CA2066872A1 - Lampshades and lamp bases - Google Patents

Abstract

BP File No. 6621-002 ABSTRACT OF THE DISCLOSURE

A method of making a lampshade and a kit for use in the method. The kit includes a base comprising a pre-formed substantially rigid polystyrene sheet in a frusto-conical shape and having an external surface coated with pressure-sensitive adhesive. A release sheet covers the adhesive but can be peeled off and used as a pattern to cut a section of fabric to be used as a covering. The fabric is laid progressively onto the adhesive so as to give a smooth and wrinkle-free covering on the lampshade.
The polystyrene sheet is translucent for permitting light transmission. The method may also be used to decorate a lamp base, for example, with a fabric to match the fabric used on the shade.

Description

BP File No. 6621-002 7 ~

Title: L~MPSHADES A~D LAMP ~AS~S

FIELD OF l~lE INVENTION
This invention relates generally to lampshades and lamp bases. Moxe particularly, the invention is concerned with a "do-it-yourself" (DIY) method of making lampshades, and a corresponding method that can be applied to the decoration of lamp bases.
BACKGROUND OF THE INVE~TION
Commercially made lampshades are available in a wide variety of different sizes and designs and with many different coverings. However, there remains a need for lampshades that can be custom made with a specially selected fabric or other covering. It is of course possible to have lampshades pro-fessionally custom made using fabric of the customer's choice. Howe~er, this is expensive and there i5 a desire for consumer to be able to custom make their own lampshades. For example, a homemaker having sewing skills may wish to buy fabric to cover, say cushions and would like to be able to use some of the same fabric to cover lampshades to be used in the same room.
Existing methods for DIY making of lampshades do not reliably produce lampshades that have a professionally finished "look". For example, certain types of professionally made lampshade are characterized by a smooth and wrinkle-free fabric layer on the exterior of the shade itself. It is very difficult to achieve this look~ in a DIY lampshade.
Perhaps the most common DIY method for making lampshades is for the consumer to purchase a pre-made metal frame over which the fabric is drawn and sewn. This method may produce quit~ at~ractive lampshades of the type that have an irregularly pleated or l'loose" type of fabric covering but it is very difficult to obtain a s~ooth and taut covering.
It has been proposed to sell a "kit" which 3 ~ ~

includes a flat backing sheet that can b~ curved to form a lampshade of frusto~conical shape. The sheet has a pressure-sen~itive adhesive on one surfac2, to which fabric is adhered while the sheet is flat. The kit also includes plastic rings that are slid over top ~nd bottom edges of the sheet after it has been formed into its frusto-conical shape, to hold the sheet in that shape.
While it is possible for the consumer to smoothly lay the fabric covering onto the adhesive surface of the backing sheet, practical problems do arise because the sheet must then be formed into its frusto-conical shape; thi~ means that the fabric must stretch to conform to the curvature of the sheet. If the fabric will not stretch sufficiently, it will tend to pull away from the sheet in the end regions thereof. In any event, the final product is not very attractive aesthetically because of the plastic rings that are required to be fitted over the top and bottom margins of the sheet to hold the sheet in its frusto-conical form.
BRIEF DESCRIPTION OF ~E INV~TIO~
Accordingly, an object of the present invention is to provide an improved DIY method for making a lampshade, and a "kit" for use in the method. Another ob~ect is to provide a method for decorating a lamp base, and a lamp base ~or use in the method.
In one aspect of the invention there is provided a method of making a lampshade which involves the steps of providing a base which comprises a substantially rigid hollow support pre-formed to a shape required for the lampshade and intended to be covered with decorative sh~et material. The support has an outer surface provided with a coating of a pressure-sensitive adhesive. A release sheet covers the adhesive and is shaped to form a template for cutting to shape a section of the decorative sheet material to be applied to the adhesive surface. The cut section is laid progressively onto ~he adhesive surface to form a substantially smoo~h and wrinkle-free covering on r~

