GB2389783A

GB2389783A - Tuft

Info

Publication number: GB2389783A
Application number: GB0214443A
Authority: GB
Inventors: Jonathon Nicholas Whaley
Original assignee: Individual
Current assignee: Individual
Priority date: 2002-06-21
Filing date: 2002-06-21
Publication date: 2003-12-24
Also published as: GB0214443D0

Abstract

A tuft assembly for fastening to upholstery comprises a tuft element (10) and an elongate attachment device (28) integrally comprising first (24) and second (26) loop means, the tuft element (10) being attached to the first loop means (24) and a retaining link (18) being attachable, in use, to the second loop means (26). The first loop means (24) and the second loop means (26) are disposed relative to one another in the attachment device (28) such that, in use, the orientation of the attachment device (28) is restricted. This minimises the amount of slack in the tuft assembly when fitted to upholstery.

Description

l 2389783 Tuft This invention relates to a tub assembly incorporating a

novel attachment device. It also relates to the attachment device and to upholstery tufted using the tubs.

Upholstery, in particular mattresses. has long been held together by means of tufts. The tuft serves to stabilise the outer layers of materials, tickings and fillings of the mattress.

The invention mill be described hereinafter with reference to the tufting ol mattresses.

However. the skilled reader will understand that the tuRts described in the present invention are suitable for the tuRinL! of all types of upholstery, for example cushions and pillows and cushion or mattress elements of more complex upholstery units such as chairs. sofas futons and the like.

In the art' the word 'tub' is generally taken to comprise two elements (hereinafter known as 'tuft elements') located so that each one is outside each principal lace of the mattress. the tub elements lacing held together by means of a cord, loop or the like (hereinafter known as a 'retaining: link') attached to each tub clement. In this specification. the word 'tub' when used alone refers to the complete arrangement of tuft

element, retaining link and further features.

One type of tub known in the art is the 'tape tuft'. Tape tubs typically comprise a flexible strip (usually made of cotton, polyester, nylon, polypropylene or a combination of any of these or similar materials) adapted to pass through the mattress, which interacts at either end with a tuR element, typically a retainer bar (which may be made of metal or plastic) so that, in use, the bar is present on the outside of the mattress. Tape tufts are described and illustrated in GB 814651, and are also known in the trade as POPPED tufts or 'long/long tapes'.

Although tape tufts are commonly used in the art, mattresses tufted using such tufts are generally less comfortable to sit or lie on due to the rigidity of the tuft elements.

( Moreover. the customer may consider such tuft elements detrimental to the aesthetics of the mattress.

Another type of tub element well known in the art is the rosette tub element. illustrated in Figs. I a and I b.

The rosette tuft element 1() may. for example. be made by winding yarn around two spindles, securing the windings together in the middle (illustrated by reference number 12) while they remain wound around the two spindles, and withdrawing the spindles.

The windings may be secured together by. for example, tying. clasping or stapling. The resulting tuft element has a substantially circular or oval shape (the overall impression heing similar to a rosette). The vans may he w-,ollen yarn. synthetic yam (such as rayon or nylon) resembling wool. or a combination of the two. optionally including other yarn strinL:-like or ribbon-like material. Such rosette tub elements are often preferred by the customer due to their perceived aesthetic quality. and as a mattress tuned using such eltmcnts is generally more comfortable to sit or lie on than a mattress tubed with tape tufts. Other types of known tuft clement include elements made of soft material such as cotton, rayon, nylon. polyester. felt. Icather. fur or a combination of any of these or similar materials. Such elements may he take the forth of a patch (of regular or irregular shape), disk. wad or the like.

Upholstery buttons may also form the tuft element. The precise construction of upholstery buttons is known in the art and is not the subject of this invention. Examples of upholstery buttons are disclosed in, for example, GB 1379401, GB 1378636, GB 1378635, GB 1254970, GB 531261, US 4577373, US 4198733, US 4123825 and US 2077691.

A problem traditionally encountered in the art with rosette tub elements and the like, when used solely with a retaining link, is that the tension in the retaining: link may lead to the rosette tub element being pulled through the mattress. This is illustrated in Fig. 2,

( where the lower tuft element] ()h has started to pull through into the mattress 20 under the tension of cord 14.

