Abstract:
A method and apparatus for fabricating upholstered furniture articles and components is disclosed. The method employs an assembly line with work stations. A selected beginning part such as a wooden frame or skeleton is transported along the assembly line using a specially configured fixture or jig to hold the frame or skeleton. At selected work stations, the fixture can be rotated or tilted depending upon the work to be performed. A locking arrangement secures the fixture to the track at each work station.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   Priority of U.S. Provisional Patent Application Ser. No. 60/663,495, filed Mar. 17, 2005, incorporated herein by reference, is hereby claimed. 

   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable 
   REFERENCE TO A “MICROFICHE APPENDIX” 
   Not applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a method and apparatus for assembling furniture components. More particularly, the present invention relates to a method and apparatus for assembling components that features a railway having a plurality of workstations spaced along the railway, a locking device that secures a traveling fixture or jig to a selected work station, wherein the jig or fixture securely holds a wooden frame or skeleton that is the beginning part of an upholstered article (or component) of furniture. At each workstation, a different operation can be performed or a different item added to the skeleton or frame, the added items including for example, foam padding, molded foam material, fabric, paper tacking strips, or cardboard. 
   2. General Background of the Invention 
   Furniture manufacturers frequently begin the construction of an upholstered furniture article with a wooden frame or skeleton. Additional materials are attached to this skeleton or frame using staplers, nails or like fasteners. These additional materials can include foam padding, fabric upholstery, paper tacking strips and the like. During the manufacture of upholstered furniture, the piece has typically been moved manually from one worker to the next in the prior art. Each worker in sequence performs different operations on the frame or skeleton until the upholstered furniture article is complete and ready for shipment to a furniture distributor, wholesaler, retailer, or the like. 
   Patents have issued that are directed generally to assembly line construction of various articles including furniture articles. The following table lists examples of such patents. 
   The following U.S. Publication and Patents are incorporated herein by reference: 
   
     
       
             
             
             
           
         
             
               TABLE 
             
             
                 
             
             
               U.S. Pat. No. 
               TITLE 
               ISSUE DATE 
             
             
                 
             
           
           
             
               1,963,710 
               Upholstery Making Apparatus 
               Jun. 19, 1934 
             
             
               3,439,397 
               System of Making Fibrous-Filled 
               Apr. 22, 1969 
             
             
                 
               Furniture Seat and Back Cushion 
             
             
                 
               Elements 
             
             
               3,727,903 
               Furniture Truck Frame 
               Apr. 17, 1973 
             
             
               3,914,154 
               Method and Device for the Production 
               Oct. 21, 1975 
             
             
                 
               of Layered Pressed Panels 
             
             
               4,575,059 
               Method and Jig for Furniture 
               Mar. 11, 1986 
             
             
                 
               Construction 
             
             
               4,765,122 
               Conveyor 
               Aug. 23, 1988 
             
             
               4,914,873 
               Work Environment System 
               Apr. 10, 1990 
             
             
               5,054,178 
               Process and Apparatus for the 
               Oct. 8, 1991 
             
             
                 
               Production of Innersprings for 
             
             
                 
               Mattresses and Upholstered Furniture 
             
             
               5,608,956 
               System for Automatically Assembling a 
               Mar. 11, 1997 
             
             
                 
               Seat 
             
             
               6,763,573 
               Assembly System for Monitoring 
               Jul. 20, 2004 
             
             
                 
               Proper Fastening of an Article of 
             
             
                 
               Assembly at More than One Location 
             
             
               2004/0098850 
               Apparatus for Upholstering Components 
               May 27, 2004 
             
             
                 
               of Chairs, Armchairs or the like 
             
             
               DE019813373 
               Assembly jig for Furniture Carcasses 
               Oct. 7, 1999 
             
             
               EP001046481 
               Furniture Assembly Line 
               Oct. 25, 2000 
             
             
                 
             
           
        
       
     
   