the said surface.
Preferably, the support has open opposite ends.
It may be possible to cut the decorative material precisely to the template provided by the release sheet so ~ 5 that the edges of the decorative material at the top and bottom of the support fini~h exactly co-extensively with the top and bottom edges of the suppor~ itself and in effect become finished edges. Preferably, however, the decorative sheet material is cut to project slightly above and below the top and bottom edges of the support and an appropriate finishing operation is performed ~o give a finished edge. For example, the pro~ecting edges may be folded inside and secured using ~white craft gluel~ of the type typically used by hobbyists and the like. This type of glue is readily available from craft s~ores and other retail outlets.
While various materials may be used to form the support to which the fabric is adhered, it has been found that a thin sheet of translucent white or black polystyrene is eminently suitable. Polystyrene sheets can readily be curved to form many of the shapes typically required for lampshades and will then provide a relatively rigid and smooth supporting surface for the decorative sheet (e.g. fabric). The thickness of the polystyrene sheet can be selected according to the size of the lampshade. For example, a very large lampshade will require a thicker sheet to provide a firm supporting surface.
It has been found that translucent polystyrene is also ideal in terms of light transmission from the bulb inside the lampshade, through most types of fabric coating. Fully transparent sheets, e.g. of plastic, could alternatively be used if greater light transmission is required.
The lampshade support can be made in a variety of shapes. Nhile frusto-conical is perhaps the most common, full conical ~hapes, cylindrical shapes or shapes that are oval in cross-section can of course also easily be made. It may also be possible to form sguare or other polygonal cross-section tubes by providing appropriate support for the sheet.
S Preferably, ~he pressure-sensitive adhesive is of an air drying type that is brushed or sprayed onto the support and which ~hen dries to leave a tacky surface~
Adhesives having these characteristics are readily available commercially. For example, water-based adhesives of ~his type are used by bookbinders and leather goods manufacturers.
The release sheet can be a silicone-coated paper sheet. It will be under~ood that the release sheet should be shaped to pxecisely fi~ the adhesive-coat~d surface of the support. The sheet can be dimensioned to allow for an overlap seam running from top to bottom of the support, in which case the decorative covering material will have a similar seam. Again, white craft glue can be used to secure the ~flap~' of decorative material at the seam. Alternatively, the release sheet could be dimensioned to provide a butt jointed seam.
However, it may be more difficult to obtain a satisfactory lampshade with a seam of this form.
The support will normally be provided with appropriate fittings to attach the lampshade to the bulb or to the so-called "harp" tthe heavy wire bracket that is often provided on a lamp to hold the shade). For example, in a preferred embodiment, a wire ring is provided at the top end of the support and the top margin of the polystyrene sheet is 3ecured to the ring using tape.
diametral element then extends across the ring and is formed to provide two circular wire hoops that embrace the bulb for supporting the lamp3hade. Of course, the fittings are provided during manufacture of the lampshade kit and nothing is required of the consumer in this connection. A similar wire ring' but without the bulb engaging fitting may be provided at the bottom edge of the lampshade support.
As indicated previously, a further aspect of the invention provides a kit for use in the me~hod. The kit includes a base comprising a substantially rigid hollow support pre-formed to a shape required for the lampshade and intended to be covered with decorative sheet material, the support having an outer suxface provided with a coating of pressure-sensitive adhesive, and a release shaet covering said pressure-sensitive adhesive. The sheet is shaped to form a pattern for cutting a covering of said decorative sheet material to be applied to said adhesively coated surface.
The kit provided by the inven~ion has a number of significant advantages in terms of sales appeal as compared with the prior art kits that are sold flat. For example, the inventive kit is readily recognizable to the consumer as a lampshade. Also, the consumer can more easily select the coxrect size and shape from a display of different kits.
A further aspect of the invention involves the provision of a lamp body that can be decorated with sheet material, for example a fabric, in a fashion similar to a lampshade. A lamp body provided by the invention consists of or includes a support suitable for covering with decorative sheet material. The support has an outer surface provided with a coating of pressure-sensitive adhesive and a release sheet covers the pressure-sensitive adhesive. The sheet is~shaped to form a template for use in cutting said covering of decorative sheet material rom a length of said material.
A method of decorating a lamp base is also provided and involves the provision of a lamp base of the form referred to above. According to the method, the release sheet is removed from the base and used as a template to cut a section of decorative sheet material to form said covering for the outer surface of the support.
The cut section of decorative ~heet material is laid $ ~ J~