GB-A-2349332 to Handy Limited attempts to solve this problem by providing a tuft assembly comprising a tuft element, especially a rosette tuft element, provided with an attachment device for allowing a retaining link to be attached. This enables the tuft assembly to be attached to upholstery by means of the retaining link. Throughout this specification the expression 'tuft assembly' should be understood to comprise in

general. a tuft element provided with an attachment device. but lacking the retaining link. As illustrated in Fig!. 4 of'GB-A-9349339. the tub assembly 1 () typicaliv comprises a rosette tuft element I I provided with an attachment device in the i'orm of' circular ring 13. The windings 12 used to hold the rosette tuft element 11 together are used to secure the rosette tuft clement I 1 to the attachment device 13. The tuft assembly I () may be attached to a mattress by any suitable retaining little including a tape tuft or a twine loop (see Figs. 6 and 9 respectively of'GB-A-9349339).

A problem exists with the tuft assembly descriLcd in GB-A-734'1332 when used with a tape tuft (an example of which is illustrated in Fig. 5 of'this prior art document) in that

the ring needs to he large enough to enable the retainer her of the tape tuft element to comfortably pass through when the tuft assembly is fitted to a mattress. When the mattress fitted with such tuRs is at rest. the retainer bar of the tape tub bears the compression load. As a result of this' a tuft assembly including such a ring becomes relatively loose in relation to the tape tuft head and mattress surface.

To attempt to overcome this problem, the commercially available embodiment of the tuft disclosed in GB-A-2349332, illustrated in Fig. 3 of this specification, incorporates

an attachment device in the shape of an oval loop 16 of length A I. The term 'loop' when used alone in this specification includes any closed loop, the exact shape of which

is not critical unless specified otherwise.

( However. the oval loop 16 is not a stable attachment in that its orientation cannot be fixed. Therefore' when fitted to a mattress. the orientation of the oval loop starts out in the condition leR by the manufacturing process. As illustrated in Figs. 4 and 5. under the tension of the retaining link 18, the loops 1 6a, 1 6b tend to reorientate such that the long axis thereof is generally transverse to the face of the mattress 20, thereby maximising the retainer-face distance and amount of slack in the tub. As shown by the; distance A2 in Fig. 5, the reorientation of the loop 1 6a can lead to the amount of slack I in the tuft increasing by as much as 50%. it would therefore be desirable to restrict the orientation of the attachment device so as to mindnise the amount of slack in the tub.

It is therefore an objective of the present invention to provide an attachment device for a tuft assembly. the orientation of which can easily he restricted. I There is therefore provided according to a first aspect of the present invention a tuft assembly for fastening to upholstery comprising a tuft clement and an elongate attachment device integrrully comprising first and second loop means, the tuft element hcing attached to the first loop means and a retaining link Acing attachable. in use, to the second loop means. the first loop means and the second loop means hcing mutually disposed such that. in use. the orientation of the attachment device is restricted, thereby minimisinL: the amount of slack in the tuft assembly when fitted to upholstery.

There is further provided according to a second aspect of the present invention an attachment device for a tuft element. the attachment device comprising a first loop means to which a tuft element is attachable. the first loop means being integral with a second loop means to which a retaining link is attachable. the first loop means and the second loop means being: mutually disposed such that in use, the orientation of the attachment device is restricted, thereby minimising the amount of slack in the tuft assembly when fitted to upholstery.

There is additionally provided according: to a third aspect of the present invention a tuft comprising a retaining link to which is attached at least one tuft assembly according to the first aspect of the present invention.

( There is also provided according to a fourth aspect of the present invention upholstery, in particular a mattress, fitted with at least one tuft assembly according to the first aspect of the present invention.

in the present invention, the precise nature of the tuft element is not critical: any tuft element known in the art will suffice provided it is attachable to the first loop means of the attachment device. Exampics of suitable tuft cicments include those described above, for example a bar. a disc, a wad of'felt. leather or fur. a button (for exampic those disclosed in the prior an patents listed above) and a rosette tuft clement. We prefer that the tuft element is a rosette tuft element' for reasons of aesthetics. comfort and case of manufacture. The rosette tuft elcmcn1 confers an additional advantage in that the rosette tuft element may be attached to the first loop means of the attachment device via the windings used to hold the rosette tuft element toL!cther. This allows the tuft assembly to he manufactured more easily and from tower pans.

The attachment device enables troth a tuft ciemcnt. described above. and a retaining link. described hclow. to he attached thereto. The uttacilment device is elongate. By elongate' in the prescut specification is meant that the length of the attachmcut device

exceeds its width. Attachment devices having cLIual length and width would not allow the slack in tufts to which they are attacilecl to be minimised even if'their orientation were restricted. and are therefore excluded from the present in\,cotion.

The attachment device comprises two or more loop means. the tuft cicmcnt heinL: attachable to the first loop means and the retaining link to the second loop means. The term 'loop means' as used in the present specification refers to any closed or partially

open loop, hook or similar device capable of retaining the tuft element and the retaining link thereon.

