Patent Application
20220071398
The present disclosure generally relates to upholstered furniture and, more particularly, upholstered furniture including one or more molded components.
Upholstered seating furniture where essentially the entirety of the exposed furniture items are covered by upholstery coverings is one of if not the highest volume items sold in the residential retail furniture markets and thereby provides one of the highest revenue sources for retail furniture stores. The market for such upholstered seating furniture is fiercely competitive and any improvements in manufacturing resulting in an improved product, better value to the customer, and/or lower manufacturing costs are welcomed by the industry.
In the manufacture of such upholstered seating furniture items, such as sofas, love seats, recliners, and similar items, the structure for the upholstered furniture items is provided by a frame or chassis, which gives the furniture structural support and also provides its basic shape. Traditionally, frames for upholstered furniture items have been typically constructed of wood materials, such as hardwood, softwood, engineered woods (for example, plywood, hardboard, millboard, chipboard, and fiberboard). Portions of the wooden frame may typically be covered by padding or cushioning, such as foam, and then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery. Due to the large number of parts and the weight of their materials, wooden furniture frames are often heavy and have long assembly times due, in part, to the large number of parts they include. For example, a single arm alone for upholstered chairs, recliners, and sofas can include up to and over 10 or 15 different wood parts not including the multitude of fasteners needed for assemble. Each wood part, of course, needs to be precisely cut. Further, a single backrest for a chair or recliner can include up to and over 10 or 15 different wood parts not including the multitude of fasteners.
Additionally, attaching upholstery to the complex shape of wooden sofa frame arms also can be painstakingly tedious in that the wooden frames have gaps that need to be covered with cardboard or the like, the upholstery components, including padding, does not slide on the wood frame for positioning and as such, the upholstery needs to be precisely positioned by hand. Any improvement in ease of attaching upholstery components to sofa frame arms would be well received by furniture manufacturers.
Moreover, due to non-uniformity of wood, the use of multiple wood pieces in constructing sofa and chair components, such as arms, is only as strong as the weakest wood piece and can present difficult quality control issues. Moreover, wood pieces can crack when fasteners, are driven into the pieces during assembly of the furniture item.
The above-described process of manufacturing upholstered furniture items is time consuming and costly due to the number of parts must be manually assembled to construct the final upholstered furniture item. As such, there is a need for a simplified method for manufacturing upholstered furniture items that reduces labor and material costs while providing a product that provides a sufficient or improved level of support and comfort to the user.
Although there have been efforts to utilize plastic components in seating furniture, such efforts have not been commercially successful with regard to upholstered seating furniture and have not taken advantage of the respective attributes and disadvantages of plastic and wood.
The embodiments of the present disclosure include upholstered seating furniture in which the number of components that need to be assembled is minimized, that is simpler to assemble, where the time for assembly is minimized, and where the finished product is robust and sturdy. The inventors have identified an optimal and synergistic use of polymer structural components and non-polymer structural frame components, such as wood frame members, to provide such attributes.
In embodiments, an upholstered seating furniture item configured as a sofa includes a seat base with seating cushions, a cushioned back rest and a pair of arm rests with padding. The seat base, the cushions, the pair of arm rests all covered with upholstery on all visually exposed regions, specifically the top and sides of the sofa. The sofa having a sofa frame or chassis including a pair of blow molded arm rest forms separated by a separation distance, and a plurality of spanning wood frame members, each of the plurality of spanning wood frame members extending between the pair of molded arm rests, each spanning wood frame member having a length greater than the separation distance and having wood frame member ends nested within recesses in the respective blow molded arm rest forms. Each spanning wood frame member received in recesses extending open upwardly or forwardly or rearwardly. In embodiments, the recesses may be configured as four sided pockets or slots open upwardly, forwardly, or rearwardly, the slot dimensioned to provide an interference fit with the thickness of ends of the spanning wood frame members such that the spanning wood frame members are forced into their final seating position. A feature and advantage of embodiments is that with the ends of the spanning wood frame members retained in the pockets or slots with an interference fit eliminates or minimizes the need for further fasteners to attach the spanning wood frame members to the polymeric arm rest forms. Particularly where such spanning members are secured to other wood frame members.
