Abstract:
A material application system for applying a panel of material to a framework with a shoe for retaining the framework, a nest, opposed mechanisms for retaining opposite portions of the panel of material traversing between the shoe and the nest, an arrangement for selectively moving the shoe and the nest into and out of an engaged position wherein the panel of material is sandwiched between the shoe and the nest and a disengaged position, and an arrangement for inducing an attachment of the panel of material to the framework. The opposed mechanisms can be clamping mechanisms, which can be segmented and individually moveable to enable variable pretensioning. A contoured deflection control member can alternatively produce variable pretensioning. A pressing arrangement with a tooth member can press a locking spline into a groove in the framework to secure the material.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to fabric application systems and methods. More particularly, disclosed and protected herein are systems and methods for the application of elastomeric materials. 
     BACKGROUND OF THE INVENTION 
     In traditional upholstered furniture construction, a layer of fabric, commonly referred to as any “A” layer, is retained relative to a frame structure overlying one or more subsurface layers, commonly referred to as “B”, “C”, and possibly further layers. The subsurface layers, which can comprise additional fabric layers, foam layers, springs, bands, and the like, generally provide continuous support to the “A” layer. As such, the “A” layer itself need only be attached to the frame structure; it need not provide substantial support. With this, attachment methods for “A” layers in such structures commonly involve simple stapling, adhering, or the like. 
     More recently, furniture constructions have been developed wherein one or more panels of fabric span a framework with no central support. Commonly, the fabric comprises an elastomeric material, such as an elastomeric mesh material. Since the fabric panel acts as the sole means of support to furniture occupants and the like, the peripheral edges of the fabric panel must be attached particularly securely. 
     Attempting that that secure attachment presents unique challenges to the furniture maker. This is particularly the case relative to elastomeric materials and especially so relative to elastomeric mesh materials. For example, for optimal appearance and performance, elastomeric materials normally must be pretensioned and secured in place while maintaining that pretensioning. 
     Additionally, since elastomeric material, particularly elastomeric mesh, is formed by numerous individual elastomeric filaments, continuous support must be provided over substantially the entire periphery of the fabric panel to ensure that each elastomeric filament is fixedly retained. Even further still, it can be desirable to provide different support characteristics relative to different areas of the panel of elastomeric material, which may demand a variable pattern of pretensioning, thereby further complicating the attachment process. 
     Prior art methods and structures have struggled in seeking to confront the aforementioned and further challenges of applying a fabric panel to a framework. Many attachment methods and systems have proven to be undesirably inefficient. Other methods and arrangements have failed to provide adequate retention of the fabric panel. Still further, particularly since the fabric panel acts as the sole means of support to furniture occupants and the like, it has been found that many prior art attachment arrangements have left the fabric panel and the edges thereof disadvantageously vulnerable to dislodging, damage, and tampering. Also, many prior art structures and methods are unable to adapt to varied framework structures. 
     These and further disadvantages have heretofore prevented elastomeric material application methods and arrangements from achieving widespread use and commercial success. As a result, it is clear that there remains a discernable need for systems and methods for the application of elastomeric materials that meets the needs and overcomes the disadvantages that have been left by the prior art. 
     SUMMARY OF THE INVENTION 
     Advantageously, the present invention is founded on a basic object of overcoming the disadvantages suffered by the prior art while providing a number of previously unrealized advantages thereover. 
     A more particular object of embodiments of the invention is to provide systems and methods for applying material to a framework in an efficient and effective manner. 
     Another object of the invention is to provide systems and methods for applying material to a framework to be retained securely thereby. 
     A related object of embodiments of the invention is to provide systems and methods for applying material to a framework to enable substantially continuous support over at least a portion of a periphery of a fabric panel to provide a reliable retention of individual fibers forming the fabric panel. 
     Another object of particular embodiments of the invention is to provide systems and methods for applying material to a framework that enables a selective pretensioning of the fabric, including with a variable pretensioning pattern. 
