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.

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.