Upholstered furniture with integrated back rest portion webbing support

Abstract

A upholstered sofa covered by a form fitting upholstery sack where the upholstery sack incorporates a supportive material panel that has integrated support webbing into the material panel. The support webbing comprising a plurality of webbing straps. With the upholstery sack properly positioned on the back rest portion, the supportive material panel is positioned on the front of the back rest portion frame. The material panel with webbing is incorporated as a component of the upholstery sack where the upholstery sack is pre-formed to snugly fit over the back rest portion of a furniture frame. The back rest portion or the frame is inserted into the sack and the material panel with integrated webbing is attached to the frame. Once the material panel is positioned and fastened, the remaining components, for example, the back panels and side panels, of the upholstery sack are attached to the frame at the back rest portion. Due to the construction of the material panel with webbing, installation time is decreased when compared to the time required for conventional webbing and upholstery installations.

Claims

1. An upholstered sofa comprising: a frame having a rectangular seat base, an upright back rest portion integral with the seat base, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side, wherein the back rest portion is affixed to the back side of the seat base so that the back rest portion is in an upright position, the back rest portion further having a front side, a back side, and a lower portion, and comprising a top rail; and an upholstery sack having a back material panel, a left side material panel, a right side material panel, an integrated upholstery support assembly including a back support material portion and integrated webbing, the back support material portion comprising a first material panel, the back support material portion having a top end and a bottom end, the integrated webbing comprising a plurality of straps, the webbing sewn to the back support material portion at the top end and at the bottom end of the back support material portion; wherein the upholstery sack is disposed on the frame with the webbing and attached back support material portion top end attached to the top rail, and wherein the at least one webbing and attached back support material portion bottom end are attached to the lower back rest portion, and wherein the back material panel is fixedly attached to the frame at the lower portion of the back rest portion and with the webbing pulled taught therebetween.

2. The upholstered sofa of claim 1, wherein the webbing comprising a plurality of straps extending between the top end and the bottom end of the back support material portion.

3. The upholstered sofa of claim 1, wherein the back support material portion further comprises a second material panel, the second material panel providing a liner for laying against the frame.

4. The upholstered sofa of claim 1, wherein the upholstery sack further comprises one or more integrated back rest cushion cases defined by the back support material portion.

5. The upholstered sofa of claim 4, wherein the upholstery sack comprises at least one zipper and wherein each of the integrated back rest cushion cases is accessible for insertion of cushion material by way of the at least one zipper and wherein each of the cushion cases are filled with cushion material.

6. The upholstered sofa of claim 1, wherein the webbing and the attached back support material portion bottom end are attached to a back side of a breast rail at the lower portion of the back rest portion.

7. The upholstered sofa of claim 1, wherein the back support material portion comprises a plurality of material panels, wherein each material panel is sewn on at least one edge to an edge of a different material panel.

8. An upholstered sofa comprising: a frame having a rectangular seat base with an integral spring rail, an upright back rest portion integral with the seat base, and a right arm rest and a left arm rest integral with the seat base and back rest portion wherein the seat base and back rest are disposed between the right arm rest and the left arm rest, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side defining an open interior space, wherein the back rest portion is affixed to the back side of the seat base so that the back rest portion is in an upright position, the back rest portion further comprises a back side, a back side outwardly facing surface, a bottom side, a top rail, and a breast rail; an upholstery sack having a back material panel, a left side material panel, a right side material panel, an integrated upholstery support assembly, and a back support material portion having a top end and a bottom end, the integrated upholstery support assembly comprising a plurality of webbing straps, each strap having a length, a first end, a middle portion, and a second end wherein each webbing strap's first end is fixedly attached to the material portion top end and wherein each webbing strap's second end is fixedly attached to the material portion bottom end, wherein the length of the webbing straps and a length from the material portion bottom end to the material portion top end are about equidistant, wherein the upholstery sack is disposed on the back rest portion and the plurality of webbing straps are disposed adjacent a top side of the top rail, and wherein each of the plurality of webbing straps' first ends and attached material portion top end are fixedly attached to a back side of the top rail and wherein each of the plurality of webbing straps' middle portions are disposed adjacent a front side of the breast rail, and the plurality of webbing straps and material portion proximate the plurality of webbing straps' second ends are fixedly attached to a top side of the spring rail, wherein the left side material panel and right side material panel are disposed on the back rest portion, and wherein the back material panel is fixedly attached to the back rest portion.

