U.S. patent application number 10/843676 was filed with the patent office on 2005-07-07 for frameless chair.
Invention is credited to George, Daniel C. II.
Application Number | 20050144726 10/843676 |
Document ID | / |
Family ID | 27005739 |
Filed Date | 2005-07-07 |
United States Patent
Application |
20050144726 |
Kind Code |
A1 |
George, Daniel C. II |
July 7, 2005 |
Frameless chair
Abstract
A frameless chair comprising: a flexible, substantially
spherical outer liner, wherein the outer liner is at least
partially gas permeable, and a plurality of polyurethane foam
pieces retained within the outer liner.
Inventors: |
George, Daniel C. II; (Grand
Rapids, MI) |
Correspondence
Address: |
King & Jovanovic, PLC
170 College Avenue
SUITE 230
HOLLAND
MI
49423
US
|
Family ID: |
27005739 |
Appl. No.: |
10/843676 |
Filed: |
May 11, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10843676 |
May 11, 2004 |
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09973416 |
Oct 9, 2001 |
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6732391 |
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09973416 |
Oct 9, 2001 |
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09941064 |
Aug 28, 2001 |
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6725482 |
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09941064 |
Aug 28, 2001 |
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09372369 |
Aug 11, 1999 |
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6279184 |
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Current U.S.
Class: |
5/652 |
Current CPC
Class: |
A47C 27/086 20130101;
A47C 3/16 20130101 |
Class at
Publication: |
005/652 |
International
Class: |
A47C 020/02 |
Claims
What is claimed is:
1. A frameless chair, comprising: a unitary outer liner, wherein
the unitary outer liner is flexible and at least partially gas
permeable, and further wherein the unitary outer liner comprises
two substantially circular lobes which emanate contiguously from
opposite ends of a regular or non-regular polygonal member, and
further wherein the two substantially circular lobes are secured to
each other to, in turn, form a substantially spherical outer liner;
and a plurality of polyurethane foam pieces retained within the
outer liner.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation-in-part of co-pending
U.S. application Ser. No. 09/941,064, filed on Aug. 28, 2001, which
is a continuation application of U.S. Pat. No. 6,279,184, the
entirely of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates in general to frameless
chairs, and more particularly, to a frameless chair having a
structural configuration which, among other things, increases
longevity, durability, washability, and shapability of the
same.
[0004] 2. Background Art
[0005] Frameless chairs have been known in the art for several
years. Furthermore, frameless chairs filled with beads of
polystyrene foam have likewise been known in the art. While such
conventional frameless chairs have become popular, their
shapability and durability, among other things, remains largely
problematic. In particular, after a conventional frameless chair
has been occupied by a person, the beads of polystyrene foam which
are held within the liner of the chair result in the chair having
depression where the person was sitting. The depression remains in
the chair unless and until a person reshapes the chair by exerting
physical force upon it--such as by rolling, shaking, or fluffing
the chair.
[0006] A second problem associated with conventional frameless
chairs is that once the outer liner of the chair has been worn
through by normal wear and tear or otherwise damaged by accidental
puncturing, the beads of polystyrene foam are readily released from
the chair and, in turn, can endanger, for example, small children
and/or animals. Moreover, inasmuch as conventional chairs have only
one liner, washing such a liner is extremely difficult because the
numerous beads of polystyrene foam must first be removed before the
liner can be machine washed. In addition, conventional frameless
chairs have material and stitching patterns that are not conducive
to promoting chair longevity. Specifically, for example, the
stitching used in conventional frameless chairs is externally
exposed making it vulnerable to "catching" and/or "snagging" by an
occupant.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a frameless chair
comprising: (a) a unitary outer liner, wherein the unitary outer
liner is flexible and at least partially gas permeable, and further
wherein the unitary outer liner comprises two substantially
circular lobes which emanate contiguously from opposite ends of a
regular or non-regular polygonal member, and further wherein the
two substantially circular lobes are secured to each other to, in
turn, form a substantially spherical outer liner; and (b) a
plurality of polyurethane foam pieces retained within the outer
liner.
[0008] In a preferred embodiment of the present invention, the
regular or non-regular polygonal member may comprise a
substantially rectangular member.
[0009] The present invention is also directed to a frameless chair
comprising: (a) a unitary outer liner, wherein the unitary outer
liner is flexible and at least partially gas permeable, and further
wherein the unitary outer liner comprises two substantially
circular lobes which emanate contiguously from opposite ends of a
regular or non-regular polygonal member, and further wherein the
two substantially circular lobes are secured to the regular or
non-regular polygonal member to, in turn, form a substantially
spherical outer liner; and (b) a plurality of polyurethane foam
pieces retained within the outer liner.