A feature and advantage of embodiments, is the blow molded arm rest forms may be positioned a fixed distance apart in an assembly jig and a plurality of spanning wood frame members may be positioned in place on the blow molded arm rests by installing the spanning wood frame members without moving the arm rest forms, that is without adjusting the distance between the blow molded arm rests. In embodiments, spanning wood frame members include a wood lower forward or front rail defining a forward lower margin of the sofa frame and a wood lower back rail defining a back lower margin of the sofa frame. Each of the two ends of the lower front rail are received in recesses having three rail confronting wall portions, a forward facing wall portion, a downward facing wall portion, and an inward facing wall portion, that is, toward the opposite end of the front rail. Each of the two ends of the lower back rail are received in recesses having three rail confronting wall portions, a rearward facing wall portion, a downward facing wall portion, and an inward facing wall portion, “inward” meaning toward the opposite end of the lower back rail.
A feature and advantage of embodiments is a preassembled backrest frame may be placed on an assembly table and a pair of blow molded arm rest forms may be placed on each end of the preassembled backrest frame and the blow molded arm rest forms may be engaged with the preassembled backrest with ends of spanning frame members that extend from each end of the preassembled backrest frame. Specifically, the back side of the arm rest forms can be engaged with the ends of the lower back rail wood frame member at the recesses at the lower rear margin of the blow molded arm rest forms. Other ends of spanning wood frame members, for example a breast rail and a spring rail, can seat in slots or recesses with an interference fit. Bolts or screws can be inserted through the ends of the lower back rail spanning wood frame member into threaded fasteners embedded or attached to the rear face of the arm rest forms. The lower front rail can then be attached to the front of the arm rest forms at the lower inwardly positioned recesses with bolts or screws extending through the ends of the lower front rail into threaded fasteners embedded or attached to the wall of the arm rest forms at the wall defining the recess. The inventors have found that the ends of the breast rail and spring rail are adequately retained in slots defined by the wall of the arm rest forms and do not necessitate fasteners. Two spring rails may then be attached, one end to a forward spring rail on the forward lower rail and the rearward spring rail that is integrated with the preassembled backrest frame.
A feature and advantage of embodiments is that a single arm sofa may be assembled utilizing only one blowmolded are rest form with the backrest frame attached thereto. A feature and advantage of embodiments is that two mirror image blowmolded arm rests can be utilized to form different size seat frames, for example a full size sofa, a love seat, and a single seat chair, just by utilizing shorter spanning frame members and using the appropriate number of upright backrest frame members.
One or more of the plurality of wood frame members attached to each of the pair of blow molded arm rest forms by way of a plurality of metal screws extending into a plurality of metal threaded inserts in the respective arm rest forms. Vertical back rest frame members and seat deck components are supported by and attached to the spanning frame members. The upholstery covering the side arm rest forms, the back rest, and the cushions such that substantially the entirety of the exposed regions of the sofa are covered by the upholstering.
A feature and advantage of embodiments is a furniture item including a pair of opposing arm member forms each unitarily formed from a single piece of polymeric material. This structural arrangement provides ease of assembly and cost efficiencies by minimizing the number of parts and minimizing the number of assembly steps. In embodiments, wooden cross members extend between the pair of opposing arm member forms. In embodiments, each arm member defines a plurality of corresponding recesses, each of the corresponding recesses being dimensioned and positioned to receive an end portion of a wooden cross member. In embodiments, a plurality of threaded metal inserts are supported by each of the arm members. Each of the threaded metal inserts may receive a threaded fastener that aids in constraining a wooden cross member relative to the arm member.
A feature and advantage of embodiments is a pair of mirror image blow molded polymer arm rest forms each having a horizontal elongate through-slot extending most of the forward backward depth distance of the arm rests. The through hole providing enhanced structural integrity and facilitates attachment of upholstery and decking materials.
