GB2551718A

GB2551718A - Textile support cover for a chair

Info

Publication number: GB2551718A
Application number: GB1611136.1A
Authority: GB
Inventors: Hallett Phil; Banks Gareth
Original assignee: Orangebox Ltd
Current assignee: Orangebox Ltd
Priority date: 2016-06-27
Filing date: 2016-06-27
Publication date: 2018-01-03
Also published as: GB201611136D0

Abstract

The present invention relates to chairs, in particular mesh seats and back support chairs. A textile support cover 2 for a chair comprises at least one knit textile material having a plurality of chair structure connection openings 10 knit into the material for connecting a chair structure to the cover 2. The cover 2 may have chair connection and user support zones defined by different knit patterns. These patterns may include a malt yarn. The textile material of the cover 2 may be three dimensionally knitted. Also disclosed are a chair comprising a frame 4 including connection structures which are received into the holes 10 in the support cover 2, and a method of manufacturing such a chair. In the case that the material of the cover 2 comprises a melt yarn, this yarn may be thermally shrunk after the cover 2 is applied onto the frame 4.

Description

(54) Title of the Invention: Textile support cover for a chair Abstract Title: Chair and textile support cover therefor (57) The present invention relates to chairs, in particular mesh seats and back support chairs. A textile support cover 2 for a chair comprises at least one knit textile material having a plurality of chair structure connection openings 10 knit into the material for connecting a chair structure to the cover 2. The cover 2 may have chair connection and user support zones defined by different knit patterns. These patterns may include a malt yarn. The textile material of the cover 2 may be three dimensionally knitted. Also disclosed are a chair comprising a frame 4 including connection structures which are received into the holes 10 in the support cover 2, and a method of manufacturing such a chair. In the case that the material of the cover 2 comprises a melt yarn, this yarn may be thermally shrunk after the cover 2 is applied onto the frame 4.

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

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-1Textile Support Cover for a Chair

The present invention relates to chairs, in particular mesh seats and backs for chairs.

An existing technique for manufacturing user supports for chairs, particularly but not exclusively for chair backs, is to manufacture a frame typically of a polymeric material to generally correspond to the shape of a seat or back. The frame comprises a plurality of frame projections adjacent a peripheral edge extending generally perpendicular to the plane of the seat or back, each providing connections for connecting with a textile support cover. This textile support cover for a user comprises a woven mesh which forms the structure that directly supports a user and around the peripheral edge of the woven mesh is sewn a plastic trim having a plurality of apertures formed therein, each of the apertures comprising a chair structure connection opening. During assembly the textile support cover is positioned so that the chair structure connection openings are received by the projections on the frame.

At this point during assembly there is minimal tension in the woven mesh. The tension is achieved through the inclusion within the woven mesh of a thermally shrinkable yarn. The assembled frame and user support are heat treated following assembly to cause shrinkage of the woven mesh causing tensioning of the woven mesh such that the plastic trim is pulled into tension on the projections. This is achieved through administering UV radiation to the assembly.

A limitation of this method of assembly is the difficulty, time and associated cost of sewing the plastic trim onto the woven mesh. A further significant downstream problem is after the chair has completed its useful life, disassembly for recycling and disposal is difficult. A further disadvantage is the potential weakness in the sewn join between the woven mesh and the plastic trim. Aspects of the present invention overcome these problems.

According to a first aspect of the present invention there is a textile support cover for a chair comprising at least one knit textile material having a plurality of chair structure

-2connection openings knit into the textile material for connecting a chair structure to the support cover.

The applicant has determined that by knitting the textile support cover, the chair structure connection openings can be knit directly into the support covering, meaning the step of adding the plastic trim has been removed. There is therefore direct attachment of the knit mesh to the chair structure whether a seat or a back. This improves speed of manufacture and thus reduces cost by removing a manufacturing step of securing the plastic trim to the textile support cover. Furthermore, downstream recycling is made easier. Furthermore, the strength of the join between chair structure and textile support cover is increased as the knit connection opening(s) is stronger than a sewn joint between the plastic trim and the woven mesh known in the art.

The term ‘knit’ takes a standard meaning of interlacing or interlocking loops of yam. The textile support cover provides a surface against which a user rests a body part. The textile support covering comprises a chair’s seat or back.

The textile support cover comprises one or more chair structure connection zones into which the chair structure connection openings are knit and a user support zone, wherein the knit pattern in the one or more chair structure connection zones is different to the knit pattern in the user support zone.

The user support zone is the area of the textile support cover that the user typically engages with. For example, if the textile support cover is for a chair back, then the user support zone is the area that contacts the back of the user of the chair.

There may be a plurality of independent chair structure connection zones or one continuous chair structure connection zone. A chair structure connection zone preferably surrounds the plurality of chair structure connection openings.

The knit pattern in the one or more chair structure connection zones is preferably denser than the knit pattern in the user support zone. The tensile strength of the one or more chair

-3structure connection zones is preferably greater than the tensile strength of the user support zone. It is important that the change in knit pattern means the strength of the knit around the plurality of chair structure connection openings increases the strength of the seat user support in this area.