     These and in all likelihood further objects and advantages of the present invention will become obvious not only to one who reviews the present specification and drawings but also to those who experience an embodiment of the systems and methods for applying material to a framework disclosed herein. However, it will be appreciated that, although the accomplishment of each of the foregoing objects in a single embodiment of the invention may be possible and indeed preferred, not all embodiments will seek or need to accomplish each and every potential advantage and function. Nonetheless, all such embodiments should be considered within the scope of the present invention. 
     In carrying forth these objects, one embodiment of the present invention for a material application system for applying a panel of material to a framework includes a shoe for retaining a framework to which the panel of material is to be applied, a means for retaining the framework relative to the shoe, a nest, a means for retaining the panel of material traversing between the shoe and the nest, a means for selectively moving the shoe and the nest into and out of an engaged position wherein the panel of material is sandwiched between the shoe and the nest and a disengaged position, and a means for inducing an attachment of the panel of material to the framework. 
     The means for retaining the panel of material between the shoe and the nest can take the 4 form of opposed mechanisms for retaining opposite portions of the panel of material. Means can be provided for selectively moving at least one of the opposed mechanisms proximally and distally relative to the other whereby a pretensioning of the panel of material can be induced. In certain embodiments, there can be longidutinally opposed mechanisms and laterally opposed mechanisms. While many types of opposed retaining mechanisms would readily occur to one skilled in the art, the opposed mechanisms can comprise clamping members. 
     In certain embodiments, the material application system can additionally incorporate a means for inducing a varied pretensioning of the panel of material. That means could vary widely within the scope of the invention. In one embodiment, the means could be achieved by a segmenting of at least one of the opposed mechanisms for retaining opposite portions of the panel of material. For example, where the opposed mechanisms comprise clamping arrangemens, at least one of the clamping arrangements can be segmented into multiple, individually moveable clamping arrangements. 
     Alternatively, the means for inducing a varied pretensioning of the panel of material can take the form of a deflection control member in combination with a means for retaining the deflection control member with at least a portion thereof interposed between the opposed mechanisms for retaining opposite portions of the panel of material and the shoe and the nest. The deflection control member can have a surface that varies in effective height to yield a varied pretensioning in the panel of material when the shoe and the nest are in an engaged position. 
     The framework can have a groove therein and a locking spline can be received into the groove with a portion of the panel of material disposed therebetween thereby to secure the panel of material relative to the framework. In such a case, the means for inducing an attachment of the panel of material to the frame member can comprise a means for pressing the locking spline into the groove. That means could in one embodiment comprise a pressing arrangement with a tooth member and a means for reciprocatably driving the tooth member. There can additionally be a means, such as a rail contoured to match a contour of the framework, for enabling the tooth member to travel along an edge of the framework to enable a progressive pressing of the locking spline into the groove. 
     The framework and the shoe can each be considered to have a peripheral edge. The peripheral edges of the framework can project beyond the peripheral edges of the shoe relative to the nest. With this, the peripheral edges of the framework will tend to make first contact with the nest when the shoe and the nest are in an engaged position such that a mutual frictional engagement will be achieved between the framework, the panel of material, and the nest. To facilitate that frictional engagement, the nest can have an engaging surface sized, shaped, and contoured to correspond to the size, shape, and contour of a peripheral surface of the frame member. An O-ring can be disposed along the engaging surface. 