9. The upholstered sofa of claim 8, wherein a plurality of staples are used to fixedly attach the plurality of webbing straps and the material portion to the furniture frame.

10. The upholstered sofa of claim 8, wherein the material portion comprises a plurality of material panels, wherein each material panel is attached on at least one edge to an edge of a different material panel.

11. The upholstered sofa of claim 10, wherein each material panel has at least one edge sewn to an edge of a different material panel.

12. The upholstered sofa of claim 8 wherein the plurality of webbing straps and back rest material portion proximate the at least one webbing second end is fixedly attached to a back side of the breast rail by staples.

13. The upholstered sofa of claim 8 wherein the plurality of webbing straps comprise at least 6 straps.

14. A method of assembling an upholstered sofa comprising: providing a sofa frame having a rectangular seat, an upright back rest portion integral with the seat base, and a right arm rest and a left arm rest integral with the seat base and back rest portion wherein the seat base and back rest are disposed between the right arm rest and the left arm rest, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side, wherein the back rest portion is affixed to the back side of the seat base, the back rest portion further comprises a back side, a back side outwardly facing surface, a bottom side, a top rail, and a breast rail; receiving an upholstery sack having a back material panel, a left side material panel, a right side material panel, and an integrated upholstery support assembly, wherein the upholstery support assembly is further comprised of a material portion having a top end and a bottom end and at least one webbing having a length, a first end, a middle portion, and a second end wherein the at least one webbing first end is fixedly attached to the material portion top end and the at least one webbing second end is fixedly attached to the material portion bottom end; and disposing the upholstery sack on the back rest portion and disposing the at least one webbing first end adjacent a top side of the top rail, fixedly attaching the at least one webbing first end and attached material portion top end to a back side of the top rail and disposing the at least one webbing middle portion adjacent a front side of the breast rail, and fixedly attaching the at least one webbing and material portion proximate the at least one webbing second end to a top side of the spring rail, fixedly attaching the left side material panel and right side material panel to the back rest portion, and fixedly attaching the back material panel to the back rest portion and seat base back side.

15. The method of claim 14, comprising fixedly attaching the at least one webbing and the material portion to the furniture frame with fasteners.

16. The method of claim 14, comprising fixedly attaching the at least one webbing and material portion proximate the at least one webbing second end to a back side of the breast rail.

17. An upholstery sack having a back material panel, a left side material panel, a right side material panel, an integrated upholstery support assembly, and a back support material portion having a top end and a bottom end, the integrated upholstery support assembly comprising a plurality of webbing straps, each strap having a length, a first end, a middle portion, and a second end wherein each webbing strap's first end is fixedly attached to the material portion top end and wherein each webbing strap's second end is fixedly attached to the material portion bottom end, wherein the length of the webbing straps and a length from the material portion bottom end to the material portion top end are about equidistant, wherein the upholstery sack is disposed on the back rest portion and the plurality of webbing straps are disposed adjacent a top side of the top rail, and wherein each of the plurality of webbing straps' first ends and attached material portion top end are fixedly attached to a back side of the top rail and wherein each of the plurality of webbing straps' middle portions are disposed adjacent a front side of the breast rail, and the plurality of webbing straps and material portion proximate the plurality of webbing straps' second ends are fixedly attached to a top side of the spring rail, wherein the left side material panel and right side material panel are disposed on the back rest portion, and wherein the back material panel is fixedly attached to the back rest portion.

