Upholstered furniture

The invention relates to the field of furniture typically described as upholstered furniture and relates to both individual chairs and multiple seats such as sofas, chesterfields, love seats and the like. The furniture comprises a tubular base having wire springs across the upper surface to comprise a seating surface. Supporting material may be glued to the tubular base. Fabric of an upholstered appearance is placed on the base and extends downwardly around the base and then upwardly ending adjacent the spring wires. The fabric is fixed in place by use of staple fasteners such as wire rings adjoining the fabric to the wire springs. Back and side elements are detachably affixed to the base by screws so that the furniture may be knocked down for shipment.

This invention relates to the field of furniture normally described as 
upholstered furniture. Such furniture is basically used for supporting 
individuals in a sitting position and may be of sufficient extent to 
support one person as in a chair or a plurality of persons in which case 
the furniture is identified by such names as a love seat, a chesterfield 
or a sofa. In this patent the term "seating furniture" is used to 
collectively describe all such furniture. 
The traditional structure of seating furniture involves the construction of 
a wooden frame to which suitable springs are added and then the frame is 
upholstered with suitable padding and fabric. The task of upholstering 
such furniture either in the initial manufacture of the furniture or 
rebuilding the furniture after excessive wear is a time consuming and 
expensive procedure involving the use of skilled craftsmen. Typically, 
upholstery is attached to the frame of such furniture by means of tacks, 
nails or the like and the installation of such upholstery on such frames 
is a time consuming and costly procedure. 
Seating furniture, particularly, larger versions capable of seating two or 
more persons are relatively bulky items which are expensive to ship long 
distances. By the nature of typical seating furniture the furniture 
cananot be made in a modular or knock-down fashion as the arms, back and 
base are normally permanently fastened together in the furniture 
manufacturing facility. With such typical furniture the completed chair or 
sofa must be shipped to the selling facility requiring an extensive amount 
of shipping room in view of the nature of the product and the steps that 
must be taken to protect the upholstery during the course of shipping. 
Accordingly, it is an object of this invention to provide a form of seating 
furniture having the comfort and appearance of typical seating furniture 
which does not require the traditional skills and time of upholstery. 
Another object of this invention is to provide seating furniture which is 
readily taken apart or knocked down for shipment between the manufacturing 
facility and the selling facility or between the selling facility and the 
users premises. 
According to the invention, seating furniture is provided comprising a base 
for supporting at least one seat cushion and an element for supporting at 
least one back cushion. There is also provided at least one end element. 
Fastening means are provided for removably securing the back element and 
the end element to the base. The base comprises a plurality of tubular 
members affixed to one another and defining the perimeter of a 
substantially rectangular prism. A plurality of spring wires extend 
between two of the tubular members of the base and comprise a seat cushion 
supporting plane. A sheet of resilient cushioning material is affixed to 
at least one of the tubular members and overlies the plane of spring 
wires. An upholstery fabric overlies at least the plane and the cushioning 
material and has a panel which depends from the plane. The panel extends 
from the plane around at least one of the tubular members of the base and 
extends to an edge which is adjacent the plane. A plurality of staple 
fasteners fasten the panel of the fabric to the base.

In the preferred embodiment illustrated in the figures the seating 
furniture comprises a base portion 10 for supporting one or more seating 
cushions which are illustrated in phantom lines only for purposes of 
clarity of illustration of the structure of the base 10. In addition, the 
furniture comprises an element 12 for supporting one or more back cushions 
which are not illustrated for purposes of clarity in illustrating the 
structure of the element. The furniture further comprises at least one end 
element 14 which may constitute an arm for the furniture. 
The construction of the various components of the furniture is illustrated 
in FIG. 2. Each of the components comprises a plurality of members 
defining a framework. The base portion 10 comprises a plurality of members 
affixed to one another and defining the perimeter of the base portion 
which has the shape of a substantially rectangular prism. The base portion 
comprises four lower members 16, 18, 20 and 22, all lying in substantially 
the same plane. In addition, there are four similar upper members 24, 26, 
28 and 30, and all lying substantially in a second plane. The upper 
members are supported above the lower members by six upstanding members 
32, 34, 36, 38, 40 and 42. All of the members comprising the base are 
advantageously manufactured from square, tubular, metallic members readily 
available. The material is chosen such that these members may be readily 
affixed to one another such as by welding. Of course, it will be obvious 
to those skilled in the art, that any one or more of the various members 
may be made from a single piece of tubing suitably bent to constitute the 
members described herein. 