[0010] The present invention is further directed to a frameless
chair comprising: (a) an outer liner, wherein the outer liner is at
least partially gas permeable, and further wherein the outer liner
comprises: (1) a first flexible component having a substantially
lemniscate peripheral geometry; and (2) a second flexible component
having a substantially lemniscate peripheral geometry, wherein the
first flexible component is secured to the second flexible
component to, in turn, form a substantially spherical outer liner;
and (b) a plurality of polyurethane foam pieces retained within the
outer liner.
[0011] In accordance with the present invention a frameless chair
is disclosed as comprising: (a) an outer liner, wherein the outer
liner is at least partially gas permeable, and further wherein the
outer liner comprises: (1) a first flexible component having a
substantially circular peripheral geometry; and (2) a second
flexible component having a substantially circular peripheral
geometry, wherein the first flexible component is secured to the
second flexible component to, in turn, form a substantially
spherical outer liner; and (b) a plurality of polyurethane foam
pieces retained within the outer liner.
[0012] The present invention is also directed to a frameless chair
comprising: (a) an outer liner, wherein the outer liner is at least
partially gas permeable, and further wherein the outer liner
comprises: (1) a first flexible component having a substantially
biconvex peripheral geometry; (2) a second flexible component
having a substantially biconvex peripheral geometry; and (3) a
third flexible component having a substantially biconvex peripheral
geometry, wherein the first flexible component is secured to the
second flexible component, and wherein the second flexible
component is secured to the third flexible component, and further
wherein the third flexible component is secured to the first
flexible component to, in turn, form a substantially spherical
outer liner; and (b) a plurality of polyurethane foam pieces
retained within the outer liner.
[0013] The present invention is further directed to a frameless
chair comprising: (a) an outer liner, wherein the outer liner is at
least partially gas permeable, and further wherein the outer liner
comprises at least three flexible components having a substantially
biconvex peripheral geometry, and further wherein each one of the
at least three flexible components is secured to two others of the
at least three flexible components to, in turn, form a
substantially spherical outer liner; and (b) a plurality of
polyurethane foam pieces retained within the outer liner.
[0014] In accordance with the present invention a frameless chair
is disclosed as comprising: (a) an outer liner, wherein the outer
liner is at least partially gas permeable, and further wherein the
outer liner comprises four flexible components having a
substantially pyriform peripheral geometry, and further wherein the
four flexible components are secured to each other to, in turn,
form a substantially spherical outer liner; and (b) a plurality of
polyurethane foam pieces retained within the outer liner.
[0015] The present invention is further directed to a frameless
chair comprising: (a) an outer liner, wherein the outer liner is at
least partially gas permeable, and further wherein the outer liner
comprises eight flexible components having a substantially
hemipyriform peripheral geometry, and further wherein the eight
flexible components are secured together to, in turn, form a
substantially spherical outer liner; and (b) a plurality of
polyurethane foam pieces retained within the outer liner.
[0016] Moreover, the present invention is directed to a frameless
chair comprising: (a) a unitary outer liner, wherein the unitary
outer liner is flexible and at least partially gas permeable, and
further wherein the unitary outer liner comprises an unassembled
outer peripheral geometry represented by one of the following
structures: 1
[0017] plurality of polyurethane foam pieces retained within the
outer liner.
[0018] The present invention is also directed to a frameless chair
comprising: (a) an outer liner, wherein the outer liner is at least
partially gas permeable, and further wherein the outer liner
comprises two flexible components comprising outer peripheral
geometries represented by one of the following structures: 2
[0019] and (b) a plurality of polyurethane foam pieces retained
within the outer liner.
[0020] The present invention is further directed to a frameless
chair comprising: (a) an outer liner, wherein the outer liner is at
least partially gas permeable, and further wherein the outer liner
comprises at least three flexible components comprising outer
peripheral geometries represented by the following structure: 3
[0021] and (b) a plurality of polyurethane foam pieces retained
within the outer liner.
[0022] Furthermore, the present invention is directed to a
frameless chair comprising: (a) an outer liner, wherein the outer
liner is at least partially gas permeable, and further wherein the
outer liner comprises four flexible components comprising outer
peripheral geometries represented by the following structure: 4
[0023] and (b) a plurality of polyurethane foam pieces retained
within the outer liner.
