Note: Descriptions are shown in the official language in which they were submitted.
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Attorney Docket ~o. 1202-00183
- METHOD OF UPHOLSTERING A CHAIR
AND THE PRODUCT PRODUCED THEREBY
BACKGROUND OF THE INVENTION
The present invention relates generally to a method of
upholstering articles of furniture, and more particularly, to
methods of upholstering chairs having a shell supported by a base
assembly.
S In general, articles of furniture such as chairs include a
frame assembly which is upholstered. Traditionally, such
articles of furniture are manufactured by first forming the frame
from multiple pieces of wood or man-made materials or a
combination of both, and subsequently providing the frame with
padding in the form of a foamed material which is permanently
attached. Thereafter, an upholstered covering is applied over
the padding by tacking the upholstery to the frame. The
upholstery is intended to be secured to the frame structure for
many years of use. Thereafter, the upholstery may be removed
lS from the frame and another upholstered covering applied.
However, the process of reupholstering an article of furniture
including tacking on new upholstery can be unduly time consuming,
tedious and costly.
Likewise, under another common method of manufacturing
articles of furniture, the covering material may be applied over
the padding and attached thereto by sewing or through the use of
some other means such as adhesives. Thereafter the integral
upholstery covered padding is permanently attached to thè frame.
Hereto, significant effort would be required to reupholster such
articles of furniture.
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Attorney Docket No. 1202-00183
Somewhat in contrast, there has been a relatively recent
trend toward manufacturing furniture which includes a removable
layer of upholstery material. For example, United States Patent
No. ~,007,676 to Lien discloses a quickly detachable vehicle seat
cover having a plurality of cloth strips attached thereto for
fastening the seat cover to fastening elements disposed on the
vehicle seat. ~ikewise, U.S. Patent No. 4,400,030 to Maruzzo et
al. discloses a removable upholstery portion for a vehicle seat
member which is useful as a protective covering to protect the
seat from wear and tear on -the original, underlying seat
covering. Still further, U. S. Patent No. 3,2~8,147 to Testa
discloses an invention relating to upholstered furniture having
removable upholstery therefor.
While removable upholstery per se is known, it appears that
lS the art is directed to utilizing the removable upholstery as a
protective covering for an underlying layer of upholstering
material, or, alternatively, as a new covering for an underlying
layer of worn or soiled upholstering material. Further, the
removable upholstery embodiments heretofore described appear to
be unnecessarily difficult to attach to and detach from the
frame.
Thus, although some removable upholstery embodiments have
performed satisfactorily for their intended purpose, namely for
protecting or removing the underlying original seat covering
material or concealing any padding applied over a seat frame, the
removable upholstery assemblies presently known have done little
if anything to simplify the often complicated process of
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Attorney DGcket No. 1202-00183
manufacturing articles of furniture. To this end, the need
exists to develop articles of furniture which aesthetically
pleasing and are relatively easy to manufacture, upholster and
selectively reupholster without requiring an extensive amount of
work or expense.
SUNM~RY OF THE INVENTION
Accordingly, it is an object of the present invention to
provide a method of upholstering articles of furniture and, more
particularly, chairs such as office chairs. Under the methods
disclosed, the chair assemblies of the present invention are
easily upholstered initially, thus, reducing the total
manufacturing steps required~ which in turn results in a
relatively low cost per unit.
As a related object, the chair assemblies of the present
invention can be readily reupholstered as desired by
interchangeably replacing the previously applied upholstery with
a variety of different upholstery packages.
Another object of the present invention is to allow the
consumer the opportunity to choose replacement upholstery
packages which can be easily installed without requiring
specialized tools or professional reupholstering services.
Further objects, advantages and novel features of the
present invention will become apparent from the following
description, with reference being made to the accompanied
drawings whereïn preferred embodiments of the present invention
are clearly shown.