The upper plane of the base 10 defined by members 24, 26, 28 and 30 
comprises the plane upon which the seat cushions will rest. Standard 
furniture springs 44 extending between the members 24 and 28 serve to 
further comprise this plane. It will be obvious to those skilled in this 
field that the number and placement of such springs is a matter of choice 
depending upon the strength of the springs and the load to be supported by 
the furniture. Advantageously the springs are retained in place by 
down-turned elements of the spring wire which are received in apertures 
drilled in upper surface of members 24 and 28 respectively. 
Members 32 and 40 most readily apparent in FIG. 2, include a series of 
holes extending completely through the tubing for receiving bolts. Member 
32 comprises two holes 46 in the front face and two holes 48 in the side 
face. It will be observed that holes 46 and 48 are each respectively 
offset vertically one from the other in order to permit a bolt to be 
passed horizontally through the member, one through each of the holes 46 
and one through each of holes 48. Similar holes are provided in member 40. 
Member 42 may also have holes 46 if desired. The front upstanding members 
34 and 38 each comprise a pair of holes 48 extending completely through 
the tubular members, in each case in the side face. 
Holes 46 are provided in members 32 and 40 in order that screws may be 
passed through the holes to retain the element for supporting the back 
cushions against the base. Holes 48 are provided for securing end elements 
14 to either end of the base. The manner of attaching the back element and 
one or more end elements will be more readily apparent after describing 
these individual structures. 
The element 12 for supporting the back cushions 12 is clearly shown in FIG. 
2. The element 12 is most readily constructed from a tube bent into a 
downwardly opening U-shape having a substantially horizontal run 50 and 
two downwardly extending runs 52 and 54. The lower perimeter of the 
element comprises a tube 56 welded at either end to the extremity of runs 
52 and 54. For additional support, member 58 is welded to run 50 and tube 
56. Additional such members may be included as length requires. 
The two runs 52 and 54, and, if desired, member 58, are each provided in 
their front facing surface with a pair of apertures 60. These apertures 
advantageously extend substantially horizontally directly through members 
52 and 54. Nuts 62 for receiving threaded fasteners are retained at each 
of the front facing portions of the apertures 60. Such snap-in nuts for 
being retained in such apertures are readily available under the trade 
name SNAP-NUT. Other types of nuts such as wing nuts may be utilized if 
desired. 
The element 12 may be fixed to the base portion 10 by simply passing bolts 
64 horizontally through each of the apertures 46 and threading the bolts 
64 into the nuts 62 received within apertures 60. This is shown in chain 
dotted lines in FIG. 2. Thus, the back element is readily removably fixed 
to the base portion 10. The element 12 should preferably be affixed by at 
least four bolts, more being utilized if length so requires. 
The end elements 14 may be constructed in a manner similar to the back 
element 12. The end element 14 advantageously comprises a downwardly 
opening U-shaped tube having a substantially horizontal run 66 and two 
downwardly extending runs 68 and 70. The lower perimeter of the panel 
comprises a tube 72 welded at either end to the extremities of runs 68 and 
70. The two runs 68 and 70 are each provided in their inwardly facing 
surface with a pair of apertures 74 which extend substantially 
horizontally through the runs. Each aperture contains a similar nut 62. 
The end element 14 may be fixed to the base portion 10 by passing four 
bolts 76 horizontally through each of the four apertures 48 and threading 
the bolts 76 into the nut 62 retained in apertures 74. This is shown in 
chain dotted lines in FIG. 2. Thus, the end element is readily removably 
fixed to the base portion 10. 
The method of covering the structural portions of the furniture will now be 
explained. After metal assembly of base 10 is finished and the spring 
wires 44 are in place, the upper surface of the prism is first covered 
with a supporting web 80 which may be affixed to the upper surface 
comprising elements 24, 26, 28 and 30 so as to extend completely over the 
plane constituted by these four elements and the spring wires. The purpose 
of the supporting web is to cover the springs and to provide support for 
the subsequent layers of material. It is suggested that in most cases the 
supporting web be affixed to the base by gluing the web to the elements 
24, 26, 28 and 30. Examples of particularly suitable materials for the 
supporting web include the sheet products identified by the Dupont Company 
as FABRINE and TY. 
After the sheet of supporting web 80 is in place, a synthetic foam 
cushioning material 82 is used to cover the upper surface and the frontal 
portion of the base 10. The cushioning material may be polyurethane foam 
or the like. This material is retained in place by gluing to the 
supporting web 80 or to the various members of the base. The material is 
shown in partial section in FIG. 2. 
In order to provide the base with an upholstered appearance without 
actually undertaking the usual steps of upholstery a sheet of fabric 
comprising an upper panel 84 and a depending panel 86 is prepared. The 
fabric shown in FIGS. 3, 4 and 6 comprises a fabric having the appropriate 
appearance of the finished furniture. At least the panel 86 of the fabric 
84 which will rest against members 34, 36 and 38 will comprise a pleasing 
upholstered appearance. It is suggested that the remainder of the fabric 
also be manufactured of the same material, although this is optional. 
From review of FIGS. 3, 4 and 6, it will be apparent as to how the fabric 
is attached to the base element 10. The fabric extends forwardly from the 
vicinity of the member 24 across the plane comprised by the spring wires. 
The fabric having the desired appearance extends over element 28 and down 
the front of the sofa. The fabric then traverses around element 20 and 
extends up the rear of the front panel of the base terminating in an edge 
which is located closely adjacent to the plane comprised of the spring 
wires. 
The edge of the depending panel comprises a flap which extends back and 
which is sewn to the panel to comprise two longitudinal pockets 88 
extending along the edge of the fabric on either side of member 36. A 
reinforcing rod 90 is contained within the pocket 88. The reinforcing rod 
may comprise a straight spring wire or the like. The reinforcing rod 90 is 
closely adjacent to a plurality of the spring wires 44. 
As shown in FIGS. 4 and 6 the fabric is attached to the base by use of 
staple fasteners 92. The term, :staple fasteners" as used in this 
disclosure and claims is intended to cover looped wire fasteners of the 
type which are formed into a closed loop by a machine such as a stapler or 
the like and which retain their folded over configuration after 
installation. Such staples are often referred to in the furniture industry 
as "hog rings". Equipment is readily available for the installation of hog 
rings. 
The reinforcing rod 90 and pocket 88 at the edge of the depending panel 
comprise the attachment point for the fabric to the base 10. A similar 
configuration is used to attach the upper rearward portion of the fabric 
84 to the base. By reference to FIG. 6 it will be observed that the fabric 
84 extends downwardly around member 24 passing under that member and then 
back upwardly to the vicinity of the plane comprised of the spring wires 
44. A similar pocket 88 is provided at this edge of the fabric material 
and a reinforcing bar 90 is inserted in the pocket 88. Staple fasteners 92 
are used to attach this reinforcing bar to the spring wires 44 thereby 
permanently affixing the fabric to the base. 
In order to assure that the fabric remains tightly in placae it is 
desirable in most cases that the fabric 84 be fastened to the base at each 
end. Thus the fabric 84 extends around member 26 and member 30 at each end 
and then passes upwardly to the vicinity of the plane comprised of the 
spring wires. A similar reinforcing bar 90 is inserted into pockets 88 at 
each end and additional staple fasteners 92 are used to clip the fabric 84 
to the spring wires 44. 
If desired the depending panel 86 may comprise a flap 87 to extend along 
the side of the base to provide a finished appearance to the front 
corners. The panel is provided with apertures 89 to accommodate bolts 76. 
From reference to FIG. 6 it will be appreciated that the urethane foam may 
extend across the seating portion and down the front of the base, if 
desired. 
The method of covering the back element 12 and the end element 14 is 
essentially similar. The method will be explaned with reference to the end 
element 14. 
The end element 14 is first covered by passing an envelope 100 of FABRINE 
or TY downwardly over the bent tubular member 66, 68 and 70. This 
fabric is strong enough to provide the support for any cushions supported 
by the end elements 14. Next an envelope 102 comprised of synthetic foam 
cushioning material is passed downwardly over the first envelope 100. 
Lastly, an envelope 104 of fabric having an upholstered appearance is 
passed downwardly over the first and second envelopes. 
Envelope 104 illustrated in FIG. 5 comprises a zipper 106 along its lower 
edge for retaining the envelope in place. The envelope also comprises four 
button holes 108 which are located so as to exactly overlie the apertures 
74 in the runs 68 and 70. The envelopes of FABRINE or TY and of 
synthetic foam also comprise suitable openings overlying apertures 74. 