   BRIEF SUMMARY OF THE INVENTION 
   The present invention is designed for the manufacturing of component upholstery furniture. The present invention provides a method and apparatus for manufacturing upholstered furniture or a component of an upholstered furniture article. The apparatus features a specially configured assembly line that eliminates unnecessary handling and specialized skilled labor. 
   The method and apparatus of the present invention reduces fatigue, increases production capacity, and economizes space on production floor. 
   Using the method and apparatus of the present invention, a manufacturer of upholstered furniture or a component of upholstered furniture feeds a continuous flow of parts from start to finish without the need of an individual on line having to load and unload the item in between the beginning and the end of the assembly line. 
   In the manufacture of a component of upholstered furniture, a beginning furniture part (i.e. a wooden skeleton or frame) is initially placed on a fixture or a jig, held with a clamping device. The fixture or a jig rolls on bearings which travel in a track. The jig or fixture can be rotated (e.g. 180°) and can be tilted or inclined such as, for example, a measure of about 45°. 
   Spaced along the line are multiple work stations. At each work station there is provided an air cylinder which extends a specially shaped holder, preferably fork shaped to hold the jig or fixture in place. At the work station, the jig or fixture can be rotated or tilted to accommodate a particular operation that is being performed at that work station. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
       FIG. 1  is a plan view of the preferred embodiment of the apparatus of the present invention; 
       FIG. 2  is sectional view of the preferred embodiment of the apparatus of the present invention taken along lines  2 - 2  of  FIG. 1 ; 
       FIG. 3  is a partial side view of the preferred embodiment of the apparatus of the present invention; 
       FIG. 4  is a perspective view of an preferred embodiment of the apparatus of the present invention showing the fixture; 
       FIG. 5  is a partial sectional view of the preferred embodiment of the apparatus of the present invention taken along lines  5 - 5  of  FIG. 1 ; 
       FIG. 6  is a sectional view taken along lines  6 - 6  of  FIG. 1 ; 
       FIG. 7  is a partial perspective view of the preferred embodiment of the apparatus of the present invention; and 
       FIG. 8  is a partial sectional elevation view of the preferred embodiment of the apparatus of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In  FIGS. 1-7 , furniture assembly apparatus  10  includes a railway  11  upon which travels one or more fixtures or jigs  30 . The railway  11  includes one or more elongated tracks or channels and can include for example, a line channel  12  and return channel  13  the two being spaced apart and connected with a transfer box  70  at one or at both ends of railway  11 . In this fashion, a fixture or jig  30  can travel from a point of beginning on the line channel  12  and then from one work station to the next until it reaches the end of the line channel  12  at transfer box  70 . The fixture  30  can travel from the line channel  12  to the return channel  13  via the transfer box  70 . The completed furniture article can be removed/unloaded from the jig  30  at the transfer box  70 . The empty jig  30  then returns via the return channel  13  to a position near the point of beginning where the fixture  30  is removed from return channel  13  and placed upon line channel  12  at the point of beginning—loaded with a new frame, skeleton component or the like. 
   The railway  11  can be supported with a plurality of legs  15 . Legs  15  can be telescoping legs so that the elevation of the railway  11  can be adjusted. The legs  15  form an interface with floor  16  that supports the line channel  12 , return channel  13  and transfer box  70 . Line channel  12  is shown in more detail in  FIG. 2 . 
   Each channel  12 ,  13  provides a channel member  17  having a pair of spaced apart, generally parallel flanges  18 ,  19  that are connected with web  20 . The flanges  18 ,  19  extend upwardly in relation to the web  20 . The web  20  provides a structure upon which the wheels  32  of jig or fixture  30  can travel as the fixture  30  moves along the line channel  12 . 
   Each work station is defined by a transverse or a cross support brace  14  as will be discussed more fully hereinafter. A locking device  57  is mounted upon each cross support brace  14  that will function as a workstation. In order to maintain the wheels  32  of each fixture  30  within channel member  17 , a pair of inwardly directed flanges  21 ,  22  are provided respectively upon the flanges  18 ,  19  as shown. Return channel  13  likewise provides a channel member  23  comprised of web  26 , flanges  24 ,  25  and flanges  27 ,  28 . 
   In the drawings, arrows  29  schematically illustrate the travel path of each fixture or jig  30  as it travels from line channel  12 , to transfer box  70  to return channel  13  and then along channel  13  until a point of unloading. 
   In  FIGS. 3 and 4 , fixture or jig  30  is shown in more detail. Fixture  30  includes a base  31  that can be in the form or a square or generally rectangular plate as shown. A plurality of preferably four wheels  32  are attached to base  31 . Pedestal  33  is a vertically extending pedestal that extends upwardly from base  31 . The pedestal  33  preferably includes an internal sleeve  34  and an external sleeve  35 . The separate sleeves  34 ,  35  enable a rotating connection to be made between the sleeves  34 ,  35  so that the fixture top and bottom plates  38 ,  39  can be rotated as a unit with respect to the base  31 . A connection  36  such as a bolted connection joins the internal and external sleeves  34 ,  35 . Multiple openings can be provided in each of the sleeves  34 ,  35  at selected circumferentially spaced apart positions so that the internal and external sleeves  34 ,  35  can be rotated to selected angular positions relative to one another, such as 90 degrees, 120 degrees, 180 degrees apart, etc. 