     One will appreciate that the foregoing discussion broadly outlines the more important features of the invention to enable a better understanding of the detailed description that follows and to instill a better appreciation of the inventor&#39;s contribution to the art. Before any particular embodiment or aspect thereof is explained in detail, it must be made clear that the following details of construction, descriptions of hardware and software designs, and illustrations of inventive concepts are mere examples of the many possible manifestations of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the accompanying drawing figures: 
         FIG. 1  is a perspective view of an elastomeric material application system according to the present invention; 
         FIG. 2  is a perspective view of a nest and clamping portions of the elastomeric material application system of  FIG. 1 ; 
         FIG. 3  is a top plan view of the elastomeric material application system of  FIG. 1 ; 
         FIG. 4  is a view in rear elevation of pressing and clamping arrangements pursuant to the present invention; 
         FIG. 5  is a view in front elevation of the pressing and clamping arrangements of  FIG. 4 ; 
         FIG. 6  is a view in rear elevation of pressing and clamping arrangements according to the present invention in combination with a rail for enabling a traveling of a hook member of the pressing arrangement; 
         FIG. 7  is a further view in front elevation of pressing and clamping arrangements pursuant to the present invention; 
         FIG. 7A  is a view in front elevation of a deflection control member according to the present invention; 
         FIG. 8  is a view in front elevation of an elastomeric material application system in a first stage of material application; 
         FIG. 9  is a view in front elevation of the elastomeric material application system of  FIG. 8  in a second stage of material application; 
         FIG. 10  is a view in front elevation of the elastomeric material application system of  FIG. 8  in a third stage of material application; 
         FIG. 11  is a view in front elevation of the elastomeric material application system of  FIG. 8  in a fourth stage of material application; 
         FIG. 12  is a view in front elevation of the elastomeric material application system of  FIG. 8  in a fifth stage of material application; 
         FIG. 13  is a view in side elevation of an elastomeric material application system pursuant to the present invention; 
         FIG. 14  is a view in front elevation of an elastomeric material application system according to the present invention configured for pressing a locking spline into a lateral groove; 
         FIG. 15  is a graphical depiction of unaltered initial tensioning of a panel of elastomeric material; 
         FIG. 16  is a graphical depiction of lateral east and west support zones of a panel of elastomeric material; 
         FIG. 17  is a graphical depiction of longitudinal north and south support zones of a panel of elastomeric material; 
         FIG. 18  is a perspective view of a segmented clamping arrangement pursuant to the present invention; 
         FIG. 19  is a perspective view of a frame member with segmented locking splines in a first stage of manufacture; and 
         FIG. 20  is a perspective view of the frame member of  FIG. 19  in a second stage of manufacture. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The elastomeric material application systems and methods disclosed herein are subject to a wide variety of embodiments. However, to ensure that one skilled in the art will be able to understand and, in appropriate cases, practice the present invention, certain preferred embodiments of the broader invention revealed herein are described below and shown in the accompanying drawing figures. Before any particular embodiment of the invention is explained in detail, it must be made clear that the following details of construction, descriptions of geometry, and illustrations of inventive concepts are mere examples of the many possible manifestations of the invention. 
     Looking more particularly to the drawings, an embodiment of an elastomeric material application system according to the present invention is indicated generally at  10  in  FIGS. 1 through 3 . The elastomeric material application system  10  has a rectangular frame  12  that is supported by a plurality of legs  14 . The frame  12  has first and second support posts  16 A and  16 B that retain a header  18 . A shoe  20  is reciprocatably retained relative to the header  18  by a reciprocating means  34 , which in this case comprises a piston arrangement  34 . A nest  22  is supported by a cross member  15 . 
     In this exemplary embodiment, the shoe  20  and the nest  22  are generally rectangular. The shoe  20  and the nest  22  are identically oriented relative to one another and are catercorner relative to the plane of the rectangular frame  12 . With that, first and second adjacent sides of the shoe  20  and the nest  22  are disposed to a first side of the rectangular frame  12  and second and third adjacent sides of the shoe  20  and the nest  22  are disposed to a second side of the rectangular frame  12 . A plurality of control knobs  28  are disposed along the cross member  15 . A control box  30 , which houses system circuitry and certain control mechanisms, is disposed below the cross member  15  to a first side of the shoe  20  and nest  22 . A hydraulics box  30 , which houses system hydraulics and certain control mechanisms, is disposed below the cross member  15  to a second side of the shoe  20  and nest  22 . 
     Turning more particularly to  FIG. 2 , one sees that first and second opposed clamping arrangements  24 A and  24 B are respectively disposed to opposed longitudinal north and south sides of the nest  22  and third and fourth opposed clamping arrangements  24 C and  24 D are respectively disposed to opposed lateral east and west sides of the nest  22 . A first pressing arrangement  26 A is slidable along the north side of the nest  22  along a first rail arrangement  40 A while second, third, and fourth pressing arrangements  26 B,  26 C, and  26 D are respectively slidable along the south, east, and west sides of the nest  22  along second, third, and fourth rail arrangements  40 B,  40 C, and  40 D. As is shown relative to the second pressing arrangement  26 B, each pressing arrangement  26 A,  26 B,  26 C, and  26 D receives power through a power supply line  38 , which can be electric, hydraulic, or any other effective type. 
     As is shown relative to the second clamping arrangement  24 B, each clamping arrangement  24 A,  24 B,  24 C, and  24 D is reciprocatable proximally and distally relative to the nest  22  by operation of a clamp translation mechanism  42 , which is shown relative to the second clamping arrangement  24 B. The clamp translation mechanism  42  can comprise a clamp translation piston, which is also indicated at  42 . As is also shown relative to the second clamping arrangement  24 B, each clamping arrangement  24 A,  24 B,  24 C, and  24 D is capable of being opened and closed by operation of a clamp opening and closing mechanism  36 , which can comprise a clamp opening and closing piston  36 . Of course, plural other translation mechanisms  42  and opening and closing mechanisms  36  would readily occur to one skilled in the art after reading this disclosure. Each such mechanism is within the scope of the present invention. 
     While the elastomeric material application system  10  certainly could be fully automated, the present embodiment of the invention can be operated manually as is depicted in  FIG. 3 . By exploitation of the rectangular nature of the frame  12  and the catercorner orientation of the shoe  20  and nest  22  relative thereto, a manual operation of the elastomeric material application system  10  can be readily carried out by two persons  100 A and  100 B disposed to first and second sides of the frame  12 . More particularly, a first person  100 A can operate relative to, for example, the north and west sides of the nest  22  while the second person  100 B can operate relative to, for example, the south and east sides of the nest  22 . Under one embodiment, this can be carried out advantageously be a pivotable seat arrangement (not shown) for each person  100 A and  100 B such that each can pivot between a first position aligned with a first side of the nest  22  and a second position aligned with a second side of the nest  22 . 
     By combined reference to  FIGS. 4 through 7 , one sees that each pressing arrangement  26  has what may be termed a beaver tooth  50 . The beaver tooth  50  can be caused to reciprocate relative to the pressing arrangement  26  by any appropriate means including, for example, a trigger  52 . The pressing arrangement  26  further includes a hook member  44  that rides along a first side of the rail  40  opposite to the beaver tooth  50  and a spring-loaded rider arrangement  55  that rides along a second side of the rail  40 . The clamping arrangement  24  in this embodiment is disposed outboard of the pressing arrangement  26 . 
     The shoe  20  retains a frame member  46  relative to which an elastomeric material, which is shown at  54  in  FIGS. 8–12 , can be applied by use of the elastomeric material application system  10 . The frame member  46  can be any type of frame member  46  including, by way of example, a furniture frame member  46  relative to which one might seek to apply one or more panels of elastomeric material  54 . In this example, the frame member  46  comprises a seat bottom  46  with an obverse side for providing support, a reverse side, and a peripheral edge. The frame member  46  has a groove  48  therein into which a locking spline  56  can be pressed by operation of the pressing arrangement  26  in general and the beaver tooth  50  in particular. When the locking spline  56  is pressed into the groove  46 , the panel of elastomeric material  54  can be retained in place relative to the frame member  46  by a mutual frictional and mechanical engagement between the locking spline  56 , the groove  46 , and the panel of elastomeric material  54 . 
