Abstract:
A method and system that allows a user to create patterns for removable furniture covers employs a data input device to trace a piece of furniture. The data input device is traced over predetermined areas of the furniture known to those in the art of furniture cover design. The data input device transfers the trace data to a processor that renders an image of the traced portion of the piece of furniture. The processor permits the user to print off, or output to a cutter, appropriately shaped working patterns to cover the predetermined areas, and to assemble a removable furniture cover or slipcover for the piece of furniture.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Patent Application No. 61/598,989 filed on Feb. 15, 2012. The entire disclosure of the above application is hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates to methods and systems for creating furniture slipcovers and, in particular, a method and a system for generating individual fabric pieces from trace data collected for a specific piece of furniture. 
     BACKGROUND OF THE INVENTION 
     A slipcover is a removable furniture cover generally used in the furniture industry in lieu of fully reupholstering a piece of furniture. A slipcover may be applied to a piece of furniture, for aesthetic purposes, in order to change the appearance, or for functional purposes such as protecting the furniture from degradation. While universal slipcovers are available, they are prone to improper fit which can affect the aesthetics of the slipcover, and make the slipcover more difficult to install on the furniture piece. To achieve an optimal fit, common slipcovers are custom made to ensure they fit a respective furniture piece. 
     Producing a custom slipcover typically requires manual measurement of a furniture piece, creating individual fabric panels based off these measurements, and sewing the fabric panels together. The fabric panels generally correspond to the external surfaces of the respective piece of furniture, such as the arms, back, and seat. This manual process is not exact, and requires a degree of craftsmanship to properly size the individual panels and ensure a clean fit. The process becomes increasingly more difficult as curves and complexities are introduced to the shape of a furniture piece. 
     There is a continuing need for a method and system to improve the manufacture of furniture slipcovers. Desirably, the system allows electronic measurement of a furniture piece and automatically generates the individual panel shapes of the furniture slipcover. The system accounts for curvature and complexities in the furniture piece in determining a proper size and shape of each respective panel. The desirable system improves quality and efficiency, allowing an upholsterer to produce slipcovers in a more cost effective manner. 
     SUMMARY OF THE INVENTION 
     In concordance with the instant disclosure, a method of producing customized slipcovers for individual pieces of furniture, performed by taking electronic measurements of a respective furniture piece and generating an output of the necessary slipcover panel shapes, is surprisingly discovered. 
     In one embodiment, a method for manufacturing a slipcover for a furniture piece includes a step of measuring the furniture piece with a data input device to acquire trace data. A plurality of working patterns is then created for the slipcover from the trace data. A plurality of fabric panels are then cut based upon the working patterns for the slipcover. The fabric panels are assembled to form the slipcover for the furniture piece. 
     In an exemplary embodiment, a method of generating slipcovers involves the upholsterer using a data input device, such as a coordinate measurement machine or an electric stylus, to trace the outer profile of the furniture piece. The upholsterer then transfers this data to a processor that converts the trace data into a digital image of the furniture piece. Using this digital image, the processor will generate the necessary patterns for the fabric panels to be sewn together by the upholsterer. The processor then communicates these patterns to a two-dimensional output, such as a cutter or plotter. Upon cutting the respective panel shapes, the upholsterer then sews the panels together to form the slipcover. 
     In another embodiment, a system for manufacturing a slipcover for a furniture piece, includes a data input device, a memory, and a processor. The data input device is configured to generate trace data indicative of a shape of a surface of the furniture piece. The memory is in communication with the data input device. The memory includes at least one database for receiving the generated trace data. The processor is in communication with the memory. The processor executes instructions to render a plurality of working patterns based upon the trace data from the data input device. 
