Chair upholstery attachment method

• US 10,441,089 B2
• Filed: 12/23/2016
• Issued: 10/15/2019
• Est. Priority Date: 05/30/2014
• Status: Active Grant

• Current Assignee: Steelcase Incorporated
• Original Assignee: Steelcase Incorporated
• Inventors: Peterson, Gordon Jay
• Primary Examiner(s): Cozart, Jermie E
• Application Number:
  US15/389,654
• Publication Number:
  US 20170099957A1
• Time in Patent Office: 1,026 Days
• CPC Class Codes: A47C 31/023 connecting upholstery to frames, e.g. by hooks, clips, snap fasteners, clamping means or the like
• CPC Class Codes: A47C 31/026 passing through the upholstery, e.g. upholstery nails or buttons
• CPC Class Codes: A47C 5/12 of plastics, with or without reinforcement
• CPC Class Codes: A47C 7/24 Upholstered seats A47C7/18 takes precedence
• CPC Class Codes: A47C 7/40 for the back
• CPC Class Codes: B21D 39/00 Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating joining mitred profiles B21D53/745; riveting B21J; uniting components by forging or pressing to form integral members B21K25/00; welding B23K; press-fitting, force-fitting, or shrinking in general B23P11/00, B21D19/00; by adhesives F16B11/00 ; Connections as such F16L, F16B; Tube expanders
• CPC Class Codes: B68G 7/05 Covering or enveloping cores of pads in plastics material using a matching die B29C63/025
• CPC Class Codes: B68G 7/10 Finishing of edges
• CPC Class Codes: B68G 7/12 Other elements specially adapted for fastening, fixing, or finishing, in upholstery work

Abstract

A method of constructing a seating arrangement that includes providing a first chair structure comprising a first polymeric material having a first surface and a second surface, the first chair structure including at least one attachment area, providing a second chair structure, locating the second chair structure proximate the first chair structure such that at least a portion of the second chair structure covers the first chair structure, providing at least one staple member comprising a second polymeric material, wherein the second polymeric material of the at least one staple member may be recycled with the first polymeric material of the first chair structure without requiring separation of the at least one staple from the first chair component and inserting the at least one staple member through the first chair structure and the second chair structure, thereby securing the first chair structure to the second chair structure.

Claims

1. A method of constructing a seating arrangement, comprising:

providing a first chair structure comprising a first polymeric material having a first surface and a second surface opposite the first surface, the first surface and the second surface cooperating to define a first thickness therebetween, the first chair structure including at least one attachment area;

providing a second chair structure;

locating the second chair structure proximate the first chair structure such that at least a portion of the second chair structure covers the first chair structure;

providing at least one staple member comprising a second polymeric material, wherein the second polymeric material of the at least one staple member may be recycled with the first polymeric material of the first chair structure without requiring separation of the at least one staple from the first chair component; and

inserting the at least one staple member through the first chair structure and the second chair structure, thereby securing the first chair structure to the second chair structure.

2. The method of claim 1, wherein the first chair structure includes a plurality of apertures that receive the at least one staple member therein.

3. The method of claim 1, wherein the second polymeric material of the at least one staple is different than the first polymeric material of the first chair structure.

4. The method of claim 1, wherein the at least one staple comprises a thermoplastic polymer.

5. The method of claim 4, wherein the at least one staple comprises polypropylene.

6. The method of claim 1, wherein the at least one staple includes a pair of prongs.

7. The method of claim 6, wherein each of the prongs are tapered along a length thereof.

8. The method of claim 7, wherein each of the prongs are tapered along a majority of a total length of each of the prongs.

9. The method of claim 1, wherein the at least one staple member includes a barb located at a distal end thereof.

10. The method of claim 9, wherein the barb is elastically deformable.

11. The method of claim 1, wherein the first chair structure further includes at least one raised portion extending from the second surface, the first surface and the at least one raised portion define a second thickness therebetween that is greater than the first thickness, a majority of the first chair structure comprises the first thickness, and wherein the at least one attachment area is located within the at least one raised portion.

12. The method of claim 1, wherein the second chair structure comprises a cover.

13. The method of claim 12, wherein the cover comprises a fabric.

14. The method of claim 1, wherein the first chair structure includes a back shell.

15. The method of claim 1, wherein the seating arrangement comprises an office chair assembly.

16. A method of constructing a seating arrangement, comprising:

providing a first chair structure comprising a first polymeric material having a first surface and a second surface opposite the first surface, the first chair structure including a densely-spaced array of apertures extending between the first and second surfaces;

providing a second chair structure;

locating the second chair structure proximate the first chair structure such that at least a portion of the second chair structure obscures at least a portion of the densely-spaced array of apertures;

providing at least one fastener comprising a second polymeric material; and

securing the second chair structure with the first chair structure by inserting the at least one fastener into at least one of the obscured apertures of the densely-spaced array of apertures subsequent to the locating of the second chair structure proximate the first chair structure.

17. The method of claim 16, wherein the array of apertures includes at least one aperture equally spaced from at least two other apertures of the array of apertures.

18. The method of claim 16, wherein the array of apertures includes at least one aperture equally spaced from at least six other apertures of the array of apertures.

19. The method of claim 16, wherein the array of apertures extend completely between the first surface and the second surface.

20. The method of claim 16, wherein the at least one fastener member comprises a thermoplastic polymer.

21. The method of claim 20, wherein the at least one fastener comprises polypropylene.

22. The method of claim 16, wherein the second polymeric material of the at least one fastener is different than the first polymeric material of the first chair structure.

23. The method of claim 16, wherein the at least one fastening member includes at least one staple member having a pair of prongs received within apertures of the array of apertures.

24. The method of claim 16, wherein the first chair structure further includes at least one raised portion extending from the second surface, the first surface and the at least one raised portion define a second thickness therebetween that is greater than the first thickness, a majority of the first chair structure comprises the first thickness, and wherein the densely-spaced array of apertures is located within the at least one raised portion.

25. The method of claim 16, wherein the second chair structure comprises an upholstery element.

26. The method of claim 25, wherein the upholstery element comprises a fabric.

27. The method of claim 16, wherein the first chair structure includes a back shell.

28. The method of claim 16, wherein the seating arrangement includes an office chair assembly.