U.S. patent application number 11/119673 was filed with the patent office on 2006-11-02 for outdoor seat cushions.
Invention is credited to Robert Jeffries.
Application Number | 20060244301 11/119673 |
Document ID | / |
Family ID | 37233761 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060244301 |
Kind Code |
A1 |
Jeffries; Robert |
November 2, 2006 |
Outdoor seat cushions
Abstract
An embodiment of a cushioning pad for use on the seat backs and
seat bottoms of outdoor stadium seating is described along with
embodiments of stadium seats incorporating the cushioning pads.
Additionally in another embodiment, a method of retrofitting
stadium seating is further described. One embodiment of the
cushioning pad comprises a self-skinning polyurethane foam having
attachment fasteners integrally formed therein.
Inventors: |
Jeffries; Robert;
(Englewood, CO) |
Correspondence
Address: |
LEYENDECKER LEMIRE & DALEY, LLC
C/O PORTFOLIO IP
P.O. BOX 52050
MINNEAPOLIS
MN
55402
US
|
Family ID: |
37233761 |
Appl. No.: |
11/119673 |
Filed: |
May 2, 2005 |
Current U.S.
Class: |
297/452.55 |
Current CPC
Class: |
A47C 7/02 20130101; A47C
1/12 20130101 |
Class at
Publication: |
297/452.55 |
International
Class: |
A47C 7/02 20060101
A47C007/02 |
Claims
1. An outdoor stadium seat comprising: a support structure, the
support structure being adapted to be secured to a ground surface;
a seat back, the seat back being coupled with the support structure
and being adapted to support a back of a person sitting in the
outdoor stadium seat; a seat bottom, the seat bottom being coupled
with the support structure and being adapted to support the person
sitting thereon; and a first cushioning pad, the first cushioning
pad comprising (i) a self-skinning foam polymeric material and (ii)
a first plurality of fasteners around which the self skinning foam
polymeric material is at least partially molded; wherein the first
plurality fasteners are fixedly coupled with one of the seat back
and the seat bottom on a seating surface thereof.
2. The outdoor stadium seat of claim 1, wherein the seat bottom is
pivotally coupled to the support structure and is adapted to move
between a generally horizontal orientation and a generally vertical
orientation.
3. The outdoor stadium seat of claim 1, further comprising a second
cushioning pad, the second cushioning pad comprising (i) the
self-skinning foam polymeric material and (ii) a second plurality
of fasteners around which the self skinning foam polymeric material
is at least partially molded, wherein the second plurality
fasteners are fixedly coupled with the other of the seat back and
the seat bottom on a seating surface thereof.
4. The outdoor stadium seat of claim 1, wherein the first
cushioning pad is 0.75''-1.25'' thick.
5. The outdoor stadium seat of claim 4, wherein the self-skinning
foam polymeric material includes a foam portion and a skin portion,
the foam portion having a density of about 10-14 pounds per cubic
foot, and the skin has a density of about 40-90 pounds per cubic
foot.
6. The outdoor stadium seat of claim 1, wherein the self-skinning
foam polymeric material comprises polyurethane.
7. The outdoor stadium seat of claim 6, wherein the first
cushioning pad further includes an ultraviolet radiation resistant
layer overlying the self-skinning foam polymeric material.
8. The outdoor stadium seat of claim 7, wherein the ultraviolet
radiation resistant layer comprises an aliphatic material that
integrally bonds with the self-skinning foam polymeric material
during the formation of the first cushioning pad.
9. The outdoor stadium seat of claim 1, wherein the first plurality
of fasteners each comprise a plastic ratchet fastener.
10. A row of interconnected seats in an outdoor stadium comprising
the stadium seat of claim 1.
11. A section of stadium seating comprising a plurality of the rows
of interconnected seats of claim 10.
