Arm rest using vertical lapped fiber

Abstract

An arm rest for furniture or other chair or seating applications is described. The arm rest includes a cushion member, a frame component, and an optional covering or protective layer. In certain applications, the arm rest is formed from a vertically lapped fibrous batt.

1 . An arm rest adapted for use in a chair or furniture component, the arm rest comprising:
 a frame member; and   a cushion member disposed on the frame member, the cushion member having first and second oppositely directed faces;   wherein the cushion member includes a region of vertically lapped fibers, the region extending generally across a face of the cushion member, at least a majority of the fibers in the region extending in a direction generally transverse to the face of the cushion member.   
   
   
       2 . The arm rest of  claim 1  wherein the fibers in the region of vertically lapped fibers have a size of from 0.9 to 300 denier. 
   
   
       3 . The arm rest of  claim 1  wherein the region of vertically lapped fibers is used at a thickness so as to exhibit a weight of from about 100 g/m 2  to about 2000 g/m 2 . 
   
   
       4 . The arm rest of  claim 1  wherein the region of vertically lapped fibers includes from about 10% to about 100% of the total weight of fibers in the cushion member. 
   
   
       5 . The arm rest of  claim 1  wherein the region of vertically lapped fibers comprises:
 from about 5% to about 95% of a first fiber, and   from about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.   
   
   
       6 . The arm rest of  claim 5  wherein the first fiber is used in a proportion of about 60% and the second fiber is used in a proportion of about 40%. 
   
   
       7 . The arm rest of  claim 5  wherein the first fiber has a size of from about 0.9 denier to about 300 denier. 
   
   
       8 . The arm rest of  claim 5  wherein the second fiber has a size of from about 2 denier to about 15 denier. 
   
   
       9 . The arm rest of  claim 5  wherein the cushion member has a thickness of from about 0.5 cm to about 7.6 cm. 
   
   
       10 . The arm rest of  claim 1  wherein the frame member comprises:
 from about 30% to about 100% of a binder polymer; and   from about 70% to about 0% of a matrix fiber.   
   
   
       11 . The arm rest of  claim 10  wherein the frame member comprises about 70% of the binder polymer and about 30% of the matrix fiber. 
   
   
       12 . The arm rest of  claim 1  wherein the arm rest generally defines first and second major sides, and first and second minor sides, and wherein three of these four sides are convex in shape. 
   
   
       13 . The arm rest of  claim 12  wherein a remaining side of the four sides is concave in shape. 
   
   
       14 . The arm rest of  claim 1 , wherein the arm rest defines an upwardly facing surface that is convex. 
   
   
       15 . The arm rest of  claim 1  wherein the frame member includes a first substrate and a second substrate. 
   
   
       16 . The arm rest of  claim 1  further comprising:
 a covering layer disposed on the cushion member.   
   
   
       17 . The arm rest of  claim 16  wherein the covering layer includes a nonwoven material. 
   
   
       18 . The arm rest of  claim 1  wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers. 
   
   
       19 . An arm rest defining a first convex side, a second convex side opposite from the first side, a third convex side extending between the first and second sides, and a fourth concave side extending between the first and second sides and opposite the third side, the arm rest comprising a region of vertically lapped fibers, the region extending generally across a face of the arm rest, at least a majority of the fibers in the region extending in a direction generally transverse to the face of the arm rest. 
   
   
       20 . The arm rest of  claim 19  wherein the fiber of the region of vertically lapped fibers has a size of from 0.9 to 300 denier. 
   
   
       21 . The arm rest of  claim 19  wherein the region of vertically lapped fibers comprises:
 from about 5% to about 95% of a first fiber, and   from about 95% to about 5% of a second fiber having a melting point less than that of the first fiber.   
   
   
       22 . The arm rest of  claim 19  wherein the arm rest includes a frame member which comprises:
 from about 30% to about 100% of a binder polymer; and   from about 70% to about 0% of a matrix fiber.   
   
   
       23 . The arm rest of  claim 22  wherein the arm rest further includes a cushion member disposed on the frame member, the cushion member has a thickness of from about 0.5 cm to about 7.6 cm. 
   
   
       24 . The arm rest of  claim 23  further comprising:
 a covering layer disposed on the cushion member.   
   
   
       25 . The arm rest of  claim 23  wherein the cushion member also includes a second region of a cushioning material, disposed adjacent to the region of vertically lapped fibers.