Abstract
An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.
Claims
1. An upholstered chair having two blowmolded arm rest forms, a backrest and a seat connecting to and extending between each of the two blowmolded arm rest forms, each of the two blowmolded arm rest forms being hollow and having a continuous polymeric wall extending around a top, two lateral sides, a forward side, a rearward side, and a bottom side, the two blowmolded arm rest forms separated by a separation distance, wherein a rearward rail having a length greater than the separation distance extends between and is attached to the rearward sides of each of the two blowmolded arm rest forms into recesses defined on the respective rearward sides of the two blowmolded arm rest forms, wherein the chair is covered with upholstery including two arm rest sock portions.
2. The upholstered chair of claim 1, wherein the backrest and seat comprise a plurality of wood spanning members extending between the two blowmolded arm rest forms, each of the plurality of wood spanning members having a length greater than the separation distance, and wherein each of the blowmolded arm rest forms have a through slot that extends from one lateral side to the opposite lateral side of the respective arm rest form, and wherein the slot is elongate in a forward rearward direction, and wherein the seat comprises a seat deck that is stapled to each of the two blowmolded arm rest forms at the respective through slots.
3. The upholstered chair of claim 1, wherein the chair is a recliner and wherein the backrest is blowmolded and the backrest has a pair of steel brackets with respective recesses attached thereto, and wherein the seat comprises a recliner mechanism with a pair of recliner mechanism arms, wherein the recliner mechanism is attached to each of the two blow molded arm rest forms and the pair of recliner mechanism arms are attached to the pair of steel brackets.
4. The upholstered chair of claim 3, wherein the blowmolded arm rest forms each have a respective reinforcing plate on a lateral side of each of the blow molded arm rest forms.
5. The upholstered chair of claim 4, wherein the reinforcing plates are formed of metal and secure the seat deck in place.
6. An upholstered sofa comprising: a pair of blow molded or rotationally molded polymer arm rest forms, each of the arm rest forms being hollow and having a continuous wall extending around a top, two lateral sides, a forward side, a rearward side, and a bottom side, the pair of polymer arm rest forms separated by a separation distance; a wood breast rail, a wood rear spring rail, a lower forward wood rail, and a lower back rail extending between and connecting to each of the pair of blow molded polymer arm rest forms, each of the wood breast rail, the wood rear spring rail, the lower forward wood rail, and the lower back rail having respective lengths that are greater than the separation distance; each of the polymer arm rest forms having an inset wall portion defining a breast rail slot and an inset wall portion defining a rear spring rail slot, the two respective breast rail slots having an interference fit with two respective ends of the breast rail, the two respective rear spring rail slots having an interference fit with two respective ends of the rear spring rail.
7. The upholstered sofa of claim 6, wherein each of polymeric arm rest forms having a recess for the lower back wood rail and each of the recesses having a threaded insert therein and secured to the continuous polymer wall of the respective arm rest form, wherein the lower back rail is attached to each of the polymeric arm rest forms with a threaded screw extending through the lower forward rail into the threaded insert.
8. The upholstered sofa of claim 6, wherein each arm rest form has a recess for receiving an end of the lower back wood rail, each respective recess defined by an inset wall portion with a rail engagement surface area of greater than 12 square inches.
9. The upholstered sofa of claim 6, wherein each arm rest form has a respective recess for receiving an end of the lower front wood rail, and each arm rest form has a rail engagement surface area at the respective recess of greater than 12 square inches.
10. The upholstered sofa of claim 6, wherein each arm rest has an internal volume defined by the continuous polymeric wall of at least 1 cubic foot.
11. The upholstered sofa of claim 6, wherein a lower margin of the lower forward wood rail is flush with lower margins of each polymer arm rest form.
12. The upholstered sofa of claim 1, wherein each of polymeric arm rest forms having a recess for a lower forward wood rail and each of the recesses having a threaded insert thereat and being secured to the continuous polymer wall and the lower forward rail is attached to each of the respective polymeric arm rest forms with a threaded screw extending through the lower forward rail into the respective threaded insert.
13. An upholstered sofa comprising a plurality of spanning wood frame members extending between and attached to a pair of spaced hollow polymer arm rest forms, each polymer arm rest form having a continuous single exterior wall, each end of the plurality of spanning wood frame members received in a form fit recess on an exterior surface of the respective exterior wall, wherein the respective continuous single exterior wall defining each recess does not extend completely around a circumference of the respective ends of the respective spanning wood frame members.
14. The upholstered sofa of claim 13, wherein a plurality of such spanning members are secured to other wood frame members that are primarily in an upright orientation at a backrest of the sofa.
