GB2151133A

GB2151133A - Method of manufacturing furniture

Info

Publication number: GB2151133A
Application number: GB08333251A
Authority: GB
Inventors: Philip Hawtree; David Alan Seymour
Original assignee: BRANDYWELL INVESTMENTS Ltd
Current assignee: BRANDYWELL INVESTMENTS Ltd
Priority date: 1983-12-13
Filing date: 1983-12-13
Publication date: 1985-07-17
Also published as: GB2151131A; GB8421307D0; GB8333251D0

Abstract

The invention relates to a method of manufacturing a seat which comprises providing two pre-upholstered lateral end assemblies 10, securing in spaced relation to each pre-upholstered lateral end assembly a respective mounting plate 14, mounting between the plates a seat support and back support, and fitting over the seat support and the back support a preformed upholstered fabric cover 30 having end flaps passing in the space between each mounting plate and the associated pre-upholstered end assembly. <IMAGE>

Description

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GB 2 151 133 A

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SPECIFICATION

Method of manufacturing furniture

5 The present invention relates to a method of manufacturing furniture.

A serious problem experienced by retail outlets selling furniture is that of the large amount of space that is required for display and storage. To mitigate 10 this problem it has become increasingly common in recentyears for furniture to be sold in kit form for assembly by the ultimate userandthis has been welcomed not only by the retailers but by the public to whom the savings are passed on in the form of 15 reduced price.

The types of furniture which lend themselves to such self assembly are kitchen cabinets, bedroom furniture, garden tables, and so forth, where the purchaser is called upon merely to assemble exposed 20 timber or board. It has not been possible, however, to sell upholstered furniture such as settees and armchairs for assembly by the user as the upsolster-ing is beyond the skills of even a dextrous untrained person.

25 The present invention seeks to provide a method of manufacture which permits upholstered furniture to be sold in kit form for assembly by the purchaser and in particular with the construction of seats.

According to the present invention, there is pro-30 vided a method of manufacturing a seat which comprises providing two pre-upholstered lateral end assemblies, securing in spaced relation to each pre-upholstered lateral end assembly a respective mounting plate, mounting between the plates a seat 35 support and back support, and fitting overthe seat supportandthe backsupporta preformed upholstered fabric cover having end flaps passing in the space between each mounting plate and the associated pre-upholstered end assembly.

40 As used in this specification, the term "seat" is intended to include an armchair, a sofa, a settee orthe like.

In accordance with a second aspect with the invention there is provided a kitfor assembly by a user 45 to form a seat, the kit comprising two pre-upholstered lateral end assemblies, two mounting plates each securable in spaced relation to a respective one of the pre-upholstered lateral end assemblies, a front rail, a back rail and a top rail the ends of which are adapted to 50 be secured to the said mounting plates, a seat support adapted to be located between the front and back rails, a back support adapted to be mounted between the back and top rails and an upholstered seat cover arranged to fit overthe seat support and the back 55 support and having end flaps arranged to pass between the plates and the end assemblies.

The rails may be secured to the plates by means of knock down fittings several varieties of which are in common use. For example, the heads of bolts 60 projecting from the plates may pass through holes in the rails into cylindrical recesses which receive captive nuts engaging the heads of the bolts and urging the rails and the plates towards one another.

The base supportandthe back support may either 65 be in theform of a rigid board or a resilient platform having theform of aframe mounting an arrangement ofspringsor elastic webs.

The upholstered fabric cover may conveniently be held in position by means of an elastic diaphram stretched across the back and the underside of the seat to ensure that the fabric cover should remain in constanttension during use.

The proposed method and kit construction enable a settee to be assembled from structural parts which occupy relatively little space in a warehouse but a problem is still presented bytheconsiderablebulkof the upholstery secured to the cover and of any loose cushions which may be sold with the seat.

In a particularly preferred feature of the invention, the seat cover and any cushions are packaged in compressedform,forexample undervacuum or rolled underpressure, so as to occupy a smaller volume when in the kitthan the fully expanded volume which they occupy during normal use.

The invention will now be described further, byway of exampIe, with reference to the accompanying drawingsin which:

Figures 1 to 6 show the different stages in the assembly ofthearmchairfrom a kitand by the method ofthe invention.

In the drawings. Figure 1 shows a fully upholstered end assembly 10. The end assembly 10 may be formed of a wooden frame upholstered in a conventional manner but it is preferred in the interest of reducing weight and manufacturing costs that the end assembly should comprise a plastics moulding, for example expanded polystyrene, which is upholstered in a conventional manner using stuffing orfoam and a suitable fabric. Holes 12 are formed in the upholsered end assembly and these register with nuts which are suitably retained on theframe ofthe end assembly.

Referring now to Figure 2, a mounting plate 14 is secured onto the end assembly 10 by means of bolts 16 which pass through the holes 12. Washers or spacers are arranged about the bolts 16 so that the plate 14 remains spaced from the end assembly 10 for reasons which will become apparent. This part of the assembly procedure may either be effected in the manufacturing plant priorto the kit being sold or may be entrusted to the purchaser.

Afterthe plates 14 have been moiunted in spaced relation on both the end assemblies 10, theframe of the seat is completed by suitably fixing a front rail 18, a back rail 20 and a top rail 22 between the two mounting plates 14 as shown in Figure 3. It is preferred that the three rails be connected to the plates 14 by a form of interlocking engagement.

In the preferred construction, the heads of bolts project from each plate and pass through holes in the rails into cylindrical recesses receiving captive nuts. Such knock down fittings are well known intheartand need not therefore be described within the context of the present application.

The plates 14 and rails may be manufactured of metal, wood or plastics material or a combination of such materials.