12. A cushion adapted for use in outdoor stadium seating, the
cushion comprising: a generally rectangularly-shaped pad
0.75-1.25'' thick comprising a self skinning polyurethane material
and including an integrally formed skin and foam portions, the skin
portion having a density of about 40-90 pound per square foot with
a thickness of 0.90''-0.135'', the foam portion having a density of
about 10-14 pounds per cubic foot; and a plurality of plastic
ratchet fasteners with a shank extending generally perpendicularly
outwardly from a first face of the pad, each ratchet fastener
including a head, the pad being molded around the head during
fabrication of the cushion.
13. The cushion of claim 12, wherein the skin portion further
comprises a ultraviolet radiation resistant layer, the ultraviolet
radiation resistant layer covering substantially the entire
exterior surface of the pad and being about 0.004-0.007''
thick.
14. The cushion of claim 13, wherein the plurality of plastic
ratchet fasteners comprise Catalog Number PC47617 from Index
Fasteners, Inc. of Ontario, Calif.
15. The cushion of claim 12, wherein the ultraviolet radiation
resistant layer comprises an aliphatic polyurethane material.
16. A method of retrofitting a plurality of seats in an outdoor
stadium, the method comprising: determining the size of a
cushioning pad to be added to the seats by measuring one of (i) a
representative seat of the plurality of seats and (ii) an old
cushion from the representative seat; determining the type,
location and number of fasteners to be included on the cushioning
pad based on one of (a) the location and type of fastening points
on the representative seat relative to the old cushion, and (b) the
size of a seating surface on the representative seat on which the
cushioning pad is to be fitted; fabricating a plurality of
cushioning pads, each cushioning pad being generally rectangularly
shaped and comprising (1) a self skinning polyurethane material
including integrally formed skin and foam portions, and (2) a
plurality of fasteners molded into the self skinning urethane
material during fabrication of the cushioning pad; installing the
plurality of cushioning pads on a plurality of seats.
17. The method of claim 16, further comprising: removing a
plurality of old cushions from the plurality of seats.
18. The method of claim 16, further comprising preparing each seat
of the plurality of seats to receive the cushioning pad by drilling
a plurality of holes in the seating surface of the seat
corresponding to locations of the plurality of fasteners on an
associated cushioning pad of the plurality of cushioning pads.
19. The method of claim 16, wherein each cushioning pad is
0.75-1.25'' thick and includes a skin portion and a foam portion,
the foam portion having a density of about 10-14 pounds per cubic
foot, and the skin portion having a thickness of about
0.90''-0.135'' with a density of about 40-90 pound per square
foot.
20. The method of claim 19, wherein the skin portion of each
cushioning pad includes an ultraviolet radiation resistant layer
cover the exterior of the cushioning pad, the ultraviolet radiation
resistant layer being 0.004-0.007'' thick and comprising an
aliphatic polyurethane material.
Description
FIELD OF THE INVENTION
[0001] This invention relates to outdoor seating and associated
padded seat cushions.
BACKGROUND
[0002] Outdoor stadium seats typically comprise a hard plastic,
wood or metallic seat back, a hard plastic, wood or metallic seat
bottom that pivots or folds upwardly to allow people to more easily
pass in front of the seat when accessing their seats or leaving
their seats. Stadium seats may also comprise wood, plastic or
metallic benches with or without back rests. Stadium seats are not
known for their comfort and one can surmise the lack of comfort of
stadium seating help give rise to the popular baseball tradition
known as the "Seventh Inning Stretch". Stadium seat comfort has
improved substantially in the last 15-20 years with the advent of
somewhat ergonomically shaped molded plastic seat bottoms and
backs, but stadium seats are still not particularly
comfortable.
[0003] While most outdoor stadium seating continues to comprise
hard seating services, such as plastic and wood, in the more
expensive "club" levels of some stadiums, cushioned seat bottoms
and/or backs are sometimes provided. The cushion typically
comprises a foam pad overlying a thin plastic substrate, such as
polyethylene or polypropylene sheet, and a vinyl fabric stretched
tautly over the top of the foam and secured to the bottom side of
the plastic substrate with staples. Means for securing cushion to
the seat back or seat bottom of an associated stadium seat are
typically secured to the plastic substrate.
