Installation of a textile deck assembly in an article of furniture

• US 9,004,604 B2
• Filed: 02/01/2012
• Issued: 04/14/2015
• Est. Priority Date: 02/04/2009
• Status: Expired due to Fees

• Current Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Original Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Inventors: Bogard, Jeremy, Mazza, Mark, Simon, Bernard R., Bullard, Larry I.
• Primary Examiner(s): CRANMER, LAURIE K
• Application Number:
  US13/363,613
• Publication Number:
  US 20120153703A1
• Time in Patent Office: 1,168 Days
• Field of Search: 297/452.13, 294/48, 29/911, 29/915, 160/378
• US Class Current: 297/452.13
• CPC Class Codes: A47C 31/026 passing through the upholstery, e.g. upholstery nails or buttons
• CPC Class Codes: A47C 7/28 with tensioned springs, e.g. of flat type
• CPC Class Codes: B68G 7/12 Other elements specially adapted for fastening, fixing, or finishing, in upholstery work
• CPC Class Codes: Y10T 29/481 Method
• CPC Class Codes: Y10T 29/486 Cover stretching
• CPC Class Codes: Y10T 29/49863 with prestressing of part
• CPC Class Codes: Y10T 29/49867 of skin on frame member
• CPC Class Codes: Y10T 29/53657 to apply or remove a resilient article [e.g., tube, sleeve, etc.]

Abstract

A method, apparatus, and seating product that include a seat deck assembly with a tensioned fabric decking are described. The seat deck assembly includes one or a pair of frame rails attached along opposite edges of the decking. The decking includes an elastomeric textile. The decking or a first of the frame rails is attached to a first side of the frame. The second of the frame rails is placed in a rigid fixture. A force is applied by an actuator to the frame to move the second side of the frame toward the second frame rail and to stretch the elastomeric fabric. The second frame rail is couple to the second side of the frame and the assembled frame is removed from the fixture. Cushions, padding or an upholstered covering can complete embodiments of the seating product.

Claims

1. A method for installing a deck assembly in an article of furniture, the method comprising:

attaching a deck assembly to a first side of a frame of an article of furniture, the deck assembly including a decking and a first frame rail, a first edge of the decking being attached to the first side of the frame by the first frame rail and a second opposite edge of the decking being attached to a second frame rail, and the frame including the first side, an opposing second side, and a pair of opposing ends;

removeably disposing the second frame rail in a fixture;

applying a force on the frame to move the opposing second side of the frame toward the second frame rail and to stretch the decking between the second frame rail and the first side of the frame; and

attaching the second frame rail to the opposing second side of the frame.

2. The method of claim 1, wherein the decking comprises an elastomeric textile.

3. The method of claim 1, wherein the decking includes a body and at least one first textile border coupled to the body and extending between the body and the first side of the frame, thereby coupling a first side of the body to the frame.

4. The method of claim 3, wherein the at least one first textile border comprises an elastomeric fabric.

5. The method of claim 3, wherein the decking further comprises a second textile border coupled to the body and extending between the body and the frame rail, thereby flexibly coupling a second side of the body to the frame rail.

6. The method of claim 5, wherein the second textile border comprises an elastomeric fabric.

7. The method of claim 3, wherein the body comprises a wire grid with the first textile border coupled along at least one edge.

8. The method of claim 7, wherein the first textile border is coupled to the wire grid by weaving the border into the wire grid.

9. The method of claim 1, wherein one or more of a pneumatic, hydraulic, mechanical, or electronic actuator applies the force on the frame.

10. The method of claim 9, wherein the actuator and the fixture are rigidly coupled to a surface and the frame is slidably disposed on the surface with the second side placed between the actuator and the fixture such that the actuator applies the force to the second side of the frame to move the second side toward the fixture.

11. The method of claim 9, wherein the actuator and the fixture are disposed interior to the frame and the actuator applies the force to the first side of the frame to move the second side of the frame toward the fixture.

12. The method of claim 1, wherein the first edge of the decking is coupled to a second frame rail and the second frame rail is coupled with the first side of the frame.

13. An apparatus for installing a decking assembly in an article of furniture, the apparatus comprising:

a rigid fixture configure to removeably accept a frame rail of a decking assembly for an article of furniture and to rigidly retain the frame rail against an applied force, the decking assembly including a decking that is coupled to the frame rail along a first edge and coupled to a first side of the frame of the article of furniture along a second edge, the frame including the first side, an opposing second side, and a pair of opposing ends;

an actuator configured to apply a force on the frame to move the second side of the frame toward the frame rail that is retained in the fixture; and

a surface configured to support the frame and to rigidly couple to the fixture and the actuator.

14. The apparatus of claim 13, wherein the decking comprises an elastomeric textile.

15. The apparatus of claim 13, wherein the decking includes a body and at least one first textile border coupled to the body and extending between the body and one of the frame rail or the first side of the frame, thereby coupling the body to the frame rail or the first side of the frame.

16. The apparatus of claim 13, wherein the at least one first textile border comprises an elastomeric fabric.

17. The apparatus of claim 13, wherein one or more of the fixture and the actuator are adjustable to accommodate frames from multiple different articles of furniture.

18. A seating product comprising:

a frame having a first side, an opposing second side, and a pair of opposing ends; and

a deck assembly having a frame rail coupled along a first edge of a decking, the decking including an elastomeric textile and being installed in the frame by

attaching a second edge of the decking to the first side of the frame, the second edge being opposite the first edge,

placing the frame rail in a fixture,

applying a force to the frame to move the second side of the frame toward frame rail in the fixture and to stretch the decking between the first side of the frame and the frame rail, and

coupling the frame rail to the second side of the frame.

19. The seating product of claim 18, wherein the decking assembly includes a second frame rail that is coupled along the second edge of the decking and is attached to the first side of the frame.

20. The seating product of claim 18, wherein the decking includes a body and at least one textile border that is secured to a first edge of the body by weaving the textile border into the body during manufacture, the textile border thereby forming the first or second edge of the decking.