US2458588A - Upholstery pad - Google Patents

Description

Jah. 11, 194.9. LE ROY GORDQN -rAL 2,458,588

- I UPHOLSTERY PAD Filed NOV. l0, 1945 2 Shee'tS-Sheet 1 Jan. 11, 1949. L E ROY GORDON ET A1. 2,458,538

BHOLSTERY PAD Filed` Nov. 1o, 1945 2 Sheets-Sheet 2` IN V EN T0125 im@ ,www www@ Patentecl'Jan. 11, 1949 hatte UPHOLSTERY PAD Le Roy Gordon, Richmona,riich.,.ana Leo L.

Williams, Cleveland Heights; Ohio Application November 10, 1945-, Serial No:v 627,875

l 6 Claims. l.

This inventionv relates topads of the kind embodied in. various upholstered structures and, as one. of its objects, aimsto provide. an improved construction for a pad' of this kind which will enable the pad to retain its shape. and integrity during handling. and. installation and to. also retain its cushioning and' decorative. value during the subsequent use. of the structure in which the pad isembodied..

Another object oi. the present invention is to provide an improved construction for a pleated upholstery pad of. the. kind. embodying a layer of. coextendingfbatts, which. enable. the pad to. be more economically manufactured and shipped and which will facilitate the installation of the. pad. as well as improve the quality and durability of the. upholstered structure. in which the pad is used.`

A further object oithis invention is. to provide an. improved construction for an `upholstery pad of this kind, in which. glazedwadding is used. as a cover sheetior the batts. and contributes to the padl certain desirable characteristics which are important inthe handling and installation thereof as welles to the quality and. durability of the upholstered structure..

Still another object of the invention isto provide Aan improvedY upholstery. pad of this character, in which the backing4 and. cover sheets are connected by rows of stitching between the batts and in. which the glazed. wadding forming the cover sheet. has a tensile strength. such that it provides a retaining means for. the hatts during handling and installation but is thereafter Subj ect to. tearing. or separationat points between the rows of stitching for obtaining the full available resiliency and cushioning value inthe pad..

Yet another object of the invention is to provide an improved upholstery padof the character mentioned, in which the cover andlcackingy sheets have gathers therein for. forming pleatsbetween the contiguous batts which furtherstrengthen the pad and enable it to retain its shape.

Other objects and" advantages of theinvention will' become apparent. in thezfollowing. detaileddescription. f

The present. invention is an improvement over our earlier patent No. 1,903,424 granted April' 11', 1933;

In the accompanying sheets of'. drawings,

Fig. l is a perspective sectional View taken throughanupholstery pad. embodying the present invention, the pad having the. finish cloth or wear sheet extending over the topf thereof.

Fig. 2 is a similar perspective sectional view 2 showing the pad with the wear sheetv omitted therefrom..

Fig..3 is atransverse sectional detail View on an.y enlarged scalatak'en as. indicated by line- 3,-3 otV Fig. l and further illustrating the construction ofthe pad andthe. stitching used-in the pleats thereof. y Figs. 4 and. 5 are perspective sectional detail views. illustrating another form of stitching. which can be used'in the ,pleats ofthe pad shown. in

Fig. 1.. Fig.. 6 is. a partial.- transverse sectional. View showing the parts. ot the pad'. oi' Fig. 2 in: their assembled relation and. prior. to the stitching operation..

. Fi'g. ,'7 is` a partial. transverse .sectionalview taken through an upholstered structure embodying the improved pad. and illustrating. one step inthe upholstering` operation by .which thev tearing of the glazed wedding cover sheet can be effected. x v

Fig. 8 is a partial perspective. view show-ing an rautomobile door on which a modified formI of. the improved upholstery pad isused as a covering, and,b j Fig.` 9 is a partial transverse, sectional view taken through themodified pad' of Fig. 8 substantially as indicated. by section line 9 9..