progressively onto the adhesive surface 50 as to form a substantially smooth and wrinkle-free covering on said surface.
BRIEF DESCRlpTloN OF l~ DRANI~ 5 In order that the invention may be more clearly understood, reference will now be made to the accompanying drawings which illustrate a particular preferred embodiment of the invention by way of example, and in which:
Fig. 1 is a perspective view of a lampshade kit in the form in which i, would be purchased by a consumer;
Fig. 2 is a view similar to Fig. 1 showing the release sheet "exploded~ from the surface of the support;
Fig. 3 shows the release sheet in position on a sheet of fabric for cut~ing out a fabric section to be applied to the support;
Figs. 4 and 5 illustra~e the steps of applying the fabric covering to the support and finishing the ends of the fabric covering; and, Fig. 6 is an elevational view of a lamp base in accordance with a further embodiment of the invention.
DESCRIPTIQN OF PREFERRE~:D l~QDI~
Referring now to Fig. 1 of the drawings, a lampshade making Xit is shown to include a base 20 of hollow frusto-conical shape such as is typically used for a lampshade. The base comprises a substantially rigid hollow support 22 made up of a thin sheet of polystyrene having wire rings 24 and 26 at its upper and lower ends respectively. As described preYiously, the base is intended to be covered with decorative sheet material such as a sheet of fabric and has an outer surface provided with a coating of pressure-sensitive adhesive. The base also includes a release sheet 28 which covers the adhesive and forms the outer surface of the base as sold.
In Fig. 2, the release sheet 2g is shown in an l~exploded" position clear of the surface of the support 20 so that the adhesive surface of ~he suppor~ can be seen.

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That surface is denoted by reference numeral 30. The polystyrene sheet is cut to an arcuate shape corresponding to the required height of the lampshade and has a circumferential extent sufficient to allow for the formation of a narrow overlapped seam 22a which extends vertically of the support. The overlapping portions of the sheet are glued together. The two wire rings 24 and 26 fit inside the top and bottom margins respectively of the formed sheet. Each ring is ~ecured ~o the polystyrene sheet by a paper tape 32 that embraces the relevant margin of the sheet and the wire ring. The two sections of tape are secured to the polystyrene sheet and around the wire rings by adhesive. The top ring carries a conventional wire fitting designed to clip over a light bulb, and the fitting is shown in dotted outline at 34.
In manufacturing the ki~, the polystyrene sheet is cut to shape and the top and bottom wire rings are secured to the sheet using the paper tape mentioned above.
Seam 22a is then formed by gluing. Finally, the entire external surface 30 including the ou~er surfac~s of the portions of the raspective ~apes is coated with the pressure-sensitive adhesive. ~he adhesive is allowed to dry to its final "tacky~ form and the release sheet 28 is applied. As best seen in Fig. 1, the release shaet is designed to conform exactly to the height of the support 22 and to cover the entire adhesive surface 30, leaving a narrow overlap 28a of the marginal end portions of the release sheet. The overlapping portions of the relea~e sheet are not secured together; the outer marginal portion is usually free, but may be tempor~rily held down by tape on small size lampshades, for shipping and handling. The release sheet itself is a silicone-coated paper sheet.
In order to begin making a lampshade, the consumer grasps the free end 28a of the release shee~ and peels the sheet off the support 22. The release sheet is then u`sed as a template or pattern to cut a section of fabric or other sheet material which is to be used to S,~J ~ 7 cover the lampshade. In Fig. 3, the release sheet 28 is shown laid flat on a piece of fabric 36. By cutting the fabric exactly on the outer edge of tha release sheet 28l a section of fabric i~ obtained that exactly fits the adhesively coated surface 30. The fabric can be cut exac~ly to the shape if the top and bottom margins are to be left with the fabric simply secured to the support by the adhesive on surface 30. Preerably, howe~er, the fabric is cut slightly above and below ~he curved edges of the release sheet as indicated in ghost-outline at 36a and 36b. This lea~es extra portions at the ~op and bottom of the fabric section that can be used to produce finished edges as will be described.
Once the fabric section has been cut, the cut section is laid onto the adhesive surface 30 in a smooth and even manner so as to produce a wrinkle-free covering on the ~upport. Preferably, the consumer is instructed to apply the fabric section (denoted 38) starting at the seam 22a in the polystyrene sheet as shown in Fig. 4 and to in effect wrap the fabric sheet around the support generally as indicated by the arrow denoted 40 in Fig. 4. When the fabric sheet has been completely wrapped around the support, the marginal end portion 38a that is shown free in Fig. 4 overlaps the marginal end portion 38b of the sheet that was first placed on the support and an overlap seam is formed in substantially similar fashion to the overlap seam 28a of the release sheet 28 as shown at 42 in Fig. 5. In this case, however, white craft glue is applied to the inner surface of the free marginal portion of the fabric sheet so that a closed seam is formed. The finished seam may also be formed by folding the free marginal edge in towards the support and gluing the folded edge down.
Finally, glue is applied to the inner surface of the portions of the fabric sheet that pro~ect above and below the support and those portions are then folded inside as indicated by arrows 44 and held in place by the glue. If necessary, the o~erlapping portions of the fabric sheet can be trimmed down before gluing (e.g. to about 3/8" in height). Additional trimmings such as fabrics, braids, fringes or plastic snap-on U~sections can - 5 of course be applied to the top and bottom edges if desired.
~ sing the method of the invention, it is possible for even a relatively unskilled person to reliably make lampshades with a professional ~look~. No special tools or equipment are required. The underlying support provides a firm backing for the fabric or other decorative material and the adhesive coating ensures that the fabric is held down over its entire surface. The use of the backing sheet as a template ensures that the fabric covering fits precisely.
Fi~. 6 shows a complete lamp comprising a lamp shade 46 and a lamp base 48. The lamp shade may be a conventional lampshade or may be made by the method referred to above. In accordance with a further aspect of the invention, the lamp base 48 may be made so as to include or consist entirely of a ~upport that may be decorated by essentially the same method as that described previously in connection with a lampshade. Primed reference numerals have been u~ed in Fig. 6 to denote parts that correspond with parts shown in Figs. 1 - 5.
In Fig. 6, the lamp base 48 is shown to comprise a cylindrical support 22' from which a narrow tube 50 extends axially upward and caxries a holder 52 for a bulb 54 on which the lampshade 46 is carried in conventional fashion.
In this embodiment, the cylindrical support 22' forms the entire base of the lamp. ~owever, th~ areas indicated in ghost outline at 56 and 58 illustrate the fact that the support may form part only of the overall lamp base. It should also be noted that any one lamp base may include several separate supports each to be covered with decorative material. For example, several cylindri-? ~