   The fixture top plate  38  and fixture bottom plate  39  are attached along respective edge portions with hinge  40  as shown in the drawings. Fixture bottom plate  39  is supported upon cam lock bracket  41 . Bracket  41  can be in the form of one or more plates that are welded to the underside of fixture bottom plate  39 . The cam lock bracket  41  has a shaped slot  42  that enables the fixture bottom plate  39  to be either horizontally positioned or inclined. Slot  42  has laterally extending section  42 A and generally vertically extending section  42 B. A pair of bolted connections  43 ,  44  are provided, bolted connected  43  being an upper connection that can occupy laterally extending  42 A section of slot  42 . Bolted connection  44  always occupies a position in the generally vertically extended section  42 B of slot  42 . Bolted connection  43  occupies lateral section  42 A when a tilted orientation is desired ( FIG. 4 ). 
   Flanged connectors  45  are affixed to the underside of fixture bottom plate  39 . Each of the flanged connectors  45  can include flanges  46  and  47  that are integrally joined or welded and which form an angle of about 90 degrees. Openings  48  in flange  47  are receptive of fasteners for attaching clamps  50  to flanged connectors  45 . In a preferred embodiment, there are two flanged connectors  45 , each equipped with a clamp  50 . The clamps  50  can be commercially available clamps such as those that are manufactured and sole by Destaco, for example model  608 , part number 56080-608. Bolted connection  68  extends through openings in both fixture top plate  38  and fixture bottom plate  39 . The bolt  68  provides a threaded end portion that is joined at connection  52  to clamp  50 . A pair of clamps  50  can be used, the clamps  50  connected by a handle  53  that moves the clamps  50  between clamping and releasing positions. 
   Arrows  54  indicate schematically the upward and downward movement of handle  53  that effects a clamping or unclamping of the fixture top  38  and bottom  39  plates. In the clamping position, the plates  38 ,  39  pivot upon hinge  40 , coming together and compressing spring  51 . The clamps  50  are not sufficiently strong to overcome spring  51 . They also pull the plates  38 ,  39  together with sufficient force to clamp a wooden frame  85  or a skeleton that is to be the beginning of a piece of upholstered furniture. Arrow  55  in  FIG. 4  shows the spacing between top plate  38  and bottom plate  39  in an open position. The space  56  in between plates  38 ,  39  is greater when the clamps  50  are open and smaller when the clamps  50  are closed. 
   When the fixture or jig  30  reaches a work station that can include a selected cross support brace  14 , that cross support brace  14  is equipped with a locking device  57  ( FIGS. 5 and 7 ). The fixture or jig  30  can be rigidly secured so that any desired operation can be performed on the frame  85  at a work station. The locking device  57  employs a cylinder  58  such as a pneumatic cylinder having a push rod  59  that moves between extended and retracted positions. Workstation bracket  60  attaches to pushrod  59 . The workstation bracket  60  is comprised of a pair of spaced apart plates  61 ,  62  having respective slots  64 ,  65 . The workstation bracket  60  employs an ell shaped arm  63  having a shaped plate  66  attached to it. The shaped plate  66  provides a semicircular recess  67  that conforms to the outer surface of lower, external sleeve  35  of pedestal  33 . Shaped place  66  engages sleeve  35  at a position near its joint to base  31 . Inclined plate  69  provides support for fixture bottom plate  39  and thus the upper portion of jig  30  when the jig  30  is inclined in the orientation of  FIG. 8 . 
   The transfer box  70  is shown in detail in  FIGS. 1 and 6 . The transfer box  70  includes a pair of spaced apart tracks  72 ,  73  that are receptive of correspondingly shaped wheels  80  of carriage  71 . Carriage  71  provides a generally rectangular plate  79  to which the wheels  80  are attached at the underside of the plate  79 . A flanged beam  82  is attached to the upper surface of plate  79 . The flanged beam  82  includes spaced apart vertical flanges  74 ,  75  connected with web  76 . Inwardly extending flanges  77 ,  78  help retain fixture  30  during transfer upon rails  72 ,  73 . A stop  81  prevents the fixture  30  from traveling from line channel  12  to carriage  71  and then beyond carriage  71 . The apparatus  10  of the present invention can be manufactured of steel, aluminum or other structurally sound material. 
   The following is a list of parts and materials suitable for use in the present invention. 
   PARTS LIST 
   Part Number Description
           10  furniture assembly apparatus     11  railway     12  line channel     13  return channel     14  cross support brace     15  telescopic let     16  floor     17  channel member     18  flange     19  flange     20  web     21  angle member     22  angle member     23  channel member     24  flange     25  flange     26  web     27  flange     28  flange     29  arrow     30  fixture     31  base     32  wheel     33  pedestal     34  internal sleeve     35  external sleeve     36  connection     38  fixture top plate     39  fixture bottom plate     40  hinge     41  cam lock bracket     42  slot     42 A lateral section     42 B vertical section     43  bolted connection     44  bolted connection     45  flanged connector     46  flange     47  flange     48  opening     49  arrow     50  clamp     51  return spring     52  connection     53  handle     54  arrow     55  arrow     56  space     57  locking device     58  cylinder     59  pushrod     60  work station bracket     61  plate     62  plate     63  ell shaped arm     64  slot     65  slot     66  shaped plate     67  semicircular recess     68  bolt     69  inclined plate     70  transfer box     71  carriage     72  track     73  track     74  flange     75  flange     76  web     77  flange     78  flange     79  plate     80  wheel     81  stop     82  flanged beam     85  wooden frame       

   All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
   The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.