[0004] While the cushions do significantly increase the comfort of
the outdoor stadium seats over uncushioned seats, they present
additional drawbacks. Most significantly, seats having cushioned
backs and/or bottoms are significantly more expensive to maintain.
The vinyl fabric is easily ripped, punctured or otherwise damaged.
Further, the vinyl fabric tends to degrade quickly when exposed to
ultraviolet light cause the color to fade and the strength of the
fabric to be reduced substantially. Finally, the foam used in
relatively thin thicknesses is not particularly effective in
providing cushioning. Experience in various stadiums using these
cushions has shown their effective lifespan to be a single season
or less. Because of the propensity for the seat cushions to become
damaged, stadium maintenance personal must regularly inspect the
cushions, and as required, replace the damaged cushions.
Accordingly, the cost of outfitting a section of a stadium with
cushioned seats includes not only the cost of the cushions and
cushion replacements but also the additional labor cost of
regularly inspecting and repairing the seating. These costs would
be prohibitive if cushioned seating were utilized in the entirety
of a stadium as opposed to just the premium level club seating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is isometric view of a stadium seat including cushion
seat pads according to one embodiment of the present invention.
[0006] FIG. 2 is a partially exploded view of a stadium seat
according to one embodiment of the present invention.
[0007] FIG. 3 is an isometric bottom view of a bottom cushioned
seat pad according to one embodiment of the present invention.
[0008] FIG. 4 is cross sectional side view of a cushion pad
according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0009] Embodiments of seat back and seat bottom cushioning pads
that are comprised of a self-skinning polymeric closed cell foam
material, such as urethane, and outdoor stadium seats incorporating
the same are described. The cushioning pads are adapted to be
secured to stadium seating to substantially increase the comfort of
a person using the seat when compared to typical hard plastic or
wood seating. The skins of self-skinning urethanes are inherently
tough and resistant to puncturing. Even when punctured or slit, the
damaged area is self-healing thereby reducing (i) the tendency of
the damaged area to grow or spread and (ii) the visibility of the
damage to a person using the associated seat. Accordingly, the
seats have a longer lifespan than traditional outdoor stadium
cushions that comprise vinyl fabric over foam.
[0010] The cushioning pads are typically molded in closed molds
into which the urethane constituents in liquid form (or
constituents of another foaming polymer) are injected. The ensuing
reaction generates a gaseous byproduct that causes the urethane to
foam. The high pressures generated during the fabrication process
facilitate the formation of a skin on all surfaces of the mold. In
some embodiments of the cushioning pads, fasteners used to join the
cushions to an associated seat are placed in the mold prior to the
molding operation such that the resulting skin forms over a portion
of each fastener to effectively secure it in place. The labor
required to fabricate each cushioning pad is low when compared to
the labor required to fabricate a prior art outdoor stadium
cushion, thereby making embodiments of the cushioning pads
cost-competitive with prior art cushions. Further, stadiums using
embodiments of the cushioning pads described herein may be able to
eliminate or reduce the staffing of upholstery departments thereby
realizing overhead expense reductions.
Terminology
[0011] The term "or" as used in this specification and the appended
claims is not meant to be exclusive rather the term is inclusive
meaning "either or both".
[0012] References in the specification to "one embodiment", "an
embodiment", "a preferred embodiment", "an alternative embodiment"
and similar phrases means that a particular feature, structure, or
characteristic described in connection with the embodiment is
included in at least an embodiment of the invention. The
appearances of the phrase "in one embodiment" in various places in
the specification are not necessarily all referring to the same
embodiment.
[0013] Directional and/or relationary terms such as, but not
limited to, left, right, nadir, apex, top, bottom, vertical,
horizontal, back, front and lateral are relative to each other and
are dependent on the specific orientation of an applicable element
or article, and are used accordingly to aid in the description of
the various embodiments and are not necessarily intended to be
construed as limiting.
