Device and method for assembly of furniture

• US 8,844,105 B2
• Filed: 04/22/2011
• Issued: 09/30/2014
• Est. Priority Date: 04/22/2011
• Status: Expired due to Fees

• Current Assignee: Jeffco Fibres Incorporated
• Original Assignee: Jeffco Fibres Incorporated
• Inventors: LaRoche, John
• Primary Examiner(s): Nelson, Jr., Milton
• Application Number:
  US13/092,623
• Publication Number:
  US 20120267938A1
• Time in Patent Office: 1,257 Days
• Field of Search: 29/911, 29/91
• US Class Current: 29/91.1
• CPC Class Codes: A47C 17/02 Sofas, couches, settees, or the like, without movable parts
• CPC Class Codes: A47C 3/16 of legless type, e.g. with seat directly resting on the floor A47C3/14 takes precedence; detachably mounted on stadium benches A47C1/16; children's chairs mounted on back-rest of chair A47D1/10 , legless beach chairs A47C1/146; inflatable chairs A47C4/54; Hassocks; Pouffes
• CPC Class Codes: A47C 31/11 for chairs for headrests only A47C7/386; removable protective covers for car seats B60N2/60
• CPC Class Codes: A47C 5/125 completely made of foam material
• CPC Class Codes: Y10T 29/481 Method

Abstract

Furniture, such as a chair, and method of assembly thereof includes the steps of configuring an upholstery fabric outer covering and a flap having one or more open sides, the flap affixable on one side to the outer covering. A number of foam blocks are configured in shapes, which, taken together, conform to the shape of the furniture to be assembled.

Claims

1. A method for constructing a piece of furniture comprising the steps of:

a. configuring an upholstery fabric outer covering comprising a plurality of sockets and a flap comprising one or more open sides, the flap affixed on one side to the outer covering;

b. selecting a plurality of foam blocks;

c. inserting one of the plurality of foam blocks within one of the plurality of sockets of the outer covering and repeating said inserting step until each of the plurality of foam blocks have been inserted into one of the plurality of sockets and all of the sockets are filled with a foam block, whereby the plurality of foam blocks completely fill the outer covering and form the piece of furniture;

d. attaching the open sides of the flap to the outer covering by a fastener; and

,

e. stabilizing the plurality of foam blocks such that the plurality of foam blocks cannot move relative to each other.

2. The method of claim 1, wherein said fastener comprises a zipper.

3. The method of claim 1, wherein step (c) further comprises inserting a plurality of slippery film sheets about one or more of the plurality of foam blocks.

4. The method of claim 1 wherein said piece of furniture comprises a chair.

5. The method of claim 1 further comprising the step of

pulling a tab after a seat block is inserted into a seat socket, and

removing wrinkles in the outer covering of the piece of furniture.

6. The method of claim 1 wherein said fastener comprises a hook and a loop.

7. The method of claim 1, wherein the plurality of foam blocks are comprised of polyurethane.

8. The method of claim 1, wherein the piece of furniture further comprises an arm, a back, and a base, and, wherein step (c) comprises inserting one or more foam blocks into the outer covering to form the arm of the piece of furniture, inserting one or more foam blocks into the outer covering to form the back of the piece of furniture, and inserting one or more foam blocks into the outer covering to form the base of the piece of furniture.

9. The method of claim 8, further comprising the step of shipping the outer covering and the unassembled plurality of foam blocks wherein the plurality of foam blocks are not inserted into the outer covering before shipping.

10. The method of claim 9, further comprising the step of offering the piece of furniture for resale whereby the purchaser is responsible for the reassembling of piece of furniture from the outer covering, the plurality of foam blocks, and the slippery film sheets.