Upholstered furniture with integrated back rest portion webbing support

Patent metadata

Field	Value
Publication number	US-10034554-B2
Application number	US-201615299235-A
Country	US
Kind code	B2
Filing date	Oct 20, 2016
Priority date	Oct 20, 2015
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A upholstered sofa covered by a form fitting upholstery sack where the upholstery sack incorporates a supportive material panel that has integrated support webbing into the material panel. The support webbing comprising a plurality of webbing straps. With the upholstery sack properly positioned on the back rest portion, the supportive material panel is positioned on the front of the back rest portion frame. The material panel with webbing is incorporated as a component of the upholstery sack where the upholstery sack is pre-formed to snugly fit over the back rest portion of a furniture frame. The back rest portion or the frame is inserted into the sack and the material panel with integrated webbing is attached to the frame. Once the material panel is positioned and fastened, the remaining components, for example, the back panels and side panels, of the upholstery sack are attached to the frame at the back rest portion. Due to the construction of the material panel with webbing, installation time is decreased when compared to the time required for conventional webbing and upholstery installations.

First claim

The invention claimed is:

1. An upholstered sofa comprising:
a frame having a rectangular seat base, an upright back rest portion integral with the seat base, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side, wherein the back rest portion is affixed to the back side of the seat base so that the back rest portion is in an upright position, the back rest portion further having a front side, a back side, and a lower portion, and comprising a top rail; and
an upholstery sack having a back material panel, a left side material panel, a right side material panel, an integrated upholstery support assembly including a back support material portion and integrated webbing, the back support material portion comprising a first material panel, the back support material portion having a top end and a bottom end, the integrated webbing comprising a plurality of straps, the webbing sewn to the back support material portion at the top end and at the bottom end of the back support material portion;
wherein the upholstery sack is disposed on the frame with the webbing and attached back support material portion top end attached to the top rail, and wherein the at least one webbing and attached back support material portion bottom end are attached to the lower back rest portion, and wherein the back material panel is fixedly attached to the frame at the lower portion of the back rest portion and with the webbing pulled taught therebetween.

2. The upholstered sofa of claim 1 , wherein the webbing comprising a plurality of straps extending between the top end and the bottom end of the back support material portion.

3. The upholstered sofa of claim 1 , wherein the back support material portion further comprises a second material panel, the second material panel providing a liner for laying against the frame.

4. The upholstered sofa of claim 1 , wherein the upholstery sack further comprises one or more integrated back rest cushion cases defined by the back support material portion.

5. The upholstered sofa of claim 4 , wherein the upholstery sack comprises at least one zipper and wherein each of the integrated back rest cushion cases is accessible for insertion of cushion material by way of the at least one zipper and wherein each of the cushion cases are filled with cushion material.

6. The upholstered sofa of claim 1 , wherein the webbing and the attached back support material portion bottom end are attached to a back side of a breast rail at the lower portion of the back rest portion.

7. The upholstered sofa of claim 1 , wherein the back support material portion comprises a plurality of material panels, wherein each material panel is sewn on at least one edge to an edge of a different material panel.

8. An upholstered sofa comprising:
a frame having a rectangular seat base with an integral spring rail, an upright back rest portion integral with the seat base, and a right arm rest and a left arm rest integral with the seat base and back rest portion wherein the seat base and back rest are disposed between the right arm rest and the left arm rest, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side defining an open interior space, wherein the back rest portion is affixed to the back side of the seat base so that the back rest portion is in an upright position, the back rest portion further comprises a back side, a back side outwardly facing surface, a bottom side, a top rail, and a breast rail;
an upholstery sack having a back material panel, a left side material panel, a right side material panel, an integrated upholstery support assembly, and a back support material portion having a top end and a bottom end, the integrated upholstery support assembly comprising a plurality of webbing straps, each strap having a length, a first end, a middle portion, and a second end wherein each webbing strap's first end is fixedly attached to the material portion top end and wherein each webbing strap's second end is fixedly attached to the material portion bottom end, wherein the length of the webbing straps and a length from the material portion bottom end to the material portion top end are about equidistant, wherein the upholstery sack is disposed on the back rest portion and the plurality of webbing straps are disposed adjacent a top side of the top rail, and wherein each of the plurality of webbing straps' first ends and attached material portion top end are fixedly attached to a back side of the top rail and wherein each of the plurality of webbing straps' middle portions are disposed adjacent a front side of the breast rail, and the plurality of webbing straps and material portion proximate the plurality of webbing straps' second ends are fixedly attached to a top side of the spring rail, wherein the left side material panel and right side material panel are disposed on the back rest portion, and wherein the back material panel is fixedly attached to the back rest portion.

9. The upholstered sofa of claim 8 , wherein a plurality of staples are used to fixedly attach the plurality of webbing straps and the material portion to the furniture frame.

10. The upholstered sofa of claim 8 , wherein the material portion comprises a plurality of material panels, wherein each material panel is attached on at least one edge to an edge of a different material panel.

11. The upholstered sofa of claim 10 , wherein each material panel has at least one edge sewn to an edge of a different material panel.

12. The upholstered sofa of claim 8 wherein the plurality of webbing straps and back rest material portion proximate the at least one webbing second end is fixedly attached to a back side of the breast rail by staples.

13. The upholstered sofa of claim 8 wherein the plurality of webbing straps comprise at least 6 straps.

14. A method of assembling an upholstered sofa comprising:
providing a sofa frame having a rectangular seat, an upright back rest portion integral with the seat base, and a right arm rest and a left arm rest integral with the seat base and back rest portion wherein the seat base and back rest are disposed between the right arm rest and the left arm rest, wherein the seat base has a rectangular shape and forms a box frame having a left side, a right side, a front side, and a back side, wherein the back rest portion is affixed to the back side of the seat base, the back rest portion further comprises a back side, a back side outwardly facing surface, a bottom side, a top rail, and a breast rail;
receiving an upholstery sack having a back material panel, a left side material panel, a right side material panel, and an integrated upholstery support assembly, wherein the upholstery support assembly is further comprised of a material portion having a top end and a bottom end and at least one webbing having a length, a first end, a middle portion, and a second end wherein the at least one webbing first end is fixedly attached to the material portion top end and the at least one webbing second end is fixedly attached to the material portion bottom end; and
disposing the upholstery sack on the back rest portion and disposing the at least one webbing first end adjacent a top side of the top rail, fixedly attaching the at least one webbing first end and attached material portion top end to a back side of the top rail and disposing the at least one webbing middle portion adjacent a front side of the breast rail, and fixedly attaching the at least one webbing and material portion proximate the at least one webbing second end to a top si

Assignees

• Ashley Furniture Ind Inc

Inventors

• Lewis James Allen
• Stokes Philip Lee
• SUDDUTH James Anthony
• Holley Jimmy Dale

Classifications

• A47C17/02

  Sofas, couches, settees, or the like, without movable parts · CPC title

• A47C31/11 Primary

  for chairs {(for headrests only A47C7/386)} · CPC title

• A47C17/86

  Parts or details specially adapted for beds, sofas or couches not fully covered by any single one of groups A47C17/02 - A47C17/84 · CPC title

• A47C27/001

  with several cushions, mattresses or the like, to be put together in one cover · CPC title