Upholstered module and method for manufacturing same
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- C GEX SYSTS
- Filing Date
- 2024-11-14
- Publication Date
- 2026-07-08
AI Technical Summary
Traditional filling modules face challenges during manufacturing, including difficulty in stretching covers to position them correctly on the filling body and problematic sewing operations due to a lack of skilled labor.
A filling module design featuring a support face with a cross-section having at least one angle, a plate face with a similar cross-section, and lateral faces with edges that include packing slots. The excess corner fabric is inserted into these slots, forming a fabric clamp that secures the cover without the need for extensive sewing.
This solution simplifies the manufacturing process by eliminating the need for complex sewing operations and allows for easier cover tensioning and centering, while also avoiding excess thickness on the rear face of the module.
Smart Images
Figure EP2024082408_22052025_PF_FP_ABST
Abstract
Description
Description Title of the invention: Filling module and its manufacturing method [Technical field]
[0001] The invention relates to a filling module, in particular for furnishing, decoration or insulation. The invention also relates to the method of manufacturing a filling module according to the invention. [State of the prior art]
[0002] Traditionally, a filling module comprises a filling body covered with a decorative fabric which is then secured to the back of the filling module, usually by staples. The excess fabric of the cover in the corners of the filling body is usually sewn or folded over to form an overlay which is then sewn as shown in Figure 1.
[0003] Such a filling module can present several pitfalls during its manufacturing process, on the one hand, it is complicated to stretch covers in order to position them correctly on the filling body, on the other hand, sewing operations have become problematic due to the lack of skilled labor. The sewing and filling profession is particularly impacted by this lack of labor.
[0004] The invention aims to overcome all of these drawbacks. [Statement of the invention]
[0005] The invention aims to provide an alternative technical solution for managing excess fabric in the corners and behind the upholstery module.
[0006] In particular, the invention aims to provide a technical solution for covering the filling body without crushing it when the latter is deformable, for example, in the case of a foam filling body.
[0007] Furthermore, the invention aims to reduce or even eliminate sewing operations to manage excess fabric in the corners of the filling body.
[0008] For this purpose, the invention relates to a filling module, in particular for furnishing, decoration or insulation, comprising: a filling body of defined three-dimensional shape which comprises: o a support face arranged behind said body and comprising a cross-section comprising at least one angle, o a plate face arranged in front of said body and opposite the support face, the plate face comprising a cross-section comprising at least one angle and a shape similar to the shape of the cross-section of the support face, o at least one lateral face which extends between the plate face and the support face, o at least one edge connecting, along a longitudinal axis, the angle of the support face and the angle of the plate face, the edge defining a height H of the lateral face of the packing body, o at least one packing slot extending along a cutting plane which passes through the longitudinal axis of the edge,the filling slot extending longitudinally along the longitudinal axis of the edge from the support face over a height h less than the height H of the side face so that the filling slot is open in the corner of the support face and on the longitudinal axis of the edge; and a fabric cover covering the tray face and the side face of the filling body, the cover being secured behind the filling body on the support face while an excess of corner fabric, at the edge of the filling body, is inserted into the filling slot and forms a fabric clamp.,
[0009] The use of a split edge on a part h of its length H makes it possible to manage the excess fabric in the corners by inserting it into the filling slot without necessarily carrying out a sewing operation on this excess fabric. The fact that the slot is open on the edge but also on the support face makes it possible to insert the excess fabric into the corner at the level of the support face and then to attach it to the support face which is behind the filling module. Alternatively, the excess fabric can be embedded in the same slot by folding the excess according to a procedure described below. This makes it possible to avoid excess thickness on the rear face of the module.
[0010] In embodiments, the filling slot may extend transversely along a bisector of the support face angle and by a determined distance d. Wedging the excess corner fabric in the bisector of the support face angle but also in the bisector of the edge, facilitates the centering of the cover on the filling body.
[0011] In embodiments, the support face and the tray face may respectively comprise a cross-section having at least one side curved. The packing module can thus have a three-dimensional shape with curved sides. The packing module can then be adapted to various applications.
[0012] In embodiments, the support face and the tray face may respectively comprise a polygonal cross-section, the filling body comprising ridges connecting the corners of the support face to corners of the tray face which respectively face each other, the filling module comprising filling slots which are provided in the edges of the filling body, excess corner fabric of the cover being pinched and inserted into the filling slots.
[0013] In embodiments, the support face and the tray face may respectively comprise a rectangular cross-section, the filling body thus comprising four edges each comprising a filling slot into which the excess corner fabric of the cover is pinched and inserted. The use of a parallelepiped-shaped filling body is a very common shape in the fields of sound and / or thermal insulation but also in the field of furniture.
[0014] In embodiments, the tray face may be planar or may include one or more domed portions.
[0015] In embodiments, the tray face may be elastically deformable. This is particularly the case when the filling body comprises a deformable and / or elastic material such as filling foam. In this case, inserting the excess corner fabric into the filling slots allows the cover to be stretched without crushing the tray face and the filling body.
[0016] In embodiments, the filling body may comprise at least one filling material selected from the following list: sound insulation material such as polyurethane foams, composite panels; thermal insulation material such as polystyrene, wood wool panels, compressed; furnishing material such as wood, wood derivatives, polymers, metal, resins, composite materials; and furnishing material for seating or bedding such as polyurethane foams.