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Attorney Docket No. 1202-001~3
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective assembly view of a chair
embodiment constructed utilizing the method of upholstering an
article of furniture according to the teachings o~ the present
invention;
Figure 2 is a perspective assembly view of a second chair
embodiment assembly constructed utilizing the methods of the
present invention;
Figure 3 is a blown apart perspective assembly view showing
the chair embodiment of Figure 1 including the fastener
arrangement of the present invention disposed on the chair shell
and associated cushions;
Figure 4 is a bottom view of the chair embodiment of Figures
1 and 2 with the seat portion cushion attached to the seat
portion of the chair;
Figure 5 is a rear view of the seat back cushion separated
from the chair's shell illustrating the disposition of fasteners
thereon;
Figure 6 is a bottom view of the seat portion cushion
separated from the chair's shell illustrating the disposition of
fasteners thereon;
Figure 7 is a sectional side view illustrating the seat back
and seat portion cushions attached to the chair shell;
Figure 8 is a sectional side view of a first seat back
cushion embodiment detached from the seat back portion of the
chair's shell;
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Attorney Docket No. 1202-00183
Figure 9 is a sectional side view of a second seat back
embodiment detached from the seat back portion of the chair's
shell; and
Figure 10 is a schematic view setting forth the methods of
upholstering a chair assembly according to the teachings of
present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawings, and particularly to ~igures
1 and 2, first and second alternative embodiments of the chair
assembly 10, upholstered according to the methods disclosed
herein are illustrated. The first and second chair assemblies
differ only in that the first embodiment relates to an office
chair having a wheeled pedestal base assembly and the second
embodiment includes four spaced-apart legs having a buc~et (not
shown) which receives the seat portion of the chair In all
other respects, the chair embodiments illustrated with references
to Figures 1 and 2 are to be considered the same. As such, like
reference numerals will hereinafter be utilized for like elements
of the invention.
As illustrated more clearly in Figure 3, the chair assembly
10 includes a preformed unitary frame portion, otherwise known
as the shell 12, having an upwardly extending seat back 14 and
a substantially horizontally disposed~seat portion 16. Ideally,
the shell 12 is made from a rigid material, such as wood,
plastic, or other man-made material sufficient in strength to
support the weight of a seat occupant. Dlsposed over the
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Attorney Docket No. 1202-0û183
marginal edges 18 and 18A, the top edge 20 and back surface 22
as illustrated more clearly in Figure 7, is a decorative co~Jering
material 24. The decorative covering material 24 is attached to
the shell by gluing, stapling or sewing the material directly to
shell. Typically, the decorative covering 24 is selected from
a variety of different materials including but not limited to
leathers, viny~s and cloth.
In an effort to save on material cost, the inner surface 26
of the shell 12 preferahly remains uncovered except for the
marginal edges 18 and 18A and top edge 20. The downwardly
sloping leading edge 28 of the seat portion 16 does not require
the decorative covering material as this portion will eventually
be covered by the seat portion cushion as will be described in
greater detail below. A relatively thin layer of padding
material (not shown) may be optlonally applied to the shell 12
prior to applying the decorative covering or, alternatively, the
thin layer of padding material may be attached to the inner
surface of the decorative covering material prior to being
applied over the shell.
Disposed on the inner surface 26 of the chair shell 12 are
a plurality of fasteners 30 spaced apart sufficiently to retain
the seat back and seat portion cushions upon application.
Fasteners 30 may be the hook and loop variety such as VELCR0~ or
other known brands with one component (either the hook or loop
component) disposed on the shell 12 and the other component
disposed on the cushion to be attached. Typically, the hook and
loop fasteners 30 are in the form of elongated strips disposed
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Attorney Docket No. 1202-00183
proxi~ate to the marginal edges 18 and 18A of the shell, with at
least one strip 30A transversing the shell along the junction
between the seat back 14 and seat portion 16 of the shell.
Likewise, the back surface 22 of the shell 12 includes hook and
look fasteners 30B disposed along the top edge 20 for retaining
the overlapping portion of the seat back cushion. Preferably,
the hook and loop fasteners 3OB are arranged in a downwardly
pointing V-shape as this arrangement tends to best secure the
overlapping portion of the seat back cushion. Likewise, while
the hook and loop fasteners 30 are generally disposed near the
marginal edges and the top edge of the shell as this arrangement
tends to retain the seat back and seat portion cushions in the
most advantageous way it should be understood by those skilled
in the art that other hook and loop fastener arrangements are
possible. In this regard, it should also be understood by those
skilled in the art that, while hook and loop fasteners are
preferred, other fastening means such as buttons and snaps could
be utilized herein.