A feature and advantage of embodiments is a pair of mirror image blow molded polymer arm rest forms that receive a plurality of wooden cross members spanning between the forms. Each arm rest portion having an elongate horizontal through-slot extending forwardly and rearwardly. The wooden cross members and polymer arm rest portions defining a seat box for receiving a textile deck assembly. The textile deck assembly may have rearwardly extending straps to attach to a spanning spring rail member and lateral flaps to extend through the respective horizontal through-slots for attachment, such as by staples to the arm rest forms at the exteriorly facing wall surface. In embodiments, a cushion sheet material for covering the textile seat deck can lay on the deck and also have ends that extend through the respective through-slots and be attached to the arm rest forms such as by staples
A feature and advantage of the blow molded arm rest forms is that fasteners such as Christmas tree polymer fasteners and expanding wing fasteners are readily accommodated by the thin wall structure of the arm rest forms. Recesses may be provided to seat the head of an expanding wing fastener flush with the surrounding wall surface or below the wall surface. A Christmas tree connector may be integrated into an upholstery panel to be pushed into place on the front face of an arm rest portion. Pre-placed holes positioned on recessed platforms hold the connectors under tension providing a secure fit of the upholstered piece.
A feature and benefit of embodiments is an upholstered furniture item have covering material in the form of an upholstery sack positioned over at least a portion of the upholstered furniture item, including each of the arm portions. In embodiments, the upholstery sack includes padding that provides a higher level comfort for users of the upholstered furniture item. In embodiments, the upholstered furniture item further includes a padding, wherein at least a portion of each of arm portions is covered by the padding, such that the pad is intermediate the molded component and covering material.
A feature and advantage of embodiments is a furniture item including a pair of opposing arm rest forms members, each of the arm members comprising a hollow body comprising a polymeric wall that extends continuously about a top side, two lateral sides, a forward side, a rearward side, and a bottom side. In embodiments the wall does not have an exposed edge of the wall thickness. The wall having an inward facing surface defining an interior with a void volume. The interior and void volume extending from a top side wall portion, two lateral side wall portions, a forward wall portion, a rearward wall portion, and a bottom wall portion. In embodiments, the continuous wall substantially defines an enclosed interior. In embodiments, the void volume is greater than about 1 ft.3 and less than about 3.5 ft.3.
In embodiments the polymeric arm rest forms have an outer wall surface having low coefficient of friction with respect to receiving upholstery coverings, particularly loose fitting upholstery coverings. In embodiments, the low friction polymeric outward facing surfaces provided by the polymeric shell wall facilitate the pulling of upholstery covering materials over the arm portions of the furniture item. The exterior surface may have less of a coefficient of friction with respect to wood frame members. In embodiments, the polymeric wall gives structural support and also provides a fundamental shape to the arm portions of the furniture item. In embodiments, the polymeric wall has structure defining recesses and slots. The recesses and slots can be sized to receive frame members. In embodiments, the wall portions defining the recesses and or slots can provide an interference fit on opposing sides of the frame member. A feature and advantage of embodiments is with such an interference fit the exterior surface of the wall portion at the recess engages an exterior surface of the frame member, which may be wood, and provides a relatively high coefficient of friction that may effectively retain the frame member within the recess or slot.
A feature and advantage of embodiments is a furniture item including an arm portion integrally formed from a single piece of thermoplastic material. This arrangement allows the arm portion body to be fabricated using an automated and efficient thermoplastic injection molding processes.
A feature and benefit of embodiments is a furniture item including an arm member having cross member receiving recesses that orient wooden cross members of the furniture. In embodiments, each of the cross member receiving recesses is shaped and dimensioned to receive an end portion of a wooden cross member while the wooden cross member is disposed in a predetermined orientation relative to the arm member. In embodiments, the arrangement facilitates fixture-less alignment and assembly of the subcomponents.
A feature and benefit of embodiments is a furniture item including an arm member having a plurality of mounting features. In these embodiments, the plurality of mounting features allow the arm member to be utilized in various types/models of furniture items. Examples of furniture items include sofas, loveseats, chairs, sectional sofas, seating units, sleeper sofas, futon frames, and recliners.
A feature and benefit of embodiments is a furniture item including an arm member defining a groove, the groove receiving the distal end of a cross member to form a tongue and groove joint. In embodiments, the groove extends upward and downward along a groove axis. In embodiments the groove is shaped and dimensioned to receive an end portion of a wooden cross member, an end portion of a wooden cross member having a uniform thickness along its length. In embodiments, a wooden cross member may be slid downward with each of the ends of the cross member being received in grooves defined by opposing arm member to facilitate fixture-less alignment and assembly of the subcomponents of a furniture item.