18. An upholstery sack comprising an exterior exposed upholstery material, an interior liner fabric, and a plurality of straps arranged to be parallel, each of the straps arranged to be sewn at a connection of the exterior exposed upholstery material and the liner fabric, whereby stapling the upholstery sack to a sofa frame attaches thereto the exterior exposed upholstery material, the liner fabric, and the plurality of straps.

19. An upholstery sack for a sofa frame, the upholstery sack having a back material panel, a left side material panel, a right side material panel, and an integrated upholstery support assembly, wherein the upholstery support assembly is further comprised of a material portion having a top end and a bottom end and at least one webbing comprising a plurality of webbing straps, the at least one webbing having a length, a first end, a middle portion, and a second end wherein the at least one webbing first end is fixedly attached to the material portion top end.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a prior art upholstery sack being installed on a prior art frame with preinstalled webbing.

(2) FIG. 2 is a representative view of a back rest portion of a furniture frame being inserted into an upholstery sack according to an embodiment of the disclosure.

(3) FIG. 3 is a representative front view of a furniture frame according to an embodiment of the disclosure.

(4) FIG. 4 is a representative back view of a furniture frame according to an embodiment of the disclosure.

(5) FIG. 5A is a representative front view of an upholstery sack with an integrated upholstery support assembly according to an embodiment of the disclosure.

(6) FIG. 5B is a representative back view of the upholstery sack of FIG. 5A with an integrated upholstery support assembly according to an embodiment of the disclosure.

(7) FIG. 6A is a representative front view of an upholstery sack with an integrated upholstery support assembly according to an embodiment of the disclosure.

(8) FIG. 6B is a cross section of the upholstery sack of FIG. 6A taken at line 6B-6B.

(9) FIG. 6C is a piece part view of the upholstery sack of FIG. 6B illustrating exemplary stitch regions of the separate panels, material portions and webbing.

(10) FIG. 7 is a representative view of an upholstery support assembly according to an embodiment of the disclosure.

(11) FIG. 8 is a representative view of an upholstery support assembly according to an embodiment of the disclosure.

(12) FIG. 9A is a representative cross sectional view of a portion of an upholstery support assembly according to an embodiment of the disclosure.

(13) FIG. 9B is a representative cross sectional view of a portion of an upholstery support assembly according to an embodiment of the disclosure.

(14) FIG. 10A is a representative cross sectional view of a back rest portion of a furniture frame having an upholstery sack with an integrated upholstery support assembly attached according to an embodiment of the disclosure.

(15) FIG. 10B is a representative cross sectional view of the upholstery sack with an integral back rest cushion attached to a sofa frame.

(16) FIG. 11 is a representative view of the placement and attachment of the webbing on a back rest portion of a furniture frame according to an embodiment of the disclosure.

(17) FIG. 12 is a representative cross sectional view of a back portion of a furniture frame having an upholstery sack with an integrated upholstery support assembly attached according to an embodiment of the disclosure.

DETAILED DESCRIPTION

(18) FIG. 1 illustrates a prior art upholstery sack 10 having a first material panel 14, a top material panel 16, a back material panel 18, and side material panels 20. The upholstery sack 10 is a preassembled piece of upholstery that is a form fitting cover that corresponds to a back rest portion 24 of a furniture frame 22, see FIGS. 3 and 4, where the furniture frame 22 is the structural base for a sofa, love seat, chair, or similar item of furniture. The frame 22 of FIG. 1 has had webbing 25 pre-attached by staples on the top rail 26 and breast rail 28 prior to receiving the form fitting cover.