[0017] In embodiments, the support face may comprise a plate of rigid material which is integral with the packing body, the packing slots being transverse to said plate. The plate of rigid material improves the fixing of the cover on the support face. In addition, in certain applications, for example, when the filling body comprises a deformable / elastic material, the rigid material plate makes it possible to limit the deformation of the filling body under the effect of pressure or force which is applied to the filling body.
[0018] In embodiments, the fabric clamp may include a seam to hold the fabric pinched. In this embodiment, the slot allows the seam plug to be inserted. The seam is typically recessed relative to the fold, the seam plug corresponds to the recessed area interposed with the edge of the fabric and the seam
[0019] In embodiments, the fabric cover may comprise at least one material selected from the following list, natural fabric such as cotton, silk, linen, wool, woven or non-woven synthetic fabrics such as polyurethane, polyvinyl, polyethylene.
[0020] In embodiments, the cover may be delimited by a peripheral edge which is secured to the support face, by a pulling string and / or by fixing means such as staples, nails or screws or fixing profiles.
[0021] In particular embodiments, the peripheral edge of the cover is folded so as to form a cuff which is secured to the support face of the filling body. This improves the longevity of the filling module by making the attachment, of the peripheral edges, to the support face more robust.
[0022] In embodiments, the peripheral edge and the fabric clamp are folded so as to overlap and be secured together at the corner of the support face. Securing the fabric clamp and the peripheral edge at a corner of the support face improves the longevity of their attachment and therefore the finishing quality of the upholstery module. This also reduces the use of staples, thereby reducing manufacturing costs, for example, by using two staples per corner, one staple attaching the clamp and a peripheral edge.
[0023] In embodiments, the filling module may comprise a pull wire mounted to slide in a seam of the peripheral edge and a slide formed by the fabric clamp folded down on the support face. According to this embodiment, the pull wire presses the peripheral edges against the support face between the corners of the latter.
[0024] In embodiments, the upholstery module may be configured to form a seat or back of furniture.
[0025] In embodiments, the trim module may be configured to form a sound insulation panel and / or a thermal insulation panel.
[0026] In embodiments, the filling module may be configured to form a bedding mattress.
[0027] In embodiments, the filling slot has a width at least equal to four times the thickness of the cover fabric so as to fold the clamp into the filling slot, the excess corner fabric then being fully inserted into the filling slot. This makes it possible to manage the excess corner fabric without using fixing means and to achieve a finish without excess thickness on the rear face of the filling module.
[0028] The invention also relates to a method for manufacturing a filling module according to the invention, the manufacturing method comprising: incising the support face and the edge of the filling body, the incision being made along a cutting plane passing through the longitudinal axis of the edge, the incision being made at a height h less than the height H of the lateral face of the filling body so that the tray face is full and so as to provide an open filling slot on the support face and at a height h along the longitudinal axis of the edge, positioning the filling body on the fabric cover in a spread state, folding a first corner fabric excess of the cover at least at one edge and / or one corner of the support face of the filling body, inserting the first fabric excess into the filling slot of the filling body,tensioning the fabric cover while the first excess fabric is inserted into the filling slot, and securing the peripheral edges of the fabric cover to the support face of the filling body.,
[0029] Splitting the edge allows excess fabric to be managed in the corners by inserting it into the filling slot without necessarily sewing this excess fabric. The excess fabric in the corner thus passes through the slot and protrudes behind the filling module at the support face, it is then possible to easily attach it to the support face, for example using staples which requires a less technical intervention than sewing.
[0030] In addition, the first excess fabric inserted into a first filling slot provides, during the tensioning step, a point of attachment for the cover. This allows the cover to be tensioned easily and simplifies centering the cover on the filling body.
[0031] In embodiments, the insertion of the excess corner fabric into the upholstery slot may be accomplished with a blade, preferably a blunt blade. The blade allows the fabric cover to be inserted while avoiding the formation of creases.
[0032] In embodiments, folding of the excess corner fabric may be performed with said blade. In particular, the blade allows folding to be performed without forming a crease on the plate face.
[0033] In embodiments, inserting the excess corner fabric into the upholstery slot forms a fabric clamp, at least one portion of which can extend into the upholstery slot while a second portion projects from the support face. Folding the excess fabric into a clamp shape limits the formation of creases, whether on the tray face or on the side faces.
[0034] In these embodiments, the manufacturing method may include longitudinally sewing a portion of the fabric clamp that projects from the packing slot through its opening on the support face. This improves the strength of the clamp and thus the longevity of the packing module.
[0035] In some embodiments, the folding of a first corner fabric surplus and the insertion into the stuffing slot can be carried out simultaneously. This makes it possible to limit and share the steps of the manufacturing process and thus accelerate it.
[0036] In some embodiments, when the stuffing body may include several edges, each edge comprises a stuffing slot. Thus, after the sleeve is tensioned while the first corner fabric surplus is inserted into a first stuffing slot, the corner fabric surpluses located at the level of the other edges of the stuffing body are inserted into the corresponding stuffing slots.
[0037] In some embodiments, the manufacturing process may include: A cutout of the clamp which projects from the slot at the support face, and A corner finish in which a corner end of the peripheral edge is inserted into the slot overlapping a remaining portion of the clamp which is at least partially inserted into the slot.