A feature and advantage of embodiment is a furniture item having blow molded arm rest forms with less than three layers of material between the arm rest form and the upholstery covering. In embodiments, the arm rest form has a top curved surface about a horizontal axis. In embodiments, the layers between the arm portion and the upholstery covering comprise an EVA underlayer and a second layer of fibrous material thereon. A feature and advantage is arm portion that does not have a cardboard layer extending across a wooden frame as in many conventional assemblies.
A feature and advantage of embodiments is a recliner which, compared to conventional recliners, the number of components needed to assemble the recliner is greatly reduced, the difficulty of assembly is greatly reduced, the time of assembly is greatly reduced, and the expense is correspondingly greatly reduced. Moreover the structural integrity is generally greater.
In embodiments, a method of making an upholstered seat includes providing a seat frame including a front frame member, an opposing back rest, and two arms at opposite ends of front frame member and backrest, wherein at least one of the front frame member and opposing back rest includes a wood component, and wherein the arms are made of molded plastic; coupling at least one of the arms is coupled to the wood component; and covering at least a portion of the at least one of the arms with a covering material.
A feature and advantage is that the inventors have discovered that utilizing certain polymers, such as polyethylenes, can received staples comparable to wood frame members. This facilitates utilization of the polymer arm rest forms in existing furniture assembly lines.
A feature and advantage of embodiments, a blow molded arm rest form may have a nominal wall thickness of from 2 to 6 mm. This thickness provides stabilization and secure holding of frame components connected thereto, while providing an arm rest form that is more resilient that a prior art wooded arm rest frame. In embodiments, the top wall portion of the arm rest form may be deflected more than 0.5 inches under loading, for example under a 100 lb. loading of a hand or foot of a person, and will return to the original position when the loading is removed, the arm rest form is not damaged. In embodiments, the top wall portion of the arm rest form may be deflected more than 0.75 inches in localized regions under loading, for example under a 100 lb. loading of a hand or foot of a person, and the localized region of the top wall will return to the original position when the loading is removed, the arm rest form is not damaged. In embodiments, each of the top side wall portion, the two lateral side wall portions, the forward side wall portion, the rearward side wall portion, and the bottom side wall portion may be deflected 0.5 inches and each said side will return to the original position without damage. In embodiments, each of the top side wall portion, the two lateral side wall portions, the forward side wall portion, the rearward side wall portion, and the bottom side wall portion may be deflected 0.75 inches and each said side will return to the original position without damage. In embodiments, each of the top side wall portion, the two lateral side wall portions, the forward side wall portion, the rearward side wall portion, and the bottom side wall portion may be deflected 1.0 inches and each said side will return to the original position without damage. Such resilience can reduce the amount of cushioning material needed compared to conventional wood framed arm rest form and can provide an increased measure of safety over a wood framed arm rest when, for example, an individual inadvertently collides with or falls onto the arm rest.
A feature and advantage of embodiments is that front to back spanning wood boards have been eliminated. The pair of blow molded arm rest forms and a pair of metal spring seat stretchers are the only front to rear structural members.
A feature and advantage of embodiments is that the pair of blow molded arm rest forms each have a forward face of a significant area to interface with the lower front rail, and each have a rearward face of a significant area to interface with a forward face of a lower rearward rail. These interfaces provide a high degree of rigidity to initially position the arm rest portions and lower spanning frame members in a precise rectangular geometry when initially assembled and secure that rectangular geometry during assembly, transportation, and ultimately use for the life of the sofa. A feature and advantage is that rectangular structural rigidity, when viewed from above, the rectangle in a horizontal plane, is provide by only four structural components, each component a unitary component, the components attached together with threaded fasteners.
A feature and advantage of embodiments, is the entire laterally outward wall surface of each polymer arm rest form is comprised of a single unitary closed wall with no apertures extending through the wall. A feature and advantage of embodiments, is the entire laterally inward wall surface of each polymer arm rest form is comprised of a single unitary closed wall with no apertures extending through the wall.
A feature and advantage of embodiments, a blow molded arm rest form may have a nominal wall thickness of from 2 to 3.5 mm, where the arm rest form does not carry the majority of the loading of persons or pets on the sofa seat. A feature and advantage of embodiments, a blow molded arm rest form may have a nominal wall thickness of from 2 to 3.5 mm, where upright portions of the arm rest form does not carry the majority of the loading of persons or pets on the sofa seat.