The two or more loop means of attachment device are integral with one another. They may. for example, be integrally formed (in other words' form a one-piece attachment device). However, the attachment device may alternatively be constructed from a plurality of parts (the parts may comprise the whole or part of the loop means) which may then be interlocked together to form the finished attachment device.

( It is preferred that the attachment device comprises two integrally formed loops. The! two loop means of the attachment device may comprise a first loop and a second loop (as defined above). the tuft element being secured to the attachment device via the first loop and the retaining link via the second loop. However, the attachment device need not comprise a closed loop: other fonns of attachment device may suffice provided that they are elongate and are capable of retaining the tub element and the retaining link, while the orientation of the attachment device may be suf'ficientlv restricted to minimise the amount of slacl; in the tub when fitted to upholstery. For example, the attachment device may comprise an incomplete loop.

The retaining lint; may take any lorrn lnovn in the, art. It is preferred that the retaining link includes a retainer for retaining the tie on the second loop means of the attachment device. to avoid the retaining link fiom becoming detached Prom the remainder of'the tub. For example. the retaining link may comprise the known tape tuR. the retainer bar (tape tuft head) being inserted through the second loop means during installation.

However. this is not critical to the present invention: the retaining! link may alternatively comprise. for example' a prettied nylon loop.

The first loop means is disposed relative to the second loop means such that the orientation of the attachment device is restricted. thereby minimising the amount of slack in the tub while allow ing maxhllum space for the retaining link to pass through the second loop means. Typically' such a restriction involves the long axis of the attachment device remaining substantially parallel to the face of the upholstery.

It is preferred that the attachment device is generally oval in shape. In a particularly preferred embodiment. the attachment device may have two generally semicircular ends, one straight side parallel to its long axis. and one double convex longitudinal side incorporating the first loop means. Alternatively, both longitudinal sides may be straight on the outside, one longitudinal side being convex on the inside to incorporate the first loop means. However. other general shapes for the attachment device, such as rectangular or distorted polygonal, are also encompassed within the scope of this

( invention' provided that the attachment device is elongate and its orientation can be restricted as described above.

The first and second loop means may have the same general shape.

The first and second loop means may share a common edge.

The first loop means is preferably smaller in area than the second loop means. This confers a particular advantage in that the orientation of the attachment device is particularly easy to restrict. as the tuft element cannot he disenLrased from the first loop llleanS. 3 In a preferred embodiment. the first Top means may be surrounded by the second loop means. The first loop means may be indcnte3 into the second loop means.

The first loop means may he fondled partially or complctclv on the longer side of the attachment device. In particular. when the attachment device takes the preferred straight sides/semicirclar ends shape described above' the first loop means may be fonned on one of the straight sides of the attachment device.

The invention also provides a tuft comprising a rctaininL: link to which is attached at least one tuft assembly of the invention. It is preferred that the retaining link has attached thereto two tuft assemblies according to the invention. However. the nature of the second tuft assembly is not critical: any known tub element, such as the prior art tuft

elements described above, may suffice.

The invention will now be described by way of example with reference to the accompanying drawings, in which: Figs. I a and lb illustrate the known rosette tuft element. showing how it is secured together;

( Fig. 2 illustrates two rosette tuft elements in use with a mattress, showing the rosette tuft element being pulled through the mattress: Fig. 3 illustrates the oval attachment device used in the commercially available embodiment ofthe tub assembly according to GB-A-2349332?: Fig. 4 illustrates the tub assembly incorporating the attachment device of Fig. 3: Fig. 5 illustrates two tub assemblies of Fig. 4 fitted to a mattress in compression; Fig. 6 illustrates an attachment device according to a preferred embodiment of the invention; Fig. 7 illustrates an attachment device according to an alternative embodiment of the invention: Fill. 8 illustrates a tub assembly incorporating the attachment device of Fig. 7: and Fig. 9 illustrates two tuft assemblies of Fig. 8 fitted to a mattress.

Fig. 6 illustrates an attachment device according to a preferred embodiment of the invention. The attachment device 22 comprises a t!cneraliv oval loop 24. The two ends are generally semicircular. One longituclinal side of the device is straight on troth the outsicic and the inside. The other longitudinal side is double convex in shape. the device reaching its broadest dimension B I at its short axis. The attachment device 22 defines a large loop 24 within which is indented smaller oval loop 2?. donned on the double convex side of the lurL!e loop 24. Such an attachment device is stronger than the device of Fig. 7 below and is therefore preferred.

