Patent Document

BACKGROUND OF INVENTION 
     The present invention relates to chairs having cushion assemblies and covers, and more particularly relates to chairs having cushion assemblies and covers that can be removed for cleaning, repair, and maintenance. 
     Modern chairs often include fabric-covered cushions to improve comfort. A problem is that fabric-covered cushions get dirty, worn, and damaged, such that they need cleaning and maintenance. However, they are typically permanently attached to the chairs, and are not easily removed or repaired. In schools, medical facilities, and high-use areas such as airports, it is often desirable to sanitize the chairs, but cushioned chairs with fabric are porous and not easily sanitized. Certainly, wiping them is not sufficient. Even beyond these problems, customers often want to upgrade or change the color schemes and designs of their offices. However, it is costly to recover chairs. Also, there are problems with using customer&#39;s own fabrics. Customer&#39;s own fabrics are specific fabrics picked out by a customer. A problem with using them is that they often have unusual or specialized color schemes or other special characteristics. A problem with these customer&#39;s own fabrics is that they may not have the properties desired by the chair manufacturers. For example, fabrics vary widely in their physical properties, such as their stretchability, strength, color-fastness, and the like. For all of these reasons, it is desirable to have cushion assemblies that are able to incorporate customer&#39;s own fabrics in a manner that allows cushions to be structurally “semi-independent” of the seat and back support structures of a chair, so that they can be removed for cleaning or replacement, and so that the chair design does not require certain properties in the fabric for the fabric to look acceptable and wear acceptably on the chair. Still further, attachment and covering schemes are desired that provide a modernistic appearance, yet that facilitate assembly and repair. Also, accessories are desired to help store extra cushion and covering assemblies that may be used. 
     Accordingly, chair constructions are desired that solve the aforementioned problems and that have the aforementioned advantages. 
     SUMMARY OF THE INVENTION 
     In one aspect of the present invention, a chair includes a seating unit including a seat structure and a back structure where at least one of the structures includes a face adapted to support a person seated thereagainst, with the face having an arrangement of first connectors thereon. A removable cushion assembly includes a cushion, a top covering, and a stabilizing bottom covering that has less than a 5% elongation when stretched and that is sewn to the top covering around the cushion. The removable cushion assembly also has an arrangement of second connectors attached to the bottom covering proximate corners of the cushion and that are releasably attached to the first mechanical connectors for securing the cushion assembly to the one structure. The first and second connectors are configured to release and disengage when the removable cushion assembly is pulled from the one structure. 
     In another aspect of the present invention, a cushion assembly includes a cushion, a covering on the cushion, and a sheet under the cushion. The sheet is attached along edges to the covering to encapsulate the cushion. The sheet is chosen for its dimensional stability and has an elongation when stretched of less than about 5%. A plurality of mechanical connectors are attached to the sheet and arranged in a predetermined pattern on the sheet so that the mechanical connectors can be accurately attached to a seating component. 
     In another aspect of the present invention, a method includes steps of providing a seating unit and a cushion assembly attached in at least four corner locations to the seating unit with releasable connectors. The method further includes steps of removing the cushion assembly from the seating unit by disengaging the connectors. The method also includes performing maintenance on the cushion assembly including one of cleaning and refurbishing a component of the cushion assembly and reattaching the cushion assembly to the seating unit by re-engaging the connectors. 
     In another aspect of the present invention, a seating unit includes a back with a front face, an upper edge, and a lower edge. A removable fabric vest covers a majority of the front face of the back and includes an upper portion releasably attached to the upper edge and a lower portion releasably attached to the lower edge. 
     In yet another aspect of the present invention, a seating unit includes a back, and a covering attached to the back including a top connector and a bottom connector. The bottom connector includes a stretchable material. A fire-resistant covering is provided that covers the stretchable material to provide improved resistance to fire damage. 
     Another aspect of the present invention includes a chair comprising a seating unit which includes a seat structure and a back structure, both of which are supported for synchronous movement upon recline. At least one of the structures includes a face adapted to support a person seated thereagainst. The face has an arrangement of first mechanical connectors thereon. The chair also includes a removable cushion assembly with an arrangement of second mechanical connectors that releasably snap-attach to the first mechanical connectors and also secure the cushion assembly to the one structure. 
     In another aspect of the present invention, a chair comprising a seating unit includes a seat structure having an arrangement of six fixed snap-attach connectors thereon. A removable cushion assembly with an arrangement of six mating snap-attach connectors are releasably attached to the fixed snap-attach connectors and secure the cushion assembly to the one structure. 
     In another aspect of the present invention, a hanger is provided that is adapted to support a back covering for a chair, where the back covering includes a front panel shaped to cover a front surface of the chair back and where the back covering also includes a rear panel sewn to the front panel along a top edge of the rear panel to define a pocket for engaging and hanging on a top edge of the chair back. The hanger includes a center section having a hook adapted to hang on a bar and has an elongated stem. Opposing wing sections attach only to a bottom of the elongated stem. The opposing wing sections have an upper edge shaped to replicate the top edge of the chair back so that the vest will hang on the hanger when the wing sections are extended into the pocket. In a narrower aspect, a cushion assembly and a vest are hung as a set on the hanger. 
    
    
     These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
     DESCRIPTION OF FIGURES 
     FIG. 1 is a front perspective view of a chair embodying the present invention; 
     FIG. 2 is a front view of the chair in FIG. 1; 
     FIG. 3 is a side cross sectional view taken along line III—III of the chair shown in FIG. 
     FIG. 4 is an exploded side perspective view of FIG. 1; 
     FIGS. 5 and 5A are mating faces of the seat cushion assembly and the seat, respectively, each having a pattern of mating snap-attach connectors thereon; 
     FIGS. 6 and 6A are side cross sectional views of one of the snap-attach connectors, FIG. 6 showing the connectors engaged and being enlarged from the circled area VI in FIG. 3, FIG. 6A showing the connectors disengaged; 
     FIGS. 7,  7 A and  7 B are side cross sectional views of three different top hem arrangements on the back cushion assembly, FIG. 7 being enlarged from the circled area VII in FIG. 3; 
     FIGS. 8,  8 A, and  8 B are side cross sectional views of three different bottom hem arrangements on the back cushion assembly, FIG. 8 being enlarged from the circled area VIII in FIG. 3; 
     FIG. 9 is a front perspective view of a chair embodying the present invention; 
     FIG. 10 is a front view of the chair in FIG. 9; 
     FIG. 11 is an exploded side perspective view of FIG. 10; 
     FIG. 12 is a plan view of a hanger and a vest positioned on the hanger; 
     FIG. 13 is a plan view of the hanger shown in FIG. 12; and 
     FIG. 14 is a plan view of the hanger shown in FIG.  12  and seat cushion assembly hung on the hanger. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     A chair  20  (FIG. 1) embodying the present invention includes a cushioned seat  21  and a cushioned back  22 . The details of the support structure forming the present seat and back are disclosed in U.S. Pat. No. 5,871,258, issued Feb. 16, 1999, entitled CHAIR WITH NOVEL SEAT CONSTRUCTION, and the entire contents of the &#39;258 patent are incorporated herein for the purpose of providing a complete disclosure of the same. In the present invention, the seat  21  (FIG. 3) has a seat support structure  23  with an upwardly oriented face covered by a fabric covering  24  for aesthetics. An arrangement of several male snap connectors  25  are secured in recesses  25 ′ to the seat support structure  23 , such as by attaching the snap connectors  25  to a resilient polymeric seat shell of the support structure  23 . A seat cushion assembly  26  includes a mating pattern of mating female snap connectors  27  that are configured and arranged to snappingly engage the male snap connectors  25 . By this arrangement, the seat cushion assembly  26  can be snap-attached to the seat support structure  23  for quick removal, such as for washing, dry-cleaning, repair, or maintenance. 
     The fabric covering  24  covers the seat support structure  23  (FIG. 4) for aesthetic reasons when the seat cushion assembly  26  is removed, and also covers the seat support structure  23  for functional reasons, such as to prevent articles from falling into the mechanisms within the seat support structure  23 . Preferably, the covering  24  is a durable material that will not easily rip or wear. Where the fabric covering  24  is sufficiently strong, the snap connectors  25  can be attached only to the covering  24 , and edges of the covering  24  are adhered or otherwise secured to the seat support structure  23 . However, in a preferred form, the snap connectors  25  extend through and are secured in recesses  25 ′ to a flexible plastic shell that forms part of the seat support structure  23 . 
     The seat cushion assembly  26  (FIG. 6A) includes a cushion  28 , a top covering  29 , and a bottom covering  30 . The cushion  28  can be a conventional polyurethane resilient foam, or can be a non-woven resilient fibrous material, or can be any reasonable material capable of providing resilient comfortable support to a seated user. The top covering  29  can be a manufacturer-chosen covering material or a customer&#39;s own material. Where a customer&#39;s own material is used, a secondary stabilizing covering sheet  31  is used to provide integrity to the assembly. The bottom covering  30  must provide stable support for the snap connectors  27 , both so that the snap connectors  27  do not rip out of the covering  29  during pull-off of the seat cushion assembly  26 , and also so that the arrangement of snap connectors  27  stay in a dimensionally accurate position so that they can be easily re-attached to the other connectors  25 , even though it is a “blind” process. Preferably the bottom covering  30  is a sheet of nonwoven fabric having a stretch of less than 5%. For example, a 10-15 ounce non-woven sheet of polyester cloth can be used for this purpose. Notably, the combination of the seat cushion assembly  26  snap-attached to the seat support structure  23  provides a novel, crevice-shaped appearance at a location  26 ′ (FIG. 6) sometimes referred to as a “throw-rug” type look. This “look” provides a novel “relaxed” appearance that is well-liked by computer operators and “high-tech” consumers. 
     The seat cushion assembly  26  is a separate unit that is easily removed by pulling on the assembly  26  in direction “A” (FIG. 6) and can be easily re-attached by pressing through the cushion  28  against the snap connectors  27 . This arrangement greatly improves the ability of a chair manufacturer to competitively make chairs that incorporate customer&#39;s own materials, because the cushion assembly  26  is stable and thus does not depend on the customer&#39;s own material for strength or integrity. Further, the customer&#39;s own materials can be used without major logistic problems, since the cushions are separable and can be shipped from separate locations. For example, the cushions can be prepared at a local manufacturing site separate from the chair manufacturing plant. The present arrangement is considered to have surprising and unexpected qualities of dependability and reliability, even where customer&#39;s own materials are used that do not have the requisite strength and other properties normally required by customers and chair manufacturers. Alternatively, it is noted that the snap connectors  27  can extend through the cushion  28  and be located in depressions in the fabric  29 . Three zippers  30 ′ (FIG. 4) are provided in the bottom covering  30  so that the cushion  28  can be stuffed into the seat cushion assembly. Notably, one or more of the zippers  30 ′ can be replaced by hook-and-loop material, snaps, or other attachment means to reduce cost and facilitate assembly. 
     The back  22  (FIG. 4) includes a back support structure or shell  35  and a back cushion assembly  36 . The back cushion assembly  36  includes a cushion  38 , a front covering  39 , and a back covering  40 . A crescent-shaped section of material  41  is sewn along a top edge of the coverings  39  and  40  to form a top seam  42  and a downwardly facing pocket or sock-like cavity  41 ′. The seam  42  can be created in numerous ways, three of which are illustrated. In FIG. 7, the seam  42  is created by sewing edges of the three materials  39 ,  40 , and  41  together, with all edges facing a same inward direction. In FIG. 7A, the three edges are rolled before sewing, which creates a smoother and more rounded appearance where the seam  42 ′ is not emphasized. In FIG. 7B, the edges of the materials  39  and  40  are sewn together at a first seam  42 ″, with the edges overlapping and facing in opposite directions. The back covering  40  is then sewn along a separate seam  43  to the crescent-shaped section of material  41  at a location spaced below the seam  42 ″. This creates a visual separation at location  43 ′ along its edges that is reminiscent of the “throw-rug” look discussed above, such that the combination of the snap-attached seat cushion of FIG.  6  and the back cushion of FIG. 7A is very attractive and believed to be non-obvious in appearance. 
     A bottom edge of the back cushion assembly  36  (FIG. 8) includes a zipper  44  with a top strip  45  sewn to a lower edge of the back covering  40  and a bottom strip  46 . The bottom strip  46  is sandwiched together with bottom edges of the front covering  39  and a stretchable elastic strip  47  in an inwardly extending orientation and then sewn together. The elastic strip  47  is highly stretchable, such as 200% elongation or more. It includes a stiff strip  48  sewn along its lower edge. A thickened section  49  extends along a lower portion of the back shell  35  (i.e. its back shell), and includes a downwardly facing recess  50 . The elastic strip  47  is stretched and the stiff strip  48  is rolled over and tucked into the recess  50  while maintaining tension on the elastic strip  47 . This pulls the back cushion assembly  36  downwardly. This tension is important because a center of panel  54  (i.e. the lumbar region)(FIG. 4) of the back shell  35  is flexible. Thus, when the back shell  35  is flexed to a more planar condition, the back cushion assembly  36  must “absorb” some of the excess material. The elastic strip  48  helps accomplish this purpose. In FIG. 8, all edges of materials  39 ,  46  and  47  extend inwardly in the same direction. In FIG. 8A, the strip  46  extends downwardly. This creates a “puffy” condition such that a lower edge of the cushion assembly  36  bellows out in a forward direction. This creates a “throw-rug” appearance complimentary of the structure shown in FIGS. 6 and 7B, although it is noted that the lower edge of the back cushion assembly  36  is so low that it is not particularly easy to see. 
     In FIG. 8A, there is shown a fire-resistant material  51  that overlays a front of the elastic strip  48 . The fire-resistant material  51  is sewn loose to the elastic strip  48  when the elastic strip  48  is in a relaxed state, so that when the elastic strip  48  is stretched, the fire resistant material  51  does not limit stretching the elastic strip  48 . When attached and the back shell  35  is in its natural concave condition, the fire resistant material  51  is basically in a semi-taut condition. When the back shell  35  is flexed toward a planar condition, the fire resistant material  51  becomes loose, but this is not a problem since a person seated in the chair covers up an objectionable appearance. The fire-resistant material  51  is included when a local ordinance or law requires that chairs be resistant to fire damage. 
     A vest or back covering  52  (FIGS. 9-11) includes a semi-transparent front panel  53  of material sewn to a crescent-shaped rear panel  54  (FIG. 11) of similar material to form a sock-like cavity  41 ′. The particular material of panels  53  and  54  are sold under a tradename “Powernet” by Milliken &amp; Company, and are warp knit, gauge 64 GG, 85% nylon and 15% Lycra, with a square weight of 4.2 per yard. The material can be colored to match chair aesthetics, and has an elasticity of about 10% to 25%. They provide a see-through property where the images through the material are visible and distinguishable, but have a ghost-like quality. An important aspect is that they are transparent, semi-transparent or translucent so that the horizontal slots  55  in the lumbar region  56  can be seen, both for aesthetics and function. Also, this allows the position of a vertically-adjustable lumbar panel (not specifically shown) between the shell  35  and the vest  52  can be seen. At the same time, the panel  53  prevents a seated user&#39;s back from being pinched within the slots  55  as the seated user flexes their lower back. Attachment of the vest  52  is similar to that of back cushion assembly  36 . Specifically, the back covering  52  is pulled downwardly onto a top of the back support structure  35  in direction “B” (FIG.  11 ). A stiff strip  48  sewn along a lower edge of the panel  53  is rolled and tucked into the recess  50  (FIG.  8 B). The material of panel  53  is sufficiently elastic to stretch and keep tension on the material of panel  53  even when the back shell  35  is flexed toward a more planar condition. 
     In one form, a back cushion assembly is provided that can be pulled downwardly in direction “B” (FIG. 4) onto a back support structure for assembly. The back cushion assembly includes a top section forming a sock that engages the back support structure, and a stretch fabric strip along its bottom edge that assists in retaining the back cushion assembly to the back, and further potentially includes a fire-resistant strip that overlays the stretch fabric strip to reduce damage in the event of a fire. To remove the back cushion assembly for cleaning, the procedure is reversed. In another form, a removable fabric vest is provided that is configured to pull downwardly over the back (FIG. 11) and releasably attach to a bottom edge of the back. The vest covers a majority of the face of the back and, in a preferred form, is of a see-through material such that horizontal slots in the back can be seen. To remove the vest, the above procedure is reversed. A seat cushion assembly is provided that snap-attaches to a seat support structure. To remove the seat cushion assembly, the procedure is reversed. Accordingly, the seat cushion and the back cushion (or the back vest) can be quickly and easily removed for cleaning (dry-cleaning or washing), repair, maintenance, and sanitizing, and then reinstalled quickly and easily. Also, customer&#39;s own materials can be easily used in the present inventive arrangement. 
     A hanger  65  (FIGS. 12-14) is provided that is configured to releasably hold an extra vest  52  or back cushion assembly  36  in a non-wrinkling hung-up position. Multiple vests  52  may be sold for a given chair, and chair owners will want to store these vests in a manner that prevents wrinkling or that facilitates drying or display. The present hanger  65  accomplishes that purpose. The hanger includes a bottom horizontal runner  76  and stiffening flange  77 . Side wings  78  and  80  extend arcuately upwardly from ends of the runner  76 , and inwardly angled stiffeners  79  and  81  extend from the side wings  78  and  80  toward a center of the runner  76 . A vertical runner  82  extends up from the center of the runner  76 , and includes a hooked section  83  for engaging a coat-hook or clothes-bar. The sections  83 ,  82 ,  76 ,  77  and  79  have a round cross section for optimal material flow, such that they define the equivalent of runners in the molding dies for the hanger  65 . while the sections  77 ,  79  and  81  are relatively flat for reduced material consumption and to prevent distortion of the hanger portions forming the pocket. The wings  78  and  80  form an arc that is similar to a top edge of the back shell  35 . The vest  52  is hung on the hanger  65  by placing the members  78 ,  79 ,  80  and  81  into the cavity, but with the panels  53  and  54  of the vest  52  (or of the back covering  40 ) being positioned on one side of the vertical runner  82 . The panel  54  (or back covering  40 ) extends through spaces  84  and  85  when the vest  52  is hung on hanger  65 . One or more snaps or fastening devices  86  are provided on flange  77  so that an extra seat cushion assembly  26  can be snap-attached to the hanger  65  and supported thereon. 
     In the foregoing description, those skilled in the art will readily appreciate that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.

Technology Category: 1