In embodiments, attachment of the upholstery is simplified by the very low coefficient of friction between the sofa arm form and the upholstery material, allowing conformingly sized upholstery arm portions to be readily slid over the arm forms. In embodiments, this facilitates construction of more complete upholstery kits at locations remote from the final sofa assembly site of the sofa. For example, upholstery kits can include arm rest sock portions that already have arm rest padding attached to the upholstery covering material. This can eliminate the steps of manually having to attach one or more layers of padding at the final sofa assembly site before attaching the arm rest upholstered portions.
A feature and advantage of embodiments is that segregation of manufacturing sites for components of the upholstered seating furniture items is enhanced. For example, padding for arm rests can be attached to arm rest upholstery portions as part of an upholstery kit in remote locations from the final seating furniture assembly location. Additionally, the arm rest forms may each be molded at a location remote from the final seating furniture assembly location and transported to the final seating furniture assembly location.
A feature and benefit of embodiments is an arrangement for furniture items in which the number of components that need to be assembled is minimized, is simple to assemble and the time for assembly is minimized, and is robust and sturdy.
A feature and advantage of embodiments is that the specific attributes of polymers and wood have been combined in a synergistic fashion for construction of a wood frame or chassis for upholstered seating furniture. For example, conventional polymers suitable for geometrically large components, such as furniture components, for example polyethylenes, when subjected to tensile loading or significant sheer loading may creep over time and may loose load carrying strength and may effectively collapse. Although, three-dimensional polymer forms, particularly hollow polymer forms have reasonable compressive load carrying capabilities depending on loading. That is downward weight loading will not generally cause noticeable creep of the polymer making certain polymers such as polyethylenes suitable for arm rest forms. The inventors have discovered where such arm rest forms are utilized for some limited downward compressive loading, any diminishment of the strength of the polymer over time should not affect the integrity of the sofa frame and sofa. The inventors have discovered that a thin walled blow molded arm rest provides Polymers have great capabilities and flexibilities in securing components, such as wood frame members that are not continually loaded. In embodiments of the invention, no loading from seating is isolated on the polymer arm rest forms, rather the loading is carried directly downward from the seating deck to a lower front rail and a lower back rail that are both positioned at the lower margin of the sofa. Where there are no feet on the sofa, the loading from seating will be transferred to the floor surface along the length of both the front rail and back rail. Where, there are feet on the sofa, the front rail and rear rail will act as end supported beams, and the floor engaging feet will be positioned under the ends of the front and rear rail and transfer the seating load to the floor by way of the feet.
Wood has great load carrying capability between supported ends when properly oriented. The use of wood spanning frame members to support the weight of people sitting on sofas in association with the polymer arm rest forms provides more than sufficient strength to support people sitting on the sofa, and provides same with minimal component parts, minimal assembly time, and potentially reduced cost. An optimal solution is to minimize load carrying of large blow molded components and allow the wood components to transfer a majority of carried load to the floor. In embodiments seat load carrying components transfer seat loading from occupants to a lower front rail that has a lower edge defining the lower margin of the sofa frame, and a lower back rail with a lower edge also at the lower margin of the sofa frame.
A feature and advantage of embodiments is the use of a plurality of spanning wood frame members between a pair of polymer arm rest forms, where seating load carrying spanning wood frame members seat on upwardly facing surfaces of the polymer arm rest. In embodiments the upwardly facing surfaces are load carrying platforms portions formed in an inner wall portion of hollow arm rest form whereby the seating load transferred to the platform portions by ends of the spanning wood frame members is distributed to the inner facing wall portion above, below, forwardly and rearwardly of the platform portion. In embodiments, the spanning frame members may be formed of metal rather than wood with some of the same advantages.
A feature and advantage of embodiments is that a plurality of spanning wood frame members extend between and are attached to a pair of spaced hollow polymer arm rest forms, each end of the spanning wood frame members received in a form fit recess, none of the recesses being a recess closed at the top, bottom, and two lateral sides.