The chair assembly lO of the present invention additionally
includes seat back and seat portion cushions 32 and 34,
respectively, which are disposed mainly over the inner surface
26 of the shell 12. The seat back cushion 32, which for the
chair shown generally has a substantially rectangular shape,
includes an outer upholstery layer 36 and at least one layer of
padding material 38 made from polyurethane foam or the like as
best illustrated in Figures 8 and 9. With regard to the
upholstery layer 36, the seat back cushion 32 includes an outer
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Attorney Docket No. 1202-00183
show surface 40 disposed about the peripheral edges 42 and the
front face 44 of the cushion. The back side 46 of the seat back
cushion 32 may be made from any one of a number of different
- wear-resistant materials, which preferably are less expensive
than the material of the show surface. Disposed on the back side
46 of the seat back cushion 32 are a plurality of mating hook and
loop fasteners 48 arranged such that the seat back cushion can
be applied as illustrated most clearly in Figure 7. Typically,
the hook and loop fasteners 48 are disposed proximate to the
peripheral edges 42, transversely along the top overlapping
portion SO and on a flange 52 which extends from the lower
portion 54 of the seat back cushion 32. Also disposed on the
back side 46 of the seat back cushion 32 is a zipper 56 extending
the length of the cushion which provides access to the pocket 58
formed between the peripheral edges, top portion and lower
portion of the seat back cushion for receiving the padding
material 38.
Under an alternative seat back cushion embodiment 32A, shown
in Figure 9, separate layers of padding materials 38 and 38A,
respectively, are provided within the pocket 58. This
arrangement allows the seat occupant to modify the firmness or
softness of the seat back cushion 32A by adding or subtracting
the layer of padding material 38A as desired. Depending on the
amount or thickness of padding in the seat back cushion 32, its
thickness may change, unless foam padding 38 and/or 38A having
a varying density is utilized.
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Attorney Docket No. 1202-00183
To provide the seat back cushions 32, and alternatively 32A,
with the buttoned or tucked appearance as illustrated most
clearly in Figures 1, 2 and 3, drawable strips 62 shown in
Figures 8 and 9 are attached to the inner surface 64 of the outer
upholstery layer 36. The drawable strips 62 are fed through
apertures (not shown) provided in the padding material 38 and
back side 46 of the seat back cushion, and are drawn relatively
tightly to pull portions of the show surface 40 inwardly thus
providing the buttoned or tucked appearance. After the strips
62 have been drawn, the strips are maintained in position by
attaching them to panels 66 typically disposed on the back side
of the seat back cushion. Optionally, the panels 66 can be
maintained within the pocket 58 on the first layer of padding
material 38 as illustrated in phantom in Figure 9.
i5 The seat portion cushion 34, which also has a substantially
rectangular shape, similarly includes an outer show surface 68
disposed along the peripheral edges 70 and front face 72 of the
cushion. The back side 74 of the seat portion cushion 34 as
illustrated most clearly in Figure 6, again can be made from any
one of a number of different wear-resistant materials. Included
along the leading end 76 of the seat portion cushion 34 is flange
78 which includes a J-shaped elongated retainer 80. As with the
seat back cushion 32, the seat portion cushion 34 also includes
a zipper 82 through which padding material can be added and
subtracted in the above described manner relating to the seat
back cushion.
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Attorney Docket No. 1202-00183
The methods of upholstering an article of furniture, and
more particularly, the chair assemblies lO will now be described
in greater detail with additional reference being made to Figure
10 .
Initially, a first piece 24A of decorative covering material
24 is applied over the shell's back surface 22 and thereafter
wrapped around the marginal edges 18 and 18A and top edge 20 of
the shell's seat back. Second and third pieces 24B and 24C of
the covering material 24 are then attached to the inner surface
26 of the seat portion 16 and wrapped over the marginal edges 1~
and 18A of the seat portion such that the second and third pieces
of covering material subtly Gverlap the lower ends of the first
piece 28A of covering material. Thereafter, the second and third
pieces of decorative covering material are permanently attached
to the under surface 84 of the shell's seat portion. Once the
decorative covering material 24 has been applied to the shell,
a dust cover 92 as shown in Figure 4 may be applied to the under
surface of the shell.
Next, a J-shaped retainer 86 is attached to the under
surface 84 of the seat portion 16 along its leading edge 28. The
tongue portion 88 of the retainer is stapled, sewn or otherwise
adhered to the under surface of the shell such that the hook
portion 90 of the retainer extends rearwardly. Typically, the
J-shaped retainer extends almost the entire length of the leading
edge 28 to provide sufficient anchoring for the corresponding
retainer 92 contained on the seat portion cushion.