Fig. 7 illustrates an attachment device 28 according to an alternative embodiment of the invention which differs from the attachment cievicc illustrated in Fig. 6 in that both sides are straight on the outside. One longitudinal side of the attachment device is convex on the inside. The small oval IDOL 26 is formed on the straight/convex side of the attachment device.

Fig. 8 illustrates the attachment device 28 of Fig. 7 fitted to a rosette tuft clement 10 and a tape tuft retaining link 18. The rosette tuft element 10 is secured to the attachment device 28 by the grindings 12 used to hold the rosette tub element together being threaded through the small oval loop 26. The head of tape tuft 18 is threaded through the large loop 24 of the attachment device.

( Fig. 9 illustrates two tuft assemblies fitted to a mattress 20. Each tub assembly comprises a rosette tub element 1 Oa. 1 Ob provided with an attachment device 28a. 28h.

A rctaininL: link 18 in the forth of a tape tub. threaded through the large loop 26a. 26b of each attachment device, connects the two tuft assemblies.

As can he clearly seen from Figs. 8 and 9, the relative positioning of the small loop 26 and the large loop 24 restrains the attachment device 98 from reorientation, even when under the tension of retaining link 18. This restriction is assisted by the small area of loop 26 relative to hoop 24 so that movement of the rosette tub windings 12 within loop 26 is severely restricted.

These features enable the longitudinal axis of attachment 28 to remain substantially parallel to the face of mattress 20. The slack in the tub assembly (represented by the listancc B2 in Fig. 8) may thereby he reduced by as much as 30% when compared with the slack distance A2 in the commercially available prior art tub asscmb]y (see Fig. 4).

Th,. present invention has hereinabove hccn described in relation to various preferred emhodUnent thereof. However. the skilled reader will appreciate that numerous modifications may he made within the scope of the invention which is determined by the appended claims.

Claims

( 1() CLAIMS

1. A tuft assembly for fastening to upholstery. comprising: a tuft element; and an elongate attachment device integrally comprising first and second loop means. the tuft clement being attached to the first loop means and a retaining link being attachable. in uses to the second loop means; the first loop means and the second loop means being mutually disposed such that. in use. the orientation of the attachment device is restricted. thereby minimising the amount of slacl; in the tuft assembly when fitted to upholstery.

2. A tuft assembly according! to claim 1. wherein the first and the second loop means are mutually disposed such that. in use. the orientation of'the attachment device is restricted such that the long axis ol'the attachment device remains substantially urallcl to the face of the upholstery.

3. A tuft assembly according lo claim I fir claim 2. wherein the first loop means is smaller in area than the second loop means.

4. A tuft assembly according tat claim -. \vLercin the first loop means is surrounded by the second loop means.

5. A tuft assembly according to any one of claims I to 4' wherein the attachment device comprises two integrally formed loops.

6. A tuft assembly according; to any one of claims 1 to 5, wherein the attachment device is substantially oval shaped.

7. A tuft assembly according to claim 6, wherein the attachment device has two substantially semicircular ends, the two longitudinal sides being substantially straight on the outside. the inside of one longitudinal side of the device being substantially straight and the inside of the other longitudinal side of the device being convex.

8. A tub assembly according to claim 6. wherein the attachment device has two generally semicircular ends. one substantially straight longitudinal side. and one doubic convex longitudinal side.

9. A tuft assembly according to any one of claims 1 to 8. wherein the first loop means is indented into the second loop means.

10. A tuft assembly according to any preceding claim. wherein the tub element is attached to the first portion of the attachment device by means which form an integral part of the tub element

11. A tuft assembly according to any preceding claim' wherein the tuft cicmeilt is a rosette tuft clement

I 2. A t'.,tt assembly according to claim 1 1., herein the rosette tuft clement is attached to the first loop means of the attachment LleN ice via the Indians used to hokl the rosette tuft element together

13. A tub comprising a retaining link to which is attached at least OtlC tuft assembly according to any of claims I to 19.

14. An attachment device for a tuft clement. the attuchmcut device comprising a first loop means to which a tuft clement is attacilahle. the first loop means being integral with a second loop means to which a retaining link is attachable, the first loop means and the second loop means hcinLr mutually disposed such that, in use. the orientation of the attachment device is restricted. thcreLv minimising the amount of slack in the tub assembly when fitted to upholstery.

15. Upholstery fitted with a tuft according to claim 12.

16. A tuft assembly for fastening to upholstery, substantially as described herein with reference to Fig. 8.

( 1 /. An attachment device for a tuft element. substantially as described herein with reference to Figs. 6 and 7.

18. A tuft for fastening to upholstery. substantially as described herein with reference to Figs. 8 and 9.

19. Upholstery substantially as described herein u ith reference to Figs. 8 and 9.