15. The upholstered sofa of claim 14, further comprising a textile seat deck extending between the forward lower wood rail and a spanning wood rail of the backrest frame.
16. The upholstered sofa of claim 15, wherein each of the arm rest forms has a through slot extending through opposing lateral sides of each arm rest form, and wherein the textile seat deck has a pair of side flaps attached to each of the arm rest forms at the respective through slot.
17. The upholstered sofa of claim 14, wherein the spanning members are part of an integrated backrest frame.
18. The upholstered chair of claim 1, wherein the backrest comprises a preassembled back rest frame and a forward lower wood rail, the preassembled backrest frame attached to each of the pair of blowmolded arm rest forms and the rearward rail spanning between and attached to rearward sides of each of the pair of blowmolded arm rest forms.
19. The upholstered chair of claim 1, comprising a plurality of spanning wood frame members extending between and attached to the pair of spaced hollow polymer arm rest forms, each of the hollow polymer arm rest forms deflectable downwardly at least 1.0 inches at a top of the arm rest form without damage to the arm rest form.
20. The upholstered chair of claim 19, wherein two of the spanning frame members are attached to the respective polymer arm rest forms with a threaded fastener at each end of the two spanning frame members.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) 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.
(2) FIG. 1A is a perspective view of an upholstered sofa in accord with embodiments.
(3) FIG. 1B is a perspective view of an upholstered love seat in accord with embodiments.
(4) FIG. 1C is a perspective view of an upholstered single seat chair in accord with embodiments.
(5) FIG. 1D is a perspective view of a single arm sofa in in accord with embodiments.
(6) FIG. 1E is a perspective view of an upholstered recliner in accord with embodiments.
(7) FIG. 1F is an exploded view of the sofa of FIG. 1A in accord with embodiments including two molded polymer arm rest forms.
(8) FIG. 2A is a perspective view of a PRIOR ART sofa frame formed primarily from wood components.
(9) FIG. 2B is an exploded view of the PRIOR ART sofa frame of FIG. 2A.
(10) FIG. 3A is a perspective view of the rearward side of a sofa frame in accord with embodiments.
(11) FIG. 3B is a front perspective view of another sofa frame according to embodiments.
(12) FIG. 3C is a rear perspective view of the sofa frame of FIG. 3B.
(13) FIG. 3D is a front perspective view of a love seat frame according to embodiments.
(14) FIG. 3E is a front perspective view of a single seat frame according to embodiments.
(15) FIG. 3F is a front perspective view of a sofa frame with a single arm according to embodiments.
(16) FIG. 4A is an exploded view of the sofa frame of FIG. 3A.
(17) FIG. 4B is a front side exploded view of a sofa frame illustrating an integrated backrest frame as one of the components in accord with embodiments.
(18) FIG. 4C is a back side exploded view of the sofa frame of FIG. 4B.
(19) FIG. 4D is a side elevational view of an arm rest form.
(20) FIG. 5A is a cross-sectional view of a wall portion of a molded arm rest form showing a recess for receiving a spanning wood frame member and a threaded fastener clamping the wall.
(21) FIG. 5B is a perspective view of a blowmolded arm rest form with embedded threaded fasteners secured to a front wall and apertures for receiving connectors for an upholstered panel.
(22) FIG. 5C is a cross-sectional view taken vertically through a blow molded arm rest form through an upright slot for receiving a spanning frame member, for example, a breast rail.
(23) FIG. 5D is a perspective sectional of the upright slot for a breast rail.
(24) FIG. 5E is an elevation sectional view of the slot of FIGS. 5C and 5D with an end of a breast rail to be received. The section is taken at line 5E-5E of FIG. 5C.
(25) FIG. 5F is an elevation sectional view of the breast rail and slot of FIG. 5E with the end of the breast rail seated in the slot.
(26) FIG. 6A is perspective view of the back side of blowmolded arm rest form with a slot.
(27) FIG. 6B is the mirror image blowmolded arm rest form of the arm rest form of FIG. 6A.
(28) FIG. 7A is a front perspective view of the slotted blowmolded arm rest form of FIG. 6A.
(29) FIG. 7B is the front perspective view of the arm rest form of FIG. 7A with seat deck and/or upholstery material extending through the slot.
(30) FIG. 7C is the front perspective view of the arm rest form of FIG. 7B with the seat deck and/or upholstery material stapled to the wall of the arm rest form.
(31) FIG. 8 is a perspective view of a sofa arm rest form and a cooperating upholstered panel for attachment thereto.
(32) FIG. 9 is a side elevation view of the upholstered panel of FIG. 8.