The upholstery pads herein disclosed are. of a type generally similar'to the padsv disclosed in our earlier patent. mentioned above but constituteA an important improvement thereover. `In Figs. 1 and.2 of the accompanying drawings the pad Iii is. shown as having a continuous backing sheet, I I on which is. arranged a pl-uralty of coextending vcontiguous batts I2` in strip form and which batts form the. maior portion of the cushioning materialor lling of the pad'. The pad alsoincludes a. cover' sheet kI3 4.which extends in continuous relation over a plurality ofthe batte lf2 and is connected with the backing sheet I l. along spaced lines extending longitudinally between the batts, as by rows of stitching I4". Fig. 1 shows the same pad'as Fig. 2 but with a continuous finish cloth cover or-wear sheet la extending over thecover sheet I3' and also connected' with the backing sheet' by the stitching I4.

The backing sheet I`I is preferably a loosely woven fabric sheet such as scrim, muslin, cheesecloth, tobacco clothorthe like. The batts I2 are inthe iorml of continuous strips made of resilient hrous material suchas cotton', hair, jute, wood wool or various combinations of these materials. "illiesebatts are arranged on the backing sheet I I yin a relatively close or contiguous coextending relation to each other and form a layer of cushioning material between the cover sheet I3 and the backing sheet. The batts are held in place by the cover` sheet which extends continuously thereover and is stitched to the backing sheet so as to form pleats or seams I6 extending longitudinally between the pairs of contiguous batts. The cover sheet and backing sheet thus form elongated pockets which are lled by the respective batts I2 and the top surface of the pad presents the appearance of a plurality of parallel rounded cushion sections or tufts I1 separated by the pleats I6.

The batts I2 and the backing and cover sheets II and I3 can be assembled into a desired relative arrangement by any suitable apparatus, such as that shown in our earlier patent and which need not be described here. Fig. 6 of the drawings shows the batts assembled in contiguous relation between the backing and cover sheets and illustrates the condition of the pad just prior to the stitching operation. It will be noted that in this preliminary assembly the batts I2 are of a substantially rectangular cross-section and that when the cover sheet I3 has been stitched to the backing sheet Il as shown in Figs. 1 and 2, the batts have been somewhat compressed or compacted to a rounded contour to which they are held by the cover sheet. The pleats I6 are formed during this stitching operation.

The cover sheet I3 is an important feature of the improved pad I and has certain characteristics which produce important new results in the improved construction. This cover sheet comprises a sheet of glazed cotton wadding of a size or length to extend in continuous relation over a plurality of the batts I2. The cover sheet is relatively thin in comparison with the depth or thickness of the batts I2 and, in the completed structure, forms a relatively smaller part of the cushioning material or filling of the pad. The cover sheet is formed of a layer or sheet of matted cotton fibers and in which the fibers on one or both surfaces thereof are connected or bonded together by an adhesive substance or sizing, such as starch or other suitable material. The glazed surface or surfaces I3a of the cover sheet I3 are of a smooth and paper-like characteristic and these surface portions have a considerably greater tensile strength than the untreated portions lying inwardly of the glazed surface or surfaces. In this glazed wadding the fibers are arranged so that, in the main, they extend in the same general direction which, in. the pad Ill, can be either in a direction substantially parallel to the rows of stitching I4 or in a direction substantially normal to such rows of stitching,

In forming the pad I 0 from the assembled batts I2 and the backing and cover sheets II and I3 as shown in Fig. 6, portions of the backing and cover sheets are gathered as indicated at I8 and I9 and these gathered portions when connected by the rows of stitching I4 form the pleats or seams I6. .The gathers I8 and I9 are formed in the backing and cover sheets at spaced points corresponding with the spaces between the contiguous batts and these gathers are formed during or just prior to the stitching operation. In forming the pleats I6, the gathers I9 of the cover sheet I3 are carried down into the gathers I8 of the backing sheet I2. The stitching I4 can be performed by suitable apparatus suchas a gangtype sewing machine of an appropriate construction. In these rows of stitching I4 the individual 4 stitches extend across the pleats I6 and through the gathers I8 and I9 thereof, thereby forming strongly sewn seams and relatively rm ribs lying at or adjacent the back of the pad.