The knit pattern beneficially includes a melt yam. This means that during the assembly process the melt yam can be heat activated thus tensioning and shrinking the dimensions of the mesh of the textile support cover. This tightens the mesh onto the chair’s seat or back stmcture during the assembly process. It is beneficial that a majority of the knit pattern comprises yarn that is not a melt yam. Typically all or a majority of the yam in the knit pattern comprises polyester and/or nylon. Such yarns are melt yams if they have not been pre-shmnk. In order to achieve pre-shrunk yams a heat treatment process is carried out prior to knitting. The majority of the yams are preferably pre-shmnk.

The knit pattern in the one or more chair stmcture connection zones preferably comprises a melt yarn. The textile material comprises a plurality of yarns, and wherein some of the yams are pre-shrunk.

The knit pattern in the user support zone beneficially does not include a melt yarn. As the yams are typically made from polyester or nylon the yarns in the user support zone are preshmnk. A melt yarn is beneficially introduced during the knitting process for knitting the one or more chair stmcture connection zones.

The chair stmcture connection zone beneficially includes a plurality of chair stmcture connection openings therein. These openings are beneficially apertures through the knit mesh. The chair structure connection zone may comprise a band. The band is beneficially adjacent a peripheral edge of the textile support cover and preferably extends substantially around the peripheral edge of the textile support cover. Accordingly, the user support zone of the textile support cover is encapsulated within the band.

The textile support cover material is beneficially three dimensionally (3D) knitted material. 3D knitting is well known. Accordingly, the textile support cover can be knit without

-4requiring any sewing or seams. The knit pattern can be changed as the knitting progresses in order that the knit pattern around the chair structure connection openings has increased strength, through increasing density of the knit pattern for example.

The textile support cover is beneficially a chair back.

Also according to the present invention there is a chair structure comprising a frame having a plurality of connection structures and a textile support cover for a chair comprising at least one knit textile material having a plurality of chair structure connection openings knit into the textile material, wherein the connection structures are received into the chair structure connection openings.

The chair structure may comprise a chair seat or a chair back.

The connection structures beneficially comprise engagement projections. It is beneficial that the connection structures engage with the textile support cover adjacent to the chair structure connection openings. The engagement projections may comprise one or more fins and preferably one or more hook formations for preventing unintentional release of the textile support cover from the frame.

Also according to the present invention there is a method of manufacturing a chair structure, wherein the textile support cover according to any preceding claim is applied onto a frame having a plurality of connection structures such that the connection structures are inserted into the chair structure connection openings.

The chair structure may comprise a chair seat or a chair back.

It is beneficial that the knit textile material comprises a melt yam therein and even more preferably wherein the melt yam is provided in a chair stmcture connection zone into which the chair stmcture connection openings are knit, and further comprising the subsequent step of thermally shrinking the melt yam through application of heat.

-5The present invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a schematic rear, side, plan and perspective view of a chair structure according to an exemplary embodiment of the present invention, and a textile support cover according to an exemplary embodiment.

Figure 2(a) is a schematic perspective view of a structural back frame, figure 2(b) is schematic view of a textile support cover, and figure 2(c) is schematic perspective view of a chair structure frame in the form of a back upholstery plate onto which the textile support cover is fitted according to exemplary embodiments of the present invention.

Figure 3 is a schematic representation of the application of a textile support cover onto a chair structure frame (such as a back upholstery plate) during assembly.

Figures 4 (a) and (b) are schematic perspective views of embodiments of the textile support cover according to exemplary embodiments of the present invention.

Referring to the figures, figure 1 shows a seat structure comprising a chair back arrangement comprising a textile support cover 2 secured to a frame 4 fixed to which is a cover 6. It will be appreciated that the textile support cover of the present invention is most predominantly used for seat backs. However, it may also be utilised for seat chairs.

Referring to figure 2(a) there is a schematic representation of a chair structure cover which is arranged to engage with the frame 4 as shown in figure 2(c). The cover 6 and frame 4 interact to engage with each other by a plurality of clips 8 to effectively sandwich the peripheral edge of the textile support cover 2 between the frame 4 and cover 6. Once these three components are secured together, this chair structure is ready for attachment to other chair components.

Referring in more detail to figure 2(b), the textile support cover 2 comprises at least one knit textile material. Various knit patterns are envisaged however it is beneficial a knit

-6pattern is three dimensional which increases the strength of the knit material. Adjacent the edge of the textile support cover 2 are provided a plurality of chair structure connection openings 10. These openings 10 are knit directly into the textile support cover 2 and are shown in figure 2(b) as beneficially elongate in order to engage with correspondingly elongated connection structures 12 provided projecting from the frame 4. The connection structures 12 are beneficially in the form of fins and are elongated in the direction substantially parallel to the general direction of the applied force as a result of the user pushing against the textile support cover 2. During assembly the textile support cover 2 is applied onto the frame 4 such that the connection structures 12 project through the openings 10. As the textile support cover beneficially comprises melt yarns the seat structure, either before or after connecting the cover 6 to the frame 4, is heat treated to effectively shrink the textile support cover 2 thus tensioning the textile support cover onto the frame 4. This therefore prevents the mesh surrounding the openings 10 from disengaging from the connection structures 12. Joining the cover 6 and frame 4 then encapsulate the peripheral edge defining the openings 10 of the textile support cover 2.

Presented in figure 3 is a more detailed presentation of the openings 10 in the form of elongated slots ready to be relocated over the connection structures 12 in the form of elongated fins.

Referring now to figure 4(a) there is a schematic perspective view of a textile support cover 2 according to an exemplary embodiment. In this embodiment there is presented a chair structure connection zone 14 in the form of a band adjacent to the peripheral edge of the textile support cover 2. Within this band are formed the chair structure connection openings 10 which are knit directly into the connection zone 14. The knit pattern in the connection zone 14 is beneficially denser that the knit pattern in the user support zone 16 surrounded by the connection zone 14. This is beneficial for two reasons. The first reason is that the provision of connection openings 10 within the knit pattern causes localised areas of reduced strength and thus increasing the knit pattern density surrounding the connection openings 10 reduces the possibility of the knit structure failing. This second advantage is that some flexibility is retained in the user support zone 16 for comfort in use.

-7The density and thus the strength of the connection zone 14 is further beneficially achieved through three dimensional knitting. This means that even in the event of a small cut occurring in the textile support cover 2 tearing of the textile support cover is unlikely. The connection zone 14 beneficially includes melt yarn which means that upon application of heat the melt yam shrinks thereby causes the overall dimensions if the textile support cover to contract. By providing melt yarn within the connection zone 14 contraction effectively causes the dimensions of the connection openings 10 to reduce and contract about the connection structures 12. It will be appreciated that melt yams may simply be nylon or polyester that has not undergone pre-treatment shrinkage. As such, all of the yams of the textile support cover may be made of the same material such as nylon or polyester. However, the majority of the yams may have been pre-shmnk. In one embodiment all the yams with a user support zone 16 may be pre-shmnk whereas the textile support cover 2 is undergoing knitting during manufacture melt yarns are introduced upon reaching the required connection zone 14.

Referring to figure 4(b), in an alternative embodiment the connection zone 14 is not in the form of band but is in the form or a plurality of individual connection zones 14. Through changing the operation of the knitting machine during manufacture exact size and shape of the connection zones 14 can be manipulated as appropriate dependent upon the desired shape of the textile support cover 2.

The present invention has been described by way of example only and it will be appreciated to the skilled addressee that modifications and variations may be made without departing from the scope of protection afforded by the appended claims.

Claims

1. A textile support cover for a chair comprising at least one knit textile material having a plurality of chair structure connection openings knit into the textile material for connecting a chair structure to the support cover.

2. A textile chair support cover according to claim 1 further comprising one or more chair structure connection zones into which the chair structure connection openings are knit and a user support zone, wherein the knit pattern in the one or more chair structure connection zones is different to the knit pattern in the user support zone.

3. A textile chair support cover according to any claim 2 wherein the knit pattern in the one or more seat structure connection zones is denser than the knit pattern in the user support zone.

4. A textile chair support cover according to any of claims 2-3 wherein the tensile strength of the one or more chair structure connection zones is greater than the tensile strength of the user support zone.

5. A textile chair support cover according to any preceding claim, wherein the knit pattern includes a melt yam.

6. A textile chair support cover according to any of claims 2-5 wherein the knit pattern in the one or more chair structure connection zones comprises a melt yam.

7. A textile chair support cover according to any of claims 2-6 wherein the knit pattern in the user support zone does not include a melt yarn.

8. A textile chair support cover according to any of claims 2-7 wherein one or more chair stmcture connection zones includes a plurality of chair stmcture connection openings therein.

9. A textile chair support cover according to any of claims 2-8 wherein the one or more chair stmcture connection zones comprises a band.

-910. A textile chair support cover according to any preceding claim wherein the textile material is a three dimensionally (3D) knitted material.

11. A textile chair support cover according to any preceding claim wherein the textile support covering is a chair back.

12. A chair structure comprising a frame having a plurality of connection structures and a textile support cover for a chair comprising at least one knit textile material having a plurality of chair structure connection openings knit into the textile material, wherein the connection structures are received into the chair structure connection openings.

13. A chair structure according to claim 12 wherein the one or more connection structures comprise engagement projections.

14. A chair structure or frame according to any preceding claim as hereinbefore described with reference to the accompanying drawings.

15. A method of manufacturing a chair structure, wherein the textile support cover according to any preceding claim is applied onto a frame having a plurality of connection structures such that the connection structures are inserted into the chair structure connection openings.

16. A method according to claim 15 wherein the knit textile material comprises a melt yarn therein, and further comprising the subsequent step of thermally shrinking the melt yam through application of heat.

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GB1611136.1

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