     In an illustrative embodiment, a system has an electronic coordinate measurement device, a data processor, a two-dimensional output such as a plotter or cutter, and a fabrication device for joining the fabric panels into a completed slipcover. The coordinate measurement device is a handheld electric stylus, capable of recording a trace path along the furniture piece as the upholsterer outlines the profile of the furniture piece&#39;s exterior. The trace paths can be transferred to the processor in real-time, or can be stored on the internal memory of the stylus and transferred at a later time. In this embodiment, the data processor comprises a laptop computer that the upholsterer can take on-site, allowing instantaneous viewing of the trace data as it is taken. Upon transfer of the trace data into the processing program, the program generates a series of two-dimensional working patterns for fabric panels. These patterns are then output to a plotter or cutter to be sewn together by the upholsterer. 
     In another embodiment, a system has an electronic coordinate measurement device, a data processor, a two-dimensional output such as a plotter or cutter, and a fabrication device for joining the fabric panels into a completed slipcover. The coordinate measurement device is a portable coordinate measurement machine comprising an articulated arm with connected to a stylus. The portable coordinate measurement machine is capable of collecting an infinite number of positional coordinates relating to the external profile of the furniture piece external profile, and creating a three-dimensional digital model of the furniture piece. This three-dimensional model is then run through the processor, wherein the processor generates a best-fit slipcover. The processor then further generates the respective panel shapes necessary to construct the slipcover. These panel shapes are then output to a plotter or cutter to be sewn together by the upholsterer. 
     In yet another embodiment, a system has an electronic coordinate measurement device, a data processor, a two-dimensional output such as a plotter or cutter, and a fabrication device for joining the fabric panels into a completed slipcover. The coordinate measurement device is a laser scanner capable of generating a three-dimensional model of the furniture piece by scanning the furniture piece with a laser. This data is then communicated to the processor in a manner similar to that of the previous embodiment. 
    
    
     
       DRAWINGS 
       The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art from the following detailed description, particularly when considered in the light of the drawings described hereafter. 
         FIG. 1  is a schematic block diagram illustrating the components of a system for creating a custom slipcover in accordance with the present disclosure; 
         FIG. 2  is a flow diagram of a method for creating a custom slipcover in accordance with one embodiment of the present disclosure; 
         FIG. 3  is a front perspective view showing an embodiment of the system and method in accordance with the present disclosure; 
         FIG. 4A  is a front perspective exploded view of the components of a slipcover in accordance with an embodiment of the present disclosure; 
         FIG. 4B  is a front perspective exploded view illustrating a fitting onto a furniture piece of a slipcover manufactured in accordance with an embodiment of the present disclosure; and 
         FIG. 4C  is a front perspective view of a slipcover manufactured in accordance with the system and method of the present disclosure, as fitted to the furniture piece. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should also be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. In respect of the methods disclosed, the order of the steps presented is exemplary in nature, and thus, is not necessary or critical. 
     In  FIG. 1 , a system  10  for manufacturing a custom furniture slipcover  54  is shown. The system  10  includes a data input device  12 , a data processor  14 , a memory with instructions  16  embodied thereon, and an output device  18 . 
     In a particular embodiment, the data input device  12  is a handheld electric stylus  20 , as shown in  FIG. 3 . The stylus  20  has the capability to track relative motion of a tip of the stylus  20  using a position sensor  21 . As nonlimiting examples, the motion of the tip of the stylus  20  may be tracked using the position sensor  21  such as an optical sensor or a roller ball. The motion may also be tracked by motion sensors such as accelerometers and gyroscopic devices, e.g., 3-axis MEMS-based gyroscopes. One of ordinary skill in the art may select other methods for detecting motion of the stylus  20 , as desired. 
     An operator  22  uses the stylus  20  to trace an external profile of faces of the furniture piece  24 . The trace paths may then stored in a memory of the stylus  20 . The trace data may be transferred to a personal computer  32  by the operator  22  at a later time, for example. 
     One skilled in the art will appreciate that the memory need not be internal to the stylus  20 , but may also be a remote memory, such as a memory of the personal computer  32  with which the stylus  20  is in real-time communication as trace data is collected. Communication between the stylus  20  and the personal computer  32  may be a hard connection such as universal serial bus (USB) or Ethernet, or may be done wirelessly over Wi-Fi, Bluetooth or any other means wireless data communication. 
