GB2372699A - Washer - Google Patents

Abstract

A support (20) for use with a tuft (12) comprises a base layer (28) having a fleece layer (26) on one side of the base. Part of the fleece layer (26) is folded under the underside of the base layer (28) and attached thereto. This avoids exposure of the base layer (28) to the user should the support (20) curl up under the tension of retaining link (16) when the tuft (12) is fitted to mattress (10).

Description

Washer This invention relates to a washer for use with tufts for upholstery units such as mattresses, futons and cushions.

In the art, the word'tuft'is generally understood to comprise a pair of elements (hereinafter known as'tuft elements') located so that one is outside each principal face of the mattress, and held together by means of a cord, strip or similar device (hereinafter referred to as a'retaining link'), attached to each tuft element. Hereinafter the word 'tuft'when used alone will be used to describe the complete arrangement of tuft element (s), retaining link and further features.

Examples of tufts include'tape tufts'such as those disclosed in UK Patent 814 651 (commonly known in the trade as POPIN tufts), and tufts comprising moulded plastic tuft elements such as those described and illustrated in the present applicant's copending UK Patent Application No. 0015139. 9, and tufts comprising an elastic retaining link such as those described in the applicant's simultaneously filed UK Patent Application.

Many manufacturers use a support, such as a washer, in connection with a tuft; a support may be provided on either or both faces of the mattress. The function of such supports is to prevent the tuft element from being pulled through the mattress ticking and to make the tuft more comfortable to sit or lie on. The support has a hole (usually in its centre) through which the tuft element may pass. Typically, such supports are made from compressed felt or foam.

The known tufts and supports may be fitted to the mattress etc. using means which are readily apparent to those skilled in the art, for example, using a tufting needle or the like, such as that disclosed in UK Patent 903 464, or more advantageously using the automatic tufting device described and illustrated in the present applicant's co-pending UK Patent Application No. 0015139. 9.

However, a problem exists with the known felt or foam supports made from such materials in that the edges thereof fray easily. It would therefore be desirable to make the supports from a more wear-resistant material.

It would also be advantageous to manufacture supports from materials, such as leather, fur or artificial fleece, as such materials are generally more aesthetically pleasing to the user and more comfortable to sit or lie on. As is well known, furs and fleeces comprise a base or skin layer with a layer of softer, fibrous material (hereinafter a"fleece layer") present on one side thereof. The manufacture of artificial fleeces is well known to those skilled in the art and is not the subject of the present invention.

However, once fitted to the mattress etc. , the retaining link of the tuft element is in tension. This causes the tuft elements and the supports attached thereto to be pulled tightly to the mattress. As shown in Fig. 1, the edges of the supports curl up, exposing the underside of the base layer. This is detrimental to the comfort and aesthetics of all known supports, but particularly fleece-like supports described above where the base layer is less comfortable or aesthetically pleasing than the fleece layer.

The problem is only partially solved by attaching two supports together, so that their bases face one another, as the edges thereof would still be visible when the support curls up.

Therefore, it is an object of the present invention to provide a support for a tuft which would enable the use of more wear-resistant materials, while avoiding the aesthetic deficiencies and discomfort hitherto encountered with such materials.

According to the invention, there is provided a support for use with a tuft, comprising a base layer having a fleece layer on one face thereof, wherein part of the fleece layer is folded under the other face of the base layer and attached thereto.

The support may take any form known in the art to be capable of supporting a tuft I element. As with the prior art supports, the support typically has a hole (usually in its centre) through which the tuft element may pass. Preferably, the support takes the form of a washer.

The base layer may be made from any suitable material, of which acrylic and polyester may be mentioned as non-limiting examples.

The fleece layer is made of any suitable material. As non-limiting examples of artificial fleece layers, artificial fibres such as polyester, acrylic and nylon may be mentioned.

Alternatively, animal skins such as sheepskin or other fur may together comprise the base and fleece layers.

Part of the fleece layer is folded over on to the underside of the base layer; this part is then attached to this face of the base layer by any suitable means known in the art, examples of which include the use of adhesive, stapling, sewing or thermal or ultrasound welding.

It is preferred that the support includes one or more radial projections. These projections can be folded on to the underside of the base layer more conveniently and allow the two faces of the base to adhere more firmly. It is especially preferred that the projections extend around substantially the entire perimeter of the support, as this minimises the area of base layer exposed should the support curl up. A star-shaped support is particularly preferred, as when the projections thereof are folded over, the folded support takes the approximate shape of a regular polygon. Such a star may have any number of points. Six to fourteen points are preferred and nine are especially preferred.

The invention conveys a number of advantages over the prior art, in that supports may be produced from materials more resistant to wearing; furthermore, such supports are less prone to curling up at the edges when under the tension of the fitted retaining link of the tuft. Should the edges curl up, the fleece layer of the material is present on the outside, inside and periphery of the supports, exhibiting a superior aesthetic appearance to a support merely cut from fleece material as in the prior art. Further, such fleece supports exhibit superior wear properties to the prior art felt or foam supports.

The invention will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 represents a tuft provided with a prior art support, in use; Fig. 2 is a view of a support according to a preferred embodiment of the present invention showing the radial projections prior to folding ; Fig. 3 is an underneath view of the support of Fig. 2 with the projections folded over and adhered to the underside of the base; and Fig. 4 represents a tuft provided with the support of Figs. 2 and 3, in use.

Referring first to Fig. 1, there is provided in the prior art a mattress 10 fitted with a tuft 12, the tuft 12 comprising two tuft elements 14a, 14b disposed at either end of a retaining link 16. Washers 18a, 18b are disposed between the surface of the mattress and the tuft elements 14a, 14b, the retaining link 16 passing through a hole in the centre of each washer. As can be seen, the tension in retaining link 16 and the consequent inwardly-directed force causes the washers 18a, 18b to curl up. The underside of the washer is therefore visible.

Fig. 2 illustrates a washer 20 according to a preferred embodiment of the present invention. The washer is provided with a hole 22 through which a retaining link and tuft element may pass when the tuft is fitted. The washer is further provided with a plurality of radial projections 24, foldable on to the underside of the base.

In use, the washer 20 is prepared by folding the projections 24 onto the underside of the base, and adhering the projections to the base. As can be seen clearly from Fig. 3, fleece is thereby present on the underside and edges of the washer.

The washer and tuft are then fitted to the mattress using standard techniques readily apparent to those skilled in the art, such as those described in the references mentioned above.

Fig. 4 illustrates the support 20 in use. As is readily apparent, even when the edges of the support curl up under the tension of retaining link 16, fleece 26 is present on all parts of the support 20 which are visible in normal use, thus obscuring the less comfortable and less aesthetically pleasing base layer 28 from the user.

Claims (5)

1. CLAIMS: 1. A support for use with a tuft, comprising a base layer having a fleece layer on one face thereof, wherein part of the fleece layer is folded under the other face of the base layer and attached thereto.
2. 2. A support according to claim 1, further including one or more radial projections.
3. 3. A support according to claim 2, wherein the projections extend around substantially the entire perimeter of the support.
4. 4. A support according to claim 2 or claim 3 which is star-shaped.
5. 5. A support for use with a tuft, substantially as described and illustrated herein.