(33) FIG. 10 is a cross-sectional view of the upholstered panel with a Christmas tree connector confronting the front wall of the arm rest form prior to connection.
(34) FIG. 11 is a cross-sectional view of the upholstered panel connected to the arm rest form of FIG. 8.
(35) FIG. 12 is an arm rest form with a foot to be attached thereto.
(36) FIG. 13 is a bottom perspective view of the arm rest form of FIG. 12.
(37) FIG. 14 is a perspective view of an expanding winged connector.
(38) FIG. 15A is a cross sectional view taken at line 15A-15A of FIG. 13 showing the expanding winged connector in place in the recessed bottom wall of the arm rest form.
(39) FIG. 15B is the foot of FIG. 12 attached to the arm rest form.
(40) FIG. 15C is the foot of FIG. 12 tightened further.
(41) FIG. 16 is a perspective view of a PRIOR ART recliner frame not including any molded plastic components.
(42) FIG. 17 is a perspective view of a recliner frame with a seat deck and recliner mechanism of a recliner such as shown in FIG. 1D according to embodiments including a molded backrest portion and two molded arm rest forms.
(43) FIG. 18A is an exploded view of the recliner components of FIG. 17.
(44) FIG. 18B is a rearward exploded view of the recliner of FIG. 17.
(45) FIG. 18C is a perspective exploded view of a blow molded arm rest form with a reinforcing plate.
(46) FIG. 18D is a perspective view of a reinforced blow molded arm rest form.
(47) FIG. 18E is a cross sectional elevation exploded view of a reinforced arm rest form.
(48) FIG. 18F is a cross sectional elevation view taken at plate 18F-18F of FIG. 18D.
(49) FIG. 18G is a cross-sectional view of another embodiment of a reinforced arm rest form.
(50) FIG. 19A is a front perspective view of a recliner frame in accord with embodiments.
(51) FIG. 19B is a back perspective view of the recliner frame of FIG. 19A.
(52) FIG. 19C is an exploded view of the recliner frame of FIGS. 19A and 19B.
(53) FIG. 20 is a front perspective view of a blowmolded recliner back rest with couplings for connection to a recliner mechanism.
(54) FIG. 21A is a front perspective view of the backrest of the recliners of FIGS. 19A-19C.
(55) FIG. 21B is an exploded view of the backrest of FIG. 21A.
(56) FIG. 22 is a mounting bracket of the recliners of 19a-19c.
(57) FIG. 23A is a perspective view of a coupling for connecting the back rest to the recliner mechanism.
(58) FIG. 23B is a perspective view of the opposite side of the coupling of FIG. 23A.
(59) FIG. 24-28 show an advantageous assembly steps of a sofa or chair provided by the preassembled backrest frame.
(60) FIGS. 29-36 illustrate assembly steps where the backrest frame is constructed during the seat frame assembly.
(61) 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.
DETAILED DESCRIPTION
(62) Referring to FIGS. 1A-1E, an upholstered sofa 30, love seat 31.1, single chair 31.3, single arm sofa 31.5, collectively “seats” and a recliner 31.7 are illustrated. The seats generally each have a seat base 32 with a seat deck 33, seat cushions 34 on the seat deck, an upright back rest 38 extending from the seat base, and a pairs of arm rests 40, 42 connecting to opposing ends 46, 47 of the seat base. Upholstery 50 covers exposed portions of the arm rests, seat base, back rest and cushions. That is the top side 52, left side 53, right side 54, back side 55, and front side 56 of the sofa has upholstery thereon. The bottom side 57 may have upholstery panels folded and attached to the frame but is generally not fully covered with upholstery. Feet 59 attach to the sofa at the bottom side and provide separation of the sofa base from a floor surface. When used herein, upholstery includes fabrics, leather, synthetic fabrics, faux leather, microfibers, or other sheet materials used as coverings for sofas.
(63) Referring to FIG. 1F, further components of the sofa are depicted and include a structural frame 60, seat back upholstery portion 62, arm rest upholstery portions 64, 65, a forward base upholstery portion 67 attached to the seat deck 33. The seat deck may be a textile seat deck as described in WO 2018/081471 which is owned by owner of this application and is incorporated by reference herein for all purposes. Alternatively, the seat deck may comprise conventional steel springs as are well known. The structural frame 60 includes unitary polymer arm rest forms 68, 69 discussed in detail below. The love seat, single arm sofa, and single seat chair generally share these components in a reduced width.
(64) Referring to FIG. 1E, the recliner 70 has a seat 72 with a seat cushion 73, a pair of arm rests 74, 75, a back rest 78, and an ottoman 80. Recliner frames are discussed below with reference to FIGS. 17-18B, 19A, and 19b.
