Sofa with upholstery cover having attachment means

Patent metadata

Field	Value
Publication number	US-10869560-B2
Application number	US-201916281774-A
Country	US
Kind code	B2
Filing date	Feb 21, 2019
Priority date	Feb 21, 2018
Publication date	Dec 22, 2020
Grant date	Dec 22, 2020

Abstract

An upholstered sofa comprises a sofa frame covered with fitted upholstery. The fitted upholstery provided by a form fit upholstery cover or covers formed of upholstery material and comprising stitched upholstery panels and pieces, the cover having upholstery edge portions with attachment means for securement of the edge portion without staples to the sofa frame. The attachment means may be a resilient polymer channel sewn to the upholstery material. The attachment means may be a plurality of elastic cords with connectors on distal ends of the cords. The elastic cords may be stretched and attached to features on the sofa frame or to features on the upholstery cover thereby keeping the upholstery cover assembly taught on the sofa frame.

First claim

The invention claimed is:

1. An upholstered sofa comprising:
a wood sofa frame having a rectangular seat base frame portion with an integral spring rail, an upright back rest frame portion integral with the seat base frame portion, and a right arm rest frame portion and a left arm rest frame portion integral with the seat base frame portion and back rest frame portion wherein the seat base frame portion and back rest frame portion are disposed between the right arm rest frame portion and the left arm rest frame portion, wherein the seat base frame portion has a rectangular shape and forms a box frame portion having a left side, a right side, a front side, and a back side defining an open interior space, wherein the back rest frame portion is affixed to the back side of the seat base frame portion, the back rest frame portion is in an upright position, and the back rest frame portion has a top rail with a length extending in a left-right direction; and
a form fit upholstery cover disposed on the back rest frame portion and being attached to the top rail with one or more elongate resilient polymer fastening strips with two internal corners and a channel opening between 10 and 25 millimeters, the one or more elongate resilient polymer fastening strips aligned and extending substantially the length of the top rail.

2. The upholstered sofa of claim 1 , wherein the upholstery cover is formed of upholstery material and the one or more elongate resilient polymer fastening strips are attached to upholstery material by stitching.

3. The upholstered sofa of claim 1 , wherein the upholstery cover further has an edge portion with a plurality of spaced elastic cords under tension for maintaining the tautness of the upholstery cover.

4. The upholstered sofa of claim 3 , wherein at least one of the plurality of spaced elastic cords has an elongation of up to 50% of the length of the elastic cord under tension of between 5 pounds and 20 pounds.

5. A method of assembling an upholstered sofa comprising:
providing a wooden sofa frame having a rectangular seat base frame portion, an upright back rest frame portion integral with the seat base frame portion, and a right arm rest frame portion and a left arm rest frame portion, both integral with the seat base frame portion and back rest frame portion, wherein the seat base frame portion and back rest frame portion are disposed between the right arm rest frame portion and the left arm rest frame portion, wherein the seat base frame portion has a rectangular shape and forms a box frame portion having a left side, a right side, a front side, and a back side, wherein the back rest frame portion is affixed to the back side of the seat base frame portion;
receiving a form fit upholstery cover assembly formed of upholstery material and having a rearward lower edge portion and a forward lower edge portion, one of the rearward lower edge portion and the forward lower edge portion having a spaced plurality of at least four elastic cords, each elastic cord attached to the upholstery at a proximal end and having a rigid connector at a distal end; and
placing the form fit upholstery cover assembly over the wooden sofa frame and attaching each of the connectors by elongating the respective elastic cord to one of the sofa frame and the other of the rearward lower edge portion and the forward lower edge portion.

6. The method of claim 5 further comprising attaching a further edge portion of the upholstery cover assembly to a frame member by an elongate polymer channel sewn to the upholstery material, the elongate polymer channel extending around three sides of the frame member.

7. The method of claim 5 , wherein the upholstery cover assembly comprises two arm rest covers, and the method comprises extending each arm rest cover around four sides of one of the arm rest frame portions and connecting opposite edge portions of each arm rest cover by a plurality of elastic cords.

8. An upholstery kit for upholstering a sofa frame having a box frame portion, a pair of side arm frame portions, and a back rest frame portion, the upholstery kit comprising an back rest upholstery sack configured for covering the back rest frame portion, the back rest upholstery sack formed of upholstery material having a lower back rest edge portion sized for extending substantially a length of the sofa, the back rest portion having a first attachment means extending substantially a length of the lower back rest edge portion for securement of the back rest upholstery sack to an underside of the sofa frame, the first attachment means not requiring staples for the attachment of the lower back rest edge portion at the underside of the sofa frame, the first attachment means comprising one of an elongate polymer channel and a plurality of elastic cords with rigid connectors, the upholstery kit further comprising a box frame cover including a front side upholstery panel formed of upholstery material with a front side upholstery panel lower edge portion for attachment on the underside of the sofa frame without requiring staples, the front side upholstery panel lower edge portion having a second attachment means extending substantially a length of the lower edge portion for securement of the front side upholstery panel to the sofa frame at the underside of the sofa frame without requiring staples, the second attachment means comprising one of an elongate polymer channel and a plurality of elastic cords with rigid connectors.

9. The upholstery kit of claim 8 , wherein the first and second attachment means are each comprised of the elongate polymer channel stitched to the respective upholstery material.

10. The upholstery kit of claim 9 , wherein the polymer channel comprises a channel opening between 10 and 25 millimeters.

11. The upholstery kit of claim 8 , wherein the first attachment means and second attachment means are connectable together under tension.

12. The upholstery kit of claim 9 , wherein one of the first attachment means and second attachment means comprises the plurality of elastic cords with rigid connectors thereon.

13. The upholstery kit of claim 12 , wherein at least one of the plurality of elastic cords has an elongation of up to 50% of the length of the elastic cord under tension of between 5 pounds and 20 pounds.

14. The upholstery kit of claim 8 , further comprising a left side arm rest cover and right side arm rest cover, each of the left and right side arm rest covers attachable to the sofa frame under tension without staples.

15. The upholstery kit of claim 8 , further comprising the sofa frame and wherein the back rest frame portion and box frame cover are attached to the sofa frame under tension provided by elastic cords.

16. The form fit upholstery cover of claim 1 wherein each fastening strip is formed from a unitary homogeneous polymer.

17. The form fitted upholstery cover of claim 1 , wherein the cover has a back rest pocket conformingly sized for the back rest frame portion of the sofa frame, the back rest pocket having padding incorporated therein and further comprising a plurality of back rest webbing straps.

18. The form fit upholstery cover of claim 3 , wherein each of the plurality of spaced elastic cords has a rigid connector on a distal end thereof.

Assignees

• Ashley Furniture Ind Inc

Inventors

• Gates Earnest
• Koon Steve
• SUDDUTH James Anthony
• Lewis James A
• Bramlitt Wayne

Classifications

• A47C17/02 Primary

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

• A47C31/04 Primary

  Clamps for attaching flat elastic strips or flat meandering springs to frames · CPC title

• A47C31/023

  connecting upholstery to frames, e.g. by hooks, clips, snap fasteners, clamping means or the like · CPC title