilled in the art that the present invention is applicable to other structural components for upholstered furniture and the like, such as the front stump.
- As seen in FIG. 4, a
frame 10 according to the present invention is disclosed. While theframe 10 as depicted in FIG. 4 is made of wood, theframe 10 could also be made of metal or other suitable structural components. Theframe 10 comprises a plurality of structural components arranged in the shape required. FIG. 5 illustratesrigid foam inserts - As shown in FIG. 5, the inserts are in the form of rigid foam components. The inserts are preferably formed from molded expanded polystyrene, but could be any expanded foam or any other lightweight structural or forming material such as polyethylene, polypropylene, or a copolymer material.
- The inserts can be made by any suitable process known to those of ordinary skill in the art, including molding, thermoforming, blow molding, or even carving or cutting. In one embodiment, the inserts can be formed from by cutting, molding, or by thermoforming a sheet of plastic material. One preferred method uses expanded polystyrene molding with standard foam molding techniques and a tool customized to the desired final shape due to the consistent repeatability of the desired shape.
- In one embodiment, the
inserts inserts - One preferred type of expanded polystyrene foam has a density in the range of 0.75 to 6.0 pounds per cubic foot and a compressive stress at 10% compression (strain) of 30 to 800 kPa, more preferably has a density in the range of 1 to 3 pounds per cubic foot and a compressive stress at 10% compression (strain) of 80 to 375 kPa, and most preferably has a density in the range of 1.5 to 2.5 pounds per cubic foot and a compressive strength at 10% compression (strain) of 120 to 280 kPa. Such compressive stress values are determined at ambient (room) temperatures. One acceptable test is set forth in EN826.
- In one embodiment the inserts include two
top arm components contour pad component 16. FIG. 6 shows thefoam inserts frame 10. Thefoam inserts frame 10 by staples but could also be adhered by adhesive, nails or tape. - FIG. 7 shows an alternate embodiment in which an
additional foam insert 18 is adhered to the front of thechair arm frame 10 providing decorative ornamentation includingconcentric circles 20. It should be recognized to one having skill in the art that alternative decorative shapes can be provided. These decorative shapes can be of a more complex form than those made by traditional methods. - FIG. 8 shows a finished chair arm having
upholstery material 22 attached to theframe 10 and inserts 12, 14, 16 and 18 using normal furniture industry standards. - According to the preferred embodiments of the present invention, the
upholstery material 22 can be attached directly to theframe 10 and inserts 12, 14, 16, and 18. Alternatively, a layer of soft foam or other type of padding can be arranged between theinserts upholstery material 22. Such soft foam or padding is known to those of skill in the art. - While the embodiments illustrated in the FIGS.4-8 include a portion of the
frame 10 extending to the edge of theinserts frame 10 such that the frame is not exposed. In such embodiments, it may not be necessary to use a layer of soft foam between the inserts and the upholstery material. In those embodiments, the inserts are preferably made of the rigid foam material, as described above. - FIG. 9 illustrates another embodiment, wherein the
frame 110 includes a top substantiallyplanar surface 115 to which asemicylindrical insert 112 is attached. Asecond insert 114 is attached to aside surface 117 of theframe 110. According to this embodiment, manufacturing can be simplified by utilizing inserts having simple or complex geometric shapes and large planar surfaces. Another advantage of this embodiment is that the entire upper surface of theframe 110 is covered with asingle insert 112. Accordingly, there is no wooden portion extending to the top part of the furniture component. - Although the invention has been described in terms of particular embodiments in an application, one of ordinary skill in the art, in light of the teachings herein, can generate additional embodiments and modifications without departing from the spirit of, or exceeding the scope of, the claimed invention. Accordingly, it is understood that the drawings and the descriptions herein are proffered only to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
Claims (18)
1. An upholstered furniture component comprising:
a frame;
a rigid foam insert attached to said frame; and
upholstery material covering said foam insert.
2. The component of claim 1 , wherein, said rigid foam insert is formed of expanded polystyrene.
3. The component of claim 2 , further comprising a layer of padding between the rigid foam insert and the upholstery material.
4. The component of claim 1 , wherein the component is an arm of a chair or sofa.
5. An upholstered furniture component comprising:
a frame having a substantially flat planar upper surface;
a rigid foam insert attached to said flat planar upper surface; and
upholstery material covering said foam insert.
6. The component of claim 5 , wherein, said rigid foam insert is formed of expanded polystyrene.
7. The component of claim 6 , further comprising a layer of padding between the rigid foam insert and the upholstery material.
8. The component of claim 6 , wherein the rigid foam insert has a density in the range of 0.75 to 6.0 pounds per cubic foot and a compressive strength at 10% compression (strain) of 30 to 800 kPa.
9. The component of claim 6 , wherein the rigid foam insert has a density in the range of 1.5 to 2.5 pounds per cubic foot and a compressive strength at 10% compression (strain) of 120 to 280 kPa.
10. An insert in an upholstered furniture component, the upholstered furniture component including a frame supporting the insert and an upholstery material covering the insert, the insert comprising a rigid foam material having one portion thereof shaped to conform to the frame so that the rigid foam material can be attached to the frame and another portion of the rigid foam material shaped to correspond to an outer shape of the upholstered furniture component.