(19) FIG. 2 illustrates positioning of the upholstery sack 25, according to embodiments, over the back rest portion 24 so that the back rest portion 24 can be fully inserted into the upholstery sack 29 so that the upholstery sack 29 envelopes the back rest portion 24. The upholstery sack 29 is then attached to the back rest portion 22 using fasteners, such as staples, as described below the upholstery sack has upholstery frame covering portion 29.2 such as is shown in FIG. 1, and also has user support portion 29.4 comprising webbing attached to the upholstery frame covering portion.

(20) This disclosure provides for a furniture frame having an attached upholstery sack 29, the upholstery sack having an integrated material panel that provides webbing support. As depicted in FIGS. 2-4, a sofa furniture frame 22, according to an embodiment of the present invention, comprises a seat base 23 and an upright back rest portion 24 integral with the seat base 23, integral in that components are fixed together at the factory with permanent fasteners, glue, and may have common frame members and they are not detachable from one another without damage. In embodiments, the furniture frame 22 can further comprise a pair of arm rests 33, 35 where the seat base 23 and back rest portion 24 are disposed between the arm rests 33, 35 and are integral to the arm rests 33, 35. The seat base 23 comprises a box frame 68 comprising a rectangular shape and having a left side 70, a right side 72, a front side 74, a back side 76, so that the box frame 68 defines an open interior space 69. The back rest portion 24 can further comprise a back side 78, a bottom side 80, and a top 82 with a top rail 26. The back rest portion 24 is affixed to the back side 76 of the seat base 22. The back rest portion 24 has an upright position where it is seated and secured to the seat base 22 as shown. In embodiments, a furniture frame 22 further comprises the breast rail 28 attached at a lower portion of the back rest portion and a spring rail 30. In embodiments, the furniture frame 22 can further comprise seat springs 84. In embodiments, the furniture frame 22 comprises wood or wood products. Furniture frames 22 of varying configurations are contemplated and it is apparent that frames 22 of varying configurations are within the spirit and scope of this disclosure. Attachment of an upholstery sack 29 is made to the furniture frame using fasteners, where the fasteners can be staples, nails, brads, tacks, or other types of fasteners common in the furniture assembly industry.

(21) Referring to FIGS. 5A-6C, the upholstery sack 29 having exterior material panels 14, 16, a back material panel 18, a right side material panel 20, a left side material panel (not shown), and an integrated upholstery sack back support assembly 60, where the upholstery sack back support assembly 60 is comprised of webbing 52, as depicted in FIGS. 5 and 6. Webbing 52 is a strong fabric woven as a flat strap or tube of varying width and fibers. The webbing 52 is tightly woven, exceptionally strong and has very little to no stretch. The webbing 52 fabric can be, but is not limited to, natural jute, synthetic jute, burlap, cotton, nylon, polyester, polypropylene, and variations thereof. As described in detail below the webbing straps or strips 85 are attached to the upholstery frame covering portion at the ends of the webbing strips.

(22) Referring to FIGS. 6A-6C, an embodiment of an upholstery sack 60.2 is illustrated having integrated seat back cushion cases 87. The interiors of such cases accessible by way of a zipper 88.

(23) As depicted in FIG. 7, the upholstery back support assembly 60 portion of the upholstery sack 10 includes webbing and back support material portion 39 having a top end 41 and a bottom end 43. Each seating position on the sofa may have, for example, three webbing straps. In other embodiments four webbing straps. The material portion 39, as contemplated, can be comprised of various layered configurations and materials. In one embodiment, the material portion 39 comprises a first material panel 40 having a top end 42 and a bottom end 44 and a second material panel 46 having a first end 48 and a second end 50. The first material panel 40 and the second material panel 46 can be comprised of the same or dissimilar materials, where the materials can be comprised of upholstery covering materials, finishing materials, felt or felt-like materials, polyester, lining material, cotton materials, blended materials, etc. The second material panel 46 first end 48 and the first material panel 40 top end 42 are fixedly attached to each other so that a seam holding the panels 40, 46 together is formed along the length of the material panels 40, 46. Each length of webbing 52 having a first end 54, a middle portion 56, and a second end 58. The webbing is fixedly attached, by sewing, to the material portion 39 so that the webbing 52 first end 54 is fixedly attached to the material portion 39 top end 41 and the webbing second end 58 is fixedly attached to the material portion 39 bottom end 43. It is desirable that the length of the webbing 52 and a length from the material portion 39 top end 41 to the bottom end 43 are about equidistant. In another embodiment, a plurality of lengths of webbing 52 are fixedly attached as disclosed to the material portion 39 top end 41 and material bottom end 43. When the webbing is attached to the frame, such as by staples, the material portion is also attached.