An important characteristic of the cover sheet I3 is that the glazed wadding of which it is made has sufcient tensile strength to confine and hold the batts I2 in their assembled condition on the backing sheet II during handling, shipping and installation of the pad. Because of this tensile strength in the cover sheet I3 it is unnecessary to provide the pad with any additional retaining sheet on the top thereof for enabling it to satisfactorily withstand handling, shipping or installation stresses. It will thus be seen that the cover sheet I3, which ultimately forms a part of the desired cushioning depth or filling material of the pad, initially or temporarily forms the retaining means for the batts and temporarily gives the pad a smooth and reinforced top surface which will enable it to be handled, shipped and installed without fraying or loosening of the batts and without having the pad lose its contoured and pleated shape or otherwise becoming loose or irregular in character.

As mentioned above, the cover sheet I3 can be glazed on one or both of its surfaces and Fig. 2 shows this sheet with the glazing I3a on both its top and bottom surfaces. It is important that the cover sheet I3 always be glazed on its upper or exposed surface so as to provide the above described protective and retaining function, but if desired, the glazing can be omitted from its lower surface. In some cases this is an advantage because when the glazing is omitted from the lower surface the fibers of the cover sheet have a greater tendency to adhere to the fibers of the batts I2, thereby causing the cover sheet and the batts to become more r less amalgamated into a homogeneous filling between the glazed upper surface and the backing sheet II.

As previously mentioned above, Fig. 1 of the drawings shows the pad I IJ as having a. finish cloth or wear sheet I5 extending over the cover sheet I3. This wear sheet can be any suitable upholstery cloth, fabric, or other covering material of the character desired for the exposed surface of the upholstered structure in which the pad I0 is to be embodied. The wear sheet I5 can be applied to the pad I Il either during the operation of making the pad or can be applied after the pad has been completed. In many instances the wear sheet will be omitted from the pad as initially constructed so that a wear sheet of leather or other special form or pattern can be subsequently selected and applied to suit the customers requirements. This procedure can be safely followed because of the tensile strength and ability of the glazed wadding cover sheet to retain the batts in shape and protect them from fraying.

When the wear sheet I5 is embodied in the pad I 0 during the construction of the latter the wear sheet is folded or gathered as indicated at 2O in Fig. 3 and these gathers are carried downwardly into the gathered portions I8 and I9 of the backing and cover sheets II and I3. In this particular construction the rows of stitching I4 are formed so that the stitches will extend across the pleats and through the wear sheet I5 as well as through the backing and cover sheets I I and I 3.

When the wear sheet I5 is applied to the pad I subsequent to the formation of the pad, the gathers 2| of the wear sheet (see Figs. 4 and 5) arercarried downwardly as far as possible into the previously formed pleats I6 of the pad.' that is .to say, as far asis permitted bythe 'previously formed rows of :stitching .i ii, The ygathers ZI .of the wear sheet are then. stitched to the pad bya separate rowof stitching i22 with the stitches thereof extending through the 4backing .and cover sheets `and through the gathered portion of the wear sheet. Fig. 4 illustrates Athis operation oi applying the wear sheet to the 'previously formed pad :l .and shows rthe wear sheet .in the process of being connected to the pad Iby the stitching 2.2.. After each row of the stitching been done the wear sheet is drawn down smoothly over the next adjacent `rounded portion ci the pad. The completed pad will have .an appearance very similar to the 'pad of Fig. i and the separate stitching 22 of the .cover sheet will `be concealed in the pleats.

