Compressible upholstered furniture, high-resilience foam module, and method for producing said upholstered furniture

Abstract

The present invention relates to a modular upholstered furniture piece that is easy to assemble and comprises highly compressible foam modules. The invention relates to an upholstered furniture item comprising a set formed by at least one foam module mounted on a base, wherein said foam module set is covered with a first flexible elastic cover and a second cover, said modules being composed of a flexible foam with high compressibility and shape memory retention. The present invention further relates to a foam module comprising a flexible, highly compressible foam that retains shape memory, returning to its preferred form even after being compressed to occupy a small percentage of its original volume.

Description

Descriptive Report of Invention Patent for “COMPRESSIBLE UPHOLSTERED FURNITURE, HIGH-RESISTANCE FOAM MODULE AND METHOD OF PRODUCTION OF SAID UPHOLSTERED FURNITURE” FIELD OF INVENTION

[0001] . The present invention belongs to the technological sector of materials engineering and upholstered furniture and refers to a self-supporting modular sofa that may or may not use a rigid structure.

[0002] . Furthermore, the present invention relates to highly compressible foam modules and a method of assembling furniture from said modules. BACKGROUND OF THE INVENTION

[0003] In the furniture manufacturing and retail sector, the transportation and storage of sofas pose a complex logistical challenge due to their bulky dimensions and the diverse materials used in their manufacture. From production to delivery to the end consumer, sofas face a series of obstacles, ranging from careful handling to avoid damage to optimizing storage space. The fragility of certain materials, such as wood, fabrics, and leather, requires special precautions to ensure product integrity during handling and transportation. Furthermore, the variety of models and sizes poses additional challenges for efficient storage in warehouses and distribution centers.

[0004] . The logistics and transportation of these sofas with wooden or metal frames represent significant challenges due to the specific characteristics of these materials and the nature Bulky and heavy products. Wood and metal are common materials used in sofa manufacturing to provide support, but their density and weight can complicate logistics processes, from the transportation of raw materials to the final delivery of the product to the customer. This results in products that are not very malleable and present additional obstacles for logistics operators, requiring careful planning and specialized resources to ensure efficient and safe distribution.

[0005] . In this sense, some solutions and technologies have already been developed using these principles:

[0006] . Document US20200187654 describes a modular furniture system, such as a modular sofa set including a rigid square or rectangular base that can be fixed to different rigid modules such as side support, backrest, legs, cushions and other bases to obtain various furniture items such as a one-seater sofa, two-seater sofa, comprising appropriate connections of the various components of the modular furniture system, a user can create tables, beds, lounge chairs or the like.

[0007] . Further, document CN215126386 discloses a modular sofa comprising a sofa body and a mounting piece, the mounting piece can be removably connected to the sofa body through a connecting piece so as to change the shape of the sofa body, and the mounting piece comprises at least one of a backrest, armrests and legrests; the combined sofa comprises at least two modular sofas, and the two adjacent modular sofas can be connected through the connecting pieces so as to change the length or width of the combined sofa.

[0008] As can be seen, traditional state-of-the-art furniture, although modular, has rigid, interlocking structures and, due to its weight and bulky dimensions, requires special care during handling, packaging, and transportation to avoid damage to both the products and the structures involved.

[0009] . To solve these problems, the present invention conceives a modular construction upholstered furniture that does not require assembly, comprising an innovative construction using highly compressible foam modules in two or more layers of malleable covers to give the shape and arrangement of the modules and form a desired sofa, bench, ottoman and other furniture, as well as the support and quality to the touch and aesthetics of the furniture.

[0010] . Therefore, there is no solution in the state of the art equivalent to that presented here in the present invention that combines technical differences, economic advantages and reliability, safety. OBJECTIVES OF THE INVENTION

[0011] . Thus, it is an objective of the present invention to provide a solution to the challenges and limitations listed above, presenting a sofa that can be assembled from a highly compressible foam structure and other malleable and supporting parts.

[0012] . It is also an objective of the present invention to provide a modular sofa with a construction made from the combination of high compressibility foam modules.

[0013] . Another objective of the present invention is to provide a solution that allows the disassembled sofa to occupy the smallest possible volume so that it can be placed in a box, facilitating its storage, packaging, transportation and handling.

[0014] . It is also an objective of the present invention to provide an assembleable sofa made from high-compressibility foam that is easy to install, eliminating the need for tools or assembly by the end user.

[0015] . It is also an objective of the present invention to provide a strong, durable, safe, comfortable and reliable piece of furniture. SUMMARY OF THE INVENTION

[0016] . The present invention achieves these and other objectives by means of a compressible upholstered piece of furniture comprising an assembly formed by at least one foam module, mounted on a base, in which said foam module assembly is covered with a first malleable cover and various fillings, and said modules of a

[0017] . In yet another aspect, the present invention achieves these and other objectives through a foam module comprising a growtech foam with open cellular structures, with high performance attributed to high resilience, compressive strength, and deformation resistance, returning to its flexible foam, with open cellular structures, with high performance attributed to high resilience, compressive strength, and deformation resistance. The flexible, highly compressible cellular structure allows the self-assembly of the module, which, upon unpacking, retains its shape memory, a deprecated shape even after be subjected to a compression of 90% of its volume.

[0018] . In yet another aspect, the present invention achieves these and other objectives by means of a method of producing upholstered furniture comprising the following steps:

[0019] . - provide at least one flexible, high-compressibility foam module juxtaposed in a desirable shape on a base;

[0020] . - fix the foam modules to each other with at least one structural strap so as to form a set of fixed foam modules;

[0021] . - cover the structural belt with a first elastic layer;

[0022] . - cover the structural belt covered by the first elastic layer with a second fabric layer; and

[0023] . - fix the second cover to the base using at least one snap fastener. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] . The present invention will be described based on the drawings attached hereto, which illustrate:

[0025] . - Figure 1 represents the perspective view of the sofa assembled in a first preferred embodiment.

[0026] . - Figure 2 represents the exploded perspective view of the sofa formed by a first highly compressible foam arrangement in a first preferred embodiment.

[0027] . - Figure 3 represents the bottom exploded perspective view of the sofa formed by a first highly compressible foam arrangement in a first preferred embodiment.

[0028] . - Figure 4 represents the perspective view of the sofa mounted on a second preferred embodiment.

[0029] . - Figure 5 represents the exploded perspective view of the sofa formed by a second highly compressible foam arrangement in a second preferred embodiment.

[0030] . - Figure 6 represents the bottom exploded perspective view of the sofa formed by a second highly compressible foam arrangement in a second preferred embodiment.

[0031] . - Figure 7 represents the perspective view of the sofa assembled in a third preferred embodiment.

[0032] . - Figure 8 represents the exploded perspective view of the sofa formed by a third highly compressible foam arrangement in a third preferred embodiment.

[0033] . - Figure 9 represents the bottom exploded perspective view of the sofa formed by a third highly compressible foam arrangement in a third preferred embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0034] The present invention relates to an easily assembled modular upholstered piece of furniture. The present invention utilizes an innovative construction comprising highly compressible foam modules and the use of two or more layers of malleable covers to shape and arrange the modules to form a desired sofa, bench, ottoman, or other piece of furniture.

[0035] . The present invention presents numerous technical and economic advantages when compared with the state of the art, some of which are listed below: • The present invention presents a solution that allows the combination of similar foam modules for the production of different furniture, reducing the number of different parts required for large-scale manufacturing; • The present invention presents a simple assembly, which reduces manufacturing costs and provides the assembled furniture to the end user, eliminating the need for future assembly and the use of tools; • the present invention presents a flexible foam, with open cellular structures, with high performance attributed to high resilience, resistance to compression and resistance to deformation that allows the self-assembly of the module that when unpacked retains shape memory; • The present invention presents compressible and malleable parts which allows already assembled furniture to be packaged, stored and transported in small packages, saving space and increasing its logistical efficiency; • The present invention presents an aesthetically pleasing and highly comfortable solution.

[0036] . As illustrated in Figs. 1, 4 and 7, the present invention comprises an upholstered piece of furniture 01.

[0037] . In an example according to a first embodiment, illustrated in FIGS. 1 to 3, the upholstered furniture 01 is formed by a set of two foam modules 04 juxtaposed and joined by two lateral structural straps 07, in which one of the foam modules 04 defines the seat of the upholstered furniture 01 and the other defines the backrest of the upholstered furniture 01, mounted on a base 05 covered with a first elastic cover 03 and a second cover 02.

[0038] . In an example according to a second embodiment, illustrated in FIGS. 4 to 6, the upholstered furniture 01 is formed by a set of two foam modules 04 juxtaposed and joined by two crossed structural straps 07, in which one of the foam modules 04 defines the seat of the upholstered furniture 01 and the other defines the backrest of the upholstered furniture 01 in an 'L' shape, mounted on a base 05 covered with a first elastic cover 03 and a second cover 02.

[0039] . In an example according to a third embodiment, illustrated in FIGS. 7 to 9, the upholstered furniture 01 is formed by a foam module 04 mounted on a base 05 covered with a first elastic cover 03 and a second cover 02.

[0040] . For all embodiments, foam module 04 is preferably a Growtech® foam module, flexible, with open cellular structures, with high performance attributed to high resilience, compression resistance, and resistance to deformation. The flexible, highly compressible cellular structure allows for self-assembly of the module, which retains shape memory when unpacked, returning to its original shape even after being subjected to compression of 85% to 99% of its volume.

[0041] . Furthermore, for any embodiment, such as those illustrated, but not limited to the figures in this document, the assembly of the upholstered furniture 01 is preferably done by arranging at least one foam module 04 on the base 05.

[0042] . When the desired foam module arrangement 04 is achieved, the foam module modules 04 are fixed to each other others with at least one structural strap 07. In modalities where only one foam module 04 is used, there is no need to use said structural strap 07.

[0043] After the modules are attached, the foam module assembly 04, secured by the structural straps 07, is covered by the first elastic cover 03, which, being elastic, contains the foam module 04 and keeps the assembly tensioned and self-supporting. After being covered by the first elastic cover 03, the assembly is covered by a second cover 02, which provides the desired finish and touch feel to the furniture. The second cover 02 is a non-elastic fabric and is fastened to the base 05 with a zipper.

[0044] . The upholstered furniture 01 may also include quick-release fasteners 06 for attaching to another upholstered furniture in order to combine furniture with different foam module formats.

[0045] . Additionally, it is desirable that both the second cover 02 and the first elastic cover 03 have the same shape as the set of foam module modules 04 after fixing.

[0046] . Furthermore, base 05 is preferably a thick fabric base with a mesh zipper for closing.

[0047] . As a result, the present invention provides an upholstered piece of furniture 01 such as a sofa or ottoman without rigid parts. The composition of the foam module 04 and the malleability of the base 05, second cover 02, first elastic cover 03, and structural strap 07 allow that even with the upholstered piece of furniture 01 assembled, said upholstered piece of furniture 01 can be compacted to a small percentage of its initial volume, allowing it to be stored in boxes. small, saving space during storage and transportation, and reducing costs associated with the object's logistics.

[0048] . Preferably, the upholstered furniture 01 is compressed with a press sealed in a plastic packaging, so that after opening the packaging, the furniture returns to its original state before compression.

[0049] Another advantage of the present invention is that it improves the end-user experience, since the flexible, highly compressible cellular structure allows for self-assembly of the module, which retains shape memory upon unpacking. Thus, simply receiving a small box ordered, opening the upholstered furniture 01 , and waiting for the foam modules 04 and, consequently, the upholstered furniture 01 to return to their original shape, eliminating the need for assembly and installation. Furthermore, the present invention offers a resilient upholstered furniture 01, since it has no rigid wooden or metal parts to break.

[0050] . Having described some examples of preferred embodiments of the present invention, it should be understood that the scope of the present invention encompasses other possible variations of the described inventive concept, being limited solely by the content of the claims alone, including possible equivalents.

Claims

CLAIMS 1. Compressible upholstered furniture (1) characterized by comprising an assembly formed by at least one foam module (4), mounted on a base (5) with zipper, in which said foam module assembly (4) is covered with a first malleable elastic cover (3) and a second zipper cover (2) configured to attach to the zipper of the base (5), wherein said foam modules (4) are porous, highly compressible, and retain shape memory.

2. Upholstered furniture (1), according to claim 1, characterized in that said upholstered furniture (1) further comprises quick-release fasteners (6) configured to engage with quick-release fasteners (6) of another upholstered furniture (1).

3. Upholstered furniture (1), according to claim 1 or 2, characterized in that the set of foam modules (4) comprises two juxtaposed foam modules (4) joined by a pair of lateral structural straps (7), so that one of the foam modules (4) defines a seat of the upholstered furniture (1) and the other defines a backrest of said upholstered furniture (1), said set being mounted on a base (5) and covered with a first elastic cover (3) and a second cover (2).

4. Upholstered furniture (1), according to claim 1 or 2, characterized in that the set of foam modules (4) comprises two juxtaposed foam modules (4) joined by a pair of crossed structural straps (7), so that one of the foam modules (4) defines the seat of the upholstered furniture (1) and the other defines the backrest of said upholstered furniture (1) in an 'L' shape, said assembly being mounted on a base (5) and covered with a first elastic cover (3) and a second cover (2).

5. Upholstered furniture (1), according to claim 1 or 2, characterized in that the set of foam modules (4) comprises a foam module (4) that defines the seat of the upholstered furniture (1), said set being mounted on a base (5) and covered with a first elastic cover (3) and a second cover (2).

6. Foam module (4) characterized by comprising a flexible foam, with open cellular structures of high resilience, and high resistance to compression and deformation, porous, and which retains shape memory, returning to its previous shape even after being subjected to compression of at least 90% of its initial volume.

7. Method of producing upholstered furniture (1) characterized by comprising the following steps: - provide at least one flexible, high-compressibility foam module (4) juxtaposed in a desirable shape on a zippered base (5); - fix the foam modules (4) to each other with at least one structural strap (7) so as to form a set of fixed foam modules (4); - cover the structural belt (7) with a first elastic layer (3); - cover the structural strap (7) covered by the first elastic cover (3) with a second fabric cover (2) with zipper; and - attach the second cover (2) to the base (5) using the zipper.

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