11. The insert of claim 10 , wherein the insert is made of expanded polystyrene.
12. The insert of claim 10 , wherein padding is arranged between the insert and the upholstery material.
13. The insert of claim 10 , wherein the component is an arm of a chair or a sofa.
14. An insert in an upholstered furniture component, the upholstered furniture component including a frame having a substantially flat planar surface supporting the insert and an upholstery material covering the insert, the insert comprising a rigid foam material having a flat surface shaped to conform to the substantially flat planar surface of the frame so that the rigid foam material can be attached to the frame and another portion of the rigid foam material shaped to correspond to an outer shape of the upholstered furniture component.
15. The insert of claim 14 , wherein the insert is made of expanded polystyrene.
16. The insert of claim 14 , wherein padding is arranged between the insert and the upholstery material.
17. The component of claim 15 , wherein the rigid foam insert has a density in the range of 0.75 to 6.0 pounds per cubic foot and a compressive strength at 10% compression (strain) of 30 to 800 kPa.
18. The component of claim 15 , wherein the rigid foam insert has a density in the range of 1.5 to 2.5 pounds per cubic foot and a compressive strength at 10% compression (strain) of 120 to 280 kPa.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/418,096 US20040026970A1 (en) | 2002-05-28 | 2003-04-18 | Upholstered furniture inserts |
AU2003240816A AU2003240816A1 (en) | 2002-05-28 | 2003-05-28 | Upholstered furniture inserts |
PCT/US2003/016769 WO2003099072A1 (en) | 2002-05-28 | 2003-05-28 | Upholstered furniture inserts |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US38387602P | 2002-05-28 | 2002-05-28 | |
US36079803A | 2003-02-10 | 2003-02-10 | |
US10/418,096 US20040026970A1 (en) | 2002-05-28 | 2003-04-18 | Upholstered furniture inserts |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US36079803A Continuation-In-Part | 2002-05-28 | 2003-02-10 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040026970A1 true US20040026970A1 (en) | 2004-02-12 |
Family
ID=29587045
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/418,096 Abandoned US20040026970A1 (en) | 2002-05-28 | 2003-04-18 | Upholstered furniture inserts |
Country Status (3)
Country | Link |
---|---|
US (1) | US20040026970A1 (en) |
AU (1) | AU2003240816A1 (en) |
WO (1) | WO2003099072A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9420891B2 (en) | 2013-11-29 | 2016-08-23 | Zinus, Inc. | Foam furniture molded around a rigid foam core |
US9456696B2 (en) | 2013-11-29 | 2016-10-04 | Zinus, Inc. | Foam furniture molded around a core with a lumbar support protrusion |
US10117521B2 (en) | 2015-10-20 | 2018-11-06 | Ashley Furniture Industries, Inc. | Upholstered furniture piece having upholstered arm panels |
US10271657B2 (en) | 2013-11-29 | 2019-04-30 | Zinus Inc. | Foam furniture molded around a hollow shell of hard plastic |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10034554B2 (en) * | 2015-10-20 | 2018-07-31 | Ashley Furniture Industries, Inc. | Upholstered furniture with integrated back rest portion webbing support |
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US4092049A (en) * | 1976-10-21 | 1978-05-30 | Overman Ab | Lightweight knocked-down chair design constructed of inexpensive components |
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2003
- 2003-04-18 US US10/418,096 patent/US20040026970A1/en not_active Abandoned
- 2003-05-28 AU AU2003240816A patent/AU2003240816A1/en not_active Abandoned
- 2003-05-28 WO PCT/US2003/016769 patent/WO2003099072A1/en not_active Application Discontinuation
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US3759571A (en) * | 1972-06-06 | 1973-09-18 | Burris Industries | Seat construction |
US4092049A (en) * | 1976-10-21 | 1978-05-30 | Overman Ab | Lightweight knocked-down chair design constructed of inexpensive components |
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US4777681A (en) * | 1986-01-10 | 1988-10-18 | Lueck Werner | Cushion with stuffing of foamed material |
US5189743A (en) * | 1988-10-17 | 1993-03-02 | Difloe Donna M | Drainable cushion and furniture seating |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9420891B2 (en) | 2013-11-29 | 2016-08-23 | Zinus, Inc. | Foam furniture molded around a rigid foam core |
US9456696B2 (en) | 2013-11-29 | 2016-10-04 | Zinus, Inc. | Foam furniture molded around a core with a lumbar support protrusion |
US10271657B2 (en) | 2013-11-29 | 2019-04-30 | Zinus Inc. | Foam furniture molded around a hollow shell of hard plastic |
US10117521B2 (en) | 2015-10-20 | 2018-11-06 | Ashley Furniture Industries, Inc. | Upholstered furniture piece having upholstered arm panels |
US10694863B2 (en) | 2015-10-20 | 2020-06-30 | Ashley Furniture Industries, Inc. | Upholstered furniture piece having upholstered arm panels |
Also Published As
Publication number | Publication date |
---|---|
WO2003099072A1 (en) | 2003-12-04 |
AU2003240816A1 (en) | 2003-12-12 |
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Owner name: TUSCARORA INCORPORATED, PENNSYLVANIA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:VASSAR, MATTHEW WILLIAM;HAYNES, REGGIE A.;REEL/FRAME:014798/0090 Effective date: 20030915 |
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