[0038] Such a finish makes it possible to obtain a filling module whose support face does not have any excess thickness in the corners of the support face. According to this method of realization, the peripheral edge is then fixed to the support face by staple-type fixing means.
[0039] In particular, when cutting the clip, two pieces of fabric are folded down on either side of the filling slot and attached to the filling module support face in the form of flaps. Each corner end covers a flap when inserted into the filling slot.
[0040] In embodiments, the manufacturing method may include folding the peripheral edge of the cover to form a cuff which is then secured to the support face of the free body. The cuff increases the strength of the cover attachment to the rear of the upholstery module.
[0041] In embodiments, the peripheral edges may be secured to the support face by sewing or by mechanical fastening.
[0042] In embodiments, the peripheral edges may be secured to the support face by a draw wire. The draw wire makes it possible to adjust the tension of the cover to the filling body without crushing the latter when it is deformable.
[0043] In embodiments, the peripheral edges and excess corner fabric may be folded over to overlap and mechanically secured together in the corner of the support face.
[0044] In embodiments, a portion of the excess corner fabric may be folded over as the draw wire passes through to provide a track in which the draw wire can slide, with the tension of the draw wire being adjusted to fit the cover to the filling body. This allows the cover to be adjusted to the shape of the filling body by managing the tension of the draw wire and limiting creases but also the use of mechanical fastening means.
[0045] In embodiments, the cutting plane that can be used to make the incision can pass through the bisector of at least one angle of the support face. The use of the bisector makes it possible to improve the centering of the cover on the filling body. [Description of the drawings]
[0046] Other characteristics and advantages of the invention will become apparent from reading the description which follows. This description is purely illustrative and must be read in conjunction with the appended drawings in which:
[0047] [Fig. 1] is a schematic representation of a state-of-the-art filling module in which the excess corner fabric is folded and sewn, thereby generating an extra thickness.
[0048] [Fig. 2] is a schematic representation of an embodiment of a packing module according to the invention.
[0049] [Fig. 3] is a schematic representation of a corner of the support face of the upholstery module of Figure 2 before the cover is secured to the support.
[0050] [Fig. 4] is a schematic representation of different support faces that comprise the packing module in accordance with embodiments of the invention.
[0051] [Fig. 5] is a schematic representation of the incision step of a method of manufacturing a packing module both conforming to embodiments of the invention.
[0052] [Fig. 6] is a schematic representation of the step of positioning the fabric cover on a filling body in accordance with one embodiment of the manufacturing method of the invention.
[0053] [Fig. 7], [Fig. 8], [Fig. 9] and [Fig. 10] are schematic representations of the steps of folding and inserting excess corner fabric into a trim slot in accordance with one embodiment of the manufacturing method of the invention.
[0054] [Fig. 11] is a schematic representation of an edge of a filling body into which excess corner fabric has been folded and inserted in accordance with one embodiment of the invention.
[0055] [Fig. 12] is a schematic representation of a filling body in which excess corner fabric has been folded and inserted into each edge of the filling body in accordance with one embodiment of the invention.
[0056] [Fig. 13] and [Fig. 14] are schematic representations of methods of securing the excess corner fabric and the peripheral edge of the cover fabric to the support face in accordance with embodiments of the invention.
[0057] [Fig. 15] a schematic representation of the peripheral edge of the cover secured to the support face by staples conforming to an embodiment of the invention.
[0058] [Fig. 16] is a schematic representation of the rear face of the conformal upholstery module of an embodiment of the invention, in which the excess corner fabric is inserted into the upholstery slot.
[0059] [Fig. 17] is a schematic representation of the embodiment of Figure 16 showing the attachment of a flap from the fabric clamp to the support face of the filling module.
[0060] [Fig. 18] is a schematic representation of a flowchart schematically representing the succession of steps of the manufacturing method of a packing module conforming to the invention. [Description of embodiments]
[0061] With reference to Figures 2 to 18, the present invention relates to a filling module 20 in particular for furnishing, decoration or insulation. According to one embodiment, the filling module 20 may constitute a bedding mattress. According to another embodiment, the filling module 20 may constitute a seat or a backrest of furniture such as a seat, a sofa, an armchair, a cushion, a pouf, a chaise longue, etc. According to another embodiment, the filling module may be a sound insulation panel and / or a thermal insulation panel.
[0062] The filling module 20 is adapted in dimensions and three-dimensional shape to adapt to each of the aforementioned applications. In particular, the filling module 20 can be integrated into a frame or be secured to a furniture support or a wall support, for example, in the context of sound and / or thermal insulation panels.
[0063] As illustrated in particular in Figures 2 to 6, the packing module 20 comprises a packing body 200 which has a defined three-dimensional shape.
[0064] Depending on its application, the filling body 200 may comprise different materials. For sound and / or thermal insulation applications, the filling body 200 may comprise a sound insulation material such as polyurethane foams, composite panels or even a thermal insulation material such as polystyrene, compressed wood wool panels. According to one embodiment of the invention, the filling body 200 may also comprise a mixture of these materials.
[0065] In the case of an application of the filling module 20 in the fields of furniture, the filling body 20 may comprise materials furniture materials frequently used in these areas such as wood, wood derivatives, polymers, metal, resins, composite materials.
[0066] Furthermore, still in the field of furniture, when the upholstery module 20 can be configured to be a support surface such as a seat or a backrest for a seat or bedding, the upholstery body 200 can comprise materials comprising foams such as polyurethane foams, polyether foams, molded foams.
[0067] As illustrated in particular in FIG. 3, the filling body 200 comprises a support face 201 which is arranged behind the filling body 200. In this embodiment, the filling body 200 comprises an expanded polystyrene type material. According to one embodiment, the support face 201 can be configured to be assembled to a furnishing, decorative or insulating support element.
[0068] In the embodiment of Figure 3, the support face 201 is constituted by a face of the filling body 200. In the embodiment illustrated in particular in Figures 5 and 6, the support face 201 comprises a plate 202 made of rigid material such as wood, wood derivatives, a polymeric material, a composite material or even metal. According to this embodiment, the plate 202 is integral with the filling body 200. The plate 202 can thus be glued to the filling body 200.
[0069] According to the invention, the support face 201 comprises a cross-section comprising at least one angle 203. Figure 4 shows some examples of cross-sectional shapes that can be used to form the support face 201 of the packing module 20 in accordance with embodiments of the invention. According to these examples, the cross-section of the support face 201 may have the shape of a rectangle 900, a triangle 901, a half-moon 902, a drop 903, a trapezoid 904, a pentagon 905, a heart 906, a hexagon 907, a square 908, or a rectangle 909 with rounded corners. The drop 903 comprises a single angle 203 and the heart 906 comprises two angles 203, a first angle 203 projecting at the tip of the heart 906 and a second angle 203 entering into the shape of the cross-section. The rounded rectangle 909 comprises four rounded angles 203 in accordance with embodiments of the invention.These examples of cross-sectional shape in no way limit the scope of the invention which can be of any two-dimensional shape provided that this shape comprises at least one angle 203. This angle 203 can be projecting or re-entrant but also rounded.
[0070] According to the invention, the packing body 200 comprises a plate face 204 which is arranged in front of the packing body 200. The plate face 204 is opposite the support face 201. As illustrated in particular in figures 2 and 5, the plate face 204 comprises a cross section comprising at least one angle 203 and a shape similar to the shape of the cross section of the support face 201. According to one embodiment, the plate face 204 comprises an upper face of the packing body 200.
[0071] According to one embodiment of the invention, the tray face 204 is flat, see for example figures 2 and 6. However, for decorative or functional needs, in particular the cushioning of a seat or a seat back, the tray face 204 may comprise one or more curved portions.
[0072] In embodiments, the support face 201 and the tray face 204 may respectively comprise a cross-section having at least one curved side. As illustrated in FIG. 4, manufacturers may select a packing module 20 whose support face 201 is shaped like a drop 903, a half-moon 902, hearts 906, or other shapes comprising a curved side. In this case, the tray face has a shape similar to that of the cross-section of the support face 201.
[0073] According to the invention, the filling body 200 comprises at least one lateral face 206 which extends between the plate face 204 and the support face 201.
[0074] Furthermore, the packing body 200 comprises at least one edge 207 connecting, along a longitudinal axis AA, the angle 203 of the support face 201 and the angle 205 of the plate face 204. The edge 207 defines a height H of the lateral face 206 of the packing body 200. Furthermore, the edge 207 defines at least one lateral edge of a lateral face 206, this is particularly the case when the cross-section of the support face 201 is drop-shaped 903. However, most of the time an edge 207 forms the junction between two lateral faces 206 as illustrated in FIG. 2. In this sense, the edge 207 respectively defines the lateral edge of two adjacent lateral faces 206.
[0075] According to the invention and as illustrated in particular in Figure 2, the packing body 200 comprises at least one packing slot 208. The edge 207 can thus be described as a split edge. The packing slot 208 extends along a plane which passes through the longitudinal axis AA of the edge 207. As illustrated in Figures 2 and 11, the packing slot 208 extends longitudinally along the longitudinal axis AA of the edge 207 from the support face 201 over a height h less than the height H of the side face 206. According to this embodiment, the upholstery body 200 thus retains a full upper plate, that is to say, without a notch which can act as a useful surface for receiving objects or constituting a support surface such as a seat or a backrest.
[0076] According to this configuration, the filling slot 208 is open, on the one hand, on the support face 201 along a plane passing through the axis AA, and on the other hand, along the longitudinal axis AA of the edge 207 over a height h less than the height H of the lateral face 206.
[0077] According to the invention, the filling module 20 comprises a fabric cover 30 covering the tray face 204 and the side face 206 of the filling body 200. According to one embodiment, the fabric cover 30 may comprise at least one material chosen from the following list, natural fabric such as cotton, silk, linen, wool, woven or non-woven synthetic fabrics such as polyurethane, polyvinyl, polyethylene.
[0078] The dimensions of the cover 30 are chosen according to the three-dimensional shape of the filling body 200 and its dimensions. In particular and as is known to those skilled in the art, the dimensions of the cover 30 are determined so that the cover covers the tray face 204, the side faces 206 and that there remains sufficient fabric to attach the cover 30 to the support face 201 of the filling body. According to the embodiment of FIG. 6, the cover 30 is rectangular while the filling body 200 is a rectangular parallelepiped.
[0079] In particular, according to an embodiment notably illustrated by figures 5 and 6, the filling slot 208 extends transversely along a bisector of the angle 203 of the support face 201 and along a determined distance d. The filling slot 208 can also extend along an axis distinct from the bisector.
[0080] The distance d defines the depth of the filling slot 208. This depth can depend on two parameters, on the one hand, the value of the angle of the support face 201 and / or of the plate face 204, in fact, the greater the value of the angle, the less excess fabric there is. On the other hand, the greater the height H of the filling body 200, the greater the excess fabric. In this case, the height H corresponds to the height of the volume to be dressed. The greater the excess fabric, the greater the depth of the slot must be.
[0081] The slot should be wide enough to accommodate the excess 300 fabric folded into a clip.
[0082] As illustrated in Figures 13 to 15, the cover 30 is secured behind the filling body 200 on the support face 201. Indeed, according to one embodiment, visible in particular in Figures 11 to 14, the cover 30 is delimited by a peripheral edge 302 which is secured to the support face 201. The peripheral edge 302 can be attached to the support face 201 in several ways. According to one embodiment in Figure 13, the The filling module 20 may comprise fixing means 303 of the staple, nail or screw type or fixing profiles for attaching the peripheral edge 302. In particular, here it is staples which are used to secure the peripheral edge 302 to the support face 201 which also comprises a rigid plate.
[0083] According to the embodiments illustrated in figures 13 and 14, the clamp 301 and the peripheral edges 302 overlap in the angle 203 of the support face 201 and are secured to each other at the support face 201.
[0084] In particular in the embodiment of figure 13, the clamp 301 is pressed against the support face 201, the fixing means comprise a clip 303 at the tip of the clamp 301 which secures it to the support face 201. The peripheral edges 302 are folded over the support plate 201 and in its corners 203 over the clamps 301 already attached by a clip 303 to the support plate 201. In this embodiment, the peripheral edges 302 overlap the clamp 301 in the corners and staples 303 secure, in the corners 203, the peripheral edges 302 to the support face 201 through the clamp 301.
[0085] In the embodiment of Figure 14, the peripheral edges 302 are folded back to form a cuff 306 and have a seam 308 to hold the cuff 306. The fixing means then comprise a pulling wire 309 which is slidably caught in the seam 308. The clamp 301 is folded back along two fins 307 which overlap the peripheral edges 302 at the corners 203. The fastening means comprise staples 303 which are arranged on either side of the slot 208 in order to secure the fins 307 to the support face 201 while they overlap the peripheral edges 302 of the cover 30. In addition, the clamp 301 comprises at its end a slide 310 in which the pulling wire 309 passes and slides. The pulling wire 301 makes it possible to stretch the peripheral edges 302 between the corners 203 of the support face 201 and thus to adjust the cover to the filling body 200. According to this embodiment, the peripheral edges 302 are not fixed, outside the corners 203, to the edge of the support face 201 which joins with a side face 206.
[0086] According to an embodiment illustrated in particular in figure 15, the peripheral edge 302 of the cover 30 is secured to the support face 201 by staples 303 which constitute fixing means as described previously.
[0087] According to the invention, the cover 30 comprises an excess of corner fabric 300 which is located at the edge 207 of the filling body 200 and is pinched and inserted into the slot of filling 208. The fabric clamp 301 is thus inserted into the filling slot 208 as can be seen in particular in figures 3 and 12.
[0088] According to one embodiment, the excess corner fabric 300 that is pinched and inserted into the trim slot 208 may include a seam to keep the fabric pinched.
[0089] According to one embodiment, the filling slot 208 comprises a width which is at least 4 times greater than the thickness of the fabric of the cover 30. The fabric clamp 301 can then be folded and fully inserted into the filling slot 208. According to this configuration, the filling slot 208 receives four thicknesses of fabric and makes it possible to avoid excess thicknesses at the rear of the filling module 20.
[0090] According to another embodiment illustrated in Figures 16 to 18, the clamp 301 is cut so as to form two flaps 3010 which extend on either side of the slot 208. Each flap 3010 is then attached to the support face 201 using staples 303 as can be seen in Figure 18. The corner end 3020 of the peripheral edge 302 of the cover 30 is then inserted into the slot 208 as shown by an arrow in Figure 18. The corner end 3020 then covers the flap 3010 and provides a finish without excess thickness as can be seen in Figure 16. In this example, the peripheral edge 302 is stapled at regular intervals between two corners 203 of the support face 201.
[0091] In the embodiment illustrated in Figures 5 and 6, the support face 201 comprises a plate 202 of rigid material which is integral with the filling body 200. In this embodiment, the filling body 200 is a rectangular parallelepiped 210 made of foam. This embodiment can be useful when the filling module 20 is designed to constitute a support surface such as a backrest, a seat or a mattress. The rigid plate makes it possible to stiffen the rear of the filling body 200 which then comprises a foam-type material. Here, the filling slots 208 pass through the rigid plate.
[0092] In the embodiment illustrated in Figures 2 and 12, the support face 201 and the tray face 204 respectively comprise a rectangular cross-section. The filling body 200 thus comprises four edges 207 each comprising a filling slot 208 into which the excess corner fabric 300 of the cover 30 is pinched and inserted. According to this configuration, the filling body 200 comprises four side faces 206 and each side face 206 extends between two edges 207.
[0093] As illustrated in Figures 5 to 19, the invention also relates to a method 60 of manufacturing a packing module 20 conforming to an embodiment of the invention.
[0094] According to an embodiment illustrated in Figures 5, 6 and 19, the manufacturing method 60 may comprise a step 601 of assembling a rigid plate 202 to a filling body 200. The assembly 601 may be carried out by gluing. This step may be carried out in particular embodiments, for example, when the filling body 200 is made of deformable foam. In this case, the rigid plate 202 provides holding properties which make it possible to limit the deformation of the foam, this is particularly the case for a seat or a backrest. The manufacturer may use a filling body 200 already assembled to a rigid plate 202 which he can obtain from a supplier. This step is therefore optional, which is why it is shown in dotted lines in Figure 19.
[0095] As illustrated in Figures 5 and 19, the manufacturing method 60 comprises a step 602 of incising the support face 201 and the edge 207 of the packing body 200. As illustrated in Figure 5, the incision 602 is made along a cutting plane passing through the longitudinal axis of the edge 207. In particular, the incision is made at a height h less than the height H of the lateral face of the packing body 200. This makes it possible to obtain a solid plate face 204 and therefore a useful upper surface which does not have any weak points. Furthermore, this also makes it possible to provide a filling slot 208 open on the support face 201 and over a height h along the longitudinal axis of the edge 207. The incision step 602 can be carried out using a cutting tool 40 such as a sharp blade, cutter, mechanical / robotic cutting tool or chisel.This step can be mechanized and / or automated by holding, for example, the filling body 200 in position in a vice or a press calibrated to the dimensions of the filling body 200, the cutting tool then performs the cutting according to a determined height and depth.
[0096] According to a preferred embodiment, the cutting plane used to make the incision 602 can pass through the bisector of at least one angle of the support face 201. The result of such an incision 602 is visible on the four angles of the support face 201 of FIG. 6. In this example, the packing body 200 is also incised in the extension of the support face 201 at a height h so as to provide a packing slot 208 according to the invention.
[0097] When the filling module 20 comprises a rigid plate 202, the latter is preferably incised beforehand in order to constitute an incision guide for the cutting tool 40 as illustrated in FIG. 5.
[0098] As illustrated in Figures 6 and 19, the manufacturing method 60 comprises a step 603 of positioning the filling body 200 on the fabric cover 30 in a spread state. This step is visible in Figure 6, the cover 30 is spread on a suitable support and the filling body 200 is centered on the cover 30.
[0099] The manufacturing method 60 may comprise a step 604 of prior cutting of the cover 30 into a geometric shape similar or analogous to the geometric shape of the cross-section of the tray face 204 and / or the three-dimensional shape of the filling body 200. In the example of FIG. 6, the cover 30 is cut into a rectangular shape while the filling body 200 is a rectangular parallelepiped. Alternatively, covers 30 pre-cut to the chosen dimensions may be used by the manufacturer, which is why the cutting step 604 is optional and thus represented in dotted lines in FIG. 19.
[0100] As illustrated in Figures 7, 8 and 19, the manufacturing method 60 comprises a step 605 of folding an excess 300 of corner fabric of the cover at least at one edge 207 and / or the corner 203 of the support face 201 of the filling body 200. As illustrated in Figures 7 and 8, the excess 300 of corner fabric is folded at the edge onto the corner of the support face 201. In particular, the excess 300 of corner fabric is folded over the corner 203 of the support face 201 where the filling slot 208 is formed. The folding step 605 makes it possible to form, with the excess 300, a fabric clamp 301.
[0101] As illustrated in Figures 9, 10 and 19, the manufacturing method 60 comprises a step 606 of inserting a first excess 300 of fabric into a first filling slot 208 of the filling body 200. As illustrated in Figures 9 and 10, the insertion of the excess 300 of folded corner fabric onto the corner 203 is carried out with a blade 41, preferably a non-cutting blade. The blade 41 is inserted into the slot 208 and drives the excess 30 of fabric into the slot 208.
[0102] According to this embodiment and as can be seen in FIG. 10, the insertion 606 of the excess 300 of corner fabric into the slot 208 forms a fabric clamp 301 in said slot 208. At the end of the insertion step 606, a first portion of the fabric clamp 301 can extend into the slot 208 while a second portion of the clamp 301 can protrude from the slot 208 through its opening provided on the support face 201. Alternatively, it is possible to pinch the excess 300 of fabric before its insertion into the slot 208. This can also be done with a blunt blade.
[0103] When a first excess 300 of corner fabric is inserted into a first slot 208, the manufacturing method comprises a step 607 of tensioning the fabric cover 30. For a filling module 20 whose dimensions are large, for example for a diagonal greater than one meter, the tensioning is facilitated by inserting the first excess 300 of fabric into a slot 208 which provides a point of attachment for the cover 30. The manufacturing of the filling module 20 is thus facilitated.
[0104] When the filling body 200 comprises several edges 207, each edge 207 comprises, according to the invention, a filling slot 208. After the cover 30 has been tensioned, while the first excess 300 of corner fabric is inserted into a first slot 208, the manufacturing method 60 comprises the insertion 608 of the excess corner fabric which is located at the other edges 207 is inserted at the corresponding slots 208. At the end of this insertion step 608, the filling module 20 comprises a filling body 200 whose tray face 204 and side faces 206 are covered by the cover 30, the excess fabric 300 is inserted into the slots 208 and fabric clips 301 protrude from the slots 208 at the support face 201. According to one embodiment, the manufacturing method 60 may comprise a sewing step 609 of this protruding portion of the fabric clip 301.The seam 609 may be longitudinal so as to maintain the cohesion of the clamp 301.
[0105] As illustrated in Figures 13 to 19, the manufacturing method 60 comprises a step 610 of securing the peripheral edges 302 of the fabric cover 30 to the support face 201 of the filling body 200. This step makes it possible to finalize the manufacturing of the filling module 20 by attaching the peripheral edges 302 of the cover to the rear of the filling module 200.
[0106] According to an embodiment illustrated in Figure 13, the clamp 301 is pressed against the support face 201 and stapled to the latter. The peripheral edges 302 are then folded back onto the support plate 201 and stapled to the latter. Advantageously, one or more staples are inserted on a portion of the peripheral edges 302 which overlaps the clamp 301 in the corner 203 of the support face 201. This makes it possible to secure the attachment of the clamp 301 and on the corner 203.
[0107] According to an embodiment illustrated in Figure 14, the method comprises folding the peripheral edge 302 of the cover in order to form a cuff 306 which is secured then to the support face 201 of the filling body 200. This is illustrated in Figure 14, the peripheral edge 302 is folded according to a cuff 306 and has a seam 308 to maintain the fold. The filling module 20 here comprises a pulling wire 309 which makes it possible to maintain the cuff 306 in contact with the support face 201. The pulling wire 309 is taken in the seam 308 and comprises two ends which make it possible to carry out a pull in order to adjust / tighten the cuff 306 on the support plate 201. Subsequently, the clamp 301 is here folded along two fins 307 on the peripheral edges 302 and stapled to the angle 203 of the support face 201 through the peripheral edges 302. The end of the two fins 307 is folded over the fins 307 as the pulling wire 309 passes through so as to form a slide 310 in which the pulling wire 309 passes and can slide. It is then possible to pull on the pulling wire 309 to stretch the peripheral edges 302 at the rear of the filling module 20 in order to adjust the cover 30 to the filling body 200.
[0108] According to an embodiment illustrated in figure 15, the peripheral edges 302 are stapled to the support face 201 at the edge of the junction with a lateral face 206 of the filling body 200. Other fixing means such as nails or screws or fixing profiles can be used.
[0109] According to an embodiment illustrated in figures 17 and 19, the manufacturing method 60 may comprise a step 611 of cutting the clamp 301. In particular, the projecting part of the clamp 301 of the support face 301 is cut along a cutting plane P as illustrated in figure 17. Scissors are shown diagrammatically to carry out the cutting, however, any other manual or mechanical tools capable of carrying out such a cutting can be used. As illustrated, the cutting step 611 is carried out set back from the slot 208 so as to provide two sections of fabric which protrude from the slot 208. Said sections of fabric are folded down on either side of the slot 208 and secured to the support face 201 so as to provide the flaps 3010. A flap 3010 is visible in FIG. 18 on one side of the slot 208. Here it is stapled to the support face 201.
[0110] According to this embodiment, the manufacturing method 60 comprises a corner finishing step 612 which consists of introducing the corner end 3020 of the peripheral edge 302 in the slot 208. As illustrated in figure 18, through an arrow, the corner end inserted into the slot 208 covering the flap 3010. Note that to achieve this finish it is necessary, during the incision step 602, to incise the module so as to obtain a slot 208 whose width is at least four times greater than the thickness of the cover 30. A suitable cutting tool makes it possible to obtain such a result.
[0111] Steps 611 and 612 are repeated on all the corners of the support face 201 of the filling module 20 in order to ensure that the filling module 20 does not have any folding or excess thickness in the corners of the support face 201 as illustrated in FIG. 16.
Claims
Claims
1. Filling module (20) in particular for furnishing, decoration or insulation, comprising: A packing body (200) of defined three-dimensional shape which comprises: o a support face (201) arranged behind said body and comprising a cross-section comprising at least one angle (203), o a plate face (204) arranged in front of said body and opposite the support face (201), the plate face (204) comprising a cross-section comprising at least one angle (205) and a shape similar to the shape of the cross-section of the support face (201), o at least one lateral face (206) which extends between the plate face (204) and the support face (201), o at least one edge (207) connecting, along a longitudinal axis, the angle (203) of the support face (201) and the angle (205) of the plate face (204), the edge (207) defining a height H of the lateral face (206) of the packing body (200), at at least one filling slot (208) extending along a cutting plane which passes through the longitudinal axis of the edge (207),the filling slot (208) extending longitudinally along the longitudinal axis of the edge (207) from the support face (201) over a height h less than the height H of the lateral face (206) so that the filling slot (208) is open in the corner (203) of the support face (201) and on the longitudinal axis of the edge (207); and a fabric cover (30) covering the tray face (204) and the side face (206) of the filling body (200), the cover (30) being secured behind the filling body (200) on the support face (201) while an excess (300) of corner fabric, at the edge (207) of the filling body (200), is inserted into the filling slot (208) and forms a fabric clamp (301).,
2. Packing module (20) according to claim 1, in which the packing slot (208) extends transversely along a bisector of the angle (203) of the support face (201) and along a determined distance d.
3. Filling module (20) according to one of claims 1 and 2, in which the support face (201) and the plate face (204) respectively comprise a cross section comprising at least one curved side.
4. Packing module (20) according to one of claims 1 to 3, in which the support face (201) comprises a plate (202) of rigid material which is integral with the packing body (200), the packing slots (208) passing through said plate.
5. A filling module (20) according to one of claims 1 to 4, wherein the support face (201) and the tray face (204) respectively comprise a polygonal cross-section, the filling body (200) comprising edges (207) connecting corners (203) of the support face (201) to corners (205) of the tray face (204) which respectively face each other, the filling module (20) comprising filling slots (208) which are formed in the edges of the filling body (200), excess corner fabric (300) of the cover being pinched and inserted into the filling slots (208).
6. Filling module (20) according to one of claims 1 to 5, wherein the filling body (200) comprises at least one filling material chosen from the following list: sound insulation material such as polyurethane foams, composite panels; thermal insulation material such as polystyrene, wood wool panels, compressed; furnishing material such as wood, wood derivatives, polymers, metal, resins, composite materials; furnishing material for seating or bedding such as polyurethane foams.
7. A filling module (20) according to one of claims 1 to 6, wherein the fabric clamp (301) comprises a seam (308) in order to keep the fabric clamped.
8. Filling module (20) according to one of claims 1 to 7, in which the cover (30) is delimited by a peripheral edge (302) which is secured to the support face (201), by a seam and / or by fixing means of the staple, nail or screw type and fixing profiles.
9. A filling module (20) according to claim 8, wherein the peripheral edge (302) of the cover (30) is folded so as to form a cuff (306) which is secured to the support face (201) of the filling body (200).
10. Filling module (20) according to one of claims 8 and 9, in which the peripheral edge (302) and the fabric clamp (301) are folded back so as to overlap and be secured together at the angle (203) of the support face (201).
11. A filling module (20) according to claim 10, which comprises a draw wire (309) mounted to slide in a seam of the peripheral edge (302) and a slide (310) formed by the gripper (301) of fabric folded over the support face (201).
12. A filling module (20) according to one of claims 1 to 11, wherein the filling slot (208) has a width at least equal to four times the thickness of the fabric of the cover (30) so as to fold the clamp (301) into the filling slot (208), the excess corner fabric then being completely inserted into the filling slot (208).
13. A method of manufacturing (60) a filling module (20) defined according to one of claims 1 to 12, which comprises: the incision (602) of the support face (201) and of the edge (207) of the filling body (200), the incision (602) being made along a cutting plane passing through the longitudinal axis of the edge (207), the incision (602) being made at a height h less than the height H of the lateral face of the filling body (200) so that the tray face (204) is full and so as to provide a filling slot (208) open on the support face (204) and at a height h along the longitudinal axis of the edge (207), the positioning (603) of the filling body (200) on the fabric cover (30) in a spread state, folding (605) a first excess (300) of corner fabric of the cover (30) at least at one edge (207) and / or one corner (203) of the support face (201) of the filling body (200),inserting (606) the first excess fabric (300) into the filling slot (208) of the filling body (201), tensioning (607) the fabric cover (30) while the first excess fabric (300) is inserted into the filling slot (208), the securing (610) of the peripheral edges (302) of the fabric cover (30) to the support face (201) of the filling body (200).
14. A manufacturing method (60) according to claim 13, wherein the insertion (602) of the excess (300) corner fabric into the filling slot (208) is carried out with a blade, preferably a non-cutting blade.
15. Manufacturing method (60) according to one of claims 13 and 14, wherein the insertion (606) of the excess (300) of corner fabric into the filling slot (208) forms a fabric clamp (301) of which at least one portion extends into the filling slot (208) while a second portion projects from the support face (201).
16. Manufacturing method (60) according to one of claims 13 to 15, in which the folding (605) of a first excess (300) of corner fabric and the insertion (606) into the filling slot (208) are carried out simultaneously.
17. Manufacturing method (60) according to one of claims 13 to 16, wherein, when the filling body (200) comprises several edges (207), each edge (207) comprising a filling slot (208), after the cover (30) is tensioned (607) while the first excess (300) of corner fabric is inserted into a first filling slot (208), excess (300) of corner fabric located at the other edges (207) of the filling body (200) are inserted into the corresponding filling slots (208).
18. Manufacturing method (60) according to one of claims 13 to 17, which comprises: The cutout (611) of the clamp (301) which projects from the slot (208) at the support face (201), and The corner finish (612) in which a corner end (3020) of the peripheral edge (302) is inserted into the slot (208) overlapping a remaining portion of the clamp (301) which is at least partially inserted into the slot (208).
19. Manufacturing method (60) according to one of claims 13 to 17, in which the peripheral edges (302) and the excess (300) of corner fabric are folded back so as to overlap and be secured together, by mechanical fixing, in the corner (203) of the support face (201).
20. A manufacturing method (60) according to claim 19, wherein a portion of the excess (300) of corner fabric is folded over upon passage of a draw wire (309) so as to provide a slide in which the draw wire (309) slides, the tension of the draw wire (309) being adjusted so as to fit the cover (30) to the filling body (20).