WO2007071891A1

WO2007071891A1 - Upholstery component

Info

Publication number: WO2007071891A1
Application number: PCT/GB2005/005055
Authority: WO
Inventors: Jim Duffield
Original assignee: Springvale Leisure Limited
Priority date: 2005-12-23
Filing date: 2005-12-23
Publication date: 2007-06-28
Also published as: EP1968413A1

Abstract

An upholstery component comprising an inner shaping member and a first padding member enclosing the inner shaping member, said upholstery component being secured to any type of furniture framework, in particular all types of seating.

Description

UPHOLSTERY COMPONENT

This invention relates to an upholster}' component for securing to frameworks, particularly an upholstery component for securing to a framework of a piece of furniture. The term '"upholstery component" is used herein to describe a component formed from padding and having a textile covering. The textile covering may be permanently or removeably attached to the padding. ^v

It is known to form upholstered furniture from a framework to which shaped upholstery components are attached. The shaped components are custom made to fit a particular framework. Upholstery components may be manufactured to a particular size and shape to cover the whole of a framework, for example a chair. Alternatively, they may be sized and shaped to cover part of a framework, for example an armrest or seat of a chair or sofa. The shaped components may be fixed to the framework by any desired means, such as by glue, zips, buttons, Velcro, staples, clips or the like.

In order to replace a known upholstery component, for example one covering an armrest of a chair, it is necessary to manufacture a new component and to engage the services of an upholsterer to secure the new component into position on the frame. The process of manufacturing an upholstery component involves cutting, shaping and sewing operations. The replacement of upholstery components can, therefore, be a very expensive, labour intensive and time consuming process.

In a first aspect, the invention provides an upholstery component comprising an inner shaping member and a first padding member enclosing the inner shaping member.

The upholstery component according to the first aspect of the invention thus comprises a padding member with an inner shaping member at its core. The shape of the upholstery component is determined by the shape of the inner shaping member. In other words, the shape of the padding member generally follows the shape of the inner shaping member. The upholster}' component of the present invention can be secured to any type of framework, such as furniture frames including, for example, chairs, seats, sofas, beds, stools, benches, futons and foot stools. In particular, the upholstery component of the present invention is for securing to all types of seating, whether secured or removable seating, including, for example, seating in aeroplanes, boats, ships, trains, cars, buses, caravans, cinemas, theatres and other buildings.

The upholstery component of the invention may be manufactured to a particular size to cover the whole of a framework, for example the whole of a chair frame.

Preferably, however, the upholstery component of the present invention is sized and shaped to cover part of a framework, for example the armrest of a chair. The resulting upholstered framework will thus be made up of a number of sections, each section having its own upholstery component secured thereto, in the event that the upholstery gets damaged, only upholstery components that have been damaged need to be replaced. Thus, the need to replace all of the upholstery, covering the whole of the framework, is avoided, saving time, money and labour.

The inner shaping member of the upholstery component of the present invention is preferably in a form selected from the group consisting of sheets, grids, plating and meshing. Preferably, the inner shaping member is flat, i.e., being substantially of uniform thickness across its length.

The inner shaping member is typically made from plastic or metal. Preferably, the inner shaping member is formed from a composite material. The term "composite material" is used herein to describe material formed from more than one component, for example shape memory alloys or a combination of plastic(s) and metal(s).

In one embodiment, the shaping member is non-deformablε. The term "non- deformable" is used herein to describe a member having a substantially fixed shape. Such an inner shaping member is appropriately shaped during its manufacture. In another embodiment, in order to allow the upholstery component to be shaped into conformity with a framework or part of a framework during its manufacture or during use, the inner shaping member is deformable. The term deformable is used herein to describe an inner shaping member, the shape of which may be altered during use.

Thus, the deformable shaping member may allow a purchaser, for example, to manually shape the upholstery component to fit the shape and contours of a particular framework or part of a particular framework, for example, the back seat or armrest of a chair.

Upholstery components comprising non-deformable inner shaping members are described herein as '"non-deformable upholstery components". Similarly, upholstery components comprising deformable inner shaping members are described herein as "deformable upholstery components".

In yet another embodiment, the inner shaping member comprises both deformable and non-deformable sections. The section(s) of the shaping member that is/are non-deformable may be . shaped into conformity with sections of a framework during manufacture. The section(s) of the shaping member that is/are deformable may be shaped into conformity with sections of a framework after the upholstery component has been manufactured, for example during use. Thus, the deformable section(s) of the inner shaping member may allow a purchaser, for example, to manually shape the section(s) of the upholstery component having a deformable inner shaping member into conformity with the shape of a particular framework or part of a framework.

The term "shape into conformity" is intended to mean that the upholstery component is shaped to match the contours of a framework, or part of a framework, so that the upholstery component may be secured to the framework or part thereof, such that, when fitted to the framework or part thereof, the component has one surface substantially in contact with the frame. Once an upholstery component has been shaped into conformity with a framework the shape of the upholstery component is "in conformity with the framework", and corresponds to the shape of the framework.