[0014] The term "coupled" refers to two or more elements that are
connected together but not necessarily directly connected
together.
[0015] The term "about" unless otherwise specifically indicated
herein means plus or minus 10%.
One Embodiment Outdoor Stadium Seat
[0016] Referring to FIG. 1, an outdoor stadium seat 10 according to
one embodiment of the present invention is illustrated as might be
found in a typical baseball, football, soccer or other stadium used
for outdoor events. The seat comprises: a pair of support legs 15
that include integrally formed arm rests 20; a seat bottom 25 with
an associated seat bottom cushioning pad 35; a seat back 30 with an
associated seat back cushioning pad 40.
[0017] The support legs 15 are typically cast or forged steel
although other metals can be used such as aluminum and iron. The
legs are usually painted to prevent corrosion. In most
applications, the base 45 of the legs are bolted to ground surface
therebeneath to support the seat in the upright position, as well
as, to prevent the seat from moving during use. In certain
variations, the support legs may also or alternatively bolt to a
vertical riser behind the seat. As shown, the top ends of the legs
extend above the seat bottom 25 and form arm rests 40. The arm
rests can be padded. An associated pair of legs are spaced from
each other a sufficient distance to permit an associated seat
bottom and seat back 30 to fit therebetween and be secured to both
legs on either side thereof. Although not illustrated, each leg of
the pair may be utilized to support more than a single set of seat
backs and seat bottoms as stadium seats are typically arranged in a
row and all but the end legs will have a set of seat backs and
bottoms attached to both its left and right sides.
[0018] The seat back 30 as illustrated is comprised of a hollow
molded plastic material. Typical plastic materials utilized include
high density polyethylene and polypropylene, although others can be
utilized as well. A colorant is typically added to the plastic
material during fabrication give the seat back a desired color. The
seat back includes one or more mounting locations (not shown)
wherein it is fixedly secured to an associated pair of support legs
15 directly or through the use of suitable brackets. On the front
face of the seat back a plurality of holes 50 are arranged in a
generally rectangular pattern spaced inwardly of the edges of the
seat back. These holes are used for securing the seat back's
associated cushioning pad 40 to the seat back by way of a
corresponding plurality of plastic ratchet fasteners 55 of the
cushioning pad as shown in FIG. 2.
[0019] The seat bottom 25 typically comprises a hollow molded
plastic seating member similar in materials and construction as the
associated seat back. However, the seat bottom also typically
includes swivel mechanisms on either side of the plastic seating
member that permits the seat bottom to be pivoted between a
generally horizontal position when in use and a generally
vertically disposed position when not in use. The swivel mechanisms
(not shown) often include a biasing mechanism to return the seat
bottom to its vertical position when it is not in use and stops to
fully support the seat bottom and the weight of a user. While the
swivel mechanisms can be a component of the seat bottom, they can
also be integrated into the support legs 15. In other embodiments,
the swivel mechanisms can be dispensed with entirely and the seat
bottom can be fixedly secured to the support legs such that the
seat bottom cannot be pivoted.
[0020] Referring specifically to FIG. 2, the top face of the seat
bottom 25 includes a plurality of holes 60 are arranged in a
generally rectangular pattern spaced inwardly of the edges of the
seat bottom. These holes are used for securing the seat back's
associated cushioning pad 35 to the seat back by way of a
corresponding plurality of plastic ratchet fasteners 55 of the
cushioning pad.
[0021] A typical cushioning pad 35 or 40 for either the seat bottom
or the seat back is illustrated in FIGS. 3 and 4. It is to be
appreciated that either cushioning pad will be generally similar to
each other differing only in size and the positioning and number of
ratchet fasteners. The cushioning pad is preferably 0.5'' to 2''
thick and more preferably 0.75-1.25'' thick. The cushion pad
comprises polyurethane foam 65 that forms a tough skin 70 during
fabrication against the outside surfaces of an associated mold.