A feature and advantage of embodiments are blow molded polymer arm rest forms that have a plurality of vertical recesses in the wall portions for adding structural strength to the arm rest form. A feature and advantage of embodiments is use of a polyethylene for arm rest forms, and with threaded inserts having an internal threaded surface placed at spanning member attachment points in polymer wall portions for receiving screws that extend through spanning frame members for securing the spanning frame members to the polymer arm rest forms. In embodiments, the threaded inserts have an external thread and are threaded into the polymer wall portions of the arm rest forms. In embodiments the spanning member attachment points are at recesses in the wall portions of the arm rest forms whereby an end of the spanning member will nest into the recess, the nesting providing secure fixation of the component with respect to the arm rest forms. In embodiments, the nesting is an inference fit between the end of the spanning frame member and the slot or recess. The spanning frame member end receiving slot defined by the wall portion being form fit, having a slot width at least at a seating position sized slightly smaller than the spanning frame member end width to provide a snug interference fit and retention of the spanning frame member end therein. The wall portion defining the slot may have a shoulder portion therein above the seating position of the spanning wall portion ends. The shoulder can define a narrowing of the slot to facilitate easy placement of the spanning frame member. In embodiments, a projection of the wall portion into the slot can provide a detent structure that can deflect inward when the end is slid into place and then return to the original position to provide a blocking or inhibition of the end moving out of the seating position.
A feature and advantage of embodiments is a polymer arm rest form that has an exterior surface that is deflectable throughout the surface upon impact that is greater than any deflection of a conventional wood arm rest frame. In embodiments, all exterior corners of the polymer arm rest form have a radius of 0.5 inches or greater defined by the curvature of a corner wall portion providing deflection upon impact and a more blunt impact corner than conventional wood frame arm rest forms. In embodiments, all exterior corners of the polymer arm rest form defining the profile of the arm rest form have a radius of 0.75 inches or greater defined by the curvature of a corner wall portion.
A feature and advantage of embodiments is a furniture seating item with a rectangular base, with opposing side polymer structural supports defining opposing short sides of the polymer base and with wood base boards defining the long sides of the rectangular base, ends of the wood base boards connecting with the polymer structural supports, and wherein the rectangular base supports a seating platform, and a back rest, and wherein all load carrying components of the furniture seating item are connected directly to or connected by way of metal or wood components to at least one of the a forward and rearward non-polymer supports. In other words, none of the loaded components transfer any loading upon them exclusively to upright walls of the polymer structural supports, such loading is shared or primarily carried by the non-polymer frame structures. In embodiments, floor engaging feet are placed under the four ends of the wood base boards to support the loading of the seating item. By way of the feet, loading by sitting, other than at the sofa feet, there are no isolated upright wall structures polymer structures, such as legs, carrying the load of the furniture seating item.
In embodiments of the invention, arm rests for a stationary upholstered seating item such as a sofa, each have a hollow polymer arm rest form weighing from about 6 to 10 lbs, saving 10 to 16 pounds for both arm rest forms compared to conventional wood framed arm rest forms. In embodiments of the invention, recliner arm rest forms can save 14 to 19 pounds for two blow molded arm rests compared to conventional wood framed arm rest forms. In recliners, a 50% reduction in the weight from the arm rests is available by using blow molded polymer arm rest forms over conventional wood framed arm rests.
In embodiments of the invention, the inventors have facilitated utilizing hollow thin-walled, blow molded structures, such as chair arm rests, in load carrying applications by providing reinforcing means to the blow molded structures. Such reinforcing mean including metal or wood plates or beams inserted into receiving pockets formed in the blow molded structure. Axis of an elongate beam being arranged to be upright to provide enhanced load carrying support. In embodiments, the plane of a plate is positioned upright in a pocket defined in the blow molded structure for enhancing the load carrying capability. In embodiments, a hollow blow molded structure has a wood or metal reinforcing plate or beam on one lateral side of the blow molded structure and has another metal or wood load carrying structure on an opposite lateral side of the blow molded structure.
In embodiments, a blowmolded backrest form, such as for a recliner, can have metal reinforcing arms inserted within the blowmolded backrest form that attach to metal couplings for connecting with the recliner mechanism. The wall of the blowmolded backrest form may be sandwiched and compressed between the metal coupling and the reinforcing arms.
The above summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure.
The drawings included in the present application are incorporated into, and form part of, the specification. They illustrate embodiments of the present disclosure and, along with the description, serve to explain the principles of the disclosure. The drawings are only illustrative of certain embodiments and do not limit the disclosure.
While the embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.