As mentioned above, the cover ysheet I3 of the pad I Il has a relatively increased tensile strength and dining installation vthis enables the pad to be drawn tightly over the structure to which the pad is being applied so that the edges of the pad can be fastened to the structure while in such a taut condition. Because of this increased tensile strength, it is possible to draw the pad into a su'liciently taut condition that Ythe pad will have a smooth and regular surface characteristic and will be held securely in the desired position yon the structure. Fig. 7 ofthe drawings illustrates an upholstered structure "2d, such as an automobile seat cushion, in 'which the pad *I9 is being used. The structure 24, which is here shown in an inverted position, has a wood frame or base 26 on which the wire springs 126 are supported. A spring pad 2l extends over the springs and forms a .protective covering to which the upholstery pad I 0 can be applied. When the pad l0 is applied to the spring pad 2'! it is drawn tautly over the latter by means of the wear sheet I which 4is extended beyond the layer of batts and is attached to the frame `,'25, .as by means of the tacks 28.

When the pad i Ii has been thus embodied in an upholstered structure as just described above, the

feature of the relatively increased tensilestrength' of the cover sheet i3 has served its main purpose and it is then desirable `to vdestroy this tensile strength and cause or enable the cover` sheet to become more or less amalgamated with the batts I2`so as to augment the cushion thickness provided by the latter. This can be accomplished by tearing or stretching the cover sheet I3 between each pair of pleats I6. It is important that the cover sheet be torn at points spaced from the pleats because if it is torn too close to the stitching i4, it will result in the stitching being loosened and in the pleats losing their rounded shape and fullness and becoming irregular.

The tearing of the cover sheet can be accomplished in various ways such as by the upholsterer striking the cushion sections of the finished structure with his hand or with a paddle, or in the manner illustrated in Fig. 7, in which the upholstered structure 2l! is placed in inverted position on a iiat supporting member 29 and subliected to pressure by a loading or pressure applying device`30. If this tearing has not been previously effected. it will take place during the ordinary use of the upholstered structure. When the device SU is used the pressure thereof causes the cushion sections of the pad ID to be conipressed or compacted against the support 29 and this results in a tearing or stretching of the cover sheet I3 along longitudinal lines located at 6 points intermediate the pleats I6. The .tearing of the cover sheet is .indicated in a somewhat exaggerated manner in Fig. 7 by the reference character '3I. When the covier sheet I3 has been thus torn or stretched .it releases its holding .or compressive -action on the batts l2 to the extent that the latter are free to yield with compressive and .expansive actions thus making the full cushioning :effect -of the batts available. 'Ihis likewise `results in the wear sheet I5 'being fullyv and smoothly .lled out to the stitch lines and in the cushioning thickness of the cover sheet I3 being added to the batts.

The improved upholstery pad I li can be applied .to various other .uses and, in Figs. 8 and 9, a modified form of this pad is shown as being used as 4a lining or upholstery covering 33 for the inside of the automobile door 34. When used .for this purpose the pad comprises a layer oi contiguous batts 35 disposed between a fabric backing sheet Sii vand a 'cover sheet 3i formed on the glazed cotton wadding mentioned above. A wear sheet or finished cloth covering 33 of the desired characteristics extends over the Cover sheet 3i and the backing and cover sheets are connected together between the contiguous batts by rows of stitching which form pleats 39 in the pad similar to the pleats described above. To impart to the pad 33 a desired stiffness and strength, la relatively stili 4backing sheet 4i) formed of cardboard or other similar fibrous material attached to the pad. The stiff backing sheet "40 is connected to the fabric backing sheet 3@ by being glued thereto, or if desired, this backing sheet can be stitched to the pad. The pad 33 including the .stiff backing .sheet 45 constitutes a prefabricated 4upholstery vcovering or pad which can tbe readily attached to the structure of the vehicle door 34 to form an attractive upholstered inner lining 'or covering thereon.

From the foregoing vdescription and the accompanying drawings, it will now be readily understood that the present invention provides an improved upholstery pad having important desirable qualities. and characteristics over simi-lar pads heretofore constructed. It will also be seen that the improved pad construction above `described in detail enables .a .pad of ythis kind to be handled, shipped and installed with greater facility than the previously constructed pads and that the improved pad is better able to retain its shape, is not subject to fraying and the upholstered structure in which it is embodied has greater durability and a more satisfactory appearance.

