Note: Descriptions are shown in the official language in which they were submitted.
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This invention relates to upholstered seats, for
example a chair, sofa, or like structure providing a facility
for seating one or more persons~
A structure of this nature requires a sturdy frame
which is durable and will retain its shape and also requires
upholstery which is carefully fitted to the frame for the twin
sakes of appearance and reasonably long life~ A further
requirement of par~icular importance, especially in modern
times, is that the structure and its respective parts be
relatively simple to fabricate so that the necessary work can
be carried out adequately by relatively unskilled workers;
the day of craftsmen in this industry being now virtually over~
Conventionally~ such seating structures have been
manufactured heretofore with wood frames which gave rise to
many problems. For example, problems arose in the production
of wood frames; in ensuring that the wood used therein was
properly seasoned, and that the various frame joints were
adequate for their purposes. Wood frames-have a well-known
tendency to warp or twist over the course of time, and the
various frame members often split not only at the time of
manufacture but, as well, in later use. Wood joints notoriously
became loose, or even broken altogether, after a period of use~
--- particularly when the frame was subjected to rough usage
or to major temperature and humidity variations~ A significant
disadvantage of wood frames subsists in the fact that the
upholstering thereof must be performed on a custom basis
rather than on a production line and a still further disadvantage
thereof is incidental to storage of the wood frames between the
time of their manufacture and the time of use.
Modern attempts to overcome some of these disadvantages
by substituting plastic for wood in certain applications have
not only encountered major cost hurdles but ha~e also proven
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of dubious value for other reasons which ~re largely obvious
but do not need to be de-tailed herein, in any event,
In a conventional upholstered seating structure of
the prior art~ the upholstery of the wood frame required the
skillof a custom craftsman to produce a satisfactory finished
product. Since such work is now largely carried out by
relatively unskilled workers, rather than by the artisans of
previous years, the finished result often leaves much to be
desired and a comparatively high rejection ratio is the rule
rather than the exception mainly because of unskilled and
resultantly sloppy workmanship.
It is therefore a broad object of the invention to
provide a mode of seat construction which permits employment
of metal framing therein and largely prefabricated upholstery
which can be nicely fitted onto the metal framing by relatively
unskilled workers to produce a professional and highly
workmanlike result.
~ n upholstered seating structure according to the
invention, includes a horizontal base (sometimes called a
bed) which is the actual seat support and at least one upright
element projecting above the base which may be, for example,
a back rest or an end (or side) of the structure; the base
and the upright element having frames of metal skeletal
construction which are connected together below the top of
the base.
The upholstery for the seating structure is largely
prefabricated so that it can be drawn over the frame of the
upright element, at least, and tensed down~ardly over it.
Fastening means such as tacking strips are secured to the
respective frames at strategic and ~obtrusive locations to
permit fastening of the upholstery after it has been tensed
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and positioned.
An important aspect of the invention subsists in the
incorporation of preformed resilient padding in and as part
of the upholstery. That is to say, this padding or cushioning
may, in appropriate cases, be integrally shaped to give it any
desirable contour which then becomes a contour of the finished
seating structure after the upholstery is applied thereto.
Thus an upright member may be given a "boxy" appearance, for
example, or a rounded or overstuffed appearance or the like
as may be preferred.
Of course, this does not rule out the shaping of the
metal frame to impart a preferred appearance to a particular
part of the seating structure.
Needless to say, the upholstery mode visualized and
described in relation to the upright element or elements is
not necessarily applicable to all parts of the seating
structure nor is it limiting in the sense that it eliminates,
totally, the employment of more conventional techni~ues in
other areas.
Thus, in broad and general summary, a seating structure
according to the invention includes the described horizontal
base frame which provides the seating facility and at least
one upright frame disposed peripherally of the base frame and
extending partially above it as a back rest or as an arm for
the seating structure; spaced apart vertical standards or
posts forming part of said upright frame and having lower ends
by which they are integrally attached to the base frame,
procuring mutual re-inforcement of the base frame and the
~pright frame. Paired posts also have upper ends integrally
interconnected by a cross-piece above the base frame which~
together with the posts and cross-piece, bound a substantially
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vacant space.
A foundation hood encasing the upright frame above the
base frame is tensed thereover forming a drum-taut diaphragm
over the vacant space aforesaid capable of providing firm
support for overlying upholstery.
Other, more or less conventional appurtenances of the
described seat, such as the springing of the base, will also be
required as will be well understood.
The embodiment of the present invention selected for
the illustration purposes hereof is a sofa which ls described,
by way of example only, with reference to the accompanying
drawings, in which:-
Fig. 1 - is a perspective view~ partly broken away, of
a sofa according to one embodiment of the invention;
Fig. 2 - is a perspective view showing the complete
metal framing of the sofa;
Fig. 3 - is a sectional view taken along the line 3-3
of Fig. 1 showing the structure of the sofa base and back
rest at one end, without the arm;
Fig. 4 - is a sectional view taken along the line 4-4
of Fig. 1 showing the constructions of the arm of the sofa;
Fig. ~ - is a perspective view of a prefabricated hood
of resilient material providing padding for an arm of the sofa;
Fig. 6 - is an enlarged fragment of the front upper
corner of an arm in perspective;
Fig. 7 - is a perspective view of an outer upholstery
detail;
Fig. 8 - is an enlarged perspective view of a corner of
the base frame, and
Fig. 9 - is an exploded perspective view of the framing
shown in Fig.2 partly broken away.