These openings and the button holes provide unimpeded access of bolts 76 
to nuts 62. The zipper 106 when closed will constitute the lower surface 
of the envelope covering the element 12 and hence is not readily visible 
even from the side of the seating furniture. Closure means other than 
zippers may also be used, if desired. 
The back element 12 is essentially similar to the end element 14. The 
"button" holes in the envelopes covering the back element must overlie the 
apertures 60 in order to permit unimpeded access of bolts 64 to nuts 62. 
It will be noted that there is no requirement for either the back element 
12 or the end element 14 to be planar. The only requirement is that the 
apertures 60 and 46 must be adjacent and also apertures 74 and 48 must be 
adjacent. Above the apertures 46 the end element 14 may curve or extend 
angularly away from the base if this should be desired by the designer. 
Similarly, above the apertures 48 the end element 14 may curve or extend 
angularly away from the base as may be desired by the designer. Similarly, 
the fabric material of the end element 14 may also comprise any form of 
additional cushions, covers or the like sewn thereto to comprise arm 
cushions, all as may be desired by the designer. One such example of an 
integral cushion forming part of the envelope 104 is illustrated in FIG. 
5. Additional or other forms of arm cushions placed on the end panel 14 
may also be used. 
In the embodiment shown in the drawings the fabric of the base portion does 
not extend over the rear surface of the prism nor over either end surface. 
It is envisaged that an end element would be used on either end and thus 
there is no need for fabric at the sides. However, if it is desired to 
produce furniture having only one end element then the fabric covering the 
base portion is provided with a depending panel which extends downwardly 
to cover in the side in a manner identical with that described in 
association with the front portion of the base. Such a panel would also 
have a pocket containing a reinforcement rod and staple fastners affixing 
the panel to the base in the vicinity of the plane comprised by the spring 
wires 44. 
In the embodiment illustrated in FIG. 1 the base 10 rests upon the floor 
and the end portion 14 extends to the floor. It should be understood 
however that it is not necessary that the base 10 sit on the floor nor 
that the end or back elements necessarily terminate flush with the lower 
surface of the base. The lower surfaces of elements 16, 18, 20 and 22 of 
the base may be provided with any suitable means of socket for receiving 
legs, feet, pads or the like as the designer may wish. Alternatively, the 
height of the base may be such that the base does not reach to the floor 
and the support from the floor is comprised of two end elements 14 which 
may extend below the base to the desired amount. Within the structure 
illustrated and claimed herein substantial freedom is offered to the 
designer to give the seating furniture any desired appearance and 
proportion. 
When it is desired to support the base on two end elements, it is suggested 
that the construction of the end elements would have to be slightly 
modified to provide the required additional strength. This may be 
accomplished by using heavier gauge materials or by using additional 
bracing and tubular elements. If desired for appearances sake, the end 
elements may be manufactured from wood or the like rather than using the 
upholstered tubular configuration described above. Complete freedom of end 
element or arm configuration is provided to the designer who is 
constrained only to have the mounting holes aligned with those of the 
base. 
Although not absolutely necessary, it is suggested that with preferred 
embodiments loose or fitted cushions be used both on the upper surface of 
the base 10 as seat cushions and on the forward surface as pictured in 
FIG. 1 of the back element 12 for supporting back cushions. The shape and 
number of such cushions is a matter of choice for the furniture designer. 
It will be appreciated that a unique furniture structure has been provided. 
The structure results in seating furniture which has the appearance of 
being upholstered while not requiring the skills of the traditional 
upholsterer. The finished product is easily assembled and disassembled for 
shipment and/or repair and recovering. In addition, the furniture is 
particularly light being manufactured from tubular metallic materials 
while still possessing all of the requisite strength for long life and 
high quality. Within the structure disclosed herein the designer has 
almost unlimited freedom for the appearance of the finished product, and 
accordingly, the structure is available for use with a wide range of 
seating furniture. 
Finally, it should be realized that with the design provided, assembly and 
disassembly may be readily accomplished by unskilled labour. All that is 
required is the insertion of bolts into the apertures described which may 
then be tightened in place. It should also be appreciated that the 
furniture itself can be manufactured using jig welded arrangements to 
fabricate the base portion. The fabrics when properly cut need only be 
sewn to comprise the pockets as described and unskilled labour can quickly 
assemble the fabric to the base using a hog ring gun or similar staple 
fasteners.