(24) In another embodiment, as depicted in FIG. 8, the upholstery support assembly 60 of the upholstery sack 10 is comprised of a material portion 39 having a top end 41 and a bottom end 43. The material portion 39 comprises a single piece of material. A length of webbing 52 having a first end 54, a middle portion 56, and a second end 58 is then attached, by sewing, to the material portion 39 so that the webbing 52 first end 54 is fixedly attached to the material portion 39 at the top end 41 and the webbing 52 second end 58 is fixedly attached to the material portion 39 bottom end 43. It is desirable that the length of the webbing 52 and a length from the material portion 39 top end 41 to the bottom end 43 are about equidistant. In another embodiment, a plurality of lengths of webbing 52 are fixedly attached as disclosed to the material portion 39 top end 41 and material bottom end 43.

(25) In one embodiment, material portion 39 is comprised of a single layer of material 60. FIG. 9A illustrates the top end 41 of the single layer of material 39 attached to the webbing 52 first end 54 and the bottom end 39 of the single layer of material 39 attached to the webbing 52 second end 58.

(26) In an embodiment, depicted in FIGS. 6A-6C, the first material panel 40 top end 42 is fixedly attached to a first end 48 of a second material panel 46. In one embodiment, the second material panel 46 can be comprised of a felt batting 62 or similar material. The first material panel 40 top end 42 and second material panel 46 first end 48 are also attached to an end of a layer of upholstery or covering material 68 at a juncture 69 where the material edges are sewn together. The upholstery sack with said sewn-together junctures as a defining attachment region 71, where the covering material 68 comprises the upholstery sack 29 back panel 18. The second material panel 46 at a second end 50 is then fixedly attached to the webbing 52 first end 54. The first material panel 40 and second material panel 46 comprise the material portion 39. The length of the webbing 52 and a length from the material panel 40 bottom end 44 to the second material panel 46 second end 50 may be about equidistant. Such upholstery sack attached to a sofa frame is illustrated in FIG. 10B.

(27) In another embodiment, depicted in FIG. 9B, the back support material portion 39 can be comprised of a multi-layered configuration comprised of a liner 70 and a covering material 68, wherein a cavity 71 is formed between the liner 70 and covering material 68 to receive cushioning materials 72 such that the upholstery sack 10 provides for an integrated cushion. The covering material 68 faces a user's back and is exposed. The liner covers and contacts the frame. The liner may be formed of a thin fabric.

(28) It is contemplated that various configurations of materials and layers can be provided that comprise the back support material portion 39 and webbing 52 attachment portions and these various configurations and layers are within the spirit and scope of this disclosure.

(29) In one embodiment, the upholstery support assembly 60, integrated as a component of the upholstery sack 10A, is fixedly attached to the furniture frame 22 as shown in the cross sectional view in FIG. 10A. In the example embodiment shown, the upholstery support assembly 60 is comprised of the webbing 52 and the back support material portion 39, where the back support material portion 39 comprises the liner 70, the covering material 68, and the felt batting 62 or similar material. However, it is apparent that other upholstering support assemblies 12 comprised of various material layers are contemplated. The support assembly 60 is positioned on the back rest portion 24 of the furniture frame 22 so that the webbing 52 crosses over the top side 25 of the top rail 26 and the webbing 52 first end 54 contacts a back side 27 of the top rail 26, as shown in FIG. 11. The webbing 52 first end 54 and felt batting 62, which are attached, are fixedly attached to the back side 27 using a plurality of fasteners 38. It is desirable to attach the webbing 52 to the top rail 26 back side 27 due to the increased forces required for fastener 38 pull-out versus attachment of the webbing 52 to the top rail 26 top side 25 or front side 33.