After the frame of the seat has been assembled, a seat support 24 and a back support 26 are mounted on the frame and screwed in position onto the plates 14 and the rails (see Figure 4). The seat and back supports

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GB2 151 133 A

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24 and 26 may either be rigid boards, or, as shown, they may be constituted by a tubularframes over which elastic web 28 are stretched the webs being interwoven to form an elastic lattice. As a still further 5 possibility, the frames 26 may support metal springs in manner a analogous to the spring interior of a bed.

Once the seat supports 24 and 26 have been screwed into position, they effectively prevent distortion of the frame and provide a rigid structure onto 10 which the upholstery may be secured. The fixing ofthe supports 24 and 26 in position also serves to prevent any disengagement ofthe rails 18,20 and 22 from the plates 14.

The portion ofthe seat lying between the two 15 pre-upholstered end assemblies 10 is now upholstered in a manner generally analogous to the method employed in upholstering seats in motor vehicles. A pre-formed upholstered fabric cover generally designated 30 in Figure 5 has a back portion 32 and a seat 20 portion 34 which are sewn to each other. The overlap between these two portions forms on the underside a so-called fly which is suitably secured to the back rail 20. For example, eyelets may be formed on the fly which are clipped onto hooks on the backrail 20. 25 Alternatively, thefly may be secured to the base ofthe cover at thefront of the seat by elastic passing through eyelets in thefly and front cover, or in any other suitable manner.

Each ofthe portions 32 and 34 is stuffed on its 30 underside with foam or othersuitablestuffing and the two parts are stretched respectively overthe seat support and the back support. The cover30 has end flaps which fit in the gap between the frames 14 and the upholstered end assemblies 10 so thatthe fabric 35 coversthe mounting plates 14and gives the appearance of a fully upholstered seat.

Atthe upper rear edge ofthe cover 30, an elastic sheet stretching across substantially across the width ofthe seat is sewn to the cover 30 in addition to a loose 40 flap 38 which covers the outside back ofthe seat. The elastic sheet is stretched overthe back ofthe rails 22 and 20 and along the underside ofthe rails 20 and 18 and is secured to eyelets 36 attached to thefront edge ofthe seat portion 34. Because ofthe elasticity ofthe 45 sheettheseatand back portions34and 32are maintained taught so as to avoid the appearance of loose covers. This is once again similarto the construction sometime used in car seat manufacture where a rubberdiaphram is disposed beneath ofthe 50 base ofthe seat portion.

The end flaps which pass between the plates 14 and the upholstery end assemblies 10 are also provided with eyelets or the like means for enabling them to be secured along the side edges ofthe elasticated sheet 55 ordiaphragm.

The flap 38 extending down the back ofthe seat is provided down each side with Velcro (Registered Trade Mark) orthe like releasablefastening and is in this way secured along the back edge ofthe outside 60 backoftheseattoconcealtheelasticatedsheet.

In the last stage of manufacture, shown in Figure 6, a fringing material is secured around the lower edge of the seat the material being once again held in position by Velcro.

65 It will be clear to a person skilled in the art, that several modifications may be made both in the style of the chair and in the details ofthe assembly. As an example, in place of providing an elasticated sheet extending along the back of the seat, the upholstered cover may be clipped onto the underside ofthe rails and thecushioning material may be relied upon to maintain the fabric taught.

It will be appreciated thatthe construction proposed above allows an armchair or settee of conventional appearance to be sold and stored in a compact package.

In orderto retain the advantage ofthe compact packaging it is preferred thatthe air in the upholstery be removed by packaging under compression. The technique of vacuum packaging,which reduces the bulk of articles containing a substantial volume of air, is believed to be well known and need nottherefore be described in detail. The technique lends itself particularly well to the kit and the method of assembly ofthe invention since it enables an entire upholstered three piece suite to be driven home in the back of a family estate car. In addition to the convenience being able to buy a three piece suite instantly, this also permits further saving in the cost of delivery.

Claims

1. Amethodof manufacturing aseatwhich comprises providing two pre-upholstered lateral end assemblies, securing in spaced relation to each pre-upholstered lateral end assembly a respective mounting plate, mounting between the plates a seat support and back support, and fitting over the seat supportandthe back support a preformed upholstered fabric cover having end flaps passing in the space between each mou nting plate and the associated pre-upholstered end assembly.

2. A kit for assembly by a userto form a seat, the kit comprising two pre-upholstered lateral end assemblies, two mounting plates each securable in spaced relation to a respective one ofthe pre-upholstered lateral end assemblies, a front rail, a back rail and a top rail the ends of which are adapted to be secured to the aid mounting plates, a seat support adapted to be located between the front and back rails, a back support adapted to be mounted between the back and top rails and an upholstered seat cover arranged to fit overthe seat support and the back support and having end flaps arranged to pass between the plates and the end assemblies.

3. A kit as claimed in claim 2, wherein the rails are secured to the plates by means of knock down fittings.

4. A kit as claimed in claim 2 or 3, wherein the back support and the seat support are elasticated or sprung.

5. A kit as claimed in any one of claims 2 to 4, wherein the upholstered fabric cover is held in position by means of an elastic sheet stretched across the backand the underside ofthe seat to ensure that the fabric cover should remain inconstanttension during use.

6. A kit as claimed in any one of claims 2 to 5, wherein the seat cover and any cushions are packaged in compression so asto occupy a smaller volume when in the kit than thefully expanded volume which they occupy during normal use.

8. A method of manufacturing a seat, substantially

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GB 2 151 133 A 3

as herein described with reference to and as illustrated in the accompanying drawings.

Printed in the United Kingdom for Her Majesty's Stationery Office, 8818935, 7/85,18996. Published at the Patent Office, 25 Southampton Buildings,

London WC2A 1AY, from which copies may be obtained.