     In another embodiment, data input device  12  may be a coordinate measurement machine used to collect three-dimensional location data from the exterior profile of the furniture piece  24 . The coordinate measurement machine may be a six-axis or seven-axis articulable arm, for example, capable of reaching all exterior positions of the furniture piece  24  to create a digital image of the furniture piece  24 . The data input device  12  may also comprise a laser scanner, capable of digitizing the furniture piece&#39;s external profile by scanning the furniture piece  24  with a laser beam. Other types of data input devices  12  may also be employed within the scope of the disclosure. 
     Once trace data is collected by the data input device  12 , it is communicated to the processor  14 . In one embodiment, the data input device  12  has its own data memory capable to storing trace data as it is acquired. The data input device  12  would then be connected to the data processor  14  via a USB. In other non-limiting examples, the data input device  12  may be connected to the data processor  14  via wireless connection such as a WAN, Bluetooth, or RF Chip. It may also be appreciated that the data input device  12  may transmit trace data to the data processor in real-time as the data is collected by the operator  22 . 
     In a particular embodiment, the processor  14  executes instructions embodied on the memory, which memory is a tangible computer readable medium such as a hard disk drive or flash drive, as nonlimiting examples. The instructions, where executed by the processor  14 , facilitates an interpretation of the trace data received from the data input device  12 , and converts the trace data into a digital image of the furniture piece. The digital image may be images of each surface traced, or may be a composite or three dimensional image including all surfaces traced, as desired. The processor  14  then evaluates the digital image and generates working patterns  26  that correspond to the optimally shaped fabric panels  28  necessary to manufacture a slipcover  30 . 
     The operator  22  may also be permitted by the processor and instructions to change the size and shape of working patterns  26  for generating the fabric panels. For example, an operator may wish to allow extra material for trimming after completion of the slipcover  30 . The operator may adjust this setting prior to generating the working patterns  26 . The processor also allows the operator to tweak the generated patterns  26  individually to accommodate variables associated with the preparation of the slipcover  30 . 
     Once the operator  22  is satisfied with the working patterns  26 , the processor  14  will generate instructions  16  to be sent to the output device  18 . In one embodiment, the executed instructions  16  will create the working patterns  26  as a digital drawing format, such as a PDF, JPEG, or TIFF file format. In this embodiment, the working patterns  26  may be communicated to the output device  18  capable of printing or projecting the patterns onto a fabric. The working patterns  26  may also be output as a standard CAD file format to allow the patterns  26  to be loaded into an automatic fabric cutter. 
     There is shown in  FIG. 2  a flow diagram of a method according to the present disclosure. The method starts at circle  37 . From there, the operator  22  executes step  38  by tracing various exterior faces  30  of the furniture piece  24  with the data input device  12 , for example, the stylus  20 . In a particular method the operator  22  collects the dimensional data by tracing the exterior faces  30  of the furniture piece  24  with the stylus  20 . As described hereinabove, the stylus  20  may include a pen-shaped mechanism capable of detecting relative motion as the tip of the stylus  20  is moved along a surface. 
     To collect trace data of the furniture piece  24 , the operator  22  places the tip of the stylus  20  against the surface of the furniture piece which the operator  22  intends to trace. The operator  22  then initiates data acquisition, for example, by pressing a button on the stylus  20 . The operator  22  then moves the tip of the stylus  20  along the boundary  34  of the exterior faces  30 , thus generating trace data for that face of the furniture piece. 
     Upon completion of tracing for a respective surface, the operator  22  terminates data acquisition and the trace data is saved, for example, in either the internal memory of the stylus  20  or in a remote memory of the personal computer  32 . This step  38  is then repeated for each exterior face  30  of the furniture piece  24 . Exterior faces  30  of the seat cushion  25  may also be traced where the operator desires the seat cushion  25  to remain separate from the furniture piece  24 . 