(65) Although in FIG. 1F, the back rest upholstery portion, the arm rest upholstery portions, and the base upholstery portions (in the sofa and the other seats) are depicted as separate upholstery components to be attached to the sofa frame, in embodiments they may be combined in an integrated upholstery covering with the separate portions connecting prior to installation on the sofa or recliner frame. In embodiments, upholstery for the sofa and recliner may be furnished as a kit, the kit manufactured at a location remote from a final assembly location of the sofa. When used herein, “portion” may be all of or part of something. Portion is not to be considered as limiting.
(66) Referring to Prior Art FIGS. 2A and 2B, a wood structural frame 100 for a conventional sofa is depicted. Certain portions of frame 100 once assembled, such as arms portions, can be covered by cardboard or fiberboard for providing further shape and closing openings, and may be further covered with padding or cushioning, such as foam. Frame 100 can then be covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials. Such padding and covering materials are not depicted in FIGS. 1 and 2. As depicted, frame 100 includes dozens of different parts. These parts can include, for example, one or more lower front rails 102 (which can be made of oriented strand board or “OSB”) forming a front of sofa frame 100, one or more rear or back rails, such as breast rail 104 (which can be made of oriented strand board or “OSB”), top back rail 106 (which can be made of hardwood or “HW”), lower back rail 107 and spring rail 108 (which can be made of hardwood or “HW”), forming a back of sofa frame 100. Frame 100 front and back portions can be connected by two arms 110 and one or more seat stretchers 112 (which can be made of metal). The back of frame 100 can further include one or more uprights 114 (which can be made of oriented strand board or “OSB”) also forming a back of sofa frame 100. Frame 100 can include a plurality of tie blocks 116 (which can be made of hardwood or “HW”) for connecting the components of frame 100 together and maintaining the proper positioning and angles of frame 100. The many wood components need to be precisely shaped by sawing or milling and are typically connected with fasteners, such as staples, and sometimes with adhesives.
(67) 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.
(68) Referring to FIGS. 3A to 4A, the structural frames 60, according to embodiments of the present disclosure, include the two molded polymer components, specifically, the two arm rest forms 68, 69 for each of the seats except the frame for the one arm sofa. Frames 60, once assembled, can be covered by padding or cushioning, such as load poly, arm fiber, and/or foam, and can then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials.
(69) 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 FIGS. 9 and 10. The recesses each have a seating position for the ends of the spanning frame members. In embodiments, the wall portions at the recesses have a single continuous wall 211 with bends that define the recess without an exposed wall edge. In embodiments, the wall thickness at the recesses is generally uniform and only the exterior surface of the wall is exposed at the recesses, generally, other than a fastener opening, there is not an opening into the interior of the arm rest form.
(70) Referring to FIG. 3A, the arm rest portions 210 are separated by a distance D1 and the spanning wood frame members have lengths L1, L2, L3, L4, L5, L6 that are all greater than the arm rest separation distance D1. The spanning wood frame members may be unitary wood boards, including OSB and plywood.
(71) 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.
(72) Referring to the seat frames FIGS. 3A to 4C, molded components, arm rest forms 210, can be connected to other components of sofa frame 60 depicted in FIGS. 3A to 4C with various fasteners, such as brackets, screws, clips, dowels, staples and other fasteners. Referring to FIG. 5A, a metal insert 217 having a threaded bore 217.4 may be fastened in the hole 217.6 and onto wall portion 217.8 of the blow molded arm rest form or other blow molded component. Installation of the fastener clamps the fastener to the form wall. See U.S. Pat. Nos. 9,309,914; 7,713,011; US2013/0316123; U.S. Pat. Nos. 9,651,080 and 9,028,185, each of which are incorporated by reference herein. The metal threaded insert 217 may receive a screw 217.9, such as, by way of example only, a ¼-20 bolt, to connect molded components to other components. Such connection can be between blow-molded components and other components made of materials such as, by way of example, hardwood, softwood, engineered woods, such as plywood, hardboard, millboard, chipboard, and fiberboard, metal, and plastics. Specifically the insert can securely attach the spanning wood frame members 201. The insert 217 extends from the exterior surface 211.2 to the interior surface 211.4 of the continuous wall 211 of the arm rest form 210. The end 201.2 of the spanning wood frame member seats in the seating position 207.5 with the exterior surface 211.4 of the spanning frame member 201 confronting and then engaging the exterior surface 211.2 at the recess 207.5. Particularly with respect to the lower forward rail and the back lower rail, the end of said spanning frame members interface with a planar or substantially planar surfaces on the blow molded arm rest forms. The forward facing planar