Preferably, deformable inner shaping members or deformable sections of inner shaping members of upholster}' components according to the present invention are plastically deformable. In other words, once a deformable upholstery component or deformable section of an upholster}' component has been shaped into a particular shape, the component or section of component holds its shape during normal use, but can be redesigned into different shapes, as and when desired.

Deformable upholstery components or upholstery components comprising an inner shaping member having both deformable and non-deformable sections offer an alternative way to manufacturing custom made upholstery components to fit particular parts of furniture frames. The upholstery components may be manufactured to one standard size that will fit all parts of the particular piece of furniture. Taking a chair frame as an example, an upholstery component of one standard size could be made to fit, separately, the seat, back and arm frames, thus producing an extremely simple manufacturing process. Furthermore, since the upholstery components can be shaped into conformity with a particular framework during use, the upholstery components may be manufactured to one standard shape, further simplifying the manufacturing process.

Typically, the padding member is made of foam but any other alternative material known in the art may be used (mattresses, cushions etc). Preferably, the foam is high resilience foam, for example a shape memory foam.

The upholstery component of the present invention may comprise one or more further padding members. The one or more further padding members may completely or partially enclose the first padding member.

The upholstery component of the present invention may comprise a layer of cloth surrounding the inner shaping member enclosed within the padding member. Alternatively, or in addition, the upholstery component of the present invention may comprise a layer of cloth surrounding the first padding member. Preferably, the cloth is made of cotton or calico scrim.

The upholstery component of the present invention is secured to a particular framework or part of a framework by placing the component on top of the framework, or part thereof. The shape of the upholstery component of the present invention, which is made to match the contours of a particular framework, or part thereof, such that the component has one surface substantially in contact with the frame, maintains the upholstery component in place on the frame.

Since securing the upholstery component of the present invention to a framework, or part of a framework, does not require the use of glue, zips, buttons, Velcro, staples, clips or the like, the upholstery component can easily be removed from a framework, or part thereof, by, for example, lifting it off from the framework. Deformable upholstery components or upholstery components comprising an inner shaping member with both deformable and non-deformable sections may also be deformed to aid removal from a framework, or part thereof.

Easy removal of the upholstery component of the present invention from a secured position on a framework is advantageous as it allows the cushions to be cleaned, washed or replaced, for example.

The upholstery component is typically covered with a fabric cover. The fabric cover forms the visible, most outer layer of the component. The upholstery component may be slid out of the outer fabric cover, which then may be washed, cleaned or replaced.

In a second aspect, this invention provides an upholstered piece of furniture comprising a framework and an upholstery component according to the first aspect of the invention.

According to the second aspect of the invention, the shape of the upholstery component conforms to the framework or part of the framework to which the component is to be secured. Depending on the design of the upholstery component, the upholster}' component is either shaped to conform to a particular framework or part of a framework during its manufacture or is deformed into the appropriate shape during use. Alternatively, an upholstery component comprising an inner shaping member having both deformable and non-deformable sections, requires both of the above methods to shape the whole of the upholstery component into conformity with a particular framework, or part thereof.

The upholstery component of the present invention does not require specialists to secure the upholstery component on to a framework and can instead be fitted by, for example, the purchasers themselves, as explained above.

Once the shape of the upholster)' component conforms to a particular framework, or part thereof, in order to fit the upholstery component to the framework, or part thereof, the upholstery component is placed onto the frame such that the upholstery component has one surface substantially in contact with the framework, or part thereof.

In a third aspect of the invention, there is provided a method of producing an upholstery component of the first aspect of the invention, comprising enclosing the inner shaping member within the first padding member.

According to the method of the present invention, the inner shaping member is preferably positioned within a cavity of the first padding member. This may be accomplished by passing the inner shaping member through an aperture formed in the first padding member to a position within the cavity or, alternatively, by positioning the inner shaping member within a cavity located in a portion of the first padding member and affixing the remainder of the first padding member thereto. Alternatively, the first padding member may be adhesively secured to the inner shaping member.

Preferably, the inner shaping member comprises a smooth outer layer of cloth. The presence of the smooth cloth makes it easier to pass the inner shaping member through the aperture in the first padding member. Alternatively, or in addition, the upholstery component of the present invention comprises a layer of smooth cloth surrounding the first padding member. Preferably, the smooth cloth is made of calico scrim or cotton. Typically, the cloth, as well as being smooth, is also made from a fire retardant material.

The resulting upholstery component, comprising an inner shaping member and a first padding member, may be enclosed within one or more further padding members. This is preferably carried out using a corresponding method to the ones described above for enclosing the inner shaping member within the first padding member.

Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings in which:

Figure IA is a schematic representation of an embodiment of a upholstery component according to the first aspect of the invention;

Figure 1 B is a schematic representation of a chair frame;

Figure 2 is a cross-sectional view of a second embodiment of an upholstery component according to the first aspect of the present invention;

Figure 3 is a schematic representation of an embodiment of the second aspect of the invention in the form of an upholstered chair;

Figure 4 is a schematic representation of a third embodiment of an upholstery component according to the first aspect of the invention comprising an inner shaping member having both deformable and non-deformable sections;

Figure 5 is a schematic representation of the upholstery component of Figure 4 partially fitted to a chair frame; Figure 6 is a magnified side view of a top rail portion of a backrest of a chair frame forming a second embodiment of the second aspect of the invention;

Figure 7 is a schematic representation of an inner shaping member passing through an aperture in a padding member forming a fourth embodiment of the first aspect of the invention;

Figure 8 is a schematic representation of a cavity located in a portion of a first padding member; and

Figure 9 is a cross-sectional view of a sixth embodiment of an upholstery component according to the first aspect of the present invention.

Referring to Figures IA, IB, 2 and 3 an upholster}' component in accordance with a first aspect of the invention is designated generally by the reference numeral 1. The upholstery component 1 has a shape corresponding to the combined shape of a seat portion 3, a backrest portion 4 and a top rail portion 5 of a chair frame 2.

The upholstery component 1 comprises an inner shaping member 6 and a padding member 7, as shown in Figure 2.

The upholstery component 1 may be secured to the chair frame 2, as shown in Figure 3 to form an upholstered piece of furniture 8 in accordance with the second aspect of the invention.

In one embodiment, the inner shaping member 6 of the upholstery component 1 is non-deformable. The upholstery component is therefore shaped into conformity with the seat, backrest and top rail portions 3, 4 and 5 of the chair frame 2 during its manufacture.

In another embodiment, the inner shaping member 6 of the upholstery component 1 is deformable, thus allowing the upholstery component to be shaped into conformity with the chair frame 2, during use. Referring to Figures 4 and 5, a further embodiment of the invention in the form of a upholstery component 9 is illustrated. The upholstery component 9 comprises an inner shaping member 10. The inner shaping member 10 comprises both deformable 11 and non-deformable 12 sections. The shape of the non-deformable section 12 of the inner shaping member 10 corresponds to the shape of the seat and backrest portions 3 and 4 of the chair frame 2 and the deformable section 11 can be shaped into conformity with a top rail portion 5 of the chair frame 2 during use.

Figure 5 represents the upholstery component 9 partially fitted to the chair frame 2. At this stage, the deformable sections have not yet been shaped to conform to the top rail portion 5 of the chair frame 2. Once the deformable section 11 shown in Figure 5 has been shaped into conformity with the top rail portion 5, an upholstered chair as shown in Figure 3 is formed.

Referring to Figure 6, a magnified side view of a top rail portion 13 of a chair frame as shown in Figure IB. As illustrated, the upholstery component 14 "wraps" round the top rail portion 13, which helps secure the upholstery component 14 to the chair frame.

Referring to Figures 7 and 8, two different ways of enclosing an inner shaping member 15 within a first padding member 16 to form an upholstery component according to the invention are shown.

Figure 7 represents a process whereby the inner shaping member 15 passes through an aperture 17 in the padding member 16.

In Figure 8, an inner shaping member may be positioned within a cavity 18 located in a section 19 of the padding member 16. The remainder of the padding member can then be affixed to padding member 16 to produce a fifth embodiment of an upholstery component according to the first aspect of the invention having a cross-section as shown in Figure 2. Referring to Figure 9, yet another embodiment of an upholstery component 20 according to the first aspect of the invention is shown. The upholstery component 20 comprises an inner shaping member 21 enclosed within a first padding member 22. The first padding member is enclosed with a second padding member 23, which is enclosed within a third padding member 24.

Claims

1. An upholstery component comprising an inner shaping member and a first padding member enclosing the inner shaping member.

2. An upholster}' component according to Claim 1, wherein the inner shaping member is in a form selected from the group consisting of sheets, grids, plating and meshing.

3. An upholstery component according to Claims 1 or 2, wherein the inner shaping member is made from plastic.

4. An upholstery component according to any one of the preceding claims, wherein the inner shaping member is formed from a composite material.

5. An upholstery component according to any one of the preceding claims, wherein the inner shaping member is deformable.

6. An upholstery component according to any one of the preceding claims, wherein the inner shaping member is plastically deformable.

7. An upholstery component according to any one of the preceding claims further comprising a second padding member.

8. An upholstered piece of furniture comprising a framework and an upholstery component according to any one of the preceding claims.

9. A method of producing an upholstery component according to any one of the preceding claims comprising enclosing the inner shaping member within the first padding member.

10. A method according to Claim 9, wherein the inner shaping member is positioned within a cavity of the first padding member.

11. A method according to Claim 10. wherein the inner shaping member is . positioned within the cavity of the first padding member by passing the inner shaping member through an aperture in the first padding member.

12. A method according to Claim 10, wherein the inner shaping member is positioned within the cavity of the first padding member by positioning the inner shaping member within a cavity located in a portion of the first padding member and affixing the remainder of the first padding member thereto.