cal supports could be provided on a common central stem.Also, while a cylindrical shape has been shown, other shapes may be used as discussed previously in the context of the lampshade. As an example only, the lamp base could comprisP or include a conically shaped support.
Reverting to Fig. 6, support 22' has an outer cylindrical surface provided with a coating of pressure-sensitive adhesive which is in turn covered by a release sheet 28' that forms the ou~er surface of the support in the lamp base as sold. The release sheet serves as a template for cutting a section of decorative sheet material (such as fabric) and the material is applied to the support in exactly the same fashion as is discussed previously in connection with the lampshade. In this case, the top and bottom margins of the fabric covering will not of course be folded inside; those margins can be cut flush with the ends of the support or can be provided with decorative trim or other finishinq means. Nhere the lampshade is made by the method of the invention, the lamp base may of course be decorated using the same fabric as that used for the lampshade.
In the context of a lamp base, the support may simply be made as a cylindrical (or other appropriately shaped) part of the base by any of the techniques normally used for making lamp bases. For example, referring to Fig. 6, where lamp base portions 56 and 58 are present, the base may comprise a rigid cylinder forming support 22' and end fitments forming the base portions 56 and 58. The structure of the base itself and its method of manufac~ure are otherwise irrelevant to the invention.
A table lamp has been shown in Fig. 6 but it should be noted that the in~ention may be applied to any type of lamp base. Other examples are a floor lamp and a bedside lamp.
It will of course be understood that the preceding description relates to particular prefeLred embodiments of the invention only and tha~ many i3 7 ~

11 ~

modifications are possible. Some of those modifications have been specifically indicated above and others will be apparent to a person sXilled in the art.
In the context of the lampshade, possible modifications include use of a support made from multi-ply paper board, for example with foil laminated to the inside. Injection moulded styrene supports may also be used. In the latter case, the top and bottom wire rings referred to previously may be omitted and the bulb clip simply pushed into pre-moulded hole in the top of the form. Since there is no wire ring, the lampshade made from this type of support is best covered and then trimmed flush at the top and bo~tom edges.