[0024] The present invention is directed to a frameless chair
comprising: (a) an outer liner, wherein the outer liner is at least
partially gas permeable, and further wherein the outer liner
comprises eight flexible components comprising outer peripheral
geometries represented by the following structure: 5
[0025] and (b) a plurality of polyurethane foam pieces retained
within the outer liner.
[0026] In a preferred embodiment of the present invention, the
frameless chair further comprises an inner liner positioned within
the outer liner, wherein the plurality of polyurethane pieces are
retained within the inner liner.
[0027] In another preferred embodiment of the present invention,
the frameless chair further comprises a looped handle.
[0028] Preferably, the density of the polyurethane foam pieces
ranges from between approximately 1.0 and approximately 4.0 pounds
per cubic foot.
[0029] In a preferred embodiment of the present invention, the
outer liner includes at least one seam having an outer surface and
an inner surface, wherein the outer surface of the seam is void of
any exposed stitching.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention will now be described with reference to the
drawings wherein:
[0031] FIG. 1 of the drawings is a schematic representation of an
unassembled frameless chair according to the present invention;
[0032] FIG. 2 of the drawings is a schematic representation of an
unassembled outer liner showing the adjoining edges of the
component parts according to the present invention;
[0033] FIG. 3 of the drawings is a schematic representation of an
assembled outer liner showing the placement of a zipper according
to the present invention;
[0034] FIG. 4 of the drawings is a fragmented cross sectional
schematic representation of an outer liner showing a stitch
location according to the present invention; and
[0035] FIG. 5 of the drawings is a fragmented cross sectional
schematic representation of a prior art outer liner showing the
stitch location.
[0036] FIG. 6 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, a unitary
outer liner and the adjoining edges of the contiguous members
according to the present invention;
[0037] FIG. 7 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0038] FIG. 8 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, a unitary
outer liner and the adjoining edges of the contiguous members
according to the present invention;
[0039] FIG. 9 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0040] FIG. 10 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, an outer
liner and the adjoining edges of the flexible components according
to the present invention;
[0041] FIG. 11 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0042] FIG. 12 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, an outer
liner and the adjoining edges of the flexible components according
to the present invention;
[0043] FIG. 13 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0044] FIG. 14 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, an outer
liner and the adjoining edges of the flexible components according
to the present invention;
[0045] FIG. 15 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0046] FIG. 16 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, an outer
liner and the adjoining edges of the flexible components according
to the present invention;
[0047] FIG. 17 of the drawings is a schematic representation of an
assembled outer liner according to the present invention;
[0048] FIG. 18 of the drawings is a schematic representation of an
unassembled frameless chair showing, among other things, an outer
liner and the adjoining edges of the flexible components according
to the present invention; and
[0049] FIG. 19 of the drawings is a schematic representation of an
assembled outer liner according to the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0050] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawings and will herein be
described in detail several specific embodiments with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the invention to the embodiments illustrated.
[0051] It will be understood that like or analogous elements and/or
components, referred to herein, may be identified throughout the
drawings with like reference characters. It will further be
understood that FIGS. 1-19 are merely schematic representations. As
such, some of the components may be distorted from their actual
scale for pictorial clarity. Moreover, while drawings of frameless
chair 10 may not appear substantially spherical, frameless chair 10
will take on a substantially spherical geometry upon filling with a
plurality of polyurethane foam pieces.
[0052] Frameless chair 10 is shown in FIG. 1, prior to assembly, as
generally comprising outer liner 12, inner liner 14, and a
plurality of polyurethane foam pieces 16.
[0053] Outer liner 12 includes first end component 18, second end
component 20, and intermediate component 22. First and second end
components 18 and 20 have a substantially circular peripheral
geometry and intermediate component 22 has a substantially
rectangular peripheral geometry. Upon assembly of outer liner 12,
first and second end components 18 and 20 and intermediate
component 22 are fused together, preferably by sewing. However, any
one of a number of fusing techniques known to those having ordinary
skill in the art are likewise contemplated for use.
[0054] As is best shown in FIG. 2, the peripheral edge of end
component 18 is fused to edge 24 of intermediate component 22 and
the peripheral edge of end component 20 is fused to edge 26 of
intermediate component 22. Edges 28 and 30 of intermediate
component 22 are fused together to, in turn, form a three piece
substantially spherical outer liner. It will be understood that the
configurations disclosed herein are simple to cut (or even stamp)
and stitch making them highly desirous. As is shown in FIG. 3,
zipper 32 is preferably fused between edges 28 and 30. However, it
is also contemplated that zipper 32 can be associated with either
first and/or second end components 18 and 20, respectively. In
addition, zipper 32 can be treated with an adhesive to enhance the
lockability of zipper and, in turn, substantially prevent zipper 32
from opening inadvertently.
