HOME FURNITURE ASSEMBLY SYSTEM AND METHOD

(19)

(11)

EP 4 282 307 A1

(12)	EUROPEAN PATENT APPLICATION

(43)	Date of publication:
	29.11.2023 Bulletin 2023/48

(21)	Application number: 23175298.1

(22)	Date of filing: 25.05.2023

(51)

International Patent Classification (IPC):

A47C 31/02^(2006.01)

(52)	Cooperative Patent Classification (CPC):
	A47C 31/023

(84)	Designated Contracting States:
	AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC ME MK MT NL NO PL PT RO RS SE SI SK SM TR
	Designated Extension States:
	BA
	Designated Validation States:
	KH MA MD TN

(30)

Priority:

27.05.2022 GB 202207849

(71)	Applicant: Westbridge Furniture Designs Limited
	Flintshire CH8 7FF (GB)

(72)	Inventors:
	MILTON-PARRY, Dustyn Flintshire, CH8 7FF (GB) SIDES, Lee Flintshire, CH8 7FF (GB)

(74)	Representative: Swindell & Pearson Limited
	48 Friar Gate Derby DE1 1GY Derby DE1 1GY (GB)

(54)	HOME FURNITURE ASSEMBLY SYSTEM AND METHOD

(57) The present disclosure relates to a home furniture assembly system (200) and method. The system comprises: a frame part (210) defining at least a portion of a furniture frame (100), the frame part comprising a first face (211) to be upholstered, and a further face (212 or 213); an upholstery sheet (220) for at least the frame part (210), the upholstery sheet comprising a covering section (222) to cover the first face (211), and a flap section (224) to be tucked around an edge (215) of the first face (211) and to extend along the further face (212 or 213); and an elongate connector (230) secured to the upholstery sheet (220) along the flap section (224), wherein the frame part (210) comprises an elongate bearer (240) at the further face (212 or 213), to which the elongate connector (230) can be secured to pull the upholstery sheet (220) taut, and wherein one of the elongate connector (230) or the elongate bearer (240) comprises a socket (S) and the other comprises a plug (P). The home furniture assembly system (200) further comprises a hook and loop fastener system (900).

Description

FIELD OF THE INVENTION

[0001] Embodiments of the present invention relate to a home furniture assembly system and method. In particular, they relate to a staple-free or mostly staple-free home furniture assembly system and method for the factory manufacture of upholstered home furniture.

BACKGROUND TO THE INVENTION

[0002] Home furniture includes, among other things, chairs such as sofas, armchairs, or sofabeds, and includes other furniture such as beds. Home furniture can be used in domestic or commercial buildings, for example.

[0003] Currently, the upholstered home furniture market uses traditional methods of manufacturing. A wooden frame is built. Cards, fibre boards, etc, are stapled to the wooden frame to provide support, Foam/insulators/fibres are layered up over the frame and stapled to the frame. Finally, covers of sewn-together upholstery panels are dressed and stapled to the frame.

[0004] The use of staples to assemble the furniture creates a non-recyclable product. This is because disassembling the product would take too long. Therefore, home furniture assembled with staples are generally dismissed as uneconomical to recycle and sent to landfill.

[0005] The use of staples to assemble the furniture is also labour-intensive. The assembler must manually manipulate the upholstery to achieve consistency across the product. This requires a high degree of skill and time to achieve a perfect finish. Some upholsterers can achieve better consistency than others.

[0006] Upholsterers must also treat staple guns with care to mitigate stapling-related hazards.

BRIEF DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

[0007] According to various, but not necessarily examples there is provided a home furniture assembly system comprising:

a frame part defining at least a portion of a furniture frame, the frame part comprising a first face to be upholstered, and a further face;

an upholstery sheet for at least the frame part, the upholstery sheet comprising a covering section to cover the first face, and a flap section to be tucked around an edge of the first face and to extend along the further face; and

an elongate connector secured to the upholstery sheet along the flap section,

wherein the frame part comprises an elongate bearer at the further face, to which the elongate connector can be secured to pull the upholstery sheet taut,

wherein one of the elongate connector or the elongate bearer comprises a socket and the other comprises a plug, and

wherein the home furniture assembly system further comprises a hook and loop fastener system.

[0008] An advantage is improved recyclability because the assembly system is staple-free.

[0009] In some examples, recyclability can be further improved by additionally introducing any one or more of the following features described herein: a hooked seat back suspension system; a slat carrier with slat pockets; or a seat subassembly with a zip or zips.

[0010] Optionally, the elongate connector extends continuously or intermittently along the flap section of the upholstery sheet to define a total connection length of at least 85% of a length of the first face.

[0011] Optionally, the elongate bearer is the socket and the elongate connector is the plug. Optionally, the elongate bearer comprises a groove extending along the further face of the frame part, wherein the elongate connector comprises a strip of a material more rigid than the upholstery sheet, and wherein a width and depth of the groove are sized to enable insertion of the strip into the groove. Optionally, the further face of the frame part is opposite the first face or adjacent the first face.

[0012] Alternatively, the elongate bearer comprises the plug and the elongate connector comprises the socket. Optionally, the elongate bearer comprises an elongate bearer member, wherein a first side of the elongate bearer member is secured along the further face of the frame part, wherein a second, adjacent side of the elongate bearer member overhangs an edge of the further face of the frame part opposite the edge of the first face, and wherein the overhanging second side of the elongate bearer member provides the plug to which the socket of the elongate connector can be connected. Optionally, the further face of the frame part is connected to the first face by the edge of the first face. Optionally, the elongate connector comprises a clip defining the socket, wherein the clip is sized to be fitted to the second side of the elongate bearer member overhanging the edge of the further face. Optionally, the elongate bearer member is secured to the frame part by a reversible fixing means.

[0013] Optionally, the elongate connector is secured to the flap section of the upholstery sheet by a fabric flange.

[0014] Optionally, the home furniture assembly system comprises an internal frame part defining a further portion of the furniture frame, and comprises a furniture cover, wherein the furniture cover comprises the upholstery sheet, a horizontal seat upholstery sheet, a seat back upholstery sheet, and an internal flap section connected to an internal side of a crease between the horizontal seat upholstery sheet and the seat back upholstery sheet, wherein the internal flap section comprises an elongate connector, and wherein the internal frame part comprises an elongate bearer to which the elongate connector can be secured to pull the internal flap section taut to maintain a sharpness of the crease. Optionally, the internal flap section extends over a pair of edges of the internal frame part.

[0015] Optionally, the home furniture assembly system further comprises a hook and loop fastener system for at least one of: a second upholstery sheet; a portion of the upholstery sheet; an insulation sheet; or padding.

[0016] Optionally, the home furniture assembly system comprises a second frame part. Optionally, the second frame part comprises an arm structure of the furniture frame.

[0017] Optionally, the home furniture assembly system comprises a second upholstery sheet, wherein one edge of the second upholstery sheet comprises a hooked sheet and an opposite hidden edge of the second upholstery sheet comprises a looped sheet, the hooked sheet and looped sheet defining a hook and loop fastener system, enabling the hidden edges to be tucked under the second frame part and attached to each other via the hooked sheet and looped sheet.

[0018] Optionally, the home furniture assembly system comprises an insulation sheet, wherein a first side of the insulation sheet is connectable to a first side of the second frame part by a first hook and loop fastener system, wherein the insulation sheet extends over the top of the second frame part to a second opposite side, and wherein the second opposite side of the insulation sheet is connected to a second side of the second frame part by a second hook and loop fastener system.

[0019] Optionally, the home furniture assembly system comprises padding, wherein the padding is connectable directly to hooked sheets attached to the second frame part.

[0020] Optionally, the home furniture assembly system further comprises a seat back suspension system comprising a plurality of webbing straps hooked to a seat back structure of the furniture frame.

[0021] Optionally, the home furniture assembly system further comprises a slat carrier for carrying a plurality of slats. Optionally, the slat carrier comprises a plurality of slat pockets, each slat pocket having an open end in to which one of the slats can be inserted, wherein the slat carrier comprises an end flap foldable over one or more of the open ends of the slat pockets, and wherein the slat carrier comprises a reversible fixing means for securing the end flap when folded. Optionally, the slat carrier comprises a plurality of fixing points for reversible fixings to secure the slat carrier to the furniture frame, wherein a quantity of the fixing points is fewer than a number of the slats that the slat carrier is configured to carry.

[0022] Optionally, the home furniture assembly system further comprises a seat subassembly having a seat platform part and a protruding flap, wherein the furniture frame comprises a cross-member around which the protruding flap can be wrapped, and wherein the seat subassembly comprises a zip for securing the protruding flap to the seat platform part to define a passage through which the cross-member extends.

[0023] Optionally, the first face is an upright face of the frame part, wherein the flap section is a bottom flap section, and wherein the edge of the first face is a bottom edge of the first face.

[0024] Optionally, the furniture frame comprises a pair of opposite long frame members and a pair of opposite short frame members, each of the long and short frame members being a frame part. Optionally, the upholstery sheet comprises a plurality of elongate connectors, each securable to an elongate bearer at an underside of each of the long and short frame members.

[0025] Optionally, the home furniture assembly system comprises top and bottom elongate bearers including the elongate bearer, to connect to top and bottom elongate connectors of the upholstery sheet including the elongate connector.

[0026] Optionally, the frame part is a wood frame member, wherein the first face and the further face are faces of the wood frame member.

[0027] According to various, but not necessarily examples there is provided home furniture comprising the furniture frame and the home furniture assembly system.

[0028] According to various, but not necessarily examples there is provided a method of assembling a home furniture frame, the method comprising:

fitting an upholstery sheet over a frame part, the frame part defining at least a portion of a furniture frame, the frame part comprising a first face to be upholstered, and a further face, the upholstery sheet comprising a covering section to cover the first face, and a flap section, wherein an elongate connector is secured to the upholstery sheet along the flap section, wherein the frame part comprises an elongate bearer at the further face, and wherein one of the elongate connector or the elongate bearer comprises a socket and the other comprises a plug;

tucking the flap section of the upholstery sheet around an edge of the first face and positioning the flap section to extend along the further face;

securing the elongate connector of the upholstery sheet to the elongate bearer to pull the upholstery sheet taut; and

wherein assembling the furniture frame includes using a hook and loop fastener system.

[0029] According to various, but not necessarily examples there is provided a home furniture assembly system comprising:

a frame part defining at least a portion of a furniture frame, the frame part comprising a first face to be upholstered, and a further face;

an elongate connector secured to the upholstery sheet along the flap section,

wherein the frame part comprises an elongate bearer at the further face, to which the elongate connector can be secured to pull the upholstery sheet taut,

wherein one of the elongate connector or the elongate bearer comprises a socket and the other comprises a plug.

[0030] According to various, but not necessarily examples there is provided a method of assembling a home furniture frame, the method comprising:

tucking the flap section of the upholstery sheet around an edge of the first face and positioning the flap section to extend along the further face;

securing the elongate connector of the upholstery sheet to the elongate bearer to pull the upholstery sheet taut.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] For a better understanding of various examples of embodiments of the present invention reference will now be made by way of example only to the accompanying drawings in which:

FIG. 1 illustrates a side view of a furniture frame;

FIG. 2 illustrates a front view of the furniture frame of FIG. 1;

FIGS. 3A-3C illustrate implementations of a first embodiment of a plug-socket system for connecting an upholstery sheet to a frame part;

FIG. 4 illustrates a second embodiment of the plug-socket system;

FIG. 5A illustrates a furniture cover comprising a plug-socket system;

FIG. 5B illustrates a single upholstery sheet connected at its top and bottom edges to a frame part by a plug-socket system;

FIG. 6 illustrates a seat subassembly having a protruding flap and a zip;

FIG. 7 illustrates a seat back suspension system;

FIG. 8 illustrates a slat carrier; and

FIG. 9 illustrates a hook and loop fastener system.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

[0032] FIGS. 1-2 illustrate a side view and a front view, respectively, of a home furniture frame 100 ('furniture frame' herein). Solid lines indicate visible parts and dashed lines indicate parts that are occluded by the visible parts.

[0033] The illustrated furniture frame 100 is a chair frame. The furniture frame 100 may be a frame of an armchair or a sofa (couch), for example. Aspects of the invention may further be applicable to other types of home furniture, including but not limited to upholstered bed frames, sofa beds, footstools, corner sofas, chaise sofas, etc.

[0034] The furniture frame 100 comprises a plurality of frame parts. At least some of the frame parts can be wood frame members made of softwood, hardwood, or engineered wood. Additionally, or alternatively, metal frame members or plastic frame members may be used.

[0035] As shown, the furniture frame 100 can comprise a base structure in the form of a seat base structure 102. As shown, the furniture frame 100 can also comprise a second structure in the form of a seat back structure 104.

[0036] In use, the seat base structure 102 of the furniture frame 100 either rests on the ground or is connected to weight-supporting feet (not shown). The seat base structure 102 is configured to support most or all of the weight of the seat occupant or occupants.

[0037] The top of the seat base structure 102 provides a horizontal platform 103 onto which a seat subassembly 600 (optionally as shown in FIG. 6) or a slat carrier 800 (optionally as shown in FIG. 8) is connectable, depending on the implementation.

[0038] The seat base structure 102 comprises a pair of opposite long frame members 120F, 120R and a pair of opposite short frame members 110L, 110R interconnecting the long frame members 120F, 120R. The illustrated long frame members 120F, 120R and the short frame members 110L, 110R are assembled into a four-sided frame. The short frame members 110L, 110R may be perpendicular to the long frame members 120F, 120R. The long frame members 120F, 120R and the short frame members 110L, 110R can be wood frame members, in an example.

[0039] As shown, the long frame members 120F, 120R and the short frame members 110L, 110R can define the outer frame of the seat base structure 102. Therefore, exterior faces of the long frame members 120F, 120R and short frame members 110L, 110R may be dressed by upholstery.

[0040] If the furniture frame 100 is a sofa frame, the short frame members 110L, 110R may define at least in part the left and right sides of the furniture frame 100. The long frame members 120F, 120R may comprise a front long frame member 120F and rear long frame member 120R respectively defining the front and rear sides of the furniture frame 100, at least in part.

[0041] If the furniture frame is for a different type of furniture, the frame members 110L, 110R, 120F, 120R may be of approximately equal length or the front and rear frame members 120F, 120R may be shorter.

[0042] Arm structures may optionally be connected to the short frame members 110L, 110R. An example of an arm structure 910 is described later and shown in FIG. 9.

[0043] As shown in FIGS. 1 and 2, the seat base structure 102 can further comprise internal frame parts in the form of internal frame members 130, 132 (e.g., beams) for anchoring various components. The illustrated internal frame members 130, 132 extend parallel to the long frame members 120F, 120R. The internal frame members 130, 132 can be made of the same type of material as the other members 120F, 120R, 110L, 110R.

[0044] The seat back structure 104 is an upright part of the furniture frame 100 against which the occupant can recline. As shown in FIGS. 1-2, the seat back structure 104 can be slanted relative to the base structure at a recline angle which may be fixed or variable.

[0045] The seat back structure 104 can be configured to support a seat back suspension system 700 (optionally as shown in FIG. 7) or a slat carrier 800 (optionally as shown in FIG. 8), depending on the implementation.

[0046] As shown in FIGS. 1-2, the seat back structure 104 can comprise opposite left and right frame parts 140L, 140R, and a top frame part 150 interconnecting the left and right frame parts 140L, 140R. The left and right frame parts 140L, 140R of the seat back structure 104 may connect to and/or align with the short frame members 110L, 110R of the seat base structure 102. The top frame part 150 of the seat back structure 104 may extend generally parallel to the long frame members 120F, 120R and/or internal frame members 130, 132 of the seat base structure 102. The top frame part 150 may be a beam.

[0047] The left frame part 140L and/or right frame part 140R and/or top frame part 150 of the seat back structure 104 can be made of a same material as the long frame members 120F, 120R and/or short frame members 110L, 110R of the seat base structure 102 wood frame members, in an example.

[0048] FIGS. 1-2 further illustrate frame parts of an optional seat back suspension system 700 from FIG. 7, wherein the frame parts are in the form of rails 160, 170. The rails include an upper rail 160 and a lower rail 170. In other examples, they are different frame parts than rails. These upper and lower rails 160, 170 could be omitted or replaced with something different, for example if a traditional serpentine spring back suspension is used, or if a slat carrier 800 (e.g., FIG. 8) is used.

[0049] The upper rail 160 of the seat back suspension system 700 is connected at each end to the left frame part 140L and right frame part 140R of the seat back structure 104. The lower rail 170 of the seat back suspension system 700 is connected at each end to the left frame part 140L and right frame part 140R of the seat back structure 104.

[0050] The upper rail 160 of the seat back suspension system 700 is adjacent the top frame part 150 of the seat back structure 104, and may be parallel. The lower rail 170 of the seat back suspension system 700 is proximal to the seat base structure 102.

[0051] With reference to the cross-section views of FIGS. 3A-5B, a method and a home furniture assembly system 200 are now described, for connecting an upholstery sheet 220 to at least one frame part 210 of a furniture frame 100, such as part of the furniture frame 100 described above in relation to FIGS. 1-2.

[0052] FIGS. 3A-3B provide a first embodiment of a plug-socket system for connecting the upholstery sheet 220 to a frame part 210, and FIG. 4 provides a second embodiment of a plug-socket system for connecting the upholstery sheet 220 to the frame part 210. Some furniture frames may employ both embodiments.

[0053] In each case, the connection is reversible. The connection may be made and reversed without a need to use tools to engage and disengage the connection. The furniture frame may be stripped of upholstery in seconds or minutes.

[0054] First, the frame part 210 of FIGS. 3A-4 and 5B is defined. The frame part 210 can be any of the frame parts 120F, 120R, 110L, 110R, 140L, 140R, 150, 130, 132 shown in FIG. 1 or 2. For example, the frame part 210 can be part of the seat base structure 102. The frame part can be a wood frame member. In an implementation, the illustrated frame part 210 can be one of the long frame members 120F, 120R, one of the short frame members 110L, 110R, or one of the internal frame members 130, 132. In some implementations, the frame part 210 can be a part of the seat back structure 104 such as 140L, 140R, 150.

[0055] The frame part 210 can comprise two or more faces connected by edges. In FIGS. 3A-4, the top of the frame part 210 is cut off, but FIG. 5B shows a complete cross-section illustrating a four-sided shape in the form of a quadrilateral shape.

[0056] The illustrated cross-section of the frame part 210 comprises a first face 211 in the form of an exterior face of the furniture frame 100, wherein the exterior face is to be upholstered.

[0057] In the example in which the frame part 210 is a frame member of the seat base structure 102, the first face 211 of the frame part 210 is an upright face.

[0058] In the example in which the frame part 210 is one of the long frame members 120F, 120R of the seat base structure 102, the first face 211 of the frame part 210 may be an exterior face defining at least part of a front face or rear face of the seat base structure 102 of the furniture frame 100.

[0059] In the example in which the frame part 210 is one of the short frame members 110L, 110R of the seat base structure 102, the first face 211 of the frame part 210 may be an exterior face defining at least part of a left or right face of the seat base structure 102 of the furniture frame 100.

[0060] The illustrated frame part 210 further comprises a second face 212, a third face 213, and a fourth face 214, when viewed in cross-section. The further faces 212-214 are to the interior side of the furniture frame 100, compared to the first face 211. In other examples, the frame part 210 can have fewer than or more than four faces.

[0061] The second face 212 is downwardly-facing. The second face 212 may be generally horizontal. In the example in which the frame part 210 is a long frame member 120F or 120R or short frame member 110L or 110R of the seat base structure 102, the second face 212 may define at least part of an underside 105 of the furniture frame 100.

[0062] The third face 213 is upstanding. The third face 213 is opposite the first face 211. The third face 213 can be parallel to the first face 211. In the example in which the frame part 210 is a long frame member 120F or 120R or short frame member 110L or 110R of the seat base structure 102, the third face 213 may be interior-facing whereas the first face 211 is exterior-facing.

[0063] The fourth face 214 is upwardly-facing. The fourth face 214 may be generally horizontal. The fourth face 214 can be a top face of the frame part 210. In the example in which the frame part 210 is a front long frame member 120F or the left or right short frame member 110R of the seat base structure 102, the fourth face 214 may define at least a boundary part of the horizontal platform 103 of the seat base structure 102.

[0064] As shown, the first face 211 and third face 213 can be opposite each other. The second face 212 and fourth face 214 can be opposite each other.

[0065] In the example in which the frame part 210 is a front long frame member 120F or a short frame member 110L, 110R of the seat base structure 102, the second face 212 and fourth face 214 can each have a smaller surface area than the first face 211 and second face 212. The second face 212 and fourth face 214 can be edge faces of an upstanding wood frame member, their widths defining the thickness of the wood frame member.

[0066] The first face 211 and second face 212 are connected to each other by a first edge 215. The second face 212 and third face 213 are connected to each other by a second edge 216. The first face 211 and fourth face 214 are connected to each other by a third edge 217. The fourth face 214 and third face 213 are connected to each other by a fourth edge 218. The first to fourth edges 215-218 may be approximately right angled and may or may not comprise a transitional edge.

[0067] In the example in which the frame part 210 is a long frame member 120F or 120R or short frame member 110L or 110R of the seat base structure 102, the first edge 215 may define a bottom exterior edge of the seat base structure 102 of the furniture frame 100, the second edge 216 may define a bottom interior edge of the seat base structure 102 of the furniture frame 100, the third edge 217 may define an upper or top exterior edge of the seat base structure 102 of the furniture frame 100, and the fourth edge 218 may define an upper or top interior edge of the seat base structure 102 of the furniture frame 100.

[0068] Each of the first to fourth faces 211-214 may be approximately planar and perpendicular to the other faces to which it is connected.

[0069] In the example in which the frame part 210 is a long frame member 120F or 120R or short frame member 110L or 110R of the seat base structure 102, the width of the second face 212 and/or the fourth face 214 defines the shortest dimension (thickness) of the frame part 210. The width of the first face 211 and/or third face 213 defines the longest dimension of the frame part 210. The height of the upstanding first face 211 and/or third face 213 defines the height of the frame part 210, the height dimension being between the shortest and longest dimensions.

[0070] The shortest dimension of the frame part 210 may be in the order of less than ten centimetres. The shortest dimension of the frame part 210 may be in the order of at least approximately 1.5 centimetres. The longest dimension of the frame part 210 may be in the order of greater than 30 centimetres. The height dimension may be greater than 4 centimetres in some examples, and up to 150 centimetres in the case of some bed headboards.

[0071] Turning now to the upholstery, the upholstery sheet 220 shown in FIGS. 3A-5B can comprise natural or synthetic leather, or a woven or knit textile, for example. Optionally, hidden sections of the upholstery sheet 220 can comprise a different fabric.

[0072] The upholstery sheet 220 has an exterior side providing an aesthetic finish, and an interior side which may not have an aesthetic finish. In some, but not necessarily all examples, an insulator layer or substrate may be layered to the interior side of the upholstery sheet 220.

[0073] The upholstery sheet 220 can either comprise a single panel of upholstery material as per FIG. 5B, or can be a panel of a furniture cover as per FIG. 5A. The furniture cover comprises a plurality of such panels secured to each other by stitching or by other means to form a three-dimensional shape for fitting to at least part of the furniture frame 100.

[0074] As shown in FIGS. 3A-4, the upholstery sheet 220 comprises a covering section 222 sized to cover at least the area of the first face 211 of the frame part 210, wherein the area of the first face 211 is defined as the nominal width of the first face 211 multiplied by the nominal height of the front face.

[0075] The upholstery sheet 220 further comprises a flap section 224 at a periphery of the covering section 222. The flap section 224 is sized to be tucked around an edge of the front face to extend along another face of the frame part 210.

[0076] The flap section 224 and the covering section 222 can be integral parts of the upholstery sheet 220.

[0077] In one example, only a single edge of the upholstery sheet 220 comprises a flap section 224. In other examples, more than one edge of the upholstery sheet 220 comprises a flap section 224.

[0078] For example, the flap section 224 can have a width of at least approximately 7.5 millimetres or more, defining how far the flap section 224 overlaps the first edge 215.

[0079] FIGS. 3A and 3B illustrate the first embodiment of a plug-socket system of the home furniture assembly system 200.

[0080] First, FIG. 3A is described. In FIG. 3A, the flap section 224 of the upholstery sheet 220 extends over the first edge 215 and over at least part of the width of the second face 212 of the frame part 210. The flap section 224 of the upholstery sheet 220 is then connected to the second face 212 of the frame part 210.

[0081] In order to facilitate the connection, an elongate connector 230 in the form of a plug P is secured to the upholstery sheet 220 along the flap section 224. The frame part 210 comprises an elongate bearer 240 in the form of a groove 243 along the second face 212 of the frame part 210, wherein the groove 243 provides a socket S into which the elongate connector 230 can be inserted to apply tension pulling the upholstery sheet 220 taut.

[0082] The elongate connector 230 can be a strip 233 of a material that is more rigid than a material of the upholstery sheet 220. The material of the elongate connector 230 can be a polymeric or wood-based material, for example. The elongate connector 230 can be formed from a moulded material, in some examples. The elongate connector 230 can be formed from an extruded material, in some examples. The elongate connector 230 can have a rectangular cross-section shape, in some examples. The elongate connector 230 can comprise a strip 233 in the form of a flat bar defining a straight, linear spine, in some examples.

[0083] FIG. 3C illustrates an alternative version of the elongate connector 230, in which the strip 233 comprises a flange 236 to which the upholstery sheet 220 is attached, and a web 235 defining the plug P. The flange 236 and web 235 may be arranged as a T-section as shown, or as an L-section. The upholstery sheet 220 may be sewn to the flange 236. The web 235 may comprise flexible expanders 234 to improve retention. The flexible expanders 234 may be sufficiently weak to enable the elongate connector 230 to be pulled out of the socket S for recyclability.

[0084] In the illustrated example, the elongate connector 230 is secured to the interior side of the upholstery sheet 220 at the flap section 224. The elongate connector 230 can be secured to the flap section 224 of the upholstery sheet 220 by sewing through the elongate connector 230, and/or by enclosing the elongate connector 230 within an edge seam of the flap section 224. The stiffer elongate connector 230 may provide a spine stiffening the edge of the upholstery sheet 220.

[0085] The thickness of the elongate connector 230 may be at least 0.6 millimetres to have sufficient stiffness, but no greater than five millimetres so that it can be sewn directly to the upholstery sheet 220 by an industrial sewing machine. The thickness of the elongate connector 230 is less than the width of the groove 243.

[0086] In FIG. 3A, the elongate bearer 240 is a groove 243 (also referred to as a slot) having a width greater than the thickness of the elongate connector 230.

[0087] In some examples, the width of the groove 243 is slightly greater than the sum of the thickness of the elongate connector 230 and the thickness of the upholstery sheet 220, so that the edge of the flap section 224 of the upholstery sheet 220 and the elongate connector 230 can be pushed into the groove 243 together, with a tight fit.

[0088] In some examples, the width of the groove 243 is slightly greater than the sum of the thickness of the elongate connector 230 and a seam thickness of the upholstery sheet 220, wherein the seam thickness is approximately twice the thickness of the upholstery sheet 220, so that an edge seam of the upholstery sheet 220 and the elongate connector 230 can be pushed into the groove 243 together, with a tight fit.

[0089] The depth of the groove 243 can create a blind hole in the frame part 210. In FIG. 3A, the groove 243 is open at the second face 212 and extends upwardly into the cross-section of the frame part 210. The elongate connector 230 can be pushed upwardly into the groove 243, from below.

[0090] The depth of the groove 243 is the same as or greater than the width of the elongate connector 230. The elongate connector 230 may become fully embedded in the groove 243.

[0091] It would be advantageous for the depth of the groove 243 to be greater than the width of the elongate connector 230, such as at least 1.5 times greater, or at least twice as great, or at least three times as great. Since some fabrics are more stretchable than others, a deeper groove 243 provides more flexibility for tensioning different fabrics by controlling how far the elongate connector 230 of FIG. 3A is pushed in. The width of the elongate connector 243 may be less than 20 millimetres. The depth of the groove 243 can be in the order of tens of millimetres.

[0092] If the frame part 210 is a wood frame member, the groove 243 may be a sawn groove formed by sawing the groove 243 into the wood frame member, via a circular saw/table saw or any other type of cutting tool such as a router.

[0093] The path of the groove 243 may be parallel to the first edge 215 of the frame part 210. The path of the groove 243 may be approximately straight and linear.

[0094] In some examples, the groove 243 extends continuously by the full end to end exposed length of the second face 212 of the frame part 210. In some examples, the elongate connector 230 extends continuously by the full end to end length of the groove 243. This ensures uniform tension on the upholstery sheet 220 to prevent ripples.

[0095] In another implementation, the groove 243 and/or the elongate connector 230 extends discontinuously (intermittently) over most of the length or the whole length as mentioned above. The groove 243 may be in regularly spaced groove sections arranged in a series. Likewise, the elongate connector 230 may be in regularly spaced connector sections arranged in a series, and aligned with the groove sections. Each section may have a continuous length of hundreds of millimetres, and the gap between each section may be less than 200 millimetres.

[0096] The total connection length over which the elongate connector 230 is inserted into the groove 243, whether continuous or discontinuous, may cover at least 85% or at least 95% of the width of the first face 211/first edge 215 (not counting gaps). The width of the first face 211/first edge 215 defines the longest dimension of the frame part 210.

[0097] FIG. 3B is a second example differing from FIG. 3A because the groove 243 is in the third face 213 of the frame part 210 rather than the second face 212 of the frame part 210. The groove 243 may be within five centimetres of the second edge 216. If the groove 243 is further from the second edge 216, fabric would be wasted in reaching the groove 243.

[0098] The depth dimension of the groove 243 in FIG. 3B is therefore perpendicular to the first face 211. As shown, the depth dimension of the groove 243 in FIG. 3B can be approximately horizontal.

[0099] The flap section 224 of the upholstery sheet 220 is wider in FIG. 3B than in FIG. 3A. In the example of FIG. 3B, the flap section 224 extends over the first edge 215 of the frame part 210, over the whole width of the second face 212, over the second edge 216, and over part of the height of the third face 213 to reach the groove 243. Therefore, the flap section 224 wraps around the whole bottom face 212 of the frame part 210.

[0100] The implementation of FIG. 3B provides greater resistance to pull-out forces than FIG. 3A.

[0101] The plug-socket system shown in FIGS. 3A-3B does not require staples or adhesive. Therefore, the elongate connector 230 can be pulled out of the groove 243 during end-of-life disassembly. This enables the frame part 210, such as a wooden frame member, to be recycled or reused, as well as the upholstery sheet 220.

[0102] FIG. 4 illustrates the second embodiment of the plug-socket system, as an alternative to FIGS. 3A-3B.

[0103] The primary difference between FIG. 4 and FIGS. 3A-3B is that in FIG. 4, the elongate bearer 240 at the frame part 210 comprises the plug P whereas the elongate connector 230 comprises the socket S.

[0104] In FIG. 4, the elongate bearer 240 comprises a plug P in the form of an elongate bearer member 242 such as a plate (flat bar). The elongate connector 230 is a clip such as a spring clip 232. The illustrated spring clip 232 is in the form of a U-channel clip. The spring clip 232 is a flexible clip comprising a socket S into which a protruding portion of the plate can be inserted. The spring arms of the spring clip 232 apply a clamping force to the plate.

[0105] A first side 244 of the elongate bearer member 242 is secured along the second face 212 of the frame part 210. The first side 244 refers to the left side of the elongate bearer member 242 in the cross-section view of FIG. 4. The first side 244 of the elongate bearer member 242 is secured to the frame part 210 by a reversible fixing means 260 in the form of a plurality of screws.

[0106] A second side 246 of the elongate bearer member 242, adjacent the first side 244, overhangs the second edge 216 of the second face 212 of the frame part 210. The second side 246 refers to the right side of the elongate bearer member 242 in the cross-section view of FIG. 4, further from the first face 211 of the frame part 210 than the first side 244 of the elongate bearer member 242.

[0107] The elongate bearer member 242 may have a width of tens of millimetres, such as approximately 30 millimetres. The elongate bearer member 242 may have a width greater than that of the second face 212 of the frame part 210. The first side 244 and second side 246 may be of approximately equal width, such as approximately 15 millimetres. Alternatively, they may be of unequal width.

[0108] FIG. 4 illustrates the second side 246 of the horizontal elongate bearer member 242 being cantilevered towards the interior of the furniture frame 100. The overhanging, elongate cantilevered edge of the second side 246 of the elongate bearer member 242 provides the plug P to which the socket S attached to the upholstery sheet 220 can be connected.

[0109] The elongate bearer member 242 may be a flat plate, in some examples. The elongate bearer member 242 may be abutted against the second face 212 of the frame part 210. The elongate bearer member 242 may be horizontal and parallel to the second face 212. The elongate bearer member 242 may be perpendicular to the first face 211.

[0110] In view of the interior projection/overhang of the second side 246 of the elongate bearer member 242, the mouth of the spring clip 232 faces or can be rotated to face towards the first face 211 of the frame part 210. The open mouth of the socket S faces towards a plane intersecting the first and second edges 215, 216 of the frame part 210, when the socket S is aligned with the plug P. Therefore, the tension of the upholstery sheet 220 urges the spring clip 232 and the elongate bearer member 242 towards each other into closer engagement. The depth of the socket S may be at least 10 millimetres.

[0111] The spring clip 232 may be secured to the flap section 224 of the upholstery sheet 220 either directly or by a separate fabric flange 250. The purpose of the fabric flange 250 is to allow the upholstery sheet 220 to be attached to the spring clip 232. The upholstery sheet 220 cannot easily be sewn directly to the spring clip 232 without sealing the spring clip 232. The fabric flange 250 enables the spring clip 232 to be rotated to face the plug P.

[0112] The fabric flange 250 may be formed from a different material, such as felt, than the upholstery sheet 220. The different material can be sewn to the upholstery sheet and also can be adhered directly to the spring clip 232 via any appropriate adhesive.

[0113] The elongate bearer member 242 may comprise a metal material, or another suitably stiff material such as a hard plastics material. The material of the elongate bearer member 242 may have a higher strength and/or may be less brittle than the material (e.g., wood) of the frame part 210.

[0114] The spring clip 232 may comprise a polymeric material. The spring clip 232 may be formed from a more flexible material than the elongate bearer member 242. Therefore, the spring clip 232 can flexibly engage with the elongate bearer member 242.

[0115] In other implementations, the elongate bearer member 242 may be attached to another face such as the third face 213, and/or may be parallel to the first face 211.

[0116] A method of assembling a home furniture frame 100 can comprise connecting the upholstery sheet 220 to the frame part 210 in the following manner:

First, the upholsterer fits (dresses) an upholstery sheet 220 over at least the frame part 210;
Next, the upholsterer tucks the flap section 224 of the upholstery sheet 220 around at least the first edge 215 of the first face 211 and positions the flap section 224 to extend along the face of the frame part 210 that comprises the relevant elongate bearer 240; and
Finally, the upholsterer secures the elongate connector 230 of the upholstery sheet 220 to the elongate bearer 240 to connect the upholstery sheet 220 and pull the upholstery sheet 220 taut at the same time.

[0117] Different variants of the method and the home furniture assembly system 200 are possible, depending on the design of the furniture frame 100.

[0118] According to a first variant of the method, shown in the side view of FIG. 5A, elongate bearers 240 of the type shown in FIGS. 3A-4 are provided only at the underside 105 of the furniture frame 100, to receive a single furniture cover 101 that covers the whole furniture frame 100 (e.g., chair). FIG. 5A shows the furniture cover 101 in dashed lines.

[0119] The furniture frame 100 of FIG. 5A covers the seat base structure 102 and the seat back structure 104. Only the bottom edges of the furniture cover 101 are connected to the furniture frame 100.

[0120] The illustrated furniture cover 101 comprises a horizontal seat upholstery sheet 226 to be lowered onto the horizontal platform 103 of the seat base structure 102. The horizontal seat upholstery sheet 226 is the surface onto which seat cushions can be placed or secured.

[0121] The furniture cover 101 further comprises a seat back upholstery sheet 225 to cover a front of the seat back structure 104 and therefore cover the seat back suspension system 700. The seat back upholstery sheet 225 is the surface against which seat back cushions can be placed or secured.

[0122] The seat back upholstery sheet 225 and horizontal seat upholstery sheet 226 of the furniture cover 101 are connected to each other by a common edge defining a crease 227. The crease 227 is at an oblique angle corresponding to a recline angle of the seat back structure 104.

[0123] The furniture cover 101 further comprises a front upright upholstery sheet 220F and a rear upright upholstery sheet 220R for at least the seat base structure 102. These are types of upholstery sheet 220 as shown in FIGS. 3A-4.

[0124] The top edge of the front upright upholstery sheet 220F may be connected to a front edge of the horizontal seat upholstery sheet 226. The flap section 224 at the bottom edge of the front upright upholstery sheet 220F may be connected to the front long frame member 120F by the plug-socket system.

[0125] The top edge of the rear upright upholstery sheet 220R may extend to the top of the seat back structure 104. The rear upright upholstery sheet 220R may cover the rear of the seat back structure 104. The top edge of the rear upright upholstery sheet 220R may be connected to a rear edge of a top sheet 219 or a top edge of the seat back upholstery sheet 225. A connection to the top frame member 150 may not be required. The flap section 224 at the bottom edge of the rear upright upholstery sheet 220R may be connected to the rear long frame member 120R by the plug-socket system.

[0126] The furniture cover 101 can further comprise a left upright upholstery sheet and a right upright upholstery sheet for at least the seat base structure 102, which are not shown in the side view of FIG. 5A. These are types of upholstery sheet 220 as shown in FIGS. 3A-4.

[0127] The top edge of the left upright upholstery sheet may be connected to a left edge of the horizontal seat upholstery sheet 226. The bottom edge of the left upright upholstery sheet may be connected to the left short frame member 110L by the plug-socket system.

[0128] The top edge of the right upright upholstery sheet may be connected to a right edge of the horizontal seat upholstery sheet 226. The bottom edge of the right upright upholstery sheet may be connected to the right short frame member 110R by the plug-socket system.

[0129] The left and right edges of each of the left and right upholstery sheets may be connected to corresponding left and right edges of the front and rear upright upholstery sheets 220F, 220R.

[0130] During assembly, the furniture cover 101 is lowered over the seat back structure 104 and seat base structure 102. The bottom edges of the furniture cover 101 comprise flap sections 224 that are folded around the corresponding bottom exterior edges of the long frame members 120F, 120R and short frame members 110L, 110R of the seat base structure 102. As per FIGS. 3A-4, the flap sections 224 are then connected to the elongate bearers 240 along each of the long frame members 120F, 120R and short frame members 110L, 110R, using any one or more of the techniques shown in FIGS. 3A-4.

[0131] In order to maintain the sharp crease 227 between the horizontal seat upholstery sheet 226 and the seat back upholstery sheet 225, an internal flap section 228 in the form of a fabric fly may hang down from the crease 227 connecting said sheets. The internal flap section 228 is connected to an internal side of the crease 227 between the horizontal seat upholstery sheet 226 and the seat back upholstery sheet 225. The internal flap section 228 is to the interior side of the furniture cover 101 and hangs down internally.

[0132] The internal flap section 228 may comprise an elongate connector 230 such as described above, configured to connect to an elongate bearer 240 such as described above, wherein the elongate bearer 240 is connected to the internal frame member 130 shown in FIG. 5A. The internal frame member 130 of FIG. 5A is located beneath the crease 227, in other words beneath the intersection between the seat base structure 102 and the front of the seat back structure 104.

[0133] In an alternative implementation to that shown in FIG. 5A, the furniture cover 101 is only for a seat base structure 102, for example because the furniture frame 100 may lack a seat back structure 104.

[0134] In a further alternative implementation to that shown in FIG. 5A, one or more top edges of one or more of the upholstery sheets 220 may be connected to the furniture frame 100 via the plug-socket system or by other means.

[0135] According to a second variant of the method, shown in FIG. 5B, an upright upholstery sheet 220 comprising the plug-socket system is not part of a whole-frame furniture cover 101 such as that shown in FIG. 5A. For example, the furniture frame 100 could be configurable as a sofabed and may therefore lack a horizontal seat upholstery sheet 226. Therefore, both the top edge and the bottom edge of the upright upholstery sheet 220 are connected to the frame part 210.

[0136] FIG. 5B therefore shows a frame part 210, such as a frame member of the seat base structure 102, comprising top and bottom elongate bearers 240T, 240B, configured to secure top and bottom elongate connectors 230T, 230B of the upholstery sheet 220. The top and bottom elongate connectors 230T, 230B of the upholstery sheet 220 are connected to top and bottom flap sections 224T, 224B of the upholstery sheet 220.

[0137] Although FIG. 5B illustrates the type of connection shown in FIG. 3B, it would be appreciated that each elongate bearer 240T, 240B and elongate connector 230T, 230B can be as defined above in relation to any one of FIGS. 3A-4.

[0138] Although FIG. 5B illustrates a single frame part 210 comprising the top bearer 240T and bottom bearer 240B, it would be appreciated that separate frame parts 210 could comprise the top bearer 240T and bottom bearer 240.

[0139] In addition to the staple-free plug-socket system described above, the home furniture assembly system 200 may employ further staple-free and reversible connections to further improve the recyclability of the furniture frame 100. These further features are illustrated from FIGS. 6-9 and are now described.

[0140] FIG. 6 illustrates a staple-free system for attaching a seat subassembly 600 to a seat base structure 102 of a furniture frame 100. The seat subassembly 600 comprises a seat platform part 602. The seat platform part 602 can comprise an internal cushioning means (not shown) such as an internal seat suspension, and an internal framework (not shown) to support said internal seat suspension.

[0141] The internal seat suspension can be in the form of serpentine springs, or any other appropriate suspension. The framework can be in the form of a wooden frame, or any other appropriate frame. The framework and internal seat suspension can be manufactured and assembled prior to fitting the seat subassembly 600 to the furniture frame 100. The internal parts of the seat subassembly 600 are wrapped by a cover such as a fabric cover.

[0142] The seat subassembly 600 is dropped onto the horizontal platform 103 defined by the top of the seat base structure 102. The seat subassembly 600 may then be covered by the horizontal seat upholstery sheet 226. Alternatively, horizontal seat upholstery sheet 226 may be preattached to the seat subassembly 600 and may form at least part of the cover of the seat subassembly 600. In some examples, the seat subassembly 600 may drop into a recess at the top of the seat base structure 102, so that the top of the seat subassembly 600 is approximately flush with the top of a long frame member 120F and the short frame members 110L, 110R.

[0143] A staple-free method of securing the seat subassembly 600 to the seat base structure 102 is provided. The cover of the seat subassembly 600 is connected to protruding flaps 604F, 604R. Each protruding flap 604F, 604R may hang from the underside of the cover.

[0144] One long edge of each protruding flap 604F, 604R is secured along the seat subassembly 600. The other long edge of each protruding flap 604F, 604R comprises part of a zip 606F, 606R and the underside of the cover comprises the other parts of the zips 606F, 606R. The protruding flaps 604F, 604R can therefore each be folded into a loop and zipped closed. A protruding flap 604F, 604R can be provided at each of the front and rear sides of the underside seat subassembly 600. Alternatively, just one protruding flap 604F or 604R may be provided.

[0145] The furniture frame 100 comprises internal frame members 130, 132 in the form of crossmembers around which a protruding flap 604F, 604R can be wrapped. Each protruding flap 604F, 604R, when zipped closed, loops around and encloses one of the internal frame members 130, 132. Once a protruding flap 604F, 604R has been wrapped around the internal frame member 130, 132 and zipped closed, the seat subassembly 600 is secured.

[0146] An alternative type of seat platform is described later and shown in FIG. 8.

[0147] First, FIG. 7 illustrates a side view of a staple-free and reversible system for attaching a seat back suspension system 700 to a seat back structure 104 of a furniture frame 100. The seat back suspension system 700 comprises a plurality of parallel webbing straps 702, of which one is shown from the side in FIG. 7. Each webbing strap 702 is hooked to the seat back structure 104 of the furniture frame 100. Each webbing strap 702 is resiliently flexible to provide a comfortable backrest, and is resiliently stretchable to enable its end hook 704, 706 to be engaged with corresponding holes/slots in frame members of the furniture frame 100.

[0148] This system replaces conventional seat back suspension systems such as a support cloth or serpentine springs.

[0149] As shown in FIGS. 1, 2 and 7, the seat back structure 104 can comprise an upper rail 160 and a lower rail 170, each in the form of an elongate internal frame member such as a metal beam. In an example, each of the upper rail 160 and the lower rail 170 is in the form of a flanged section or a closed section shape. The illustrated flanged section is in the form of an angle bar (e.g., L-section).

[0150] In addition to being vertically separated, in FIG. 7 the upper rail 160 and the lower rail 170 are horizontally separated by a distance corresponding to a recline angle of the seat back structure 104. Therefore, the webbing straps 702 extend at an oblique angle relative to horizontal, to correspond to the recline angle.

[0151] The webbing strap 702 can be hooked to each of the upper rail 160 and the lower rail 170 via the corresponding end hooks 704, 706 attached to the ends of the webbing strap 702. The upper rail 160 and the lower rail 170 each comprise one or more apertures 162, 172, each aperture 162, 172 configured to receive one or more of the end hooks 704, 706 of the webbing straps 702.

[0152] As with the other features in this disclosure, the visible hook connections make it immediately clear to the recycling centre worker how to detach the seat back suspension system 700, so they are less likely to dismiss the task as too difficult and send the furniture frame 100 to a landfill stream.

[0153] In another implementation, the seat back suspension system 700 can utilise the slat carrier 800 of FIG. 8 rather than the webbing straps 702 of FIG. 7.

[0154] FIG. 8 illustrates a staple-free system for attaching slats 810 to the seat base structure 102 and/or seat back structure 104 of the furniture frame 100. The slats 810 are carried by a slat carrier 800. The slat carrier 800 carries a plurality of slats 810. Slats 810 can be an alternative to the sprung seat subassembly 600 of FIG. 6 or the seat back suspension system 700 of FIG. 7.

[0155] The illustrated slat carrier 800 comprises a main body in the form of a fabric sheet 801 to which a plurality of fabric slat pockets 804 have been sewn. The slat pockets 804 may be parallel to each other. Slats 810 are inserted into the open ends of the slat pockets 804. The slats 810 may each comprise an interior fibreglass core at least partially enveloped by a plastics material, for example.

[0156] When all slats 810 have been inserted, the open ends of the slat pockets 804 are enclosed by folding an end flap 808 of the fabric sheet 801 over the ends of the slat pockets 804. This keeps the slats 810 in place.

[0157] The folded end flap 808 may be secured by a reversible fixing means 820. The illustrated reversible fixing means comprises a hook and loop fastener system, such as Velcro(TM), to secure the folded flap. An advantage is that the slats 810 can be separated from the slat carrier 800 for reuse or recycling, or for swapping the slats 810 for slats 810 of a different stiffness.

[0158] The slat carrier 800 comprises a plurality of fixing points 806 through which reversible fixings, such as screws or push clips, can be inserted, to secure the slat carrier 800 to holes in frame parts 210 of the furniture frame 100. The fixing points 806 on the slat carrier 800 may comprise eyelets, for example.

[0159] The reversible fixings may secure the slat carrier 800 to the seat base structure 102 to provide a slatted seat structure, or may secure the slat carrier 800 to the seat back structure 104 to provide an alternative seat back suspension to that shown in FIG. 7.

[0160] To install the slat carrier 800, the slat carrier 800 may be unrolled into place. This is useful primarily for ease of handling.

[0161] At least some of the fixing points 806 may extend through locations on the fabric sheet 801 which are covered by the folded end flap 808, and the end flap 808 can have corresponding fixing points 806 alignable with those locations on the fabric sheet 801.

[0162] To enable ease of recycling (and installation), the number of fixing points 806 of the slat carrier 800 may be less than the maximum number of slats 810 (the total number of slat pockets 804) of the slat carrier 800. For example, the number of fixing points 806 may be less than two thirds the number of slats 810. The number of slats 810 may be from four to fifteen, depending on the type of furniture. The number of fixing points 806 may be at least four and no greater than eight.

[0163] FIG. 9 illustrates a staple-free and adhesive-free system for attaching padding 930 and/or an upholstery sheet 920 and/or an insulation sheet 940 to a frame part of the furniture frame 100, the frame part in the form of an arm structure 910 as shown in FIG. 9. Alternatively, the frame part could be other than an arm structure 910. In FIG. 9, a hook and loop fastener system 900, such as a Velcro^™ system, is employed. This enables the padding 930, upholstery 920, and insulation sheet 940 to be easily removed during recycling.

[0164] Respective arm structures 910 may be connected to the left and right sides of the furniture frame 100 shown in FIGS. 1-2. The arm structures 910 may be connected to the short frame members 110L, 110R by reversible fixings, such as wingnuts attached to metal-to-wood dowels. The arm structures 910 may be connected after the short frame members 110L, 110R have been upholstered.

[0165] The optional padding 930 illustrated in FIG. 9 is in the form of an arm padding cover 932 shaped to fit over the arm structure 910. The padding can comprise a bonded fibre or foam sheet or the like. The fibre may be connectable directly to hooked sheets 900A, 900B attached to the arm structure 910.

[0166] The optional insulation sheet 940 is in the form of an insulation cover 942 shaped to fit over the arm padding cover 932 and the arm structure 910.

[0167] The upholstery sheet 920 is in the form of an arm upholstery cover 922 shaped to fit over the arm padding cover 932 and the insulation sheet 940 and the arm structure 910.

[0168] A first side of the insulation cover 942 is connected to a chair-interior side of the arm structure 910 by a first hook and loop fastener system 900C. The insulation cover 942 extends over the top of the arm structure 910 to a second opposite side. The second opposite side of the insulation cover 942 is connected to a chair-exterior side of the arm structure 910 by a second hook and loop fastener system 900D.

[0169] The arm upholstery cover 922 may comprise a hook and loop fastener system 900E. One hidden edge of the arm upholstery cover 922 may comprise a hooked sheet and the opposite hidden edge of the arm upholstery cover 922 may comprise a looped sheet. The hidden edges are tucked underneath the arm structure 910 and attached to each other via the hook and loop fastener system 900E. The arm upholstery cover 922 may not be directly attached to the arm structure 910.

[0170] Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed. It is also believed that any one or more of the following systems comprises independently patentable features regardless of whether the plug-socket system is provided: the hook and loop fastener system; the hooked seat back suspension system; the slat carrier with slat pockets; or the seat subassembly with a zip or zips.

[0171] Features described in the preceding description may be used in combinations other than the combinations explicitly described.

[0172] Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.

[0173] Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1. A home furniture assembly system comprising:

a frame part defining at least a portion of a furniture frame, the frame part comprising a first face to be upholstered, and a further face;

an elongate connector secured to the upholstery sheet along the flap section,

wherein the frame part comprises an elongate bearer at the further face, to which the elongate connector can be secured to pull the upholstery sheet taut,

wherein one of the elongate connector or the elongate bearer comprises a socket and the other comprises a plug, and

wherein the home furniture assembly system further comprises a hook and loop fastener system.

2. The home furniture assembly system of claim 1, wherein the elongate bearer is the socket and the elongate connector is the plug, optionally wherein the elongate bearer comprises a groove extending along the further face of the frame part, optionally wherein the elongate connector comprises a strip of a material more rigid than the upholstery sheet, and wherein a width and depth of the groove are sized to enable insertion of the strip into the groove.

3. The home furniture assembly system of any preceding claim, comprising an internal frame part defining a further portion of the furniture frame, and comprising a furniture cover, wherein the furniture cover comprises the upholstery sheet, a horizontal seat upholstery sheet, a seat back upholstery sheet, and an internal flap section connected to an internal side of a crease between the horizontal seat upholstery sheet and the seat back upholstery sheet, wherein the internal flap section comprises an elongate connector, and wherein the internal frame part comprises an elongate bearer to which the elongate connector can be secured to pull the internal flap section taut to maintain a sharpness of the crease.

4. The home furniture assembly system of claim 3, wherein the internal flap section extends over a pair of edges of the internal frame part.

5. The home furniture assembly system of any preceding claim, comprising a second frame part.

6. The home furniture assembly system of claim 5, comprising a second upholstery sheet, wherein one edge of the second upholstery sheet comprises a hooked sheet and an opposite hidden edge of the second upholstery sheet comprises a looped sheet, the hooked sheet and looped sheet defining a hook and loop fastener system, enabling the hidden edges to be tucked under the second frame part and attached to each other via the hooked sheet and looped sheet.

7. The home furniture assembly system of claim 5 or 6, comprising an insulation sheet, wherein a first side of the insulation sheet is connectable to a first side of the second frame part by a first hook and loop fastener system, wherein the insulation sheet extends over the top of the second frame part to a second opposite side, and wherein the second opposite side of the insulation sheet is connected to a second side of the second frame part by a second hook and loop fastener system.

8. The home furniture assembly system of claim 5, 6, or 7, comprising padding, wherein the padding is connectable directly to hooked sheets attached to the second frame part.

9. The home furniture assembly system of any one of claims 5 to 8, wherein the second frame part comprises an arm structure of the furniture frame.

10. The home furniture assembly system of any preceding claim, further comprising a slat carrier for carrying a plurality of slats.

11. The home furniture assembly system of claim 10, wherein the slat carrier comprises a plurality of slat pockets, each slat pocket having an open end in to which one of the slats can be inserted, wherein the slat carrier comprises an end flap foldable over one or more of the open ends of the slat pockets, and wherein the slat carrier comprises a reversible fixing means for securing the end flap when folded.

12. The home furniture assembly system of claim 10 or 11, wherein the slat carrier comprises a plurality of fixing points for reversible fixings to secure the slat carrier to the furniture frame, wherein a quantity of the fixing points is fewer than a number of the slats that the slat carrier is configured to carry.

13. The home furniture assembly system of any preceding claim, wherein the furniture frame comprises a pair of opposite long frame members and a pair of opposite short frame members, each of the long and short frame members being a frame part as defined according to any one of the preceding claims, wherein the upholstery sheet comprises a plurality of elongate connectors, each securable to an elongate bearer at an underside of each of the long and short frame members.

14. The home furniture assembly system of any preceding claim, wherein the frame part is a wood frame member, wherein the first face and the further face are faces of the wood frame member.

15. A method of assembling a home furniture frame, the method comprising:

tucking the flap section of the upholstery sheet around an edge of the first face and positioning the flap section to extend along the further face;

securing the elongate connector of the upholstery sheet to the elongate bearer to pull the upholstery sheet taut; and

wherein assembling the furniture frame includes using a hook and loop fastener system.

Drawing

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