Furniture designed for sitting and having inner core support assembly

An article of furniture has a sitting portion inner core assembly. The inner core assembly has a frame for providing structural support. Vertical bars connect lower and upper portions of the frame. Horizontal bars connect opposite sides of an upper portion of the frame. Alternative, the upper support structure of the frame uses box springs, free-floating horizontal bars with springs, or a mesh pattern for the structural support of the top portion of the inner core assembly. A cloth or foam pad covering is disposed along a side portion and top portion of the inner core assembly. A fabric material is disposed over at least the side and top coverings and inner core assembly. A back support inner core assembly with back support bars connect to the sitting portion inner core assembly and provide structure support of the back support portion of the furniture.

CROSS REFERENCE TO RELATED US PATENT APPLICATION(S)

The present patent application is related to copending U.S. patent application Ser. No. 11/059,211, filed Feb. 15, 2005, entitled “Composite Assembly of Interconnectable Furniture” and filed concurrently herewith by Theresa A. Mulmed. The present patent application is further related to copending U.S. patent application Ser. No. 11/059,162, filed Feb. 15, 2005, entitled “Furniture with Seating Space and Entertainment Center” and filed concurrently herewith by Theresa A. Mulmed.

FIELD OF THE INVENTION

The present invention relates in general to furniture designed and constructed for sitting purposes and, more particularly, to sitting furniture having an inner core support assembly.

BACKGROUND OF THE INVENTION

Furniture designed for sitting and lounging can be found in a myriad of usages and applications. Sitting furniture has uses in the home, business, and outdoor settings. In one example, outdoor furniture is placed on the patio, under the gazebo, and around the pool to create functional spaces for entertaining and relaxing.

Some types of outdoor furniture has a thick foam cushion or pad, e.g., 10–12 inches thick, and enclosed in a durable fabric. The extra thick cushion makes the furniture very comfortable for sitting purposes. The fabric has qualities of being sunlight resilient, water repellant, and washable. The thick fabric-enclosed cushion is often placed on a solid wooden or metal base.

Sitting furniture constructed as described above is generally satisfactory when the piece is relatively new. However, over time and usage, and in the presence of outdoor elements including extreme heat and cold, such furniture tends to fatigue and fail. The foam cushion breaks down and loses its ability to support weight. The fatigue problem is particularly true of larger and thicker cushions along the edges and corners. When a person sits on the older furniture, the cushion no longer provides the same level of support as it did when it was new. The cushion will lose its shape and depress beyond the point of comfort for the user. Ultimately, the sitting furniture will have to be repaired or replaced, typically long before the end of its intended service life. In some cases, the cushion-based outdoor furniture may have to be replaced after only one or two seasons of use.

A need exists for furniture designed and constructed for sitting, which maintains its shape and support features over time and usage, including in the presence of outside elements.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is an article of furniture designed for sitting purposes, comprising a first inner core assembly. A side covering is disposed along a side portion of the first inner core assembly. A top covering is disposed over a top portion of the first inner core assembly. A fabric material is disposed over at least the side covering and the top covering.

In another embodiment, the present invention is an article of furniture, comprising an inner core assembly. A padded covering is disposed over a portion of the inner core assembly. A first fabric material is disposed over at least the padded covering and the inner core assembly.

In another embodiment, the present invention is an article of sitting furniture, comprising a first inner core assembly having a frame and upper support structure connected to the frame. A padded covering is disposed over a portion of the first inner core assembly. A first fabric material is disposed over at least the padded covering and the first inner core assembly.

In another embodiment, the present invention is a method of making an article of furniture, comprising providing a first inner core assembly, disposing a padded covering over a portion of the first inner core assembly, and disposing a first fabric material over at least the padded covering and the first inner core assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring toFIG. 1, an article of furniture10is designed for sitting purposes and shown as suitable for supporting the weight of one or more adult persons. Furniture10is useful for many applications including home, office, industry, and outdoor spaces. Furniture10is durable, inexpensive, and may be used in settings such as office waiting rooms, employee break rooms, and family room in the home. Furniture10is ideal for outdoor uses such as on the patio, under the gazebo, and around the pool for relaxing and entertaining.

Sitting furniture10has legs12which are an integral component of a sitting portion inner core assembly (not shown inFIG. 1) as described more fully below. Sitting portion14is generally rectangular in shape, although circular, oval, and other regular and irregular shapes may be utilized. Sitting portion14includes cloth pads or cushions laid along and over the sides and top of the inner core assembly. In one embodiment, sitting portion14is 36 by 36 inches. A durable exterior fabric encloses at least the side and top pads and inner core assembly. The exterior fabric material is water proof, washable, and resistance to sun exposure and other outside elements.