[0055] Components 18, 20, and 22 of outer liner 12 are preferably
sewn together so that the external seams are void of exposed
stitching. The avoidance of exposed stitching is best shown in FIG.
4 and accomplished by, for example, mating components 18 and 22
without overlapping the material and sewing at least one stitch at
point 34. As is shown in FIG. 5, if components 18 and 22 are
conventionally overlapped and sewn at point 36, a stitch is exposed
to the outer surface of outer liner 12, which is vulnerable to
catching or snagging. Components 18, 20 and 22 of outer liner 12
are preferably fabricated from a machine washable, flexible
material and/or fabric that is at least partially gas permeable--so
as to allow air to enter and exit the liner when an occupant sits
in or departs from the chair. For example, the outer liners
disclosed herein may comprise natural and/or synthetic materials,
including, but not limited to, wool, leather, denim, cotton,
polyester, etcetera.
[0056] Referring again to FIG. 1, inner liner 14 includes first end
component 18', second end component 20', and intermediate component
22'. First and second end components 18' and 20' have substantially
circular peripheral geometry and intermediate component 22' has a
substantially rectangular peripheral geometry. First and second end
components 18' and 20' and intermediate component 22' are fused
together, preferably by sewing, in an analogous manner as
previously described relative to outer liner 12 to form a
substantially spherical inner liner. Preferably a zipper, similar
to zipper 32, is associated with either one or both of first and
second end components 18' and 20', respectively. Components 18',
20' and 22' of inner liner 14 are preferably fabricated from a
machine washable, flexible material that is at least partially gas
permeable.
[0057] Once inner liner 14 is fabricated, a plurality of
polyurethane pieces 16 are inserted into inner liner 14 to, in
turn, fill out the substantially spherical space. Inner liner 14 is
then fitted into outer liner 12 to complete assembly. It will be
understood that frameless chair 10 can be fabricated without inner
liner 14. In such a case, polyurethane foam pieces 16 are inserted
directly into the outer liner.
[0058] A second embodiment of frameless chair 10 is shown in FIG.
6, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16. Although not shown, for
each embodiment provided herein, it is contemplated that an inner
liner, which is structurally analogous to inner liner 14 or any
outer liners 12 disclosed herein, may be included with frameless
chair 10. Alternatively, an inner liner may be fabricated in any
one of a number of manners known to those having ordinary skill in
the art having the present disclosure before them--the only
limitation being that the inner liner must comprise a structure and
composition which both is retained by the outer liner as well as
retains a plurality of polyurethane foam pieces.
[0059] Outer liner 12 includes first lobe 40A, second lobe 40B, and
member 42. Outer liner 12 is unitary in structure and first and
second lobes 40A and 40B, which have substantially circular
peripheral geometries, emanate contiguously from member 42, which
has a regular or non-regular polygonal peripheral geometry. As is
shown in FIG. 6, member 42 may comprise a substantially rectangular
geometry. Upon assembly of outer liner 12, first and second lobes
40A and 40B are fused together proximate their peripheral
geometries, preferably by sewing. However, any one of a number of
fusing techniques known to those having ordinary skill in the art
are likewise contemplated for use.
[0060] As is shown in FIG. 7, edge 41A of lobe 40A is fused to edge
41B of lobe 40B to, in turn, form outer liner 12, and end 43A of
member 42 is fused to end 43B of member 42 to seal outer liner 12
and to, in turn, form a looped handle from member 42. Consequently,
the length of member 42 determines the size of the looped handle.
Alternatively, although not shown, before fusing end 43A to end
43B, member 42 may be tucked inside outer liner 12 so that no
looped handle is present in frameless chair 10.
[0061] Although not shown, for each embodiment herein below, it is
contemplated that a zipper be associated with outer liner 12 and/or
an inner liner and any seams thereon. In addition, the zipper may
be treated with an adhesive to enhance the lockability of the
zipper and, in turn, substantially prevent it from opening
inadvertently.
[0062] Lobes 40A and 40B and member 42 of outer liner 12 are
preferably sewn together so that the external seams are void of
exposed stitching, including seams on the looped handle. The
avoidance of exposed stitching is best shown in FIG. 4 and is
accomplished by means analogous to what is shown therein and what
has been described above. It will be understood that, preferably,
all embodiments provided herein may incorporate such stitching in
their outer liners, inner liners, and/or handles.