     The shoe  20  and the nest  22  can be particularly sized and shaped to engage the frame member  46 . As such, shoes  20  and nests  22  can be uniquely configured, modified, or adapted based on the frame member  46  to be engaged. The shoe  20  and the frame member  46  can be configured to have the peripheral edges of the frame member  46  project beyond the peripheral edges of the shoe  20  relative to the nest  22  such that the peripheral edges of the frame member  46  will tend to make first contact with the nest  22 . The nest  22  can have an engaging surface sized, shaped, and contoured to engage the frame member  46  adjacent to the peripheral edges thereof. 
     Turning to the progressive views of  FIGS. 8 through 12 , one sees steps in an application of a panel of elastomeric material  54  relative to a frame member  46  according to the present invention. With the shoe  20  disposed in spaced relation relative to the nest  22 , a frame member  46  can be engaged with the shoe  20  to be retained thereby. The frame member  46  is engaged with the shoe  20  with the obverse side of the frame member  46  facing the nest  22  and the reverse side of the frame member  46  facing the shoe  20 . A panel of elastomeric material  54  can be disposed for being retained by the clamping arrangements  24 . The panel of elastomeric material  54  can then be clamped by the clamping arrangements  24  overlying the nest  22 . 
     The relative disposition of the clamping members  24  can be adjusted, such as by moving distally, to induce a selected initial tension in the panel of elastomeric material  54  by use of the clamp translation mechanisms  42  as is shown by the relative positioning of the clamping members  24  in  FIGS. 9 and 10 . The shoe  20  can then be lowered toward the engaging position of  FIG. 11  thereby causing the frame member  46  to press into the panel of elastomeric material  54  to induce an initial deflection of the panel of elastomeric material  54  until the shoe  20  matingly engages the nest  22 . With the panel of elastomeric material  54  sandwiched between the peripheral edge of the frame member  46  and the engaging surface of the nest  22 , the elastomeric material  54  can be maintained in its initial deflection condition by a frictional engagement between the shoe  20 , the frame member  46 , the elastomeric material  54 , and the nest  22 . An O-ring  58  of high friction material, such as rubber, disposed on the nest  22  can be incorporated to ensure a secure retention of the panel of elastomeric material  54  while the locking spline  56  is pressed into the groove  48  to permanently lock it in place. 
     The pressing arrangements  26  can ride along the rail  40  as they progressively press the locking spline  56  into the groove  48 . The rail  40  can be curved to match the shape of the frame member  46 . If necessary or desirable, the advance of the pressing arrangements  26  can be controlled by any appropriate mechanism, such as a step motor or the like, in combination with an endless drive arrangement, such as a toothed belt. A spring-loaded pulley can allow a change in overall belt length to accommodate changes in shoe  20 , nest  22 , and rail  40  shapes and structures. To prevent damage to the system and danger to the operators, a control means can also be provided to allow movement of the shoe  20  relative to the nest  22  only when all pressing arrangements  26  are disposed beyond the respective ends of the frame member  46  and, therefore, in a safe location. Furthermore, all operations of the system other than operation of the pressing arrangements  26 , including the movement of the shoe  20 , can be prevented when the pressing arrangements  26  are in operation. 
     As  FIG. 19  shows, the locking spline  56  can be subdivided into multiple segments to accommodate the sides of the frame member  46 . For example, four segments of the locking spline  56  can be employed to secure the elastomeric material  54  relative to each of the four sides of the frame member  46 . Corner sections of the locking spline  56  can then be pressed into place to secure the corner portions of the elastomeric material  54  if the same has not already been achieved. If necessary or desirable, excess portions of the panel of elastomeric material  54  can be trimmed by any appropriate means, the result of which being shown in  FIG. 20 . 
