Arm rest using vertical lapped fiber

Abstract

An arm rest for furniture or other chair or seating applications is described. The arm rest includes a cushion member, a frame component, and an optional covering or protective layer. In certain applications, the arm rest is formed from a vertically lapped fibrous batt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in detail with several preferred embodiments and illustrated, merely by way of example and not with intent to limit the scope thereof, in the accompanying drawings.

FIG. 1 is a top planar view of a preferred arm rest member according to the present invention.

FIG. 2 is a bottom planar view of the preferred arm rest member.

FIG. 3 is a side view of the preferred arm rest member.

FIG. 4 is an end view of the preferred arm rest member.

FIG. 5 is a side view of the preferred arm rest member, illustrating a side opposite that of the side shown in FIG. 3.

FIG. 6 is a perspective view of the preferred arm rest member.

FIG. 7 is another view of the bottom of the preferred arm rest member.

FIG. 8 is a schematic cross section of a preferred arm rest member illustrating a preferred combination of components.

FIG. 9 is a schematic cross section of a preferred arm rest member illustrating a preferred combination of components.

FIG. 10 is a schematic cross section of a preferred arm rest member illustrating a preferred combination of components.

FIG. 11 is a schematic cross section of a preferred arm rest member illustrating a preferred combination of components.

Claims

1. An arm rest adapted for use in a chair or furniture component, the arm rest comprising: a frame member; anda cushion member disposed on the frame member, the cushion member having first and second oppositely directed faces;wherein the cushion member includes a region of vertically lapped fibers, the region extending generally across a face of the cushion member, at least a majority of the fibers in the region extending in a direction generally transverse to the face of the cushion member.

2. The arm rest of claim 1 wherein the fibers in the region of vertically lapped fibers have a size of from 0.9 to 300 denier.

3. The arm rest of claim 1 wherein the region of vertically lapped fibers is used at a thickness so as to exhibit a weight of from about 100 g/m2 to about 2000 g/m2.

4. The arm rest of claim 1 wherein the region of vertically lapped fibers includes from about 10% to about 100% of the total weight of fibers in the cushion member.

5. The arm rest of claim 1 wherein the region of vertically lapped fibers comprises: from about 5% to about 95% of a first fiber, andfrom about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.

6. The arm rest of claim 5 wherein the first fiber is used in a proportion of about 60% and the second fiber is used in a proportion of about 40%.

7. The arm rest of claim 5 wherein the first fiber has a size of from about 0.9 denier to about 300 denier.

8. The arm rest of claim 5 wherein the second fiber has a size of from about 2 denier to about 15 denier.

9. The arm rest of claim 5 wherein the cushion member has a thickness of from about 0.5 cm to about 7.6 cm.

10. The arm rest of claim 1 wherein the frame member comprises: from about 30% to about 100% of a binder polymer; andfrom about 70% to about 0% of a matrix fiber.

11. The arm rest of claim 10 wherein the frame member comprises about 70% of the binder polymer and about 30% of the matrix fiber.

12. The arm rest of claim 1 wherein the arm rest generally defines first and second major sides, and first and second minor sides, and wherein three of these four sides are convex in shape.

13. The arm rest of claim 12 wherein a remaining side of the four sides is concave in shape.

14. The arm rest of claim 1, wherein the arm rest defines an upwardly facing surface that is convex.

15. The arm rest of claim 1 wherein the frame member includes a first substrate and a second substrate.

16. The arm rest of claim 1 further comprising: a covering layer disposed on the cushion member.

17. The arm rest of claim 16 wherein the covering layer includes a nonwoven material.

18. The arm rest of claim 1 wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers.

19. An arm rest defining a first convex side, a second convex side opposite from the first side, a third convex side extending between the first and second sides, and a fourth concave side extending between the first and second sides and opposite the third side, the arm rest comprising a region of vertically lapped fibers, the region extending generally across a face of the arm rest, at least a majority of the fibers in the region extending in a direction generally transverse to the face of the arm rest.

20. The arm rest of claim 19 wherein the fiber of the region of vertically lapped fibers has a size of from 0.9 to 300 denier.

21. The arm rest of claim 19 wherein the region of vertically lapped fibers comprises: from about 5% to about 95% of a first fiber, andfrom about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.

22. The arm rest of claim 19 wherein the arm rest includes a frame member which comprises: from about 30% to about 100% of a binder polymer; andfrom about 70% to about 0% of a matrix fiber.

23. The arm rest of claim 22 wherein the arm rest further includes a cushion member disposed on the frame member, the cushion member has a thickness of from about 0.5 cm to about 7.6 cm.

24. The arm rest of claim 23 further comprising: a covering layer disposed on the cushion member.

25. The arm rest of claim 23 wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers.