U.S. patent application number 10/074597 was filed with the patent office on 2003-08-14 for packaged furniture assembly and method thereof for compressible furniture.
Invention is credited to Nelson, Shawn.
Application Number | 20030151295 10/074597 |
Document ID | / |
Family ID | 27659912 |
Filed Date | 2003-08-14 |
United States Patent
Application |
20030151295 |
Kind Code |
A1 |
Nelson, Shawn |
August 14, 2003 |
Packaged furniture assembly and method thereof for compressible
furniture
Abstract
The present invention provides a chair having a removable outer
cover. The chair has an air permeable bladder which houses
compressible filler material. The compressible filler material
allows the chair to be selectively compressed between various
compressed states. A method for packaging the chair is provided
which significantly reduces the weight and size of the chair. The
method includes placing the chair in a vacuum chamber and
suctioning air from the chair. The vacuum chamber may be partially
open or closed during storage.
Inventors: |
Nelson, Shawn; (Salt Lake
City, UT) |
Correspondence
Address: |
WORKMAN NYDEGGER & SEELEY
1000 EAGLE GATE TOWER
60 EAST SOUTH TEMPLE
SALT LAKE CITY
UT
84111
US
|
Family ID: |
27659912 |
Appl. No.: |
10/074597 |
Filed: |
February 11, 2002 |
Current U.S.
Class: |
297/452.17 |
Current CPC
Class: |
A47C 3/16 20130101; A47C
27/086 20130101 |
Class at
Publication: |
297/452.17 |
International
Class: |
A47C 007/02 |
Claims
What is claimed and desired to be secured by United States Letters
Patent is:
1. A packaged furniture assembly, comprising: a chair comprising:
an air permeable bladder, and a filler disposed within the air
permeable bladder, the chair being selectively compressed when air
is removed from within the air permeable bladder; and a vacuum
chamber configured to house the chair therein; wherein the vacuum
chamber has a partial opening therein to thereby allow air inside
the vacuum chamber while the chair is within the vacuum
chamber.
2. The packaged furniture assembly as recited in claim 1, wherein
the partially opened vacuum chamber has a portion thereof that is
gathered together without forming an airtight seal, thereby forming
a partial opening.
3. The packaged furniture assembly as recited in claim 1, wherein
the partially opened vacuum chamber has a n opening therein that is
not sufficiently large to allow the chair to refill with air.
4. The assembly of claim 1, where in the partial opening allows the
chair to partially refill with air.
5. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed to about 1% to about 99% of the
original volume.
6. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed to about 4% to about 50% of the
original volume.
7. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed to about 5% to about 25% of the
original volume.
8. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed to about 5% to about 15% of the
original volume.
9. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed, then allowed to refill with
air until reaching about 6% to about 99% of the chair's original
volume.
10. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed, then allowed to refill with
air until reaching about 8% to about 50% of the chair's original
volume.
11. The packaged furniture assembly as recited in claim 1, wherein
the chair is selectively compressed, then allowed to refill with
air until reaching about 10% to about 25% of the chair's original
volume.
12. The packaged furniture assembly as recited in claim 1 further
comprising a storage container having an opening configured to
receive the chair and vacuum chamber when the chair is selectively
compressed.
13. The furniture assembly as recited in claim 12, wherein the
storage container is constructed from an air permeable material,
and wherein when the chair and vacuum chamber are disposed within
the storage container, the partial opening of the vacuum chamber is
opened so that at least a minimal amount of air is allowed inside
the vacuum chamber, such that the chair partially refills with
air.
14. The furniture assembly as recited in claim 12, wherein the
storage container is constructed of an air impermeable material,
the storage container having an opening which is selectively opened
and closed to seal the storage container from communication with
the atmosphere.
15. The packaged furniture assembly as recited in claim 1, wherein
a minimal amount of air is allowed inside the vacuum chamber.
16. The packaged furniture assembly as recited in claim 1, wherein
the bladder comprises a flaccid material.
17. A method for packaging a chair, the method comprising:
providing a chair comprising (i) an air permeable bladder and (ii)
a filler material disposed within the air permeable bladder, the
chair being selectively compressed when air is removed from within
the chair; placing the chair in a vacuum chamber; removing a
substantial amount of air from the chair; and allowing the chair to
partially refill with air, wherein the vaccum chamber has a partial
opening therein.
18. A method as recited in claim 17, wherein removing a substantial
amount of air from the chair comprises suctioning the air from the
chair using a vacuum source.
19. A method as recited in claim 18, wherein removing a substantial
amount of air from the chair comprises using a first vacuum source
and subsequently a second high-powered vacuum source.
20. A method as recited in claim 18 wherein the vacuum chamber is
allowed to remain partially open after the chair is placed in a
storage container.
21. A method as recited in claim 18, wherein the storage container
has an opening which is selectively opened and closed, further
comprising sealing the opening of the storage container after the
chair is allowed to partially refill out to the wall of the storage
container.
22. A method as recited in claim 21, wherein sealing the opening of
the storage container comprises: closing the opening of the storage
container so that a plume extends therefrom; and applying adhesive
to the inside of the plume.
23. A method as recited in claim 22, further comprising flaring the
plume so that the inside of the plume is exposed and constricting
the plume so that the adhesive remains on the inside of the
plume.
24. A method as recited in claim 17, wherein removing a substantial
amount of air from the chair comprises compressing the chair down
to about 1% to about 99% of the original volume.
25. A method as recited in claim 17, wherein removing a substantial
amount of air from the chair comprises compressing the chair down
to about 4% to about 50% of the original volume.
26. A method as recited in claim 17, wherein a substantial amount
of air is removed from the chair, then allowed to refill with air
until reaching about 8% to about 50% of the chair's original
volume.
27. A method as recited in claim 17, wherein a substantial amount
of air is removed from the chair, then allowed to refill with air
until reaching about 10% to about 25% of the chair's original
volume.
28. A method for packaging and shipping a chair, the method
comprising: forming a furniture assembly comprising a chair
disposed inside a vacuum chamber, wherein the vacuum chamber
comprises an opening which is selectively sealed and unsealed, the
chair having an air permeable bladder housing compressible filler
material, the compressible filler material being selectively
compressible; connecting the vacuum chamber in communication with a
vacuum source; selectively compressing the compressible filler
material using the vacuum source; and placing the furniture
assembly in a storage container with the opening of the vacuum
chamber unsealed.
29. The method as recited in claim 27 further comprising connecting
the vacuum chamber in communication with a high-powered vacuum
source to selectively compress the compressible filler material to
a highly compressed state.
30. The method as recited in claim 27, wherein selectively
compressing the compressible filler material comprises compressing
the chair down to about 4% to about 50% of its original volume.
30. The method as recited in claim 27, wherein selectively
compressing the compressible filler material comprises compressing
the chair down to about 5% to about 25% of its original volume.
31. The method as recited in claim 27, further comprising removing
the packaged furniture assembly from the storage container and
removing the chair from the vacuum chamber, wherein the chair
refills to substantially the original volume after removal from the
vacuum chamber.
32. A method for manufacturing and packaging a chair, the method
comprising: providing an air permeable bladder; placing a filler
material within the air permeable bladder such that the chair is
selectively compressed when air is removed from within the chair;
and suctioning a substantial amount of air from the chair with a
vacuum source.
33. A method as recited in claim 32, further comprising placing the
chair in a storage container such that the chair is allowed to
partially refill with air while in the storage container and is
allowed to completely refill with air when removed from the storage
container.
34. A packaged furniture assembly, comprising: a chair comprising:
an air permeable bladder, and a filler disposed within the air
permeable bladder, the chair being selectively compressed when air
is suctioned from within the air permeable bladder; a vacuum
chamber having an opening and configured to receive the chair
therein; and a storage container having an opening and configured
to receive the chair and vacuum chamber therein.
35. An assembly as recited in claim 35, wherein the air permeable
bladder comprises a fabric material.
Description
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] The present invention relates to the field of furniture.
Particularly, the present invention relates to the packaging of
furniture for storage and shipping. More particularly, the present
invention relates to a method for packaging compressible
furniture.
[0003] 2. The Relevant Technology
[0004] A variety of types of furniture have been developed over the
years to provide comfort and decoration. Consumers appreciate
furniture which can withstand a high level of use without having to
be quickly replaced. Thus, it is desirable to make furniture that
is durable and high quality.
[0005] Once purchased, consumers expect furniture to be easily
assembled. Once assembled, consumers appreciate furniture which can
be readily cleaned. Most upholstered furniture has the upholstery
nailed or stapled to the furniture, requiring new upholstery if the
furniture should become soiled or stained. It would thus be an
advantage to have furniture which is easily assembled and
disassembled for cleaning purposes.
[0006] One aspect that makes furniture cost-prohibitive is shipping
and packaging. For example, a large piece of furniture requires a
large amount of space during shipping. Usually, large pieces of
furniture comprise wood or metal pieces and/or fittings. These
pieces add additional weight which increases the cost of shipping.
Naturally, air also contributes to the weight of furniture. It
would thus be an advancement in the art to decrease the volume and
weight of furniture during shipping.
[0007] Another aspect that makes furniture cost-prohibitive is the
difficulty in stacking furniture. When large pieces of furniture
are stacked, damage frequently occurs to the furniture on the
bottom of the stack. Even when furniture is disassembled and boxed
in order to facilitate stacking, often there is still much wasted
space which increases the cost of shipping. It would thus be an
advantage to be able to have furniture which is easily
stackable.
[0008] Another problem that occurs during shipping is that cushions
or cushioned areas on furniture are often inadequately protected
such that they are easily torn or punctured.
[0009] For those consumers who cannot afford many pieces of
furniture, it is also desirable to have furniture which can provide
multiple functions. For example, a futon bed serves the function of
both a bed and a couch. However, futon beds are bulky, and thus
subject to the cost factors described above. In addition, futon
mattresses are often thin and uncomfortable both as a couch and as
a bed. Further, futon beds are difficult to transport to and from
different locations. Thus, it would be an advantage to have a piece
of furniture which can conveniently transported.
SUMMARY AND OBJECTS OF THE INVENTION
[0010] A need therefore exists for a quality, low maintenance, and
versatile piece of furniture and a method for packaging the piece
of furniture that reduces shipping costs, while eliminating the
above-described problems and disadvantages.
[0011] Thus, it is an object of the invention to provide a piece of
furniture which is durable, versatile and aesthetically
pleasing.
[0012] It is another object of the invention to provide a simple
design for a piece of furniture which reduces costs of
manufacturing.
[0013] Another object of the invention is to provide a simple
design for a piece of furniture which reduces the costs of
shipping.
[0014] It is yet another object of the invention to provide a
method for packaging a piece of furniture which reduces the weight
and volume of the piece of furniture.
[0015] Another object of the invention is to provide a method for
packaging a piece of furniture which allows the furniture to be
conveniently stacked and/or stored.
[0016] These and other objects of the invention will be apparent
from the foregoing description. Accordingly, the present invention
provides a furniture assembly which comprises a chair having a
removable outer cover. Both the chair and outer cover may be
generally spherical, generally cubical, or a variety of different
shapes. The chair has an air permeable bladder housing compressible
filler material which allows the chair to be selectively compressed
between various compressed states. A method for packaging the chair
is provided which significantly reduces the weight and size of the
chair.
[0017] The method includes placing the chair in a vacuum chamber
and connecting the vacuum chamber to a vacuum source in order to
suction out the air from inside the chair. The chair and
accompanying vacuum chamber are then placed inside a storage
container. The vacuum chamber can be closed, partially open, or
completely open while in the storage container. Leaving the chamber
partially open allows some air to enter the vacuum chamber. This
assists the chair to expand back to its original size and shape
significantly faster upon removal from the vacuum chamber than it
would with the vacuum chamber completely closed. However, in
another embodiment, the vacuum chamber is completely closed so that
the chair does not expand past the walls of a box while being
shipped and/or transported. Finally, the storage container may be
partially or completely closed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Various embodiments of the present invention will now be
discussed with reference to the appended drawings. It is
appreciated that these drawings depict only typical embodiments of
the invention and are therefore not to be considered limiting of
its scope.
[0019] FIG. 1 illustrates a furniture assembly according to the
present invention having a user resting comfortably thereon;
[0020] FIG. 2 illustrates the manufacture of an air permeable
bladder of a chair of the present invention;
[0021] FIG. 3 illustrates the air permeable bladder of the
chair;
[0022] FIG. 4 illustrates the air permeable bladder of the chair
having filler material placed therein;
[0023] FIG. 5 illustrates the chair being compressed in a vacuum
chamber by suctioning air therefrom;
[0024] FIG. 6 illustrates the chair in a suctioned, highly
compressed state;
[0025] FIG. 7 illustrates the chair in a highly suctioned,
compressed state;
[0026] FIG. 8 illustrates an exploded view of (i) the compressed
chair within the vacuum chamber; and (ii) the storage
container;
[0027] FIG. 9 illustrates the compressed chair within the vacuum
chamber and container;
[0028] FIG. 10 illustrates an alternative embodiment for a
furniture assembly;
[0029] FIG. 11 illustrates another step of the alternative
embodiment of FIG. 10;
[0030] FIG. 12 illustrates the chair being placed in an outer
cover; and
[0031] FIG. 13 illustrates a furniture assembly in accordance with
the present invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The present invention is directed toward an article of
furniture which is versatile, comfortable, and durable. While it
will be appreciated that the article of furniture may have many
uses, for purposes of this discussion, the following description
will refer to the article of furniture as a chair.
[0033] FIG. 1 shows a furniture assembly 10 according to the
present invention. FIG. 1 depicts a large furniture assembly 10
with a person resting comfortably thereon. Furniture assembly 10
may range in size from large on which two adult sized people may
comfortably rest, to small on which a small child may lie. It will
be appreciated that furniture assembly 10 will conform to the shape
of the person resting thereon to form a chair-like structure.
[0034] While FIG. 1 shows furniture assembly 10 being used in a
chair-like function, furniture assembly 10 may have a variety of
uses. Furniture assembly 10 may be flattened to provide a bed-like
surface upon which to lie. A smaller furniture assembly 10 may
function as an ottoman. Alternatively, furniture assembly 10 may
function as a toy for children to jump or land upon during play.
Further, furniture assembly 10 may be formed slightly elongated in
shape so that a household pet, or even a small infant, may sleep
comfortably thereon. Thus, it will be appreciated that furniture
assembly 10 is extremely comfortable and versatile for a variety of
uses.
[0035] Furniture assembly 10 may be constructed in a variety of
shapes. As shown in FIG. 13, furniture assembly 10 is generally
spherical in shape. However, it will be appreciated that furniture
assembly may have a generally cubical or cylindrical shape, or a
variety of other shapes. Furthermore, furniture assembly 10 is
durable and is constructed from an efficient design which reduces
the costs of manufacturing and packaging, the details of which will
be described herein in further detail.
[0036] Referring for a moment to FIG. 12, furniture assembly 10
comprises a chair 14 having a removable cover 12. As shown best in
FIG. 4, chair 14 comprises an air permeable bladder 15 which houses
filler material 24 disposed therein. While it is preferred to
employ a protective cover 12 over bladder 15, another embodiment of
a "furniture assembly" as discussed herein comprises a bladder 15
having a filler material 24 therein. An example of air permeable
bladder 15 is shown in more detail in FIGS. 2 through 4.
[0037] FIG. 2 depicts one embodiment of the manufacture of air
permeable bladder 15. Air permeable bladder 15 comprises two
portions 16A, 16B (comprising, e.g., a fabric material) which have
generally hour-glass shapes. However, it will be appreciated that a
variety of shapes may be profitably employed. Portions 16A, 16B
have end regions 18A, 18B and intermediate regions 20A, 20B. The
end region 18A of one portion 16A is placed against the
intermediate region 20B of another portion 16B. The edges of
portions 16A and 16B are sewn together so that, as shown in FIG. 3,
chair 14 forms a generally spherical structure.
[0038] One portion, e.g., 16A, has an opening 22 extending
cross-wise across intermediate region, e.g., 20A. Opening 22 may be
formed before portions 16A and 16B are sewn together. Opening 22
can be selectively opened and closed and thus comprises a structure
which facilitates such opening and closing such as, but not limited
to, a zipper, lacing, Velcro, or other connecting structure.
[0039] Preferably, air permeable bladder 15 is comprised of a
flaccid, air-permeable, material, such as a fabric or mesh
material. For example, air permeable bladder 15 may comprise a
fabric material, such as cotton, polyester, woven or stitched
materials, or various other fabric materials. In one embodiment,
air permeable bladder 15 is constructed of a flaccid fabric which
is a 7 ounce (oz.) 65% polyester 35% cotton twill with an untreated
finish. Bladder 15 may also comprise another flaccid, air permeable
material, for example.
[0040] As will be appreciated by one skilled in the art in light of
this disclosure, bladder 15 may be constructed employing a variety
of different methods and may comprise a variety of different air
permeable, flaccid materials that allow it to receive a filler
therein and comfortably conform to the shape of a user's body.
[0041] As depicted in FIG. 4, air permeable bladder 15 is filled
with a filler material 24. Filler material 24 is preferably a
compressible material which is resilient so that it selectively
expands and contracts. Furthermore, filler material 24 should be
deformable such that when the chair 14 is filled, the filler
material 24 conforms to the contours of a body. Filler material 24
may be cut into small pieces (e.g., about 1 inch pieces) of
material before being placed in air permeable bladder 15. Filler
material 24 may comprise foam, Styrofoam, and the like, for
example.
[0042] A memory foam material may be employed such that the chair
conforms to a persons body when in use, but the foam refills with
air when a person gets off the chair, enabling the chair to puff
back up. For example, in one embodiment, the filler material is a
polyurethane foam having a density in an uncompressed state of
approximately 1.5 to approximately 1.8 lb/ft.sup.3.
[0043] After chair 14 is filled with the filler material 24,
opening 22 is closed. In one embodiment, chair 14 can range in size
from 2 feet to 7 feet in diameter, for example. Assuming a
generally spherical configuration, this results in a volume of
approximately 4 cubic feet to approximately 180 cubic feet. Thus,
in one embodiment, chair 14 can weigh from approximately 7 lbs to
approximately 324 lbs. It will be appreciated that as the diameter
of chair 14, increases, so can its weight, depending on the density
of the filler material. A large chair can be cumbersome to
transport not only due to its weight but also due to the floppiness
of the chair.
[0044] As shown in FIG. 12, chair 14 is inserted into cover 12.
Cover 12 is easily removable from chair 14. One reason for this is
that cover 12 may be made from a variety of colors, patterns,
and/or fabrics so that the purchaser may select from various outer
covers for the chair. In addition, chair 14 can be packaged and/or
sold separately from cover 12. This prevents cover 12 from becoming
wrinkled during the packaging process. Further, chair 14 can be
packaged such that the volume and weight of the chair 14 is
decreased. Advantageously, when the volume of chair 14 is
diminished, the weight of the chair also decreases, thus, reducing
packaging and shipping costs of the chair. Furthermore, as the size
of chair 14 decreases, chair 14 increases in firmness which
facilitates carrying and stacking of chairs.
[0045] Packaging of chair 14 will now be described. As shown in
FIG. 5, chair 14 is placed inside a vacuum chamber 26 such that
chamber 26 houses chair 14 therein. In its uncompressed state,
chair 14 may have a very large volume. As such, it may be necessary
for some of the air to be removed from chair 14 before it is placed
inside vacuum chamber 26. One of the ways in which air can be
initially removed is to roll or fold up chair 14 and/or place a
persons weight on the chair 14 before placing it inside vacuum
chamber 26.
[0046] Vacuum chamber 26 is generally an air impermeable container
having a circular wall 27 and an opening 28. Opening 28 may be
selectively opened or closed. Wall 27 of vacuum chamber 26 is
comprised of an air-impermeable material. Preferably, chamber 26
comprises a flexible, air-impermeable material which will conform
to the shape of chair 14, such as a plastic material, e.g., a
plastic bag.
[0047] Once the chair is placed within the vacuum chamber, a vacuum
source 30 is placed in communication with vacuum chamber 26 by
being disposed through opening 28. A temporary substantially
air-tight seal between vacuum source 30 and vacuum chamber 26 is
formed, such as by pressing the vacuum chamber against the vacuum
source, and the nozzle of the vacuum source is placed against the
bladder 15. For example, opening 28 of vacuum chamber 26 can be
manually held tight against the nozzle of the vacuum source 30 at
neck 32 of vaccum chamber 26 to form a temporary air-tight
seal.
[0048] Vacuum source 30 is operated so that the air in chair 14 is
removed from bladder 15 and vacuum chamber 26. Vacuum chamber 26 at
least substantially prevents additional air from entering chair 14
from the environment during the suctioning process. As the air is
suctioned out of chair 14, the filler material 24 compresses and
condenses together such that chair 14 diminishes in volume. As
such, chair 14 changes from an uncompressed state 34 shown in FIG.
5 to a compressed state 36 depicted in FIG. 6. It will be
appreciated that as chair 14 diminishes in volume, the weight of
the chair also decreases. Thus, a chair 14 shown in FIG. 5 weighs
more than the chair 14 shown in FIG. 6.
[0049] In one embodiment, after compression of chair 14 has been
performed by vacuum source 30, chair 14 may be further compressed
by another higher-powered vacuum source 38. High-powered vacuum
source 38 may be placed in communication with vacuum chamber 26 in
much the same manner as discussed above. Opening 28 is temporarily
sealed at neck 32 of chamber 26 and the high-power vacuum source 38
is operated. After operation, chair 14 is in a highly compressed
state 40, which is depicted in FIG. 7.
[0050] In one embodiment, vacuum source 30 is a 10 gallon
ShopVac.RTM. vacuum pump having a 6.25 hp motor. In another
embodiment, vacuum source 30 is a 16 gallon Craftsman.RTM. pump
having a 5.75 hp motor. Further, in one embodiment, high-powered
vacuum source 38 is a vacuum pump with a negative pressure tank
having a maximum negative pressure of 200 psi. The resting pressure
in the tank is -22 inches Hg. The high-powered vacuum source 38 can
operate from between -22 inches Hg to -10 inches Hg. The dual
vacuum sources 30, 38 provide distinct advantages when packaging
chair 14. The first vacuum source 30 provides a quick means for
removing air from chair 14. The second high-powered vacuum source
38 provides a stronger suction action which, while slower, draws
even more air out of chair 14 than would be obtainable by the first
vacuum source.
[0051] Whether both vacuum sources 30, 38 are needed may depend on
the size of chair 14 being packaged. For example, it may be
preferred to use dual vacuum sources for a large chair which
requires more vacuum power. Alternatively, in one embodiment, only
vacuum source 30 or 38 is employed for a smaller chair. However,
both sources may be employed if desired.
[0052] In a preferred embodiment, once chair 14 is in a compressed
state 36, vacuum chamber 26 remains surrounding the chair and at
least partially preventing the refilling of chair 14 with air.
Usually, as air is suctioned out of vacuum chamber 26, wall 27
gathers together and puckers against the side of chair 14. Thus,
the vacuum chamber 26 and chair 14 form a packaged furniture
assembly 42 which may be placed in a storage container, thereby
forming another furniture assembly including the chair, vacuum
chamber, and storage container.
[0053] FIGS. 8 through 11 depict one embodiment wherein the storage
container is a bag 44 or 54. The storage container may be air
permeable or air impermeable depending upon a desired embodiment.
When the storage container is air permeable, the storage container
may be constructed of fabric material, for example. The storage
container may also comprise another flaccid, air permeable
material. In one embodiment, the storage container is made from 7
oz 100% cotton enameling duck with pure finish. For example, the
storage container may comprise a duffle bag. When the storage
container is made from an air impermeable material, it may be
constructed from a material such as, but not limited to, plastic,
or cardboard, for example.
[0054] FIGS. 8 through 9 show an embodiment wherein bag 44 is
constructed of a fabric material, such as a duffle bag. Bag 44 has
a circular wall 46 and an opening 48. Opening 48 of bag 44 is
selectively opened and closed by a drawstring 52. Preferably, bag
44 is slightly larger than packaged furniture assembly 42.
[0055] After packaged furniture assembly 42 is compressed to the
desired level, opening 28 of vacuum chamber 26 is gathered at neck
32 (e.g., by twisting packaged furniture assembly 42 at neck 32) to
minimize the amount of air that can enter into the packaged
furniture assembly, leaving a plume 50. In one embodiment, packaged
furniture assembly 42 is placed in bag 44 and assembly 42 is left
partially open to allow air to enter the packaged furniture
assembly through neck 32. This facilities the refilling of air into
chair 14 when chair 14 is removed from bag 44 and vacuum chamber
26.
[0056] In one embodiment, a partial opening is formed in assembly
42 by gathering neck portion 32 thereof together without forming an
airtight seal, thereby forming a partial opening. This can occur,
for example by twisting plume 50 (e.g., rotating plume 50 in about
one to about six revolutions) with respect to neck 32 and loosely
folding plume 50 against the remainder of assembly 42, as shown in
FIG. 9. Such rotations may also occur by holding plume 50 and
spinning the remainder of assembly 42 below plume 50 (e.g., causing
about one to about six revolutions of the portion of assembly 42
located below plume 50, such as about two, three, four or five
revolutions).
[0057] A partial opening can also be formed by merely pressing
inwardly about neck 32, such that the neck portion 32 is gathered
together. Optionally, a partial opening can be formed by folding
such a gathered plume 50 over. In another embodiment, a partial
opening can be formed by completely sealing assembly 42 in its
compressed state in an air tight manner, then forming a small
opening in vacuum chamber 26 which is not sufficiently large to
allow chair 14 to entirely refill with air or to be removed from
the chamber through the opening. As another option, a partial
opening may occur by placing a tie, sleeve, or clamp about the neck
32 of the vacuum chamber, thereby gathering a portion of the
chamber together, without sealing the vacuum chamber in an air
tight manner. As another option, a partial opening may occur by
placing an adhesive within the neck 32 of the vacuum chamber,
thereby gathering the neck 32, without sealing the vacuum chamber
in an air tight manner.
[0058] As air enters the packaged furniture assembly 42, chair 14
begins to refill with air somewhat until chair 14 expands against
wall 46 of bag 44. Because bag 44 is constructed of air permeable
material, e.g., fabric, bag 44 may be closed before chair 14
completely expands to fill the bag. One advantage of employing an
air-permeable bag 44 such as a fabric bag (e.g. a duffle bag) is
that the bag will let some air in, but only expand to a certain
size, thereby maintaining the overall assembly in a convenient size
for storage and shipping.
[0059] As discussed above, after packaged furniture assembly 42 is
placed inside bag 44, air is still allowed inside vacuum chamber 26
through plume 50. Drawstring 52 may be used to selectively open or
close opening 48 of bag 44. However, because bag 44 is air
permeable and because opening 28 of vacuum chamber 26 is still left
partially open, chair 14 may continue to expand. In one embodiment,
bag 44 is constructed of a strong, slightly expandable fabric
(e.g., cotton weave) which allows chair 14 to expand until it
presses tightly against the sides of bag 44. In one embodiment, bag
44 is cylindrical in shape so that chair 14 refills to produces a
firm, generally cylindrical shaped structure which is convenient
for carrying, storing and/or shipping chair 14. For example, a 3
foot diameter chair 14 can be reduced to a cylindrical shaped
structure having a 15 inch diameter and height of 30 inches. As
will be appreciated, the cylindrical structure is much easier to
carry than a large chair, or even a boxed structure.
[0060] The process of removing air from a bladder and forming the
bladder to a desired shape can be assisted by applying a force
against the bladder during suctioning, such as by placing the
weight of a person on the bladder during the suctioning process
(i.e., by leaning on the vacuum chamber).
[0061] FIGS. 10 through 11 depict another embodiment wherein a
first storage container 54 is placed within a second storage
container 82. In one embodiment, the first storage container 54
comprises another vacuum chamber constructed of an air impermeable
material, e.g., plastic. Container 54 has a wall 60 and an opening
62. In this embodiment, all of the steps of producing the
compressed packaged furniture assembly 42 as shown in FIGS. 5
through 7 remain the same. After chair 14 is compressed, forming
assembly 42, the packaged furniture assembly 42 is placed inside
storage container 54 (e.g, another plastic bag). The furniture
assembly so formed is then placed in container 82.
[0062] Container has an opening 62. In FIG. 10 opening 28 of
assembly 42 is positioned opposite opening 62 of container 54. This
may be employed to provide an improved seal within chamber 26
and/or for convenience in placing assembly 42 within container 54.
However, it will be appreciated that the positioning of packaged
furniture assembly 42 within container 54 is not limited to this
configuration.
[0063] While inside container 54, opening 28 of vacuum chamber 26
may be closed or partially open. When opening 28 is partially open,
air is allowed to enter the vacuum chamber 26, allowing chair 14 to
expand until it presses against wall 60 of container 54. For
example, opening 28 may be left partially open by rotating plume 50
with respect to neck 32, and folding plume 50 onto the remainder of
packaged furniture assembly 42, as shown in FIG. 10.
[0064] Alternatively, opening 28 may be sealed such as by rotating
plume 50 and tying a knot therein or placing a tie thereat. When
opening 28 is completely closed, the air in container 54 may be
sucked out by a vacuum source so that the wall 60 of container 54
presses against packaged furniture assembly 42.
[0065] Opening 62 of container 54 may be closed by forming plume 66
as discussed above. As shown in FIG. 10, a tie 68 may then be
disposed about neck 64 to prevent a significant amount of air from
flowing back into container 54. Plume 66 can then be flared open
and an adhesive 70 can be sprayed or otherwise applied on the
inside of plume 66. Plume 66 is then closed and twisted so that
adhesive 70 is secured inside the plume 66. Plume 66 is then bent
over and the end of plume 66 is secured to neck 64 by a second tie
72, as shown in FIG. 11. Advantageously, the presence of multiple
ties, adhesive, and a path which requires air to double back
results in an at least substantially air-tight configuration so
that the chances of chair 14 expanding inside container 54 are at
least significantly reduced. This process may be employed without
expensive vacuum sealing equipment. Optionally, such vacuum sealing
equipment may be employed with a single or both vacuum chambers 42,
54. As shown in FIG. 11, the assembly comprising assembly 42 within
container 54 can be stored and/or transported inside a box 82
without fear of bag 54 expanding and breaking the box. Optionally,
the assembly comprising assembly 42 within container 54 may be
stored and transported without box 82.
[0066] Advantageously, the foregoing embodiments reduce the volume
and weight of chair 14 and facilitate storing and/or transporting
the chair 14. The following table gives example calculations for
approximate measurements taken from three sizes of chairs 14.
First, the original volume of each chair in an uncompressed state
is given in light of the chair's generally spherical shape. Next,
the volume of the packaged furniture assembly 42 is calculated
based on a generally rectangular cubical structure having a height,
width and length. Finally, the volume of the packaged furniture
assembly 42 when in a storage container is calculated based on the
generally cylindrical shape of the packaged furniture assembly 42.
In addition, the percentage volume of the final product is given.
The volume percentage that is given represents that the chair is
reduced to about X% of the original volume. The percentage by which
the chair is reduced by can be easily calculated by calculating
100% less X%.
1 Small Intermediate Large Approximate Measured 7 ft.sup. 10
ft.sup. 17 ft 3 in circumference (see FIGS. 3-4) Original volume
(based on 5.79 ft.sup.3 16.89 ft.sup.3 86.68 ft.sup.3 generally
spherical configuration of FIGS. 3-4) Approximate Height, width, 9
in .times. 8 in .times. 14 in 10 in .times. 9 in .times. 26 in 15
in .times. 14 in .times. 39 in and length of highly condensed
packaged furniture assembly (see FIG. 7) Highly condensed volume
0.58 ft.sup.3 1.35 ft.sup.3 4.74 ft.sup.3 (based on generally
rectangular cubical configuration of FIG. 7) Reduced to X % of
original 10% 8% 5.5% volume Approximate Circumference 35 in .times.
18 in 50 in .times. 35 in 72 in .times. 42 in and height of
generally cylindrical storage container with packaged furniture
assembly having the opening of the packaged furniture assembly
partially open (see FIG. 9) Volume in generally 1.02 ft.sup.3 4.03
ft.sup.3 10.03 ft.sup.3 cylindrical storage container of FIG. 9
Reduced to X % of original 17.5% 24% 11.5% volume
[0067] The foregoing process provides a significant reduction in
volume of chair 14. As will be appreciated, the weight of the chair
is reduced by the amount of air removed from the chair 14. It will
be appreciated that the foregoing method for packaging chair 14
allows a significantly higher number of chairs 14 to be transported
that would be possible if the chair 14 were simply packaged in, for
example, a box, without applying the inventive steps above.
[0068] In the foregoing embodiments, as discussed the opening 28 of
vacuum chamber 26 can either be left partially open so as to allow
at least a minimal amount of air inside the vacuum chamber during
storage or the opening can be sealed closed to shut off
communication with the atmosphere. Both options have certain
advantages which will now be discussed in additional detail.
[0069] For example, as shown in FIG. 11, sometimes the user will
desire to package chair 14 in a box. Because compressed filler
material 24 can expand when exposed to air, it is sometimes
desirable to limit the amount of expansion of the chair. Because a
typical cardboard box may not have the strength to withstand the
expansion of the chair if the vacuum chamber 26 is left open, it
may be necessary to limit the expansion that chair 14 may undergo
during storage. For this reason, the opening 28 of vacuum chamber
26 and/or the opening 62 of container 54 may be closed before it is
placed in the storage container. The storage container may also be
sealed as discussed above.
[0070] However, when the storage container is a durable, flaccid,
fabric bag, the bag can withstand the expansion pressures of the
chair so that sealing the vacuum chamber 26 is not necessary. In
fact, it is often advantageous to leave vacuum chamber 26 open to
the atmosphere because it increase the rate of expansion of the
filter material 24 when chair 14 is removed from vacuum chamber 26.
When vacuum chamber 26 is left partially open, as depicted in FIG.
9 and the discussion relating thereto, chair 14 can expand to its
original size within about 1 day. In contrast, when vacuum chamber
26 is sealed to the atmosphere, it can take up to 1 week for chair
14 to expand to its original size. Of course, fluffing actions
(e.g., kicking, punching, tossing) chair 14 will accelerate the
rate of expansion. As will be appreciated, leaving vacuum chamber
26 open to the atmosphere during storing and/or transportation
significantly increases the eventual rate of expansion of chair 14,
allowing the user to enjoy the uses of chair 14 more quickly after
removing the storage container and vacuum chamber.
[0071] It will be appreciated that the foregoing embodiments for
packaging chair 14 prevent chair 14 from expanding back to its
original volume and weight during storage and/or transportation.
Advantageously, this prevents chair 14 from expanding unexpectedly
and causing a potentially hazardous situation when a number of
chairs are stacked. Furthermore, when chair 14 is compressed and
disposed within a storage container, the storage container protects
air permeable bladder 15 from coming in contact with any objects
that might rip or tear the material. It will be appreciated that
the efficient design of chair 14 does not require wood, metal, or
plastic framing or fittings of any kind. However, the present
invention also contemplates within its scope chairs 14 which might
include wood, metal or plastic framings or fittings.
[0072] When the user desires to set up chair 14, the chair is
removed from the corresponding storage container (i.e., bag 44 or
54) and separated from packaged furniture assembly 42. Chair 14 is
allowed to expand back to its normal size. The user may accelerate
the rate of expansion by fluffing chair 14. FIG. 12 shows chair 14
being inserted into cover 12. As long as the cover 12 is made from
air permeable material, the chair can be placed inside the outer
cover either before or after expansion has occurred.
[0073] Also as shown in FIG. 8, the compressed assembly 42 may have
a smaller diameter than the container 44 in which it is ultimately
placed to allow convenient placement therein and may be allowed to
partially refill within the container 44 such that the eventual
complete filling with air is more readily achieved when the chair
is removed from the container.
[0074] In one embodiment, the chair of the present invention is
selectively suctioned down to about 1% to about 99% of the original
volume. In a preferred embodiment, the chair is selectively
suctioned down to about 4% to about 50% of the original volume,
such as down to about 5% to about 25% of the original volume, e.g.,
down to about 5% to about 15% of the original volume.
[0075] In one embodiment, the chair is selectively suctioned, then
allowed to refill with air until reaching about 6% to about 99% of
the chair's original volume, preferably until reaching about 8% to
about 50% of the chair's original volume, such as about 10% to
about 25% of the chair's original volume.
[0076] The manufacture of cover 12 may be similar to that for air
permeable bladder 15 discussed above, for example. As shown in FIG.
12, cover 12 comprises two material portions 74A, 74B which may
have generally hour-glass shapes. Material portions 74A, 74B have
end regions (not shown) and intermediate regions (not shown). The
end region of one material portion is placed against the
intermediate region of the other material portion similar to that
shown in FIG. 2 for air permeable bladder 15. The edges of the
material portion are sewn together so that, when filled, cover 12
forms a generally spherical structure. However, it will be
appreciated that other shapes are contemplated within the scope of
the present invention such as generally cubical, generally
cylindrical, and other geometrical shapes.
[0077] One material portion has an opening 80 extending lengthwise
across the material portion. In one embodiment, opening 80 is
formed before the material portions are sewn together. Opening 80
can be selectively opened and closed and thus cover 12 comprises a
structure which facilitates such opening and closing such as, but
not limited to a zipper, lacing, Velcro, or other connecting
structure. Cover 12 may comprises an air-permeable material. For
example, cover 12 may comprise a fabric material, for example, or
another flaccid material.
[0078] In one embodiment, cover 12 is constructed from 7 oz 65%
polyester 35% cotton with crease resistant finish. Other air
permable materials may be employed such as, but not limited to
linen and nylon velvet. Advantageously, cover 12 can be made of
different patterns and colors or may incorporate features such as
logos or pockets.
[0079] Also, in another embodiment, such as when the cover
comprises a vinyl or leather material, an air permeable portion or
"patch" is located on the cover. This portion may be associated
with a logo, for example. In one embodiment, this air permeable
portion may comprise a suraline gabardine material that breathes
well such that air can fill bladder 15 through the portion to
thereby cause the filler material 24 to fill with air when a person
gets off the chair. The air permeable portion may comprise a
stretchable material, for example.
[0080] As shown in FIG. 12, chair 14 is inserted into opening 80 of
cover 12. Opening 80 is closed and the user can then arrange
furniture assembly 10, shown in FIGS. 1 and 14, into the
configuration desired. It will be appreciated that even after
packaging chair 14, the chair retains at least substantially all of
its original compressibility, pliability, and resiliency that it
originally had. As such, the user is provided a comfortable,
durable piece of furniture which may be applied in a variety of
uses.
[0081] In yet another embodiment of the present invention, toys,
such as toy animals comprise an air permeable material with a
filler material therein and are packaged according to one or more
of the packaging methods disclosed herein, such as by suctioning
the air from within the air permeable material, then placing the
reduced sized toy animal in a container, such as a small duffle
bag. Optionally, the reduced sized toy animal may be placed in a
vacuum chamber, such as a plastic bag as discussed above, before
being placed in the container (e.g., duffle bag). Also as discussed
above, the reduced-sized toy animals may have a smaller diameter
than the container in which it is ultimately placed to allow
convenient placement therein and may be allowed to partially refill
within the duffle bag such that the eventual complete filling with
air is more readily achieved when the toy animal is removed from
the duffle bag or other container.
[0082] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *