US2954074A - Structural units for upholstery purposes - Google Patents

Structural units for upholstery purposes Download PDF

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US2954074A
US2954074A US55349655A US2954074A US 2954074 A US2954074 A US 2954074A US 55349655 A US55349655 A US 55349655A US 2954074 A US2954074 A US 2954074A
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upholstery
compartments
partitions
elastic
structural units
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Schaller Ruth Erika Gertraud
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49789—Obtaining plural product pieces from unitary workpiece
    • Y10T29/49794—Dividing on common outline
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49789—Obtaining plural product pieces from unitary workpiece
    • Y10T29/49796—Coacting pieces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249981—Plural void-containing components

Definitions

  • This invention relates to structural units for upholstery purposes and to upholstered articles produced therefrom.
  • the term upholstered article is used to designate cushions, mattresses, upholstered chairs, sofas, couches, divans, lounges, settees, love seats, hassocks, automobile seats, airplane seats and the like.
  • the present invention provides structural units for upholstery which comprise at least two series of pieces of elastic material, the pieces of each series being spaced from one another and angularly interlocked with the pieces of the other series so as to form the partitions of a plurality of compartments, and at least one plate of elastic material forming the bottom and the top of said compartments, at least part of said elastic material consisting of an elastic foam.
  • two series of spaced pieces of elastic foamed material are interlocked at right angles so as to form the partitions of a plurality of adjoining cubic compartments, the bottom and the top of said cubic compartments being formed by at least one plate of elastic foamed material.
  • FIG. 1 shows a preferred embodiment of an upholstery unit constructed in accordance with the present invention.
  • This unit comprises the interlocked pieces 1 of elastic foamed material forming the adjoining cubic compartments 2, and the plates 3 and 5 of elastic foamed material meeting at the seam -4 and forming the bottom and the top of the compartments 2.
  • Figure 2 is a longitudinal sectional view of an upholstery unit in accordance with the invention, wherein the bottom and the top are formed by the plate 6.
  • foam and polyurethane foam are foam and polyurethane foam.
  • Figure 3 is a cross sectional view of an upholstery unit suitable for making round upholstered articles, numerals 7 and 8 designating the inner and outer covering plates, which are made from one piece of material each.
  • the interlocked partitions represented by numeral 1 in Figure 1 are preferably of equal dimensions. When shaped as illustrated in Figure 4, they may easily be put together at right angles to form cubic compartments. In order to obtain such partitions, a piece of elastic foamed material is cut as shown by the zigzag line in Figure 5, whereby two identical parts without any leftovers are formed.
  • the top and bottom of the compartments may be made.
  • the top and the bottom of the compartments may be formed by two or more pieces. Where two pieces of covering plate meet, they may be connected by gluing, sewing, welding, vulcanizing or in any other suitable manner.
  • the partitions and the covering iplates (bottom and top) of the compartments can be made of any elastic foamed material, such as rubber foam, polyvinylchlofride It is, of course, possible to combine different types of foam in one upholstery unit.
  • the partitions can be made of rubber foam and the covering plate of polyurethane foam or vice versa. It is also possible to make only certain elements, as, for example, the partitions of elastic foamed material and the remaining elements, as, for example, the bottom and the top of a different material.
  • the density of the elastic foamed material may range from about 25 kg./rn. to about 50 kg./m. densities within the range of 35 kg./m. to 45 kg./m. being preferred. Both foams with fine pores, having a diameter of between 0.1 and 0.3 mm., and foams with wide pores,
  • the new upholstery units are combined in any suitable manner. Depending upon the size of the article to be made, two or more units may be arranged side by side and/or one above the other. Small upholstered articles, such as cushions, may be made of one upholstery unit having the required dimensions.
  • the upholstery units of the invention offer the advantage of greatly simplifying the manufacture of upholstered articles. Since they consist of only two structural elements, i.e., partitions and covering plates, a work shop or factory engaged in the manufacture of the new upholstered articles need only a minimum of materials and tools. Another advantage resides in the fact that the upholstered articles made in accordance with the invention do not contain metallic parts (spiral springs). They are therefore unusually light.
  • Example A foamed material is prepared from the following reaction mixture:
  • Stripes 4 cm. thick and 8 cm. broad are cut from that foamed block material. These stripes are then further out in zigzag according to Figure 5. By this procedure a plurality of identical pieces is obtained which pieces can be put to gether to form an upholstery of any desired dimension.
  • An upholstery unit having, in combination, walls which completely enclose a cavitated interior and interlocking partitioning members dividing the said cavity into compartments having air pervious walls, at least one of said partitioning members extending across the cavity in one direction and another partitioning member extending across the cavity in an opposite direction and crossing the first said member, each of said members having a notch therein at the point of crossing, the combined depths of the two notches being substantially equal to the height of said member whereby the combined height of the partitions at the point of crossing is substantially equal to the height of the remainder of the partitions, said walls and partitioning members being formed from out resilient solidified foam thereby having a porous structure throughout which permits passage of air therethrough.
  • An upholstery unit having, in combination, walls which completely enclose a cavitated interior and interlocking partitioning members dividing the said cavity into compartments having air pervious walls, at least one of said partitioning members extending across the cavity in one direction and another partitioning member extending across the cavity in an opposite direction and crossing the first said member, each of said members having a notch therein at the point of crossing, the combined depths of the two notches being substantially equal to the height of said member whereby the combined height of the partitions at the point of crossing is substantially equal to the height of the remainder of the partitions, the resulting compartments formed by said partitions being substantially filled with air when the upholsterynnit is compressed, said walls and partitioning members being formed from cutresilient solidified foam thereby having a porous structure throughout and having a density of from about 25 kilograms per cubic meter to about kilograms per cubic meter and having pores therein of from about 0.1 millimeter to about 0.9 millimeter in cross section and a rebound elasticity of from about 20% to about 35%.
  • a method for making upholstery unit comprising preparing a partition by cutting a strip of a solidified foam material into pieces by forming alternate substantially equally dimensional and equally spaced notches and intermediate protuberances in one piece while simultaneously forming spaced complementary notches and intermediate protuberances in the other piece, assembling the resulting pieces by laying one across the other with the notches in one meshing with the notches in the other, and thereafter enclosing the assembly in a solidified foam cover.

Description

Sept. 27, 1960 D. MEYERHARDT STRUCTURAL UNITS FOR UPHOLSTERY PURPOSES I F/G.4
INVENTOR. DAGOBERT ME YERHARDT 2,954,074 Ice Patented SeP STRUCTURAL UNITS FOR UPHOLSTERY PURPOSES Dagobert Meyerhardt, Opladener Str. 127, Solingen-Landwehr, Germany; Ruth Erika Gertraud Schaller, administratrix of said Dagobert Meyerhardt, deceased Filed Dec. 16, 1955, Ser. No. 553,496
Claims priority, application Germany Dec. 21, 1954 3 Claims. (Cl. 155-179) This invention relates to structural units for upholstery purposes and to upholstered articles produced therefrom. in the present specification, the term upholstered article is used to designate cushions, mattresses, upholstered chairs, sofas, couches, divans, lounges, settees, love seats, hassocks, automobile seats, airplane seats and the like.
Heretofore, it has been common practice to use metallic springs in the manufacture of upholstered articles. These springs are usually mounted in wooden or metallic frames and covered by a layer of stufiingi Because of upholstery units which make it possible to manufacture v 5 the rather complicated construction of the conventional upholstered articles in a simple and economical manner.
Further objects will appear hereinafter.
It has now been found that a plurality of comparti ments filled with air and formed by an elastic material, at least part of said elastic material consisting of an elastic foam, constitutes a new upholstery principle. Thus, the present invention provides structural units for upholstery which comprise at least two series of pieces of elastic material, the pieces of each series being spaced from one another and angularly interlocked with the pieces of the other series so as to form the partitions of a plurality of compartments, and at least one plate of elastic material forming the bottom and the top of said compartments, at least part of said elastic material consisting of an elastic foam.
'In a preferred embodiment of the invention, two series of spaced pieces of elastic foamed material are interlocked at right angles so as to form the partitions of a plurality of adjoining cubic compartments, the bottom and the top of said cubic compartments being formed by at least one plate of elastic foamed material.
The invention will be specifically described with reference to the drawings, but it is understood that the invention is not limited by the physical limitations of the upholstery units illustrated and is capable of being embodied in upholstery units of other modifications than those chosen for the purpose of illustration.
'Figure 1 shows a preferred embodiment of an upholstery unit constructed in accordance with the present invention. This unit comprises the interlocked pieces 1 of elastic foamed material forming the adjoining cubic compartments 2, and the plates 3 and 5 of elastic foamed material meeting at the seam -4 and forming the bottom and the top of the compartments 2.
Figure 2 is a longitudinal sectional view of an upholstery unit in accordance with the invention, wherein the bottom and the top are formed by the plate 6.
foam and polyurethane foam.
Figure 3 is a cross sectional view of an upholstery unit suitable for making round upholstered articles, numerals 7 and 8 designating the inner and outer covering plates, which are made from one piece of material each.
The interlocked partitions represented by numeral 1 in Figure 1 are preferably of equal dimensions. When shaped as illustrated in Figure 4, they may easily be put together at right angles to form cubic compartments. In order to obtain such partitions, a piece of elastic foamed material is cut as shown by the zigzag line in Figure 5, whereby two identical parts without any leftovers are formed.
The top and bottom of the compartments may be made.
from one plate of elastic foamed material as illustrated in Figure 2. Alternatively, the top and the bottom of the compartments may be formed by two or more pieces. Where two pieces of covering plate meet, they may be connected by gluing, sewing, welding, vulcanizing or in any other suitable manner.
When pressure is applied to the upholstery units of the invention, as by the weight of the users of an upholstered article made therefrom, the air contained in the compartments will at first be compressed and then gradually escape through the pores of the elastic foam. As a result the upholstered article will assume. its final form slowly as distinguished'from all conventional upholstered articles which assume their final form rather quickly. It may, thus, be seen that in the upholstery units of the invention, the air contained in the compartments and the elasticity of the foamed building material coact to bring about an ideal springinessQ An upholstered article made from the upholstery units of the invention will have a high resilience in any state of compression. The use of upholstered articles made in accordance with the inven- :tion is, therefore, particularly pleasant.
The partitions and the covering iplates (bottom and top) of the compartments can be made of any elastic foamed material, such as rubber foam, polyvinylchlofride It is, of course, possible to combine different types of foam in one upholstery unit. Thus, the partitions can be made of rubber foam and the covering plate of polyurethane foam or vice versa. It is also possible to make only certain elements, as, for example, the partitions of elastic foamed material and the remaining elements, as, for example, the bottom and the top of a different material.
The density of the elastic foamed material may range from about 25 kg./rn. to about 50 kg./m. densities within the range of 35 kg./m. to 45 kg./m. being preferred. Both foams with fine pores, having a diameter of between 0.1 and 0.3 mm., and foams with wide pores,
having a diameter of between 0.6 and 0.9 mm., may beemployed in the construction of the upholstery units of the invention. Regarding elasticity foams should have a rebound within the range of about 20-35%.
In the manufacture of upholstered articles in accordance with the invention, the new upholstery units are combined in any suitable manner. Depending upon the size of the article to be made, two or more units may be arranged side by side and/or one above the other. Small upholstered articles, such as cushions, may be made of one upholstery unit having the required dimensions.
The upholstery units of the invention offer the advantage of greatly simplifying the manufacture of upholstered articles. Since they consist of only two structural elements, i.e., partitions and covering plates, a work shop or factory engaged in the manufacture of the new upholstered articles need only a minimum of materials and tools. Another advantage resides in the fact that the upholstered articles made in accordance with the invention do not contain metallic parts (spiral springs). They are therefore unusually light.
The following example is intended to be illustrative only. The invention is by no means limited to it.
Example A foamed material is prepared from the following reaction mixture:
100 parts by weight of a polyester prepared by thermal condensation of 15 mols of adipic acid, 16 mols of diethylene glycol and 1 mol of trimethylol propane; OH number 60, acid number below 1,
33 parts by weight of toluylene diisocyanate,
9.5 parts by weight of the following mixture:
3 parts by weight of his-(diethylarninoethanol)-adipate,
1.5 parts by weight of a sulfonated ricinolic acid (water content 54% 1.5 parts by weight of the sodium salt of a sulfonated castor oil (water content 54% 1 part by weight of water.
Stripes 4 cm. thick and 8 cm. broad are cut from that foamed block material. These stripes are then further out in zigzag according to Figure 5. By this procedure a plurality of identical pieces is obtained which pieces can be put to gether to form an upholstery of any desired dimension.
Having described my invention, I claim:
1. An upholstery unit having, in combination, walls which completely enclose a cavitated interior and interlocking partitioning members dividing the said cavity into compartments having air pervious walls, at least one of said partitioning members extending across the cavity in one direction and another partitioning member extending across the cavity in an opposite direction and crossing the first said member, each of said members having a notch therein at the point of crossing, the combined depths of the two notches being substantially equal to the height of said member whereby the combined height of the partitions at the point of crossing is substantially equal to the height of the remainder of the partitions, said walls and partitioning members being formed from out resilient solidified foam thereby having a porous structure throughout which permits passage of air therethrough.
2. An upholstery unit having, in combination, walls which completely enclose a cavitated interior and interlocking partitioning members dividing the said cavity into compartments having air pervious walls, at least one of said partitioning members extending across the cavity in one direction and another partitioning member extending across the cavity in an opposite direction and crossing the first said member, each of said members having a notch therein at the point of crossing, the combined depths of the two notches being substantially equal to the height of said member whereby the combined height of the partitions at the point of crossing is substantially equal to the height of the remainder of the partitions, the resulting compartments formed by said partitions being substantially filled with air when the upholsterynnit is compressed, said walls and partitioning members being formed from cutresilient solidified foam thereby having a porous structure throughout and having a density of from about 25 kilograms per cubic meter to about kilograms per cubic meter and having pores therein of from about 0.1 millimeter to about 0.9 millimeter in cross section and a rebound elasticity of from about 20% to about 35%.
3. A method for making upholstery unit comprising preparing a partition by cutting a strip of a solidified foam material into pieces by forming alternate substantially equally dimensional and equally spaced notches and intermediate protuberances in one piece while simultaneously forming spaced complementary notches and intermediate protuberances in the other piece, assembling the resulting pieces by laying one across the other with the notches in one meshing with the notches in the other, and thereafter enclosing the assembly in a solidified foam cover.
References Cited in the file of this patent UNITED STATES PATENTS 2,061,569 Fischer Nov. 24, 1936 2,371,788 Weeber Mar. 20, 1945 2,511,620 Clements June 13, 1950 2,617,751 Bickett Nov. 11, 1952 2,619,659 Futterknecht Dec. 2, 1952 FOREIGN PATENTS 434,550 Great Britain Sept. 4, 1935 782,886 France Mar. 25, 1935
US55349655 1954-12-21 1955-12-16 Structural units for upholstery purposes Expired - Lifetime US2954074A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DEM25549A DE1034336B (en) 1954-12-21 1954-12-21 Padding for seat cushions, mattresses, etc. like
GB3666155A GB821839A (en) 1954-12-21 1955-12-21 Structural units for upholstery purposes

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3047282A (en) * 1956-04-26 1962-07-31 Mobay Chemical Corp Upholstery units
US3526912A (en) * 1968-05-08 1970-09-08 Milbern Co Upholstering stuffing member
US4670960A (en) * 1986-05-20 1987-06-09 Actief N.V., Abn Trust Company (Curacao) N.V. Strip fastener material
US4843664A (en) * 1987-08-20 1989-07-04 Her Majesty The Queen In Right Of Canada, As Represented By The Minister Of National Defense Expanding insulating pad

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR782886A (en) * 1936-01-25 1935-06-14 Roth Freres & Cie Process for manufacturing rubberized animal or vegetable fiber padding and resulting product
GB434550A (en) * 1934-04-25 1935-09-04 Sorbo Ltd Improvements in or relating to the construction of seats, mattresses and the like
US2061569A (en) * 1931-11-30 1936-11-24 Albert C Fischer Composition sheet
US2371788A (en) * 1942-08-07 1945-03-20 Weeber Paul Cushion
US2511620A (en) * 1948-04-16 1950-06-13 Clements Macmillan Structural panel
US2617751A (en) * 1950-07-10 1952-11-11 Le Roy M Bickett Rubber pad
US2619659A (en) * 1950-09-26 1952-12-02 Us Rubber Co Reversible sponge cushion

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB368909A (en) * 1931-01-19 1932-03-17 Max Sherover Improvements in and relating to mattresses
US2141271A (en) * 1937-01-02 1938-12-27 Gerlofson Carl Hugo Upholstery

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2061569A (en) * 1931-11-30 1936-11-24 Albert C Fischer Composition sheet
GB434550A (en) * 1934-04-25 1935-09-04 Sorbo Ltd Improvements in or relating to the construction of seats, mattresses and the like
FR782886A (en) * 1936-01-25 1935-06-14 Roth Freres & Cie Process for manufacturing rubberized animal or vegetable fiber padding and resulting product
US2371788A (en) * 1942-08-07 1945-03-20 Weeber Paul Cushion
US2511620A (en) * 1948-04-16 1950-06-13 Clements Macmillan Structural panel
US2617751A (en) * 1950-07-10 1952-11-11 Le Roy M Bickett Rubber pad
US2619659A (en) * 1950-09-26 1952-12-02 Us Rubber Co Reversible sponge cushion

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3047282A (en) * 1956-04-26 1962-07-31 Mobay Chemical Corp Upholstery units
US3526912A (en) * 1968-05-08 1970-09-08 Milbern Co Upholstering stuffing member
US4670960A (en) * 1986-05-20 1987-06-09 Actief N.V., Abn Trust Company (Curacao) N.V. Strip fastener material
US4843664A (en) * 1987-08-20 1989-07-04 Her Majesty The Queen In Right Of Canada, As Represented By The Minister Of National Defense Expanding insulating pad

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DE1034336B (en) 1958-07-17
GB821839A (en) 1959-10-14

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