Claims (14)

1. A method of making a lampshade which comprises the steps of:
providing a base comprising a substantially rigid hollow support pre-formed to a shape required for the lampshade and intended to be covered with decorative sheet material, said support having an outer surface provided with a coating of pressure-sensitive adhesive, and a release sheet covering said pressure-sensitive adhesive, said sheet being shaped to form a pattern for a covering of said decorative sheet material to be applied to said surface;
removing said release sheet;
using said release sheet as a template, cutting a section of said decorative sheet material to form said covering for said outer surface of the support;
laying said cut section of decorative sheet material progressively onto said adhesive surface, so as to form a substantially smooth and wrinkle-free covering on said surface.

2. A method as claimed in claim 1, wherein said support has open opposite ends, and wherein the method further comprises the step of finishing portions of said decorative sheet covering at said opposite ends.

3. A method as claimed in claim 2, wherein said step of cutting a section of said decorative sheet material to form a covering for said surface includes allowing for portions of said covering to overlap said ends of the support, and wherein said step of finishing portions of said covering at opposite ends of the support includes folding and gluing said overlapping portions of the decorative sheet material inside said support.

4. A method as claimed in claim 1, wherein said decorative sheet material is a fabric.

5. A method as claimed in claim 1, wherein said support has open opposite ends and wherein said step of laying said cut section of decorative sheet material onto said adhesive surface comprises securing a first marginal end portion of said covering to said adhesive surface so as to extend longitudinally from end to end of said support, and wrapping the covering around the support so that a second marginal end portion of the covering is brought into a position overlying said first marginal portion secured to said surface, and wherein the method comprises the further step of securing said second marginal portion to the underlying first marginal portion using adhesive.

6. A kit for making a lampshade, comprisings:
a base including a substantially rigid hollow support pre-formed to a shape required for the lampshade and intended to be covered with decorative sheet material, said support having an outer surface provided with a coating of pressure-sensitive adhesive, and a release sheet covering said pressure-sensitive adhesive, said sheet being shaped to form a template for use in cutting said covering of decorative sheet material from a length of said material.

7. A kit as claimed in claim 6, wherein said substantially rigid hollow support is of frusto-conical shape.

8. A kit as claimed in claim 6, wherein said substantially rigid hollow support comprises a sheet of polystyrene.

9. A kit as claimed in claim 8, further comprising upper and lower wire rings disposed inside upper and lower marginal end portions of said support and attached by tape adhesively secured to said support over said rings, said upper ring including a fitment fox coupling said lampshade to a lamp.

10. A kit as claimed in claim 6, wherein said release sheet comprises a section of silicone coated paper.

11. A kit as claimed in claim 7, wherein said release sheet is wrapped around the support with a first marginal end portion thereof extending longitudinally from end to end of the support in contact with the adhesive, and a second marginal end portion overlying said first marginal end portion, whereby the release sheet can be removed from the support by grasping said second marginal end portion of the sheet.

12. A lamp base comprising a support suitable for covering with decorative sheet material, said support having an outer surface provided with a coating of pressure-sensitive adhesive, and a release sheet covering said pressure-sensitive adhesive, said sheet being shaped to form a template for use in cutting said covering of decorative sheet material from a length of said material.

13. A lamp base as claimed in claim 12, wherein said support forms part only of the base.

14. A method of decorating a lamp base, which comprises the steps of:
providing said lamp base in a form which comprises a support suitable for covering with decorative sheet material, said support having an outer surface provided with a coating of pressure-sensitive adhesive, and a release sheet covering said pressure-sensitive adhesive, said sheet being shaped to form a pattern for a covering of said decorative sheet material to be applied to said surface;
removing said release sheet;
using said release sheet as a template, cutting a section of said decorative sheet material to form said covering for said outer surface of the support;
laying said cut section of decorative sheet material progressively onto said adhesive surface, so as to form a substantially smooth and wrinkle-free covering on said surface.