Bean bag chairs with piles and related apparatus and manufacturing methods

Abstract

Bean bag chairs and related manufacturing methods and apparatus. Some methods comprise joining first and second panels defining corresponding surfaces. The second panel further comprises piles projecting from its surface with a portion of its surface being substantially smooth. A seam between the substantially smooth portion and the first panel joins the panels. The piles can be chenille piles and some of the piles can be removed to create the smooth portion. The second panel, though, can be received with the smooth portion being free of holes. Various methods include joining a zipper to the second panel via another smooth portion. In some chairs the seam is behind the piles. A jig can be placed in the chairs to expand the chairs and the chairs can be supported from above during filing. The chairs can also be vented during the filling via a clamped aperture defined by the chair.

1 . A bean bag chair comprising:
 a first panel defining a first surface;   a second panel defining a second surface, the second panel further comprising chenille fabric piles projecting from the second surface,   a portion of the fabric second panel defining a portion of the second surface whish is substantially smooth;   a seam joining the first and the second panels via the substantially smooth portion of the second surface wherein the seam is substantially behind the chenille fabric piles as viewed from a side of the second panel with the piles projecting therefrom; and   a zipper joined to the second panel via another seam via another substantially smooth portion of the second panel.   
     
     
         2 . The bean bag chair of  claim 1  wherein the substantially smooth portion of the second surface defines holes for at least some piles. 
     
     
         3 . A bean bag chair comprising:
 a first panel defining a first surface;   a second panel defining a second surface, the second panel further comprising piles projecting from the second surface,   a portion of the second panel defining a portion of the second surface which is substantially smooth; and   a seam joining the first and the second panels via the substantially smooth portion of the second surface.   
     
     
         4 . The bean bag chair of  claim 3  wherein the piles are chenille fabric piles. 
     
     
         5 . The bean bag chair of  claim 3  wherein the substantially smooth portion of the second surface defines holes for at least some piles. 
     
     
         6 . The bean bag chair of  claim 3  wherein the substantially smooth portion of the second hole is substantially free of holes. 
     
     
         7 . The bean bag chair of  claim 3  further comprising a zipper joined to the second panel via another seam via another substantially smooth portion of the second panel. 
     
     
         8 . The bean bag chair of  claim 3  wherein the seam is substantially behind the piles as viewed from a side of the second panel with the piles projecting therefrom. 
     
     
         9 . A method of manufacturing a bean bag chair, the method comprising:
 joining at least a first panel which defines a first surface to a second panel which defines a second surface, the second panel further comprising piles projecting from the second surface, a portion of the second panel defining a portion of the second surface which is substantially smooth,   the joining being via forming a seam between the substantially smooth portion of the second surface and the first panel.   
     
     
         10 . The method of  claim 9  wherein the piles are chenille fabric piles. 
     
     
         11 . The method of  claim 9  further comprising removing piles from the second surface to create the substantially smooth portion of the second panel. 
     
     
         12 . The method of  claim 9  further comprising receiving the second panel with the substantially smooth portion of the second panel being substantially free of holes. 
     
     
         13 . The method of  claim 9  further comprising joining a zipper to the second panel via another substantially smooth portion of the second surface. 
     
     
         14 . The method of  claim 9  wherein the seam is substantially behind the piles as viewed from a side of the second panel with the piles projecting therefrom. 
     
     
         15 . The method of  claim 9  further comprising placing a portion of a jig in the bean bag chair and expanding the bean bag chair with the jig. 
     
     
         16 . The method of  claim 15  further comprising filling the bean bag chair with beans. 
     
     
         17 . The method of  claim 16  further comprising supporting the bean bag chair from above the bean bag chair during the filing. 
     
     
         18 . The method of  claim 16  further comprising venting the bean bag chair during the filling. 
     
     
         19 . The method of  claim 15  further comprising clamping the bean bag chair to divide an aperture defined by the bean bag chair into a fill portion and a vent portion. 
     
     
         20 . The method of  claim 19  further comprising placing a filter in the vent portion of the aperture.