[0063] Outer liner 12 is preferably fabricated from a flexible,
machine washable material that is at least partially gas permeable
so as to allow air to enter and exit the liner when an occupant
sits in or departs from the chair. It will be understood that,
preferably, all embodiments provided herein may be fabricated from
such a material.
[0064] A third embodiment of frameless chair 10 is shown in FIG. 8,
prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0065] In this embodiment, outer liner 12 includes first lobe 50A,
second lobe 50B, and member 52. Outer liner 12 is structurally
unitary and first and second lobes 50A and 50B, which have
substantially circular peripheral geometries, emanate contiguously
from member 52, which has a regular or non-regular polygonal
peripheral geometry. As is shown in FIG. 8, member 52 may comprise
a substantially rectangular geometry. Upon assembly of outer liner
12, first and second lobes 50A and 50B and member 52 are fused
together proximate their peripheral geometries, preferably by
sewing. However, any one of a number of fusing techniques known to
those having ordinary skill in the art are likewise contemplated
for use. As is shown in FIG. 9, edge 51A of lobe 50A is fused to
edge 52C of member 52, and edge 51B of lobe 50B is fused to edge
52D of member 52. Edges 52A and 52B of member 52 are fused together
to, in turn, form outer liner 12.
[0066] Although not shown, a looped handle may be attached or
attachable to frameless chair 10. For example, member 52 may be
constructed such that its length permits a portion of member 52 to
form a looped handle. It will be understood that, although not
shown, all embodiments described herein may comprise a handle.
[0067] A fourth embodiment of frameless chair 10 is shown in FIG.
10, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0068] In this embodiment, outer liner 12 includes first member 60
and second member 62. First and second members 60 and 62 have
substantially lemniscate peripheral geometries. Regardless of its
original meaning, the term "lemniscate" will herein be defined as
having a continuous curve generated substantially by the formula:
r.sup.2=a.sup.2 cos 2.theta., wherein the curve may or may not
intersect at a node, and/or wherein the curve may be represented by
one of the following structures: 6
[0069] Upon assembly of outer liner 12, first and second members 60
and 62 are fused together proximate their peripheral geometries,
preferably by sewing. However, any one of a number of fusing
techniques known to those having ordinary skill in the art are
likewise contemplated for use. As is shown in FIG. 11, edge 60A is
fused to edge 62C, edge 60B is fused to edge 62D, edge 62A is fused
to edge 60D, and edge 62B is fused to edge 60C to, in turn, form
outer liner 12.
[0070] A fifth embodiment of frameless chair 10 is shown in FIG.
12, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0071] In this embodiment, outer liner 12 includes first member 70
and second member 72. First and second members 70 and 72 have
substantially circular peripheral geometries. Upon assembly of
outer liner 12, first and second members 70 and 72 are fused
together proximate their peripheral geometries, preferably by
sewing. However, any one of a number of fusing techniques known to
those having ordinary skill in the art are likewise contemplated
for use. As is shown in FIG. 13, edge 70A is fused to edge 72A to,
in turn, form outer liner 12.
[0072] A sixth embodiment of frameless chair 10 is shown in FIG.
14, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0073] In this embodiment, outer liner 12 includes first member 80,
second member 82, and third member 84. First, second, and third
members 80, 82, and 84, have substantially biconvex peripheral
geometries. Regardless to its original meaning, the term "biconvex"
will herein be defined as having a geometrical shape resulting from
the intersection of two convex curves, and/or wherein the shape may
be represented by the following structure: 7
[0074] Upon assembly of outer liner 12, first, second, and third
members 80, 82, and 84 are fused together proximate their
peripheral geometries, preferably by sewing. However, any one of a
number of fusing techniques known to those having ordinary skill in
the art are likewise contemplated for use. As is shown in FIG. 15,
edge 81B of member 80 is fused to edge 83A of member 82, edge 83B
of member 82 is fused to edge 85A of member 84, and edge 85B of
member 84 is fused to edge 81A of member 80 to, in turn, form outer
liner 12.
[0075] A seventh embodiment of frameless chair 10 is shown in FIG.
16, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0076] In this embodiment, outer liner 12 includes first member 90,
second member 92, third member 94, and fourth member 96. First,
second, third, and fourth members 90, 92, 94, and 96 have
substantially pyriform peripheral geometries. Regardless to its
original meaning, the term "pyriform" will herein be defined as
having a geometrical shape resembling a pear, and/or wherein the
shape may be represented by the following structure: 8
[0077] Upon assembly of outer liner 12, first, second, third, and
fourth members 90, 92, 94, and 96 are fused together proximate
their peripheral geometries, preferably by sewing. However, any one
of a number of fusing techniques known to those having ordinary
skill in the art are likewise contemplated for use. As is shown in
FIG. 17, edge 94A of member 94 is fused to edge 96A of member 96,
which are both proximate edges 90B and 92B of members 90 and 92,
respectively, and edge 90A of member 90 is fused to edge 92A of
member 92, which are both proximate edges 94B and 96B of members 94
and 96, respectively, to, in turn, form outer liner 12.
[0078] An eighth embodiment of frameless chair 10 is shown in FIG.
18, prior to assembly, as generally comprising outer liner 12 and a
plurality of polyurethane foam pieces 16.
[0079] In this embodiment, outer liner 12 includes eight members,
referred to as 100, 102, 104, 106, 108, 110, 112, and 114, which
have substantially hemipyriform peripheral geometries. Regardless
to its original meaning, the term "hemipyriform" will herein be
defined as having a geometrical shape resembling the cross-section
of a half of a pear, and/or wherein the shape may be represented by
the following structure: 9
[0080] Upon assembly of outer liner 12, members 100, 102, 104, 106,
108, 110, 112, and 114 are fused together proximate their
peripheral geometries, preferably by sewing. However, any one of a
number of fusing techniques known to those having ordinary skill in
the art are likewise contemplated for use. As is shown in FIG. 19,
members 100, 102, 104, 106, 108, 110, 112, and 114 are fused
together proximate their peripheral geometries to, in turn, form
outer liner 12.
[0081] Although not shown, a plurality of embodiments are
contemplated in accordance with the present invention such that
frameless chair 10 be configured with a substantially spherical
geometry upon filling with the plurality of polyurethane foam
pieces 16. As such, outer liner 12 may comprise any one of a
plurality of members of various shapes and sizes--for example,
polygonal, square, rectangular, triangular, arbitrary, and/or
curved shapes.
[0082] Commercially available polyurethane foam pieces 16 replace
conventional inexpensive polystyrene beads because the polystyrene
beads are not resiliently compressible. As such, the polystyrene
beads are void of any inherent ability to fill out an inner liner
back to its original shape after an occupant departs from the
chair. Certain species of polyurethane foam, on the other hand, are
both compressible and resilient. In particular, it has been found
that polyurethane having a density between 1.0 and 4.0 pounds per
cubic foot is sufficiently compressible to conform to an occupant's
bodily dimensions and sufficiently resilient to fill out the chair
one the occupant departs from the same. Moreover, it has been
further determined that polyurethane foam having a density of 1.3
to 2.1 pounds per cubic foot is highly desired because it offers
the desired resiliency without added weight--an important
characteristic for shipping mass quantities of chairs having such
polyurethane foam. Although not shown, it is contemplated that the
foam pieces may comprise a unitary foam piece which substantially
conforms to the outer liner.
[0083] Foam pieces 16 can also be impregnated with an organic
ester. Impregnation of an organic ester serves at least two
purposes. First, the odor of commercially available polyurethane
may be initially undesirable to certain humans and/or pets. As
such, the organic ester can neutralize the undesired odor with a
nominal amount--i.e. a very light spray is sufficient with most
esters. Second, due to the relatively amorphous characteristics of
the polyurethane foam, the foam can readily absorb household odors
that can be neutralized with such an organic ester. Any one of a
number of commercially available (Aldrich Chemical Co., Milwaukee,
Wis.) or readily synthesizable organic esters are contemplated for
use, and the combinations of esters are virtually limitless.
[0084] Although not shown, certain applications may require that
frameless chair 10 be at least water resistant, if not, water
impermeable. Several agents for creating a water impermeable bearer
on material are commercially known and treatment of any and/or all
of the components of frameless chair 10 are contemplated. For
illustrative purposes only, such water impermeable agents include
polymeric or long chain fluorocarbons and silane and siloxane based
polymers. Of course, several other agents known to those having
ordinary skill in the art are likewise contemplated for use.
[0085] The foregoing description and drawings merely explain and
illustrate the invention and the invention is not limited thereto
except insofar as the appended claims are so limited, as those
skilled in the art who have the disclosure before them will be able
to make modifications and variations therein without departing from
the scope of the invention.
* * * * *