or substantially planar first forward engagement area 229.1 of the arm rest forms that directly engages the planar back facing surface of the lower front rail may have an engagement area of at least 12 square inches. In embodiments the engagement area is at least 8 square inches. In embodiments the engagement area is at least 16 square inches. In embodiments, the engagement area is at least 20 square inches. The rearward facing planar or substantially planar first rearward engagement area 229.3 of the arm rest forms that directly engages the planar forward facing surface of the lower back rail may have an engagement area of at least 12 square inches. See FIG. 7. In embodiments the engagement area is at least 8 square inches. In embodiments the engagement area is at least 16 square inches. In embodiments, the engagement area is at least 20 square inches. Such an engagement surface that is parallel to an upright plane traversing both arm rest forms provides an enhanced rigidity to the rectangular form defined by the forward and back lower rails and the two polymer arm rest forms. Moreover at the forward lower rail a further second planar engagement area 229.5 is positioned at a right angle to the first forward engagement area 229.1 that may have an area greater than 3 square inches in embodiments. In embodiments said area is greater than 5 square inches. Moreover at the back lower rail a further second planar engagement area 229.7 positioned at a right angle to the first rearward engagement area 229.3 that may have an area greater than 3 square inches in embodiments. In embodiments said area is greater than 5 square inches. Such areas arranged at a right angle provide further structural rigidity to the rectangular shape as viewed from above of the forward and back lower rails and the molded arm rest portions, particularly where the lower rails are attached with threaded fasteners to the arm rest forms.
(73) Referring to FIGS. 4B, 4C, 5C-5F, an upright slot 231 for receiving, for example, a breast rail 204 is defined by a inset in the wall portion 231.6 at and about the slot. The slot has four slot defining wall surfaces 231.1, 231.2, 231.3, 231.4. As illustrated in FIG. 5D, the width W1 of the slot as defined by the spacing between opposing side wall portions 231.5, 231.7 of the slot is less than the thickness or width W2 of the spanning frame member, in this case the breast rail 204. When seated as in FIG. 5E, the resilient side wall portions deflect away from the end of the frame member and providing a clamping action on the end of the frame member 204. This clamping action and the coefficient of friction between particular polymers such as polyethylenes and wood effectively retains the frame member in the slot. The width of the spanning wood frame members may suitably be between 0.5 inches and 2 inches in embodiments with the width of the slot or recess reflective of same. The width of the spanning wood frame members may suitably be between 0.4 inches and 3 inches in embodiments with the width of the slot or recess reflective of same.
(74) 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).
(75) As best depicted in FIG. 5C, the thin wall 211 extends continuously without interruption about the top 218, bottom 220 and two sides 222, 224. The relatively thin wall compared to the height and volumetric size of the arm rest form allows resiliently deformability/deflectible upon impact, particularly for example if an individual unintentionally impacts the sofa with the arm rest form contained therein reducing the probability of an injury to such an individual. The average thickness T1 of the wall 0.04 to 0.25 inches. The height H1 of the hollow arm rest form may be for example, 16 inches to 30 inches. Thus in embodiments, the height of the arm rest form may be more than 60 times the average thickness arm rest form. In embodiments, the height of the arm rest form may be more than 100 times the average thickness arm rest form. In embodiments, the height of the arm rest form may be more than 200 times the average thickness arm rest form. In embodiments, the volume of the open interior 224.5 may be greater than 1 cubic foot. In embodiments, the volume of the open interior may be greater than 2 cubic feet. In embodiments, the volume of the open interior may be greater than 3 cubic feet. In embodiments, the maximum width W3 of the open interior is greater than 3.5 inches. In embodiments, the maximum width W3 of the open interior is greater than 4.5 inches. In embodiments, the maximum width W3 of the open interior is greater than 5.5 inches.
(76) 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
(77) 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.
(78) In embodiments, frame 60 depicted in FIGS. 3A to 4A can have up to and over 10 less parts, 20 less parts, or even greater than frame 100 depicted in FIGS. 1 and 2. Also, not only is the number of components that need to be assembled is minimized, but the frame is simpler to assemble and the time for assembly is minimized, in part due to there being less secondary operations. In embodiments, the sofa frame 60 has 20 or less frame member components not counting fasteners. In embodiments, the sofa frame has 18 or less frame member components not counting fasteners. In embodiments, the sofa frame has 16 or less frame member components not counting fasteners. Also, with respect to shipping, the lighter weight reduces freight costs. Yet, frame 60 is robust, sturdy, and comfortable.