As shown inFIG. 1, furniture10has back support bars16extending from the sitting portion inner core assembly to back support portion18. The back support bars16are angled to provide lumbar support. The back support portion18also has a back support inner core assembly (not shown inFIG. 1) as described below. A cloth pad or cushion surrounds the back support inner core assembly. The back support portion18is cylindrical in shape, although it may be rectangular or take other forms and shapes.

Another embodiment of the sitting furniture is shown inFIG. 2. Sitting furniture20is shown as a bench or lounge and can provide seating space for multiple persons. In one embodiment, furniture20is 36 by 90 inches. Furniture20may include one or more back support portions (not shown) similar toFIG. 1placed along one or both ends22or lengthwise side24. The back support portion allows the user to recline or lounge on furniture20. Furniture20has an irregular or contoured lengthwise side24. Furniture20has a similar sitting portion inner core assembly and cloth pads or cushions laid along and over the sides and top of the sitting portion inner core assembly. A similar durable fabric encloses at least the side and top pads and inner core assembly of furniture20.

Yet another embodiment of the sitting furniture is shown inFIG. 3. Sitting furniture30is shown as a sectional surrounding decorative center feature32. The seating area provides ample space for multiple persons. Decorative center feature32can be a table or box for holding or containing items such as plants, artwork, pictures, decorations, fountain, fire pit, rock garden, food and beverages, entertainment center, and the like.

Furniture30uses four lower assemblies34and four upper assemblies36surrounding decorative center feature32. Each lower assembly34has a sitting portion inner core support assembly. One or more thin cloth pads are disposed along and over the sides and top of each lower assembly34. The lower assembly34is then covered with a fabric material. There are four upper assemblies36, each having an interior cushion which is covered with a fabric exterior. The upper cushion assemblies36are placed on the lower assemblies34and may be held in place with Velcro. In one embodiment, the upper cushion assemblies36are offset over adjacent lower assemblies34. The upper cushion assemblies36are easily removable for cleaning and maintenance. Furniture30may include one or more back support portions (not shown) similar toFIG. 1.

One embodiment of the sitting portion inner core support assembly is shown inFIG. 4. The inner core assembly40, or variation thereof as described below, may be used in sitting furniture10,20, and30. The inner core assembly40has a box frame structure42made with interconnected bars as shown. Frame structure42has integral legs or base supports43designed to provide sturdy contact with the ground. A plurality of vertical bars45connect between upper and lower bar components of box frame42on each side of inner core assembly40. A plurality of horizontal bars46connect opposite sides of the upper portion of box frame42. The horizontal bars46may run either direction, diagonally, or criss-cross the upper portion of box frame42.

In one aspect, the horizontal bars46provide a structural weight-bearing support across the horizontal upper portion of the inner core assembly40. However, it is the combination of box frame42with vertical bars45and horizontal bars46that provide the composite structural weight-bearing support of the inner core assembly40. The inner core assembly40can be made of metal, wood, polymer, or other weight-bearing material. The inner core assembly40is sufficiently rigid and sturdy to support the weight of one or more adult persons without noticeable bending or deformation. The structure of the inner core assembly40maintains its shape and rigidity beyond the useful service life of the sitting furniture.

FIG. 5illustrates the back support inner core assembly47forming the interior assembly of back support portion18. The inner core assembly47is shown as being cylindrical in shape with circular end and center components48and connecting bars49. The inner core assembly47can be made of metal, wood, polymer, or other weight-bearing material. Back support bars16connect between box frame42and inner core assembly47. The structure of the inner core assembly47maintains its shape and rigidity beyond the useful service life of the sitting furniture.

Another embodiment of the sitting portion inner core assembly is shown inFIG. 6. The inner core assembly50has a box frame52with integral legs or base supports54similar to inner core assembly40. A plurality of vertical bars56connect between upper and lower bar components of box frame52on each side of inner core assembly50. A plurality of interconnected box springs58connect to the upper and lower portions of box frame52.