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Referring to Prior Art
Each of the prior art arm rest frames 110 can include a number of components, including a front post 118 and a back post 120 (which can be made of oriented strand board or “OSB”) providing a shape to arms 110 connected by one or more leg rails 122 (which can be made of oriented strand board or “OSB”) and one or more arm pulls 124 (which can be made of hardwood or “HW”). Each of the arm frames 110 can include one or more tie blocks 126 (which can be made of hardwood or “HW”) for connecting the components of the arm together and maintaining the positioning and angles of arms 110. As depicted, each of arms 110 of sofa frame 100 includes up to or even over 10 or 15 parts that are connected with a multitude of fasteners such as staples. Upholstery for prior art sofa frames, particularly the arm rests, require individual attachment of several layers on the arm rest form at the final assembly facility. See, for example, U.S. Pat. No. 10,117,521 which is owned by the owner of the instant invention and application and is incorporated herein by reference for all purposes.
Referring to
As depicted, frames 60 can include one or more spanning wood frame members 201 which may be configured as a lower front rails 202 (which can be made of oriented strand board or “OSB”) forming a front portion of frame 60, a lower back rail 203, breast rail 204 (which can be made of oriented strand board or “OSB”), top back rail 206 (which can be made of hardwood or “HW”), and spring rail 208 (which can be made of hardwood or “HW”) forming a back portion of frame 60. Spanning wood frame members 201 front and back are received in slots or recesses 207 defined in the wall portions of the two arm rest forms 210. The recesses 207 capture, restrain and positionally fix the ends 201.2 of the spanning wood frame members 201. Differently configured recesses 201.3 are illustrated in the arm rest forms. In embodiments, the wall portions defining slots including upwardly facing surfaces 207.3, that the spanning wood frame members seat on as part of seating positions 207.5, see in particular
Referring to
The frames 60 may include one or more seat stretchers 212 (which can be made of metal). The back of frame 60 can further include one or more upright back rest frame members 214 (which can be made of plywood or oriented strand board or “OSB”) further forming a back portion of frame 60. Frame 60 can include one or more tie blocks 216 (which can be made of hardwood or “HW”) for connecting the components of frame 60 together and maintaining the positioning and angles of frame 60.
Referring to the seat frames
Referring to
Arm rest forms 210 can be formed of by molding methods, such as blow molding (injection blow molding, extrusion blow molding, injection stretch blow molding), including more than one parison, and formed of different materials including, by way of example, polyethylene (PE), such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE), polyvinyl chloride (PVC), polypropylene (PP), nylon, and polyethylene terephthalate (PET), thermoplastic elastomers (TPE), acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), nylon/polyamids (PA), polycarbonate (PC), polyester and copolyester, urethane and polyurethane, and acrylic and polystyrene. In other embodiments, molded components can be formed by differing molding methods, such as injection molding (overmolding, insert molding, cold runner injection molding, hot runner molds, rotational molding).
As best depicted in
In embodiments, a plurality of spanning wood frame members extend between and are attached to a pair of spaced hollow polymer arm rest forms, each end of the spanning wood frame members received in a form fit recess, none of the recesses being a recess closed at the top, bottom, and two lateral sides of the recess whereby ends of the spanning wood frame members may be inserted from
In embodiments, a ballast material can be added to arm rest forms 210 to provide further stability and acoustical insulation to arms 210 and frame 60, generally. Such ballast material can include foam, such as a density foam, sand, cement, or other material. In embodiments, ballast can be added to arms 210 via a port or other opening in arm rest form (not depicted) that can include a cap or other closure structure that can be permanently or selectively closed.
In embodiments, frame 60 depicted in
Referring to
Arm rest forms can be formed in any of a number of desired furniture arm shapes including, by way of example, track, ruched, modern scroll, pad, track with nails, key, modern English, shelter, pleated, and saddle. Arm rest forms can include a top 218, a bottom 220, an outer lateral side 222, an inner lateral side 224, a front 226, and a back 228. Referring to
Referring to
In embodiments, fill material can be added to the hollow interior of the blow molded arm rest to provide enhanced weight carrying capability. The fill material a foam that becomes rigidized within the hollow interior, such as a sprayed in polymer foams, for example expanded polystyrene. In embodiments, an expanded polystyrene form may be coated with a more rigid polymer such as a polyethylene. In embodiments, the hollow blow molded arm rest form or other form may be hermetically sealed such that air is trapped within the form, the compressible air providing resistance to the form collapsing or deforming inward. In embodiments, air pressure or gas pressure can be above atmospheric in the blow molded arm rest form.