(79) Referring to FIGS. 4B and 4C, the backrest frame 225 can be an integrated preassembled backrest frame that is brought to the assembly line in one piece. Such assembly can be done at an assembly station nearby manually or by automated/robotic means. Where the backrest frame is brought to the frame assembly location, essentially six components are assembled to complete the seat frame. Specifically, two blowmolded arm rest forms 210, the preassembled backrest frame 225, a front lower rail 202 (with spring rail 202.9 previously attached), and two seat stretchers 212. In embodiments, assembly of the frame can be completed with a minimum number of fasteners, for example, eight. Specifically, four in the front lower rail, four in the back lower rail, and four for the two seat stretchers. This advantageously reduces time, and labor. FIGS. 24-28 illustrates the steps and the minimal number of fasteners 227.7.
(80) 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 FIG. 10, inside wall portion 224 can include one or more recesses 207 or slots configured for one or more rails, such as, by way of example, spring rail slot 230 for receiving rear spring rail 208 and breast rail slot 231 for receiving breast rail 204. Inside wall portion 224 can further include one or more structural recesses 232 that can provide further structure, robustness, and sturdiness to sofa. Inside 224 can further include one or more apertures or openings 233 for use with metal insert threaded connectors for connecting arms to other components of furniture structure.
(81) Referring to FIGS. 4A-5B, front wall portion 226 can include one or more recesses 207 configured for one or more rails, such as a lower front rail recess 234 and front spring rail recess 234.2. Front wall portion 226 can further include one or more apertures or openings 236 for use with threaded metal inserts 217 for connecting arms to other components of furniture structure. Rear wall portion 228 can include one or more recesses configured for one or more rails or uprights, such as a lower back rail recess 238, an upright recess 240, and a rear spring rail recess 230. Rear wall portion 228 can further include one or more apertures or openings 242 with connectors for connecting arm rest forms to other components of furniture structure. Outside wall portion 222 can further include one or more structural recesses 242 to provide further structure, robustness, and sturdiness to a sofa frame. Referring to FIG. 4D, an end view of the sofa frame 60 provides relative locations of the spanning frame members and recesses in which they are received. The sofa frame 60 has a bottom margin or datum level 243. The lower margin 243.2 of the arm rest form is at said datum level as is the lower margin 243.4 of the lower back rail 203 and the lower margin 243.6 of the lower front rail 202.
(82) 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.
(83) Blow molded arm rest forms 68, 69 are further depicted in FIGS. 6A-7C and include a horizontal through-slot 80. The lateral extensions 71 of the textile deck extend though the slot and are fastened, such as by staples 85 to the wall of the arm rest form. Also, the cushion layer 74 may extend through the through-slot and similarly be attached to the arm rest form.
(84) Referring to FIG. 8-11, upholstered arm rest panels 49 may be configured with integrated Christmas tree fasteners 88 formed of polymer having a head 89 and a forward prong 90 with catch rings 91. The head is position within the panel 49. The arm rest form front wall 94 has a plurality of recessed apertures 96 for receiving the Christmas Tree connectors. The aperture 96 is in a recessed wall portion 99 offset inwardly from the front surface 101 of the front wall 94. FIG. 11 illustrates the panel engaged with the arm rest form. The panel is forcefully pushed toward the arm rest form, such as a direct blow to the panel where the Christmas tree connectors are located. This can seat the prong of the connector fully such that the prong is under tension and the recess wall portion is flexed toward the panel providing a secure tight fit of the panel to the arm rest form. In embodiments, upholstery material my cover the front face with the material then sandwiched between the panel and the arm rest form. In embodiments such Christmas tree connectors may be utilized to attach other components to the arm rest forms. See U.S. Pat. No. 8,764,115 owned by the owner of this application, said patent is incorporated herein by reference for all purposes.
(85) Referring to FIGS. 12 to 15C, attachment of the foot 59 to the arm rest form 69 is illustrated. Said attachment means could be utilized for connecting other components to the arm rest forms as well. A expanding winged connector 110 has a head 112, a pair of expandable wings 112, a screw 114, and a screw receptacle portion 115. Molded in recessed portions 120 may have apertures 124 for receiving the winged connector 110. The foot 59, or other component, may be attached with the screw extending through the component and into the screw receptacle portion 115 of the connector. Insertion of the screw, by rotation, forces the wings to expand thereby securing the connecter in the arm rest form. Further tightening, as shown in FIG. 15C can pull the recessed portion to the component, effectively locking the component to the arm rest portion with the wall portion flexed and the screw under tension.