Although the improved upholstery pads have been illustrated and described herein in considerable detail. it will be understood, of course, that the invention is not to be regarded as correspondingly limited but includes all changes and modications coming within the spirit of the invention and the scope of the appended claims.

Having thus described our invention, we claim:

l. Upholstery padding comprising, a continuous backing sheet. a row of batts disposed in coextending contiguous relation to each other on said backing sheet and forming a layer of padding thereon, a continuous cover sheet extending over the batts, a continuous wear sheet extending over the cover sheet, and rows of stitching connecting said sheets between said batts, said cover sheet being a sheet of glazed wadding of a thickness to form a top layer of padding extending over said batts and having its bers extending mainly in the direction of said rows of stitching and having a tensile strength sufficient to retain said batts in place and also protect the same from fraying and loosening during handling and installation of the padding but being subject to tearing at points located between and spaced from the rows of stitching after installation of the padding and in response to pressure applied thereto.

2. Upholstery padding comprising, a backing sheet, a layer of batts on said backing sheet and disposed in coextending contiguous relation to each other, a cover sheet extending over the batts, said cover and backing sheets having gathers therein forming pleats at points between and coextensive with said batts, and rows of stitching connecting said sheets between said batts with the stitches of said rows extending transversely of the pleats.

3. Upholstery padding comprising, a backing sheet, a layer of batts on said backing sheet and disposed in coextending contiguous relation to each other, a cover sheet extending over the batts, said cover and backing sheets having gathers therein forming pleats at points between and coextensive with said batts, the gathers of said cover sheet extending downwardlyT into the gathers of said backing sheet, and rows of stitching connecting said sheets between said batts with the stitches of said rows extending across the pleats and through the gathers of said cover and backing sheets.

4. Upholstery padding comprising, a backing sheet, a layer of batts on said backing sheet and disposed in coextending contiguous relation to each other, a cover sheet extending over the batts, a wear sheet extending over said cover sheet, said backing sheet, cover sheet and wear sheet having gathers therein forming pleats at points between and coextensive with said batts, the gathers of said cover sheet and wear sheet extending downwardly into the gathers of said backing sheet, and rows of stitching connecting said sheets between said batts with the stitches of said rows extending across the pleats and through the gathers of said wear, cover and backing sheets.

5. Upholstery padding comprising, a backing sheet, a layer of batts on said backing sheet and disposed in coextending contiguous relation to each other, a cover sheet extending over the batts, a wear sheet extending over the cover sheet, said wear sheet, cover sheet and backing sheet having gathers therein forming pleats at points between and coextensive with said batts, and rows oi stitching connecting said sheets between said batts with the stitches of said rows extending transversely to the direction of the pleats, said cover sheet being a sheet of glazed wadding having its bers extending mainly in a given direction and having a tensile strength sufcient to retain said batts in place during handling and installation of the padding but being subject to tearing at points located between and spaced from the rows of stitching after installation of the padding and in response to pressure applied thereto.

6. A tufted upholstery pad comprising, a backing sheet, a plurality of batts in strip form disposed in coextending relation to each other` on said backing sheet and forming a layer of padding thereon, the contiguous batts of said layer having their adjacent edges extending in relatively close substantially parallel relation to each other but being separable to aord access therebetween to the backing sheet, a cover sheet extending in continuous relation over said batts and having spaced coextending substantially parallel gathers formed therein and extending down between said adjacent edges of the contiguous batts and into engagement with said backing sheet, and rows of stitching connecting said gathers with said backing sheet between the batts, said cover sheet being a sheet of glazed wadding of a thickness to form a top layer of padding extending over said batts and having a tensile strength suflicient to confine said batts and protect the same from fraying and loosening during handling of the pad.

LE ROY GORDON. LEO L. WILLIAMS.

REFERENCES CITED The following references are of record in the nie of this patent:

UNITED STATES PATENTS Number Name Date 292,187 Tyler Jan. 22, 1884 1,331,562 Foster Feb. 24, 1920 1,903,424 Gordon et al Apr. 11, 1933 2,144,544 Osborn Jan. 17, 1939

Images