Blow molded arm rest forms 68, 69 are further depicted in
Referring to
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Referring to
Each of prior art arm rest frames 306 can include a number of components, including outside arm rail 310, inside arm rail 312, and a plurality of arm fillers 314 connecting outside arm rail and inside arm rail. A plurality of tie blocks 316 can be included for connecting the components of the arm—only one being depicted in
Prior art back rest 304 can include a number of components, including a top back rail 318, a bottom back rail or wing mount 320, one or more wings 322, one or more back posts 324, one or more back post stiffeners 326, a back brace 328, a breast rail 330, and webbing 332. As depicted, backrest includes about 15 parts. A multitude of fasteners, such as staples are utilized for assembling the back rest.
Referring to
Molded components, here, arm rest forms 402, back rest form 404, and footrest 406 can be connected to other components of frame 400 with various fasteners, such as brackets, screws, clips, dowels, and other fasteners. Back rest form 404 can also be attached to recliner mechanism arms 408.4 via a coupler configured as a steel bracket 410, with a recess 411 such as depicted in
Referring to
The embodiment of
Molded components can be formed of by molding methods, such as blow molding (injection blow molding, extrusion blow molding, injection stretch blow molding), and formed of different materials including, by way of example, polyethylene (PE), such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE), polyvinyl chloride (PVC), polypropylene (PP), nylon, and polyethylene terephthalate (PET), thermoplastic elastomers (TPE), acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), nylon/polyamids (PA), polycarbonate (PC), polyester and copolyester, urethane and polyurethane, and acrylic and polystyrene. In other embodiments, molded components can be formed by differing molding methods, such as injection molding (overmolding, insert molding, cold runner injection molding, hot runner molds, rotational molding).
In embodiments, a ballast material can be added to arms 402 to provide further stability to arms 402 or chair frame 400, generally. Such ballast material can include foam, such as a density foam, sand, cement, or other material. In embodiments, ballast can be added to arms via a port or other opening in arm 402 that can include a cap or other closure structure that can be permanently or selectively closed.
Back rest form 404 is further depicted in
Arm rest forms 402 are further depicted in
Referring to
Various direction-indicating terms are used herein as a convenient way to discuss the objects shown in the figures. It will be appreciated that many direction indicating terms are related to the instant orientation of the object being described. It will also be appreciated that the objects described herein may assume various orientations without deviating from the spirit and scope of this detailed description. Accordingly, direction-indicating terms such as “upwardly,” “downwardly,” “forwardly,” “backwardly,” should not be interpreted to limit the scope of the invention recited in the attached claims.
The following United States patents and patent publications are hereby incorporated by reference herein: U.S. Pat. And Pub. Nos. 2020/0029699, U.S. Pat. Nos. 7,070,243, 6,854,806, 6,702,391, 6,679,558, 5,582,460, 5,755,489, 5,575,533, 4,775,187, 3,877,087, 3,669,495, 3,658,382, 10,299,606, 10,117,521, 10,034,554, U.S. Pat. Nos. 9,839,295, 9,474,381, 8,777,319, 8,448,314, 8,438,716, 7,988,236, 7,806,482, and 7,438,362. The above references to U.S. patents in all sections of this application are herein incorporated by references in their entirety for all purposes. Components illustrated in such patents may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07(B).
All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/525,539 filed Jul. 29, 2019, now U.S. Pat. No. 11,122,907, which claims priority to U.S. Provisional Application No. 62/711,168 filed on Jul. 27, 2018; this application is also a bypass continuation-in-part of PCT/US2021/022645, filed on Mar. 16, 2021, which claims priority to Provisional Application No. 62/990,287 filed Mar. 16, 2020, and also claims priority to Provisional Application No. 63/039,445 filed Jun. 15, 2020. All of said applications are incorporated by reference herein in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 62711168 | Jul 2018 | US | |
| 63039445 | Jun 2020 | US | |
| 62990287 | Mar 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16525539 | Jul 2019 | US |
| Child | 17481151 | US | |
| Parent | PCT/US21/22645 | Mar 2021 | US |
| Child | 16525539 | US |