(86) Referring to FIG. 16, a prior art structural frame 300 for a recliner is depicted. Certain portions of frame 300 once assembled, such as arms portions, can be covered by cardboard or fiberboard for providing further shape and, further, can be covered by padding or cushioning, such as load poly, arm fiber, and/or foam, and can then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials. As depicted, prior art chair frame 300 generally includes a seat box 302, a back rest form 304, two arms 306 and a footrest 308.
(87) 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 FIG. 16. Arm rest frame 306 can further include cardboard or fiberboard for providing further shape or support to arm (not depicted in FIG. 16). As depicted, each of arm rest frames can includes about 19 parts, not including fasteners. Typically a multitude of fasteners, such as staples, and wood glue are utilized for assembling the arm rest frames.
(88) 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.
(89) Referring to FIGS. 17-18B and 19A-19C, recliner frames 400, 400.1 according to embodiments of the present disclosure, specifically a frame for a recliner, including four molded components (specifically, two arms 402, a backrest 404, and a footrest or ottoman 406) is depicted. In the FIG. 19A-19C embodiment, foot rest 406.1 may be a conventional wood panel. Frame 400 further includes a seat platform 407, reclining mechanism 408 for reclining function and a back rail 409. Reclining mechanism 408 has a pair of connecting arms 408.4 to connect to the back rest. As depicted in FIGS. 1C and 1D, recliner frame 400, once assembled, can be covered by padding or cushioning, such as load poly, arm fiber, and/or foam, and can then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials. Fasteners such as staples may be used for attaching covering materials to molded components.
(90) 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 FIG. 19. Such brackets are known as kd clips. Wall portions defining recesses can include the insert 217, shown in FIG. 4B, in which a bolt, such as, by way of example only, a ¼-20 bolt, can be threaded to connect molded components to other components, such as the seat deck and the recliner mechanism.
(91) Referring to FIGS. 18C to 18G, blow molded arm rest forms 450 may be reinforced to provide enhanced weight carrying capacity or enhanced connectability to other componentry by utilizing plate 452 received in recesses 458 in sidewalls 462 of the arm rest form. As illustrated, the wall of the blow molded arm rest extends continuously around the top 218, two lateral sides 222, 224 walls, and bottom 220 without interruption closing the open interior 463 which defines a void volume. The reinforcing plates 452 may be secured with threaded fasteners 454 extending into the arm rest form wall 466, such as in a threaded insert 217 as illustrated in FIG. 4B. Referring to FIG. 18G, alternately, a spanning metal member, such as a piece of internally threaded tubing 469 that engages the plates and with screws 471 clamping the reinforcing plate to the ends of the tubing 469. Such reinforcing plates can be used in association with the recliner of FIG. 17 on the inside, outside or both sides of each blow molded arm rest form. Note in other embodiments, arm rest forms may be reinforced utilizing vertically extending elongate reinforcing plates or beams attached to the arm rest forms such as the upright back rest frame members 214 as is illustrated in FIGS. 3A-5B. In embodiments such beams and/or elongate plates may be received in elongate slots or recesses extending primarily vertically on the arm rest forms. Such beams and/or elongate plates may be secured with threaded fasteners or may be retained by way of an interference fit with the beam or plate, similar to what is shown in FIGS. 5E and 5F. Further structural enhancement may be provided by providing a hermetically sealed arm rest form, and further providing a positive pressure in the interior.
(92) The embodiment of FIGS. 19A-19C have brackets 480 that attach to the blowmolded arm rest form on the outside surface and have a fastener extending through the arm rest form to connect to the seat platform 407. Note the recliner mechanism is not shown in exploded view FIG. 19C. The two blowmolded arm rest forms are connected on their back side by a U-shaped plate 484 that fits into recesses 487 formed by the wall of the arm rest form. Threaded connectors 217 are imbedded into the wall to receive threaded screws or bolts 490. A wood plate 493 may be attached to provide support for an operator handle such as a handle to extend and retract the recliner. Steel interior reinforcing supports 499, configured as elongate arms, may be attached to the couplers 410 and extend into the blowmolded arm rest to provide resistance to bending. In embodiments, the reinforcing supports may be formed of other materials such as wood, fiberglass, or other rigid polymers. The reinforcing supports may be used in the arm rest forms as well, particularly where the arm rests are narrow.
(93) 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).
(94) 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.
