U.S. patent application number 09/892263 was filed with the patent office on 2003-01-02 for integral elastomeric suspension article and manufacturing process.
Invention is credited to Lehman, Gary A. II, Mundell, David, Turner, T. Ross.
Application Number | 20030001424 09/892263 |
Document ID | / |
Family ID | 25399676 |
Filed Date | 2003-01-02 |
United States Patent
Application |
20030001424 |
Kind Code |
A1 |
Mundell, David ; et
al. |
January 2, 2003 |
Integral elastomeric suspension article and manufacturing
process
Abstract
A suspension article has a frame, a substantially uniplaner
non-woven grid, and fasteners. The grid is integrally extruded with
a pair of attachment strips, and the fasteners attach the grid to
the frame through the attachment strips. In the preferred
embodiment, the fasteners are a pair of J-strips integrally
extruded with the attachment strips. The process for manufacturing
the suspension article includes the steps of extruding a grid,
extruding attachment strips integral with the grid, stretching the
grid between the attachment strips, and attaching the stretched
grid to the frame through the attachment strips.
Inventors: |
Mundell, David; (Carthage,
MO) ; Turner, T. Ross; (Carthage, MO) ;
Lehman, Gary A. II; (Carthage, MO) |
Correspondence
Address: |
HUSCH & EPPENBERGER, LLC
190 CARONDELET PLAZA
SUITE 600
ST. LOUIS
MO
63105-3441
US
|
Family ID: |
25399676 |
Appl. No.: |
09/892263 |
Filed: |
June 27, 2001 |
Current U.S.
Class: |
297/452.56 |
Current CPC
Class: |
A47C 7/282 20130101;
A47C 7/16 20130101; B60N 2/7011 20130101; A47C 7/28 20130101; A47C
7/462 20130101 |
Class at
Publication: |
297/452.56 |
International
Class: |
A47C 007/02 |
Claims
We claim:
1. A suspension article, comprising: a frame; a substantially
uniplaner, non-woven grid integrally formed with a pair of
attachment strips; and a plurality of fasteners attaching said
uniplaner, non-woven grid to said frame through said attachment
strips.
2. A suspension article according to claim 1, wherein said
plurality of fasteners is a pair of J-strip fasteners integrally
formed with said attachment strips.
3. A suspension article according to claim 1, wherein said
substantially uniplaner, non-woven grid comprises closely-spaced
primary members and points of intersection, said closely-spaced
primary members being connected by said points of intersection.
4. A suspension article according to claim 3 wherein said points of
intersection are in line between said attachment strips, thereby
forming a plurality of ribs substantially perpendicular to said
closely-spaced primary members.
5. A suspension article according to claim 3 wherein said points of
intersection are located at said attachment strips.
6. A suspension article according to claim 1, wherein each of said
attachment strips is comprised of a pre-stretched grid section.
7. A suspension article according to claim 1, wherein each of said
attachment strips has a wire embedded therein.
8. A suspension article according to claim 1, wherein at least one
of said plurality of fasteners is an actuated fastener attached to
one of said pair of attachment strips.
9. A suspension article according to claim 8, wherein said actuated
fastener comprises an individual fastener, an actuator, and a
bowden cable, said bowden cable having an unsheathed bowden cable
section connecting said frame to said one attachment strip through
said individual fastener and a sheathed bowden cable section
connecting said frame to said actuator.
10. A suspension article, comprising: a frame; and a substantially
uniplaner, non-woven grid integrally formed with a pair of J-strip
fasteners, said J-strip fasteners attaching said grid to said
frame.
11. A suspension article according to claim 10, wherein at least
one of said J-strip fasteners is an actuated fastener.
12. A suspension article according to claim 10, wherein said
substantially uniplaner, non-woven grid comprises closely-spaced
primary members and points of intersection, said closely-spaced
primary members being connected by said points of intersection.
13. A suspension article according to claim 12 wherein said points
of intersection are in line between said J-strip fasteners, thereby
forming a plurality of ribs substantially perpendicular to said
closely-spaced primary members.
14. A suspension article according to claim 12 wherein said points
of intersection are located at said J-strip fasteners.
15. A process for producing a suspension article for a support
structure having a frame, comprising the steps of: forming a grid
integrally with attachment strips; and stretching said grid between
and attaching said grid to the frame through said attachment
strips.
16. A process according to claim 15, further comprising the step
of: inserting a wire into said parallel attachment strips while
forming said grid.
17. A process according to claim 15, wherein said attachment strips
are formed intermittently.
18. A process according to claim 15, wherein said attachment strips
are a pair of J-strip fasteners.
19. A process according to claim 15, wherein said forming step is
performed by extruding said grid.
20. A process according to claim 15, wherein said forming step is
performed by injection molding said grid.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to the field of seat suspensions and
particularly to lightweight suspension systems using elastomeric
materials and the methods of their manufacture.
[0005] 2. Description of Related Art
[0006] Conventional seat suspension systems used in the furniture
and automotive industries can be broken down into several basic
seat types.
[0007] One seat type uses formed wire, commonly called sinuous
wire, to create the suspension article. Pieces of sinuous wire are
formed into uniplaner shapes, usually repeating "S" curves, along
their lengths. The wires transverse and are connected to a frame,
and the wires may be connected together as they are suspended
across the frame. This type of suspension system requires multiple
part construction during assembly which increases its cost in use.
Also, the suspension system is bulky and requires thick padding
over the suspension article to prevent the user from feeling the
wires. These systems are also quite heavy and require insulating
material to prevent noise which can be generated by contact of the
metal surfaces.
[0008] Another somewhat similar seat type is a manufactured wire
grid, in which parallel wire members attached to a border element
at their ends to form a support grid. The support grid is held to a
frame by helical springs, wire forms or by the edge of the support
grid itself. Again, this system can be time consuming to construct
and install. Also, its metal construction can be noisy and
inefficient and usually requires thick padding.
[0009] Another seat type uses elastomeric materials in the
suspension article, including suspension articles made with
individual elastomeric filaments, a sheet of elastomeric material,
or a woven or knit elastomeric fabric. These designs are numerous
but a woven elastomeric suspension article may be exemplified by
U.S. Pat. No. 4,869,554 to Abu-Isa, in which a material containing
some type of elastic or elastomeric filament is used within the
weave. The use of individual elastomeric filaments is exemplified
by U.S. Pat. No. 4,545,614, also to Abu-Isa, in which the
suspension article has individual, parallel elastomeric filaments
with ends that are secured to rods. The filaments are not connected
to each other between the rods, and as compared to the manufactured
wire grid, the rods and individual filaments perform similar
functions as the border elements and the wire elements,
respectively. Some elastomeric suspension articles may be formed
from a solid sheet of elastomeric material as exemplified by U.S.
Pat. No. 3,375,861 to Marlow, and others may start as a solid sheet
of material that is sliced and pulled into a grid of twisted strips
as exemplified by U.S. Pat. No. 3,080,579 to Gordon.
[0010] These elastomeric suspension articles are usually
pre-stretched and supported in a frame by known means, including
clips, hangers, or ties. As evidenced by U.S. Pat. No. 5,582,463 to
Linder, it is also known to sew separate J-strip fasteners onto
suspension articles for attachment to the frame. Similarly, as
evidenced by U.S. Pat. No. 2,791,807 to Morin, it is known to mold
separate J-strip fasteners onto a perforated sheet of material.
However, none of these elastomeric suspension articles
individually, or in combination, suggests a suspension article
having an integrally formed elastomeric grid including an integral
border element which may contain an integral J-strip fastener.
[0011] The disadvantages of these designs include increased
manufacturing costs due to weaving and knitting operations,
attaching individual filaments to rods, or otherwise forming a grid
from a sheet of material, as well as that of connecting attachment
elements to the suspension articles. Additionally, the cost of and
structural weakness resulting from sewing a J-strip or securing a
similar fastener to the material is a significant drawback. There
is a also a disadvantage when providing an area for a hanger,
resulting in an area where the article provides no suspension for
the user of the seat. Finally, the lack of a cost effective and
efficient method of stretching the units during installation limits
their usefulness.
[0012] Various plastic meshes and nettings have also been tried to
remedy the disadvantages of the above systems. These plastic
arrangements exhibit many of the same disadvantages of their fabric
counterparts. Specifically, their use of known methods for mounting
the mesh or net to the frame results in structural weak spots as
well as lack of effectiveness in uniformly supporting the user.
Also, these units have exhibited a tendency to be difficult to
stretch during installation.
BRIEF DISCLOSURE OF THE INVENTION
[0013] It is a purpose of the present invention to eliminate the
above disadvantages by providing a suspension article comprising a
frame, a substantially uniplaner non-woven grid, and fasteners. The
grid is integrally formed with a pair of attachment strips, and the
fasteners attach the grid to the frame through the attachment
strips. In the preferred embodiment, the fasteners are a pair of
J-strips integrally extruded with the attachment strips. In another
aspect of the invention, a process for producing a suspension
article comprises the steps of forming a grid integrally with
attachment strips, and stretching the grid between and attaching
the grid to the frame through the attachment strips. In yet another
aspect of the invention, the suspension article is attached to the
frame through an adjustment means for changing the tautness of the
grid, thereby allowing the suspension article to provide a range of
support.
[0014] A second purpose of the present invention is to produce a
lightweight suspension article comprised of an elastomeric grid
which can be quickly and easily installed in a frame.
[0015] A third purpose of the invention is to produce a suspension
article that provides effectively solid support for the user, thus
eliminating the need for thick padding to prevent feeling the
members of the suspension system.
[0016] A fourth purpose is to provide a suspension article with
integral attachment strips and fasteners to eliminate as much as
possible the weaknesses associated with subsequently attached
fasteners.
[0017] A fifth purpose is to provide a suspension article which can
be easily and efficiently stretched before or during
installation.
[0018] A sixth purpose is to provide a suspension article with
uniform or near uniform support over its entire surface and can
provide a range of support depending on the tautness of the
grid.
[0019] A seventh purpose is to provide a suspension article with
reduced noise producing capability.
[0020] Other objects of the present invention will be apparent or
pointed out herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of the preferred embodiment of
the invention;
[0022] FIG. 2 is a plan view of the grid for the preferred
embodiment in its pre-stretched form;
[0023] FIG. 3 is a perspective view of an alternate suspension
article;
[0024] FIG. 4 is a perspective view of an alternate suspension
article;
[0025] FIG. 5 is a perspective view of the preferred embodiment of
the invention installed in an automobile seat.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Turning to FIG. 1, a suspension article 10 comprises a
substantially uniplaner, non-woven grid 12 integrally formed with a
pair of attachment strips 14, 16. In the preferred embodiment, the
grid 12 is comprised of an elastomeric material, and the attachment
strips 14, 16 respectively include a pair of J-strip fasteners 18,
20. The J-strip fasteners 18, 20 attach the grid 12 to a frame 22
though the attachment strips 14, 16. The grid 12 has closely-spaced
primary members 24 that are connected by points of intersection 26
between the attachment strips 14, 16. When the grid 12 is patterned
as illustrated in FIG. 1, the points of intersection 26 line up and
form ribs 28 substantially perpendicular to the primary members 24
and the primary members 24 are substantially parallel to each
other.
[0027] The close spacing of the primary members 24 is important to
ensure that the support given by the suspension article 10 is as
close to uniform as possible. In this way, the grid 12 may be used
without padding, such as on outdoor furniture. Additionally uniform
support ensures that the user will not feel the grid 12 even if
thin padding (shown in FIG. 4) is used. The close spacing also
allows for efficient and effective stretching of the suspension
article 10 in the direction of the primary members 24. This can be
accomplished by engaging hooks, tabs or other suitable elements of
a stretching machine (not shown) between the primary members 24 at
the attachment strips 14, 16. By this secure engagement, the grid
12 can be stretched for mounting onto the frame 22.
[0028] In the preferred embodiment, the grid 12 has a count of
approximately five (5) primary members 24 per inch with equal
spacing between them throughout the grid 12. The count of the grid
12 may range from one (1) to twenty (20) depending on the
application of the suspension article 10. The grid 12 may also have
variable spacing between the primary members 24 if desired so as to
vary the amount of suspension at different regions of the
suspension article 10. Also, the spacing and count of the primary
members 24 may depend on or vary with the width of the primary
members 24. In the preferred embodiment, the primary members 24 are
approximately 0.06 inches thick with a known effective range of
0.02 inches to 0.10 inches in present applications. It should be
understood, however, that the primary members 24 can be of any
suitable size or shape and may vary in size and shape within a
single grid 12 in order to provide, among other things, varying
levels of support to the user.
[0029] The points of intersection 26 connect the primary members 24
and serve principally to maintain the spacing of the primary
members 24 between the attachment strips 14, 16, according to the
pattern of the grid 12. As presented above, the grid 12 is
integrally formed with attachment strips 14, 16 which border the
grid 12. It will be appreciated that no part of the grid 12,
neither the primary members 24 nor the points of intersection 26,
is formed as an individual filament or as an attachment element
separate from the grid 12, thereby eliminating any need to
alternatively (1) weave individual filaments together into a woven
grid structure, or (2) use separate border elements for connecting
individual filaments together in a grid structure, or (3) slice and
pull an elastomeric sheet into a grid structure with twisted
strips. Additionally, it will be appreciated that the attachment
strips 14, 16 are not formed separately from the grid 12, thereby
eliminating any need to use separate attachment devices for
connecting a grid structure to border elements.
[0030] It is possible to produce points of intersection 26 with a
different thickness than the primary members 24 but in the
preferred embodiment, the points of intersection 26 have the same
thickness as the primary members 24. Accordingly, for a grid 12
having ribs 28, such ribs 28 preferably have the same thickness as
the primary members 24. Additionally, for a grid 12 having
substantially parallel, non-intersecting primary members 24, it is
possible for the only points of intersection 26 to be located at
each end of each of the primary members 24, where the primary
members 24 join the attachment strips 14, 16, in which case there
would not be any ribs 28 in the grid 12. The grid 12 may also be
formed in other patterns which have points of intersection 26 that
do not form ribs 28.
[0031] The J-strip fasteners 18, 20 are strips of material that are
preferably extruded with the grid 12 in their hook shape. The
J-strip fasteners 18, 20 can be secured over a frame edge or a
protrusion to secure the grid 12 to the frame 22. The J-strip
fasteners 18, 20 may be continuous across the entire length of the
grid 12, as with the attachment strips 14, 16 or the J-strip
fasteners 18, 20 may be discontinuous, located only at portions of
the attachment strips 14, 16, as desired.
[0032] Various elastomeric materials can be utilized to create the
grid 12. Suitable commercially available compounds include
RIGHTFLEX sold by Ticona and HYTREL sold by DuPont. The preferred
embodiment uses RIGHTFLEX. It should be noted, however, that the
invention is not limited to using only these compounds. In general,
elastomeric compounds with thermoplastic characteristics are most
suitable for making the grid 12. Accordingly, many known extrusion
and injection molding methods can be used to make the grid 12 and
attachment strips 14, 16 as disclosed herein, although the
extrusion method is preferred. As illustrated in FIG. 2, the grid
12 may be formed by initially producing a substantially uniplanar,
pre-stretched grid 29 with integral attachment strips 14, 16. The
pre-stretched grid 29 is then stretched in the direction of the
solid arrows to produce the grid 12 as described above and also
illustrated in FIG. 2.
[0033] FIG. 3 shows a perspective view of the grid 12 with
alternative attachment strips 30, 32, each of which respectively
contains a wire 34, 36 embedded therein. The wires 34, 36 impart
sufficient strength and rigidity to the attachment strips 30, 32
that the grid 12 can be secured to a frame 22 simply by engaging
the wire with appropriate fasteners 38, 40, such as hooks, tabs,
staples, wells, or other suitable elements of the frame 22. Just as
the J-strip fasteners 18, 20 may be extruded discontinuously, when
the wires 34, 36 are inserted into the attachment strips 30, 32,
portions thereof may be extruded discontinuously, resulting in
exposed portions of the wires 42 and providing discrete locations
to attach fasteners 38, 40.
[0034] FIG. 4 shows a perspective view of the grid 12 with flat,
wide attachment strips 42, 44. The flat, wide attachment strips 42,
44 are appropriate for hooking, stapling, nailing, gluing, or other
mechanical means of securing the grid 12 to the frame 22 with
appropriate fasteners 38, 40. The thickness and width of the flat,
wide attachment strips 42, 44 may vary as necessary for a given
application. Additionally, a portion of the pre-stretched grid 29
may serve as the flat, wide attachment strip 42.
[0035] Referring to FIG. 5, the suspension article 10 is shown in a
vehicle seat 46. As illustrated, the suspension article 10 may be
integrated into a lumbar support structure 48 in the backrest
portion 50 of the seat 46 and may also be used in the bottom
portion 52 of the seat 46. As used in the bottom portion 52, the
suspension article 10 is formed and attached as discussed above. In
particular, the grid 12 is integrally formed with attachment strips
14, 16, and the grid 12 is then stretched between and attached to
the frame 22 through the attachment strips 14, 16. According to the
preferred embodiment, the attachment strips 14, 16 are respectively
extruded with a pair of J-strip fasteners 18, 20. It will also be
appreciated by those skilled in the art that the suspension article
10 may also be used in many support structures for different types
furniture. For example, the present invention could be used in a
bed, including a lightweight and inexpensive cot, futon or
hammock.
[0036] As used in the lumbar support structure 48, the grid 12 has
at least one attachment strip 16 that is attached to the frame 22
through an actuated fastener 54 such that the attachment strip 16
can be moved relative to the frame 22. The lumbar support structure
48 illustrated in FIG. 5 operates by varying the tension across the
grid 12. As the actuated fastener 54 moves closer to the frame 22
and away from the other attachment strip 14, the tension across the
grid 12 increases. Similarly as the actuated fastener 54 moves
further from the frame 22 and toward the other attachment strip 14,
the tension across the grid 12 decreases.
[0037] According to the preferred embodiment illustrated in FIG. 5,
the actuated fastener 54 has an actuator 56 and a bowden cable 58.
The bowden cable 58 has an unsheathed bowden cable section 60
connected between the frame 22 and the attachment strip 16 and a
sheathed bowden cable section 62 connected between the frame 22 and
the actuator 56. The sheathed bowden cable section 62 may be
directly attached to the frame 22 or may be attached through a
mounting 64 on the frame 22. Although the actuated fastener 54 is
shown with an individual fastener 66, separate from the attachment
strip 16, it will be appreciated that the attachment strip 16 could
be integrally formed with a J-strip fastener 20 for attaching the
unsheathed bowden cable section 58. Similarly, the attachment strip
16 could be integrally formed with an attachment notch (not shown)
for the unsheathed bowden cable section 58, thereby producing an
integral attachment element (not shown)
[0038] Of course, it will be appreciated that such a lumbar support
structure 48 could alternatively move the pair attachment strips
14, 16 rather than moving a single attachment strip 16 and such
alternative design would be within the scope of the present
invention. Additionally, it is well-known that lumbar support can
also be varied by moving a support structure towards the occupant,
and it is anticipated that the suspension article 10 according to
the present invention could function as this type of support
structure in a lumbar support device (not shown). Finally, the
lumbar support structure 48 could be fitted with a grid structure
presently known in the art, such as an elastomeric fabric (not
shown).
[0039] In view of the foregoing, it will be seen that the several
advantages of the invention are achieved and attained. The
embodiments were chosen and described in order to best explain the
principles of the invention and its practical application to
thereby enable others skilled in the art to best utilize the
invention in various embodiments and with various modifications as
are suited to the particular use contemplated.
[0040] As various modifications could be made in the constructions
and methods herein described and illustrated without departing from
the scope of the invention, it is intended that all matter
contained in the foregoing description or shown in the accompanying
drawings shall be interpreted as illustrative rather than limiting.
For example, it will be appreciated that the grid pattern may be
varied, as evident in U.S. Pat. No. 3,252,181 to Hureau, without
departing from the scope of the present invention. Thus, the
breadth and scope of the present invention should not be limited by
any of the above-described exemplary embodiments, but should be
defined only in accordance with the following claims appended
hereto and their equivalents.
* * * * *