     As  FIG. 14  makes clear, the orientation of the pressing arrangements  26  and any other components of the invention can be readily adjusted to accommodate a frame member  46  that has a lateral groove  48 . With that, a panel of elastomeric material  54  can be retained relative to the frame member  46  spanning from edge to edge of the frame member  46 . Furthermore, differently shaped and styled shoes  20 , nests  22 , and rails  40  can be readily applied. It will be clear, therefore, that the elastomeric material application system  10  provides a universal applicable machine that can be employed relative to substantially any application of elastomeric material. 
     As noted previously, the panel of elastomeric material  54  is subjected to an initial deflection and, therefore, a pretensioning prior to and while the shoe  20  and the nest  22  are engaged with one another. A symmetrical pretensioning is depicted graphically in  FIG. 15 . The astute observer will appreciate, however, that certain applications may be best served by applying differing tensions to differing portions of the panel of elastomeric materials  54  to enhance the ergonomics and general performance of the resulting structure. For example, one may wish to have greater tension and, therefore, support in a central portion of a seat frame member  46  to provide optimal support to a user as compared to more distal portions of the seat member where less support is normally required.  FIGS. 16 and 17  show possible support zones along lateral east and west and longitudinal north and south directions respectively. In the lateral direction, Zone “A” can provide the greatest support while progressively less support can be provided in Zones “B”, “C”, “D”, “E”, and “F”. In the longitudinal direction, the greatest support can be provided in Zone “I” and progressively less support can be provided in Zones “II”, “III”, and “IIII”. Of course, the arrangement and relative positioning of the various Zones can vary nearly infinitely. 
     Advantageously, the present invention provides a number of mechanisms for achieving such a controlled and varied initial and final tensioning in the panel of elastomeric material  54 . For example, a controlled and varied tensioning in the panel of elastomeric material  54  can be achieved by clamping arrangements  24  that are segmented into plural individually operable clamping arrangements, such as those indicated at  24 A,  24 B,  24 C,  24 D,  24 E, and  24 F in  FIG. 18 . Under such a construction, the panel of elastomeric material  54  can be initially retained by the clamping arrangement  24  and then the individually operable clamping arrangements  24 A,  24 B,  24 C,  24 D,  24 E, and  24 F can be moved proximally or distally relative to the frame member  46  to produce a variable tension pattern in the panel of elastomeric material  54 . 
     An alternative means for altering the initial tensions in the panel of elastomeric material  54  to produce a variable tension pattern in the panel of elastomeric material  54  can be achieved by use of what can be termed a deflection control member, which is indicated at  60  in  FIGS. 7 and 7A . The deflection control member  60  can be interposed between the clamping portion of one or more of the clamping arrangements  24  and the shoe  20  and nest  22  combination. In the embodiment of  FIG. 7 , the deflection control member  60  is retained relative to the clamping member  24  by having a rod member  62  disposed within a mouth  64  of the clamping arrangements  24 . As  FIG. 7A  shows, the deflection control member  60  can have an edge portion  66  that varies in height thereby to cause a varied initial deflection and, therefore, tension in the panel of elastomeric material  54 . Advantageously, the shape of the edge portion  66  can be varied to cause the final tensions in the panel of elastomeric material  54  to match the desired tensions of the particular application and, possibly, the particular user of the resulting product. 
     With certain details and embodiments of the present invention for an elastomeric material application system disclosed, it will be appreciated by one skilled in the art that numerous changes and additions could be made thereto without deviating from the spirit or scope of the invention. This is particularly true when one bears in mind that the presently preferred embodiments merely exemplify the broader invention revealed herein. Accordingly, it will be clear that those with major features of the invention in mind could craft embodiments that incorporate those major features while not incorporating all of the features included in the preferred embodiments. 
     Therefore, the following claims are intended to define the scope of protection to be afforded to the inventor. Those claims shall be deemed to include equivalent constructions insofar as they do not depart from the spirit and scope of the invention. It must be further noted that a plurality of the following claims express certain elements as means for performing a specific function, at times without the recital of structure or material. As the law demands, these claims shall be construed to cover not only the corresponding structure and material expressly described in this specification but also all equivalents thereof.