Apparatus and method for upholstering a rigid chair shell

• US 4,465,534 A
• Filed: 11/28/1983
• Issued: 08/14/1984
• Est. Priority Date: 05/18/1979
• Status: Expired due to Fees

• Current Assignee: Knoll International, Inc. (Dixie Group Incorporated)
• Original Assignee: Knoll International, Inc. (Dixie Group Incorporated)
• Inventors: Zelkowitz, Hyman L.
• Primary Examiner(s): Wityshyn, Michael G.
• Application Number:
  US06/555,450
• Time in Patent Office: 260 Days
• Field of Search: 156/91, 156/212, 156/213, 156/221, 156/245, 156/286, 156/382, 156/229, 156/581, 5/403, 297/218, 297/456
• US Class Current: 156/91
• CPC Class Codes: A47C 3/12 with shell-shape seat and back-rest unit, e.g. having arm rests
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith

Abstract

An apparatus and method for upholstering a rigid chair shell is disclosed. A continuous, generally C-shaped track is utilized about the peripheral edge of the shell, opening rearwardly thereof to receive a retaining element attached about the peripheral edge of the covering material. The retaining element is constructed from a strip of tubular flexible material with an integral flap member circumferentially overlying at least part of the tubular strip and accepting the track edge therebetween. The inside surface of the outer end of the flap member is attached to the inside surface of the edge of the cover or fabric and, after suitable cushioning is attached to the front surface of the shell, the covering is placed over the cushioning and rolled about the retaining element which is snapped into the C-shaped track around the periphery of the shell to hold the covering thereon. Upon rolling into the track the tubular body is seated in the track cavity, and the free edge of the track extends into the space between the tubular body and the flap member with the fabric end disposed therebetween, thus locking the element against the track edge preventing roll-out and distributing the stress on the fabric while blending the region between the cushion and shell edges and obscuring the retaining element from view. The composite cover, cushion, and shell is then placed face up in an upholstery mold and heat and pressure applied from above to conform and attach the cover to the cushion by activating a non-tacky cover-cushion adhesive on the surface of the cushion, and a finished composite chair results upon removal from the mold. For reupholstery purposes, a replacement fabric, cushion and retaining element may be preformed and locked onto a shell by rolling the retaining element into the track, after the original covering, retaining element, and cushioning have been cut and removed.

Claims

1. A method of attaching a flexible covering to a support member and utilizing a retaining element made of a length of flexible material having a central body portion and a flap integral with said central body portion, said flap being spaced from and extending adjacent to and at least partially circumferentially about an external surface of said central body portion, in which said support member includes a channel member having a free edge, comprising the steps of attaching said covering to said flap on an inside surface of said flap, adjacent to said central body portion, wrapping said covering about said central body portion and an outside surface of said flap, and positioning said central body portion within said channel member with at least part of said flap being positioned outside said channel member and said free edge of said channel member being positioned between said flap and said central body portion.

2. In a method according to claim 1, in which said support member comprises a shell that includes said channel member thereon, the further step comprising adhesively securing said flexible covering to said shell.

3. A method according to claim 2, in which said shell includes padding material secured thereto, and said flexible covering is adhesively secured to said padding material.

4. A method according to claim 1, in which said flexible covering is of stretchable material, and said support member comprises a shell that includes said channel member thereon, and in which, when said central body portion of said retaining element is positioned within said channel member, portions of said stretchable material are spaced from portions of said shell, the further steps comprising stretching said stretchable material so that said portions thereof are in contact with said portions of said shell, and adhesively securing said stretchable material portions and said shell portions together.

5. A method of attaching a covering of stretchable material to a substrate, said substrate being constituted of a foam covered shell or the like, comprising the steps of attaching a peripheral portion of said covering material to a peripheral portion of said substrate, with an interior portion of said covering material being spaced from an interior portion of said substrate, stretching said covering material so that said interior portion thereof is brought into contact with said interior portion of said substrate, and adhesively securing together said interior portion of said covering material and said interior portion of said substrate with an adhesive bond therebetween that progressively varies throughout said interior portions proceeding from said interior portions to said peripheral portions with little or no bond at said peripheral portions.

6. A method according to claim 5, in which said interior portion of said substrate is coated with a radiation-activatable adhesive, and said covering material is stretched by use of a radiation-emitting die in contact therewith.

7. A method according to claim 5, in which contact is first made between central parts of said interior portions of said covering material and substrate, and contact between said interior portions then proceeds outwardly toward said peripheral portions.

8. A method according to claim 7, in which the adhesive bond between said interior portions decreases in amount from said central parts toward said peripheral portions.

9. A method according to claim 8, in which said peripheral portions are mechanically but non-adhesively secured together.

10. A method according to claim 5, in which said covering material is stretched by use of a die having a substrate-contacting surface which is shaped to conform generally to said substrate but which is progressively more undercut with respect to said substrate proceeding outwardly from said interior portions to said peripheral portions.

11. A method according to claim 5, in which said covering material is attached at its periphery to said shell, and there is no glue bond between said covering material and the foam covering of said shell in the region immediately adjacent to the attachment of said covering material to said shell.

12. In an upholstery process for covering a surface of an article of furniture, said article including a track having a cavity and at least one free edge, with the opening to said cavity facing away from said surface to be covered, and wherein a covering material is shaped to fit over said surface, the improvement comprising attaching an edge of said covering material to an integral flap portion that is part of a retaining element that includes an enlarged portion, placing said covering material over said surface and retaining it thereon by rolling said edge of said covering material about said retaining element and inserting the enlarged portion of said retaining element in the track cavity with said free track edge extending between said enlarged and flap portions of said retaining element so that said flap portion covered by covering material is disposed outside said track.

13. A process an in claim 12, in which said shell is covered with a padding material, and comprising the further steps of applying a heat activatable adhesive to an exposed surface of said padding material before affixing the covering material to said shell, and disposing the composite covering material and padding material and shell in a heated upholstery mold and applying pressure to conform and attach said covering material to said padding material.

14. A method of attaching a covering of stretchable material to a substrate, said substrate being constituted of a foam covered shell or the like, comprising the steps of attaching a peripheral portion of said covering material to a peripheral portion of said substrate, with an interior portion of said covering material being spaced from an interior portion of said substrate, stretching said covering material so that contact is first made between central parts of said interior portions of said covering material and substrate, and contact between said interior portions then proceeds outwardly toward said peripheral portions, and adhesively securing together said interior portion of said covering material and said interior portion of said substrate with an adhesive bond which decreases in amount from said central parts toward said peripheral portions with little or no bond at said peripheral portions.

15. A method according to claim 14, in which said covering material is stretched by use of a die having a substrate-contacting surface which is shaped to conform generally to said substrate but which is progressively more undercut with respect to said substrate proceeding outwardly from said interior portions to said peripheral portions.

16. A method according to claim 14, in which said covering material is attached at its periphery to said shell, and there is no glue bond between said covering material and the foam covering of said shell in the region immediately adjacent to the attachment of said covering material to said shell.