     In another embodiment, the operator  22  may acquire dimensional data in step  38  using a three-dimensional coordinate measurement machine, such as an articulable arm or a laser scanner. Using the articulable arm, the operator  22  will collect a series of coordinates by touching the measuring tip of the arm upon a plurality of determined spaced measurement points on the exterior of the furniture piece  24 . 
     The spacing of the measurement points is dependent on the preference of the operator  22  for more or less precise conceptualization of the shape of the furniture piece  24 . For a complex furniture piece  24 , for example, with elaborate curvature or shapes, the operator  22  will desire a higher concentration of measuring points than would an operator  22  taking measurements off of a simple furniture piece  24  with only flat faces. 
     Once the data collection step  38  is completed, the trace data is communicated from the data input device  12  to the processor  14 . In a particular embodiment, communication between the data input device  12  and the processor  14  may be performed by the operator  22  connecting a USB plug on the data input device  12  to a USB port  35  on the personal computer  32 . In other embodiments, communication between the data input device  12  and the personal computer  32  may be done through a means of wireless communication  36 . 
     In a next step  40  of the method, the processor  14  will convert the respective shapes of the trace data into a composite model of the furniture piece  24 . The operator  22  then adjusts the dimensions of the composite model of the furniture piece  24  to accommodate any errors in the trace data. Once the operator  22  is satisfied with the dimensions of composite model of the furniture piece  24 , the operator  22  submits the model to the processor  14  to generate working patterns  26  for the necessary pieces of the slipcover  54 . The working patterns  26  generated are configured by the processor  14  to provide the slipcover  54  with an optimal fit over the furniture piece  24 . After generation of the working patterns  26  the operator again has the ability to make adjustments to the individual working patterns  26  to accommodate the fabrication process. 
     In the third step  42  of the method, the processor  14  communicates the working pattern  26  data to the output device  18 . In one embodiment, the output device  18  is an automatic fabric cutter  44 . In this embodiment, the operator  22  instructs the processor  14  to record the working patterns  26  as two-dimensional CAD/CAM compatible file formats. The files are then communicated to a CNC program to control the fabric cutter  44 . The fabric cutter  44  cuts all necessary fabric panels  56  from a sheet of fabric and the operator  22  is supplied with all necessary panels of the desired slipcover. 
     One skilled in the art will appreciate that the output device  18  of the third step  42  may alternatively comprise a plotter to which the processor  14  would communicate working pattern  56  shape data in an image format. In this embodiment, the plotter reproduces this shape data on a sheet of paper or directly onto fabric, and the operator  22  would be required to complete step  44  by manually cutting the fabric panels  56  based on the paper forms from the desired fabric. 
     Communication between the processor  14  and output device  18  can be accomplished through numerous means. In a primary embodiment, the processor is provided in a personal computer  32  that is in direct communication with the output device  18 , either through a wired connection  33  or through a wireless communication. In another embodiment, the processor  14  and output device  18  may both be embodied within a single machine, capable of receiving trace data from the data input  14 , processing trace data, and outputting necessary fabric panels  56 . 
     In step  48  of the invented method  28 , the individual fabric panels  56  are sewn together by the operator  22  along their respective edges  58  to create a completed slipcover  54 . The fabricated slipcover  54  is then fitted over the furniture piece  24  in step  50  of the method, and the method is completed  51 . 
       FIG. 4A ,  FIG. 4B , and  FIG. 4C  illustrate the fabrication and installation of a slipcover  54  crafted in accordance with the system and method of the present disclosure.  FIG. 4A  show the plurality of individual fabric panels  56  generated by the output device  18 . These fabric panels  56  are joined along their respective boundaries by the operator  22  to create a completed slipcover  54 , as shown in  FIG. 4B . The completed slipcover  54  is then fitted over the furniture piece  24 . In many situations, a unique slipcover  54  will be crafted for seat cushions  25  of the furniture piece  24 .  FIG. 4C  is illustrative of a completed slipcover  54  as fitted to a respective furniture piece  24 . 
     While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is further described in the following appended claims.