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The sofa S of this embodiment consists of horizontal
base B which is the actual seating facility; sofa ends E-E
and the back rest R; each consisting of upholstered framing
to be described.
The exploded view of Fig. 9, particularly re~eals the
framing F of the sofa S shown partially assembled in Fig. 1.
As will be apparent from this view, the sofa framing F
of Fig 2 is comprised of the base frarne 10 and three upright
frames located around its periphery; serving, specifically,
as the symmetrical end frames 12-12 at its ends and the back
frame 14 at its back. As is also revealed by this view (and
others) each leg frarne 12 is comprised of a pair of sub-frames
L-L joined together in spaced apart relation by a plurality
of strategicall~ disposed spacers 16.
Each said sub-frame L includes front and rear vertical
posts 18-18 which serve as sofa legs; one (innermostl sub-frarne
L of each end frame 12 being integrally attached to the base
frarne 10 by the bottoms of the leg posts 18-18 thus procuring
mutual reinforcement of said base and end frarnes 10 and 12 as
well as providing feet for the structure.
Each said sub-frame L extends well above the base frarne
10 and the upper ends of its posts 18-18 are integrally joined
by a cross-piece which ultimately serves as arm rest 20.
The base frarne 10 is, in its turn, also comprised of
congruentsub-frames 30-30 disposed in vertically spaced and
registering relation in which they are interconnected by and
with said end frames 12-12. The registering side rails 32-32
of the congruent sub~frarnes 30-30 on each side of base frame
10 are interconnected by a U shaped thwart 34 which also spans
and re-inforces the base frame 10 intermediately of its length.
Examination of the drawing will reveal that certain
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structural elements of the end frames 12-12 are integrated with
the base frame 10 and are common to both.
It need hardly be pointed out that the incorporation
of two sub-frames L-L in each end frame 12 is to impart some
breadth to the latter which is, of course, variable to suit
design requirements.
An example of the flexibility of this aspect of the
invention is afforded by back frame 14 which consists only
of a single member comprised of posts or standards 40-40 which
are attached to and interconnect the side rails 32-32 of the
congruent sub-frames 30-30 at the back of base frame 10 slightly
inwardly of the respectively proximal end frames 12-12. The
standards ~0-40 are joined at their tops by a cross-bar 42,
and~ as well, again, by another cross-bar 43 slightly above
the level of base frame 10.
Before turning to the upholstery of the sofa S, it is
deemed worthy of note that the linear parts of the several
frames and sub-frames described, being of metal~ can be pre-cut
; to reasonably precise lengths which, in turn, makes it eminently
possible for these lengths to be assernbled and welded in jigs
to produce the several frarnes; this facility being productive
of collateral manufacturing advantages which need not be
enumerated herein; being obvious in any event.
Indeed, with average skill only, it is reasonably possible
for a worker to produce finished sofa framing elements which are
accurately dimensioned within a to~erance as low as 1/8 of an
inch.
Storage of the linear parts is not a major problem or
inconvenience whether disassembled or partially assembled.
This order of accuracy makes a useful contribution to
the upholstering procedure visualized.
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In Figo 8 will be seen in fragmentary form a corner of
the base frame 10 and the manner of its integration with a leg
frame L. In additionS Figs. 8&9further reveal details of the
installation of sinuous springs 44 forming spring fabric SF on
the base frame lOo That is to say, each ~3ide rail 32 will be
seen to be slotted at intervals as at 46 to receive clips 48
in which the spring ends 49 are accomodated; the clips 48
being clinched thereafter to retain the said spring ends 49.
Other expedients (not shown) familiar to the art may also be
resorted to in order to prepare the spring fabric SF for
upholstery of the base frame 10 which will now be described.
Preliminarily to the upholstering, facilities for
fastening the upholstery to the base frame 10 are provided in
the form of (wooden) tacking or nail-receiving strips ~0
secured to the lateral peripheries of said base frame 10 and~
for purpose which will later appear, similar strips ~0 are
also provided at the specific ends of base frame 10 becoming
a part thereofO Optionally, the spacing between each pair of
sub-frames L-L may also be boarded as at 51.
Seat padding ~2 of resilient material with appropriate
fabric lining is placed on the spring fabric SF. Said padding
~2 may be ~ashioned, for example, of resilient polyurethane
foam laminated to a polypropylene backing; being dimensioned
to overhang the sides and ends of the base 10 and being tensed
over the spring fabric SF and tacked to strips ~0 at the base
sides and ends.