(95) Back rest form 404 is further depicted in FIGS. 17-18B. Back rest form 404 comprises a top portion 412 and a bottom portion 414 extending therefrom. Back rest form 404 further comprises a front wall portion 416, a back wall portion 418, and side wall portions 420. Front wall portion 416 and back wall portion 418 can include one or more structural recesses 421 to provide further structure, robustness, and sturdiness to sofa. Side wall portions 420 can include one or more apertures or openings 422 for use with connectors for connecting back rest form to other components of furniture structure. In embodiments, such as depicted in FIG. 19, back rest form includes bracket 410 for operably coupling back rest form 404 to another portion of frame 400, such as reclining mechanism 408 and/or arms 402. Bracket 410 can be connected to back rest form via apertures 422. Back rest form 404, or portions thereof, can be covered by padding or cushioning, such as load poly, arm fiber, and/or foam, and can then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials.
(96) Arm rest forms 402 are further depicted in FIGS. 24-27. Arm rest forms can be formed in any 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 402 can include a top 424, a bottom 426, an outside 428, an inside 430, a front 432, and a back 433. Referring to FIG. 26, inside 430 can include one or more recesses or slots 434 configured for connection with reclining mechanism 408 or a portion of a seat box. Inside 430 can further include one or more apertures or openings 436 for use with connectors for connecting arms 402 to other components of furniture structure and a projection 446 including an apertures or opening 436 for connecting arms 402 to other components of furniture structure, such as reclining mechanism 408. Referring to FIGS. 25 and 26, rear 433 can further include one or more recesses or slots 438 configured for connection with back rail 409 and one or more apertures or openings 440 for use with connectors for connecting arms to other components of furniture structure. Referring to FIG. 24, outside wall portions 428 can include one or more structural recesses 442 to provide further structure, robustness, and sturdiness to chair frame 400 and an opening 444 for coupling a portion of reclining mechanism 408 thereto—by way of example, a handle or lever (not depicted) for operating reclining mechanism 408. Referring to FIG. 27, bottom wall portion 426 can include an aperture or opening 450. Arm rest forms 402 or portions thereof can be covered by padding or cushioning, such as load poly, arm fiber, and/or foam, and can then covered with fabric, leather, synthetic fabric, faux leather, microfiber, or other upholstery or covering materials.
(97) Referring to FIGS. 29-36 assembly steps of sofa frame display the advantages of utilizing blow molded arm rest forms with recesses sized for receiving ends of spanning frame members. FIG. 29 illustrates a left and right arm rest portions 502, 504 seated on jig 508 configured as a table with stops 512, 514 providing positioning of the arm rest forms with respect to each other. Each of the assembly steps that follow will typically be done in association of the jig as illustrated in FIG. 29. FIG. 30 is the arm rest forms of FIG. 29 with a lower front rail 520 and lower back rail 522 in position for attachment to the arm rest forms by way of threaded fasteners 526. The front spring rail 528 is already attached to the lower front rail. FIG. 31 shows the lower front rail and the lower back rail attached and the breast rail 534 and rear spring rail 536 in position for attachment. The breast rail to be lowered into position and the rear spring rail is pushed horizontally into position. FIG. 32 shows the breast rail and rear spring rail being slid toward their respective seating positions which may be done by striking the spanning beam members with a mallet or the like. FIG. 33 illustrates the breast rail and rear spring rail seated in their respective seating positions. In embodiments these spanning frame members are secured in their seating positions by way of interference fits between the ends of the spanning frame members and the arm rest forms. FIG. 33 illustrates the breast rail and rear spring rail seated and the seat stretchers 538, 539 before placement. The seat stretchers may be attached by way of screws driven through apertures in the ends of the seat stretchers downwardly into the front spring rail 528 and rear spring rail 536, see also FIG. 4A. FIG. 34 illustrates the seat stretchers attached and the upright back rest frame members in position for attachment. The upright frame members may be attached with staples or the like to the lower back frame member, the rear spring rail, and the breast rail. The end upright back rest frame members 541, 542 may be attached to the respective polymer arm rest forms by way of screws 547 through the frame members into the arm rest forms or into threaded inserts in the arm rest forms. FIG. 35 depicts the upright back rest frame members attached and the top back rail ready for attachment to the upright back rest frame members. Said top back rail may be attached with staples applied through the top back rail into the respective upright back rest frame members. FIG. 36 illustrates the top back rail attached and the sofa frame ready for receiving the upholstery. Various alternate steps associated with the assembly of the frame are illustrated in FIGS. 37A and 37B. Selected ones of such steps may be performed in different orders to accomplish the embodiments disclosed herein. Referring to FIG. 1B, the seat deck 33 is attached as described in WO 2018/081471 and the back rest upholstery attached as described in U.S. Pat. No. 10,299,606. This publication and patent are incorporated by reference herein. The arm rest upholstery sacks may be installed as described above.
(98) 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.
(99) 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).
(100) 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.
(101) 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.
(102) 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.
(103) 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.
