Abstract:
The present invention is a sling frame member including a tubular rail and at least two channels formed within the tubular rail. Each of the channels is capable of receiving a sling. Also described herein is a furniture assembly having a set of seat sling rails of the present invention, a set of back sling rails of the present invention, and seat and back panels interconnecting the respective sets of sling rails to form a seating unit.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to sling furniture of the type having a seat panel and backrest panel stretched across a rigid skeletal frame, and more specifically to an improved frame construction for sling furniture. 
     BACKGROUND OF THE INVENTION 
     “Sling furniture” is a popular style of furniture, and is characterized by incorporation of flexible material, also known as a “sling,” that is fixed on opposite ends and supports a person sitting between the fixed ends. Generally, sling furniture is used for recreational, outdoor, or casual use. Thus, preferably, the frame is formed of material that is appropriate for temperature, moisture, and humidity fluctuations. 
     Sling furniture has a skeletal frame that defines the lateral edges of a seating unit. The unit may be a chair, a chaise lounge, a loveseat, or any other appropriate seating unit. The frame may be made of metal tubing, wood, plastic, or some other rigid material. A panel, or “sling,” of some type of flexible but resilient material is disposed between the frame to provide comfortable seating and reclining. 
     Sling rails are sections of the frame along the lateral sides of the seating unit that are formed with a single channel to receive insertion of the sling. The sling can be woven or web material formed with lateral hem pockets. Flexible rods are inserted within the hem pockets of the sling and threaded through the sling rail channels. The sling is tautly stretched across the lateral edges of the frame to form the seat and backrest of the furniture. The rods and hem pockets are retained within the channel formed within the sling rail. 
     Sling furniture frames may include lateral supports extending across the frame. Due to the tautness of the sling or the location of the lateral supports, the lateral supports are designed to minimize any physical discomfort to the seated user. In other words, when a user is in a seated position, the stretched sling will not contort with the lateral supports if designed correctly. Visually, however, the lateral supports may be unattractive. Often the design of the frame provides for lateral support directly beneath the seat portion or directly behind the backrest portion. Thus, at certain angles, the lateral supports may disrupt the overall aesthetics of the seating unit. One solution is to provide lateral rails that are formed of a similar decorative motif as the rest of the frame. Unfortunately, however, this solution is not ideal due to the miscellaneous hardware that still must be used, such as attachment hardware or weld joints that remain exposed. For such reasons, a frame construction that hides the lateral support(s), the hardware, or the weld joints would be beneficial. 
     Another design feature of most sling rail seating is the use of “end caps.” Often a cap is placed on the end of each seat and backrest sling rail to obscure the flexible rods and lateral hem pockets located within each sling rail channel. The end cap may be of any appropriate material, but generally end caps are made of plastic. Generally, however, sling furniture manufacturers would like to avoid the use of end caps due to their undesirable appearance. In other words, the use of end caps can detract from the overall appearance of the rest of the seating unit. 
     There is a need therefore for a sling furniture frame construction that presents a pleasing, finished appearance, with respect to lateral support members and end caps. Preferably, any such construction modification will not greatly complicate the manufacture of such furniture, either with respect to material cost, labor, or sling installation. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the deficiencies of the prior art by providing a sling frame member including a tubular rail and at least two channels formed within the tubular rail. Each of the channels is capable of receiving a sling. Thus, a furniture assembly having a set of seat sling rails of the present invention, a set of back sling rails of the present invention, and seat and back panels interconnecting the respective sets of sling rails will form a seating unit that presents a pleasing, finished appearance by obscuring frame hardware and obviates the need for end caps. 
     These and other aspects of the present invention as disclosed herein will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments. The description is for the purpose of describing a preferred embodiment of the invention and is not intended to limit the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top perspective view of a seating unit formed with the present invention. 
     FIG. 2 is a cross-section view of the sling rails along the lines of  2 — 2  in FIG.  1 . 
     FIG. 3 is a partial exploded view of a section of the seating unit of the present invention. 
     FIG. 4 is a partial exploded view of the back section of the seating unit of the present invention. 
     FIG. 5 is a partial exploded view of the seat section of the seating unit of the present invention. 
     FIG. 6 shows a sling of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is a novel construction for sling seating frames. Although the invention is described in conjunction with a chair frame  10 , the invention should be interpreted to include other seating units, such as chaise lounges, loveseats, sofas, or other seating units. 
     As discussed above, sling seat frames generally are formed of metal tubing, wood, plastic, or other material suitable for outdoor use. For the present invention, the frame  10  preferably is formed of extruded aluminum tubing. For general use, preferably the tubing is either ⅞″ or 1″ round tubing. Any appropriate diameter or cross-sectional shape, however, may be used. Upon extrusion of continuous tubing, individual tubular components are cut to size and assembled, e.g., by welding, to form a rigid frame  10 . Preferably, the frame  10  includes legs  16 , arms  18 , seat side frame rails  22 , back frame rails  24 , and lateral rails  20 . 
     Optionally, in higher stress areas a tube within a tube construction may be used. Thus, a tube of smaller diameter is inserted inside the frame tubing in certain areas to increase strength. Decorative accents, such as the cast aluminum leaf  12  and/or faux bamboo rings  14  illustrated in FIG. 1, also may be welded onto the frame  10 . Optional feet  17  are added to each leg by welding. The welded frame  10  is then cleaned and buffed in preparation for painting. 
     The above-described frame configuration is for use in explaining the preferred embodiment of the present invention and should not be used d to limit the scope of the present invention. Thus, the frame may incorporate any design configuration that incorporates the sling rails that are discussed below in more detail. 
     The sling holders  26 ,  28  preferably are made from aluminum extrusion as well. As shown in FIG. 2, the sling rails  26 ,  28  are formed with at least two channels. As illustrated, the preferred configuration is two channels  30 ,  32 , most preferably, diametrically opposed from one another. The channel configuration, however, may include more than two channels and may be in any desired spatial relationship. For example, the configuration may include three channels for placement of upper and lower fabrics within the slings as described in more detail below. 
     Multiple first coupling members  21 , such as a nuts, are welded onto the inside surface of the seat side frame rails  22  and the back frame rails  24 . The coupling members  21  are used to secure the respective sling rails  26 ,  28  to the frame rails  22 ,  24 . Preferably, the sling rails  26 ,  28  are formed with a plurality of apertures through which second coupling members  50 , such as screws, may be inserted therethrough for corresponding connection with the first coupling members  21  to secure the sling rails  26 ,  28  to the frame rails  22 ,  24 . 
     As shown in FIG. 1, the lateral rails  20  may be welded straight across between the frame rails  22 ,  24  or in a decorative design such as conjoining semi-circles between the legs  16 . Thus, the lateral rails  20  may be formed of a similar decorative pattern as the rest of the frame if the lateral rails are to be seen. If, however, it is preferred for the lateral rails to be obscured from view, the lateral rails may be welded to run directly between the sling rails  26 ,  28 . As will be described in more detail below, the sling will obscure such lateral rails from view in the finished seating unit. 
     Similar to the frame rails  22 ,  24  described above, the sling rails  26 ,  28  preferably are extruded as continuous multi-channeled tubing. The individual sling rails  26 ,  28  then are cut to size. Preferably, each sling rail  26 ,  28  is formed with rounded ends  34 . As will be described below, the rounded ends  34  allow the sling  40  to wrap around the end  34  of each sling rail  26 ,  28  during assembly. Thus, each sling rail  26 ,  28  preferably is a tubular rail having at least two channels  30 ,  32  formed therein. The sling rail  26 ,  28  has finished ends  34  that are aesthetically complimentary with the rail design. Thus, preferably, the finished ends  34  are integral with the tubular rail by being rounded and thereafter covered by the sling panel  40 ,  42 . The finished ends, however, may be separate elements that are mountable to the ends  34  of the tubular rails  26 ,  28  to aesthetically complement the sling panel  40 ,  42 . 
     The frame rails  22 ,  24  and the sling rails  26 ,  28  preferably are cleaned and buffed in preparation for painting. The individual rail pieces may be buffed and painted using any appropriate paint to create any desired design characteristics. 
     The fabric for the slings  40 ,  42  preferably is a blend of polyvinylchloride (“PVC”) fibers and acrylic fibers. The blended fabric is preferred to provide a softer hand (or feel) than straight PVC fabrics. One preferred fabric is sold under the tradename LAMONT-CURRY by Glen Raven Mills of Glen Raven, N.C. The seat sling  40  and back sling  42  are made the same way. As illustrated in FIG. 1, one configuration of a seating unit of the present invention has separate slings for the seat  40  and the back  42 . As will be appreciated by those skilled in the art, the frame may be configured to allow for a single, one-piece sling to provide both seat and back support. 
     Flexible plastic rods  44  are mounted to the fabric, such as by sewing into a hem on the left and right side of each sling  40 ,  42 . Preferably, the top and bottom edge  46 ,  48  of each sling is hemmed as well for a preferred finished appearance. Also, preferably the sling is configured with a flexible but resilient lateral support  52 , such as a foam spine, to provide support across the area approximately where a seated user&#39;s knees would be located. 
     The channels  30 ,  32  within the sling rails  26 ,  28  are configured to receive and retain a sling  40 ,  42 . As described above, preferably the sling is formed with flexible rods  44  within left and right side hems. The rods  44  are insertable and remain within the channels  30 ,  32 , especially upon stretching the sling panels  40 ,  42  by fastening the coupling members  21 ,  50 . The invention, however, should not be limited to this particular sling configuration. The sling rails  26 ,  28  should be formed with appropriate channels  30 ,  32  to receive and retain the sling  40 ,  42  regardless of the particular sling configuration. 
     To install the preferred seat sling, multiple second coupling members  50 , such as screws, are inserted through the sling rails  26  and mate with the first coupling members  21  on the inside of the seat side rails  22 . Preferably, the respective coupling members  21 ,  50  are not completely secured to one another until the sling  40 ,  42  has been loaded within the sling rails  26 ,  28 . 
     The sling  40  can be loaded into the sling rails  26  from either open end. The fabric-enclosed plastic rod  44  is inserted into a first channel  30  of each sling rail  26 . The sling  40  is pulled through channel  30  and then loaded into a second channel  32 . Preferably, the sling  40  is of sufficient length to allow sling  40  to be loaded into second channel  32  from each open end. The sling  40  is pulled through the second channel  32  until relatively taut. 
     As noted above, the sling rails  26  are formed with at least two channels. The preferred embodiment as herein described has two channels  30 ,  32 . Additional channels may be desired, however, and the sling fabric would be inserted similar to that described above wherein a flexible rod mounted to the sling is drawn through respective sling rail channels. As briefly described above, a frame may be formed with more than two channels so as to provide for multiple sling layers to be installed to the frame. Such multiple layers would allow for, e.g., outer slings, potentially removable, that are made from more weather-durable materials to protect less durable, but more decorative, fabric slings. 
     The sling fabric  40 ,  42  is pulled taut on top and bottom and rolled smooth around each end of the sling rails  26 ,  28 . The second coupling members  50  should then be secured with their respective first coupling members  21  to stretch the fabric to a finished state and provide a smooth seating surface. 
     The sling  40  masks the mated first  21  and second  50  coupling members, so the coupled members are hidden from view from the top and front of the chair. Thus, the sling  40  should be of sufficient length as to wrap about the ends of the respective sling rails. Preferably, the sling  40  is of such length L as to extend approximately ⅓ the depth of the seat toward the center from the end. As one skilled in the art will appreciate, should the seating unit include lateral supports, the slings  40 ,  42  should be formed of sufficient length as to mask those lateral supports as well. 
     As shown in FIG. 1, one preferred back frame design includes a rearwardly curving top portion  54 . For this preferred back portion design, preferably the sling  42  is loaded from the bottom of the back sling rails  28 . The flexible rods  44  within sling  42  are loaded into the first channel  30  of each of the respective back sling rails  28 . For the embodiment illustrated in FIG. 1, the sling  42  is pulled upwardly over the front of the back and pulled around the curve  54  at the top of the chair. 
     The flexible rods  44  within the sling  42  are then loaded into the respective second channels  32  of the back sling rails  28  at the top and pulled down to an appropriate distance to obscure the end hem from view, such as the middle of the underside of the curve  54 . The flexible rods  44  or the sling  42  are then loaded into the respective second channels  32  of the back sling rails  28  at the bottom of the back and pulled up the rear side toward the top  54 . Preferably, the sling  42  is not pulled to abut its opposite end. Rather, an opening is left between the ends of the sling  42  under the curve  54  of the chair so that the coupling members  21 ,  50  can be mated and secured to one another. Preferably, the sling  42  is pulled such that the opening and the coupling members  21 ,  50  cannot be seen from the back or the top of the piece. Thus, preferably, the opening is at or near the crux of the top curve  54 . 
     Similar to the seat described above, the back sling  42  is pulled taut front and back and rolled smooth around each end of the sling rails  28 . The coupling members  21 ,  50  are tightened to stretch the fabric and provide a smooth seating surface. 
     As will be appreciated by those skilled in the art, the frame may be formed of any shape and the present invention should not be limited to a seat with a curved back as herein described as the preferred embodiment. The multiple channel sling frame allows for the sling fabric to cover the frame hardware regardless of the design. Thus, for example, if the seat had a straight back, the sling could meet at a location near the bottom of the back to cover the back hardware from view while maintaining the aesthetic appearance of the seat. 
     Although specific embodiments of the present invention have been illustrated and described in detail, it is to be expressly understood that the invention is not limited thereto. The above detailed description of the embodiment is provided for example only and should not be construed as constituting any limitation of the invention. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.