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Attorney Docket No. 1202-00183
The various hook and loop fasteners 30 are then applied to
the inner surface 26 of the shell such that the fasteners are
disposed over substantially the entire length of the shell along
the marginal edges 18 and 18A. Again, the hook and loop
fasteners 30 can be attached utilizing a variety of different
means including staples, sewing and adhesives, among others.
Additionally, a hook and loop fastener 30A is applied to the
inner surface of the shell at the junction of the seat back and
seat portions for retaining the lower end of the seat back
cushion as will be described below. Finally, at least one hook
and loop fastener 30B is applied over the decorative covering 24
contained on the back surface 22 of the shell for retaining the
overlapping portion 50 of the seat back cushion 32 which overlaps
the top edge 20 of the shell.
Once the hook and loop ~asteners 30, 30A and 30~ and the J-
shaped retainer 82 have been attached to the shell and mating
hook and loop fasteners are attached to the cushions in a
corresponding location, the cushions are then ready for
attachment. Prior to attaching the seat back and seat portion
cushions 32 and 34, respectively, the cushions can be modified
to include more or less padding material as desired. After the
desired amount of padding material has been attained, the
drawable strips 62 which are attached to the inner surface 64 of
the outer upholstery layer 36 are then pulled through the padding
material 38 (and optional padding material 38A) and the back side
46 of the seat back cushion to provide the cushion with a
buttoned or tucked appearance; Once the buttoned or tucked
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Attorney Docket No. 1202-00183
appearance has been accomplished, the drawable strips 62 are
stapled, or otherwise fastened, to the panels 66 to maintain the
buttoned appearance. As previously noted the seat portion
cushion 34 can also be modified and provided with the buttoned
or tucked appearance.
The next step in upholstering the chair assembly lO is to
apply the seat back and seat portion cushions 32 and 34,
respectively, to the shell 12. First, the seat back cushion 32
is applied by aligning the flange 52 containing the hook and loop
fastener 48A with the transversely disposed mating hook and loop
fastener 30A provided at the junction of the seat back and seat
portion and pressing the fasteners together. Then, typically
standing behind the shell 12 the seat back cushion 32 is aligned
such that the hook and loop fasteners 30 disposed on the seat
lS back portion 14 along the marginal edges of the shell's inner
surface are aligned with the hook and loop fasteners 48 contained
on back side 46 of the seat back cushion. ~astly, the
overlapping top portion 50 of the seat back cushion 32 is rolled
over the top edge 20 of the shell 17 with the transversely
disposed V-shaped hook and loop fasteners 48B contained on the
back side 46 of the seat back cushion aligned with the hook and
loop fasteners 30B extending from the back side 22 of the shell
12. Again, the fasteners are pressed together such that the hook
and loop material takes a firm hold and retain the seat back
cushion to the shell.
Once the seat back cushion 32 has been applied to the shell
12, the seat portion cushion 34 is then attached by sliding the
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Attorney Docket No. 1202-00183
J-shaped retainer 80 contained on the flange 78 of the seat
portion cushion into engagement with the retainer 86 attached on
the under surface 84 of the shell 12. Once the retainers have
been combined in a locking relationship, the seat portion cushion
34 is aligned such that the cushion can be pulled over the
leading edge 28 of the seat portion 16. Thereafter, the seat
portion cushion 34 is laid over the seat portion 16 of the shell
with the mating hook and loop fasteners 30 disposed on the seat
portion 16 and the fasteners 48C aligned in an overlapping
manner. By firmly pressing the seat portion cushion 34 down on
the seat portion 16 of the shell 12, the hook and loop fasteners
take a firm hold and retain the seat portion to the shell.
Ideally, the trailing end of the seat portion cushion abuts the
lower edge of the seat back cushion to conceal the flange 52
which contains the hook and loop fastener 48A.
It should be noted by those skilled in the art that the
supporting base assembly 94, regardless of the embodiment, can
be attached to the shell either before or after the chair
assembly has been upholstered. Likewise, if arms 96 are included
in the chair design, they can be attached to the shell either
before or after the seat back and seat portion cushions have been
applied to the shell.
From the foregoing description, it should be appreciated
that a wide variety of modifications can be made to the chair
assemblies of the present invention. Thus, skilled practitioners
will recognize that the present invention can be implemented in
a variety of forms. Accordingly, while the above description
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Attorney Docket No. 1202-00183
constitutes the preferred embodiments of the present invention,
it will be appreciated that the present invention is susceptible
to modification, variation and change without departing from the
proper scope and fair meaning of the accompanying claims.
14