Desirably an edging 54 is then placed on the front edge
of base frame 10; the edging ~4 being preformed of resilient
material and proportioned to overhang and cover the front strip
~0. An upholstery cover ~6 is then tensed over pad ~2 and
edging ~4; the upholstery cover ~6 being doubled under edging
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54 as shown and having overhanging margins which are unobtrusively
secured to the proximal strips 50 with the fabric o~ cover 56
duly tensed of course and appropriately slitted wl~ere necessary
to accomodate the frame parts.
While the foregoing procedures are specific to the
present invention, occasional resort to additional expedients
familiar to the prior art may also be required and is not
completely ruled out in the upholstery of the base frame 10.
On the other hand, the upholstery of the upright elements
e.g. the end frames 12-12 and the back frame 14 involves techniques
which are particularly unique to the present inve~tion.
As has already been pointed out, the posts and cross-piece
of each upright element bound a vacant space.
In the upholstering of the back frame 14, the first step
is to draw thereover an envelope 60 of a fabric which has
limited resilience and is fairly sturdy. Said envelope is
pre-tailored to provide a drum-taut diaphragm 61 over the
vacant space aforesaid since it is required and does, in effect,
serve to provide firm back support for persons seated on Sofa S.
Thereafter another outer envelope 62, similarly preformed
(of upholstery fabric) is drawn and tensed over the previously
enveloped back frame 14 with its free edges 64 and 66 respectively
fastened to strip 50 at the back of the base frame 10
substantially as will be obvious from Fi~ 3.
The upholstery of each end frame 12 (and, if desired, of
back frame 14 as well) involves prefabrication not only of
envelopes corresponding to those applied to the back frame 14
but also calls for a preformed hood 70 of thick, resilient,
elastomer superficially contoured as desired.
Each said resilient arm hood 70 is hollow and open at
its bottom permitting it to be drawn onto the end frame 12 over
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which envelope 72 had been previously dra~rn; said envelope 72
providing essentially the same drum-taut result as is imparted
to back frame 14 by its envelope 60.
The hood 70 which is next drawn over end frame 12 is shown
herein in itssimplest "boxy" form Por the sa~e only of simplicity
and clarity and wholly without limitation. Necessarily, the arm
hood 70 is vested with appropriate resilience and thickness and
has an interior cavity 73 which is contoured, proportioned and
dimensioned to procure a snug fit of hood 70 over the pre~iously
enveloped end frame 12; another envelope 74 of upholstery material
being then drawn over the resilient arm hood 70 and secured to
the proximal strip ~0 substantially as shown in the drawing and
as will later be described in greater detail; said outer envelope
7~ being also provided with an interior cavity snugly accomoda-ting
said end frame 12 and its previous investments.
It is conceivable that, according to design and other
circumstances, the foundation envelope 72 and resilient hood 70
fitted over end frame 12 may or may not require to be fastened
down. However9 fastening of the outer envelope 74 is mandatory
and, for this purpose, it is made sufficiently long to provide
tacking margins 7~ and 76.
That is to say~ assuming that the panel 77 of the outer
envelope 74 is that disposed exteriorly of so~a S, it will extend
well below the bottom of end frame 12 to permit its lower margin
75 to be wrapped around the bottom of that end fra~eand be
drawn up for attachment to the nearest strip 50 at the same end
of base frame lO, substantially as shown in Fig. ~ . Conversely,
the interior panel 78 of outer envelop 74 extends well below the
surface of sofa base B with its lower margin 76 reaching and being
tacked to adjacent strip 50 as margin 75 of the exterior panel
77.
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After upholstery as aforesaid, the base B and back rest R
of the sofa S may be equipped with cushions C of any appropriate
type.
The foregoing description of the invention as applied to
sofa S, seeks to make it apparent that the fabrication of a
seating structure according to present mode consists largely of,
what might be termed, mass production types of operations.
Firstly, the metal tubing to be used in the framing is
cut to required lengths and appropriately shaped; these operations,
at least, being semi-automatic in nature and devoid of those
complexities which necessitate that they be carried out by
skilled labor.
Sub-assemblies such as the sub-frames L and the congruent
base sub-frames 30, being more or less flat, may be prefabricated
and compactly stored for final assembly with other sub-assemblies.
The sub-assemblies and final assemblies of the framing are
completed by simple welding --- preferably, in jigs which conduces
to a sturdy and uniform result.
Tailoring of the upholstery may also follow well-known
mass-production techniques in full reliance on the fact that they
will certainly fit the framing for which they are designed.
Thereafter, gi~en t~e assembled framing and the prefabricated
upholstery, the actual upholstery of a sofa frame F can be
efficiently and professionally completed in, say, less than two
hours.
Not only, therefore, does the invention provide a seating
structure with a sturdy and durable frame as well as upholstering
which is well-fitted and professional in appearance, but it
further provides a mode of construction for a seating structure
which, by lending itself to mass production techniques, is
capable of producing a seating structure as aforesaid in minimum
#1092 P~3 CA - 10 -
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time by minimally skilled workers and, hence, at correspondingly
minimal labor costs.
Vario-~s modifications to the described embodiment~ within
the scope of the invention, will be readily apparent to the man
skilled in the art, the scope of the invention being set out in the
appended claims.
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