(30) The webbing 52 middle portion 56 and liner 70 are positioned so that they cross a front side 29 of the breast rail 28. The webbing 52 and liner 70 are then positioned below a bottom side 36 of the breast rail 28 and above a top side 31 of the spring rail 30. The webbing 52 second end 58 and attached liner 70 are positioned past the breast rail 30 towards the back panel 32 and pulled taut. A plurality of fasteners 38 are driven through the webbing middle portion 56 and the liner 70 into the top side 31 of the spring rail 30 to hold the webbing 52 and liner 70 taut and in position. Pulling the webbing 52 and liner 70 under the breast rail 30 adds strength to the holding power of the fasteners 38. Pulling the webbing 52 and liner 70 together and fastening as disclosed provides a tight webbing 52 and a tight liner 70, thus providing a strong back portion 24 support assembly 60. Following attachment of the integrated upholstery support assembly 60 with the back support material portion 39, the other components of the upholstery sack 10 are fixedly attached to the appropriate areas of the frame 22. The left and right side material panels 20 are fixedly attached to the back rest portion 24 and the back material panel 18 is fixedly attached to the back rest portion 24 at the sides and to the box frame 68 back side 76 at the bottom.

(31) Referring to FIG. 10B, the discussion above with reference to FIG. 10A applies here as well. This embodiment reflects the upholstery sack of FIGS. 6A-6C, and FIG. 9B with integrated seat back cushion cases. A cavity 72 is defined for holding seat back cushion cushioning material 71 such as polyurethane foam.

(32) In another embodiment, depicted in FIG. 12, the webbing 52 middle portion 56 and liner 70 are positioned so that they cross a front side 29 of the breast rail 28 and are then positioned to wrap below a bottom side 36 of the breast rail 28. The webbing 52 middle portion 56 and liner 70 are then positioned past a back side 33 of the breast rail and pulled taut. When the proper tension is afforded to the webbing 52 and liner 70, a plurality of fasteners 38 are driven through the webbing middle portion 56 and the liner 70 into the back side 33 of the breast rail 28 to hold the webbing 52 and liner 70 taut and in position. Pulling the webbing 52 and liner 70 under the breast rail 30 adds strength to the holding power of the fasteners 38. Pulling the webbing 52 and liner 70 together and fastening as disclosed provides a tight webbing 52 and a tight liner 70, thus providing a strong back portion 24 support assembly 60. Following attachment of the integrated upholstery support assembly 60, the other components of the upholstery sack 10 are fixedly attached to the appropriate areas of the frame 22. The left and right side material panels 20 are fixedly attached to the back rest portion 24 and the back material panel 18 is fixedly attached to the back rest portion 24 at the sides and to the box frame 68 back side 76 at the bottom.

(33) While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood however, that the intention is not to limit the application to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternative falling with the spirit and scope of the disclosure as defined by the appended claims.

(34) Persons of ordinary skill in the relevant arts will recognize that various embodiments can comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the claims can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Use of end and edge herein includes the end and edge regions proximate the geometric edge. In other words, for example, the end of a strap encompasses a few lengthwise inches at such end. Attachment at an edge can include an inch or two.

(35) References to embodiment(s), disclosure, present disclosure, embodiment(s) of the disclosure, disclosed embodiments, and the like contained herein refer to the specification (text, including the claims, and figures) of this patent application that are not admitted prior art.

(36) For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(f) are not to be invoked unless the specific terms means for or step for are recited in the respective claim.