Device and Method for Assembly of Furniture

• US 20120267938A1
• Filed: 04/22/2011
• Published: 10/25/2012
• Est. Priority Date: 04/22/2011
• Status: Active Grant

• Current Assignee: Jeffco Fibres Incorporated
• Original Assignee: Jeffco Fibres Incorporated
• Inventors: LaRoche, John
• Granted Patent: US 8,844,105 B2
• Time in Patent Office: Days
• US Class Current: 297/452.48
• 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

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 affixed on one side to the outer covering the flap further having means for attaching the open sides of the flap to the outer covering. A number of foam blocks are configured in shapes, which, taken together, conform to the shape of the chair to be assembled. Finally, the foam blocks are disposed within the outer covering so that the blocks completely fill the outer covering and cause it to assume the form of the chair, with the final product having a robust structure without the use of other structural components.

Claims

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

a. configuring an upholstery fabric outer covering and a flap comprising one or more open sides, the flap affixed on one side to the outer covering, and wherein the flap further comprises attachment means for attaching the open sides to the flap to the outer covering;

b. configuring a plurality of foam blocks;

c. inserting the foam blocks within the outer covering so that the foam blocks completely fill the outer covering and cause it to assume the form of the chair; and

d. attaching the open sides of the flap to the outer covering, so that the foam blocks cannot move relative to each other.

2. The method of claim 1, wherein said attachment means further comprises a zipper.

3. The method of claim 2, further comprising the steps of inserting a plurality of slippery film sheets about one or more of the foam blocks to facilitate the insertion of said foam blocks within the outer covering.

4. The method of claim 3, further comprising inserting one or more foam blocks inserted into the outer fabric to form each arm of the chair, further comprising inserting one or more foam blocks inserted into the outer fabric to form the back of the chair, and further comprising inserting one or more foam blocks inserted into the outer fabric to form the base of the chair.

5. The method of claim 4, further comprising the steps of shipping the chair components wherein the foam blocks are not inserted into the outer covering, and wherein the slippery film sheets are packed separately from the outer covering and separately from the foam blocks.

6. The method of claim 5, further comprising the steps of offering the chair for resale whereby the purchaser is responsible for the reassembling the chair from the outer covering, the foam blocks, and the slippery film sheets.

7. The method of claim 6, wherein the foam blocks are comprised of polyurethane.

15. The chair of claim 6, wherein the foam blocks are comprised of polyurethane.

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

a. configuring an upholstery fabric outer covering and a flap comprising one or more open sides, the flap affixed on one side to the outer covering, and wherein the flap further comprises attachment means for attaching the open sides to the flap to the outer covering;

b. configuring a plurality of foam blocks;

c. inserting the foam blocks within the outer covering so that the foam blocks completely fill the outer covering and cause it to assume the form of the furniture; and

d. attaching the open sides of the flap to the outer covering, so that the foam blocks cannot move relative to each other.

9. A chair comprising:

a. a plurality of foam blocks; and

b. an upholstery fabric outer covering and a flap comprising one or more open sides, the flap affixed on one side to the outer covering, and wherein the flap further comprises attachment means for attaching the open sides to the flap to the outer covering, the flap providing a means for inserting the foam blocks,

said chair not including any supporting elements other than those recited above,

so that, when the open sides of the flap to the outer covering, the foam blocks cannot move relative to each other, and the resulting structure is robust.

10. The chair of claim 9, wherein said attachment means further comprises a zipper.

11. The chair of claim 10, further comprising a plurality of slippery film sheets, each affixed to one or more of the foam blocks to facilitate the insertion of said foam blocks within the outer covering.

12. The chair of claim 11, wherein the foam blocks further comprise one such block that forms each arm of the chair, one or more foam blocks that forms the back of the chair, and one or more foam blocks that forms the base of the chair.

16. A piece of furniture comprising:

a. a plurality of foam blocks; and

b. an upholstery fabric outer covering and a flap comprising one or more open sides, the flap affixed on one side to the outer covering, and wherein the flap further comprises attachment means for attaching the open sides to the flap to the outer covering, the flap providing a means for inserting the foam blocks,

said piece of furniture not containing any supporting elements other than those recited above,

so that, when the open sides of the flap to the outer covering, the foam blocks cannot move relative to each other, and the resulting structure is robust.