The box springs58provide weight-bearing support for the horizontal upper portion of the inner core assembly50. The combination of box frame52, vertical bars56, and springs58provide the composite structural weight-bearing support of the inner core assembly50. As described for inner core assembly40, back support bars16connect between box frame52and inner core assembly47. The inner core assembly50can be made of metal, wood, polymer, or other weight-bearing material. The inner core assembly50is rigid to support the weight of one or more adult persons without noticeable bending or deformation. The structure of the inner core assembly50maintains its shape and rigidity beyond the useful service life of the sitting furniture.

Another embodiment of the inner core assembly is shown inFIG. 7. The inner core assembly60has a box frame62with integral legs or base supports64similar to inner core assembly40. A plurality of vertical bars66connect between upper and lower bar components of box frame62on each side of the inner core assembly60. A plurality of free-floating horizontal bars with connecting springs68mount to the upper bar components of box frame62.

The free-floating bars with connecting springs68provide the weight-bearing support for the horizontal upper portion of the inner core assembly60. The combination of box frame62, vertical bars66, and free-floating horizontal bars with connecting springs68provide the structural weight-bearing support of the inner core assembly60. As described for inner core assembly40, back support bars16connect between box frame62and inner core assembly47. The inner core assembly60can be made of metal, wood, polymer, or other weight-bearing material. The inner core assembly60is rigid to support the weight of one or more adult persons without noticeable bending or deformation. The structure of the inner core assembly60maintains its shape and rigidity beyond the useful service life of the sitting furniture.

Yet another embodiment of the inner core assembly is shown inFIG. 8. The inner core assembly70has a box frame72with integral legs or base supports74similar to inner core assembly40. A plurality of vertical bars76connect between upper and lower bar components of box frame72on each side of the inner core assembly70. A mesh or weave support pattern78connects to multiple points on the upper bar components of box frame72.

The mesh or weave pattern78provides weight-bearing support for the horizontal top portion of the inner core assembly70. The combination of box frame72, vertical bars76, and mesh or weave78provide the structural support of the inner core assembly70. The mesh or weave pattern78can be made with cloth material or plastic or metal straps. As described for inner core assembly40, back support bars16connect between box frame72and inner core assembly47. The inner core assembly70is rigid to support the weight of one or more adult persons without noticeable bending or deformation. The structure of the inner core assembly70maintains its shape and rigidity beyond the useful service life of the sitting furniture.

The inner core assembly40is shown again inFIG. 9, although any one of the inner core assemblies described above could be used as well. The sides of inner core assembly40are covered with cloth pad or foam cushions80. The cloth pad or foam cushion side coverings80may be 1–2 inches in thickness. A cloth pad or foam cushion top covering82is disposed over the horizontal top portion of the inner core assembly40. In one embodiment, the cloth pad or foam cushion top covering82may be 5–6 inches in thickness. The top and side coverings are designed for comfort of the user.

In one embodiment, such as for sitting furniture10and20, the structure of the sitting portion inner core assembly40, side coverings80, and top covering82are enclosed, at least on the sides and top, with a durable fabric material suitable for outside use. Likewise, the structure of the back support inner core assembly47and pad covering over the inner core assembly47are enclosed with a similar durable fabric material. Accordingly, the sitting portion inner core assembly and back support inner core assembly mentioned inFIG. 1are illustrated and described inFIGS. 4–9. The exterior fabric provides a visually appealing and durable surface against outside elements. The exterior fabric also functions to hold the inner core assembly and cloth pads or foam cushions of the sitting portion and back support portion together as a tight assembly and single unit. The exterior fabric provides a protective covering which can withstand outside elements and be easily cleaned and maintained.

In another embodiment, such as for sitting furniture30, the inner core assembly40and padded cloth side coverings80are enclosed within a first durable exterior fabric material. The cloth pad or foam cushion top covering82is covered with a second durable exterior fabric material. The first and second exterior fabric coverings provide a visually appealing surface and functions to hold together the inner core assembly and/or cloth pads or foam cushions, as well as provide protective covering for furniture against outside elements.

FIG. 10shows a bottom side view of sitting furniture10. The bottom side of sitting furniture10may be open as shown or covered with thin fabric material. The side covering80are disposed on each of the four sides of the inner core assembly40. The top covering82is shown disposed over the top area of the inner core assembly40.

The inner core assembly described above provides significant advantages for sitting furniture, particularly of the type used in outdoor settings. The inner core assembly is rigid and maintains its shape over time and in the presence of the outside elements. The inner core assembly prevents the sitting cushions used in outdoor sitting furniture from sagging and permanently fatiguing as found in furniture using a thick cushion alone. The outdoor sitting furniture maintains its shape and support and provides years of usage without noticeable deformation.