Preferably, the foam sans the skin has a density of about 8-16
pounds per cubic feet and more preferably 10-14 pounds per cubic
foot, and most preferably about 12 pounds per cubic foot. The skin,
which is typically about 0.090-0.135'' thick, is substantially
denser preferably having a density of 40-90 pounds per cubic foot
and more preferably 60-70 pound per cubic foot. Because the skin
and the foam are integrally formed, the skin is integrated with the
foam. Accordingly, a tear or puncture to the cushioning pad does
not cause the skin to separate from the underlying foam. Further,
the foam located beneath and immediately proximate the tear or
puncture acts to pull the edges of the skin at the tear or puncture
together. Additionally, the underlying foam helps limit the
expansion or growth of a tear. A foam pad exhibiting aforementioned
properties is often referred to in the art as being self healing
since (i) the edges of a puncture or tear are pulled back together
such that the puncture or tear may not be particularly visible, and
(ii) the structure of the pad effectively limits the growths of
tears and punctures thereby limiting the life span reducing effect
of a tear or puncture.
[0022] In some embodiments of the cushioning pad, an
ultraviolet-resistant aliphatic polyurethane layer covers the skin
of the entire foam pad. This coating imparts resistance to
ultraviolet radiation that would otherwise cause the underlying
polyurethane material to degrade much more quickly when exposed to
sunlight. The aliphatic layer bonds with the skin during pad
formation and once the fabrication process is complete is
inseparably bonded to the skin. The aliphatic layer is preferably
0.004-0.007'' thick and more preferably 0.005-0.006'' thick. The
aliphatic layer has extremely good elongation (about 600%) and
flexibility, thereby helping ensure its integrity is maintained and
the underlying foam pad is protected.
[0023] A plurality of plastic ratchet fasteners 55 extend generally
perpendicularly outwardly from the lower or rear faces of the
respective seat bottom and seat back cushioning pads. As best
illustrated in FIG. 4, the flared button heads 75 of the fasteners
are secured under the skin of the pad. Essentially, the skin and
the associated pads of the foam are molded around the plurality of
button heads to secure them to the pad. The shank 80 of the
fastener comprises a plurality of thin generally annular disks 85
that extend radially outwardly of a central shaft. The outside
diameters of the annular disks are greater than the corresponding
holes in the respective seat back and bottom. One plastic ratchet
fastener includes Cat. No. PC47617 available from Index Fasteners,
Inc. of Ontario, Calif. It is to be appreciated that the annular
disks of the referenced fastener are not fully annular as opposing
coaxial grooves extend along the length of the shank essentially
splitting each annular disk into two.
[0024] The cushioning pad is coupled to the respective seat back or
seat bottom by pushing the pad's ratchet fasteners into the
corresponding holes in the seat back or seat bottom as illustrated
in FIG. 2. The annular disks flex inwardly when pushed into a
corresponding hole and once fully pushed through the hole, they
spring back to prevent the fastener from being easily pulled from
the hole.
Fabrication of a Cushioning Pad According to One Embodiment of the
Present Invention
[0025] The cushion pad with integrated fasteners is produced using
a self-skinning polyurethane foam in a pressure sealed clam shell
mold. One preferred fabricator is Universal Urethanes, Inc. of Las
Vegas, Nev.
[0026] Initially, prior to producing a cushioning pad, the interior
surfaces of the top and bottom portions of the clam shell mold are
treated with a release agent to prevent the pad from sticking to
the mold during removal therefrom. Depending on the particular
release agent used, the mold may require periodic reapplication of
the release agent after a certain number of cushioning pads are
produced.
[0027] Next, an aliphatic polyurethane coating is sprayed onto the
interior surfaces and permitted to dry. Prior to spraying the
aliphatic coating, the coating can be compounded with a desired
colorant the ratchet fasteners are placed into openings on one side
of the clam shell. The button heads of the fasteners are placed in
one half of the mold offset inwardly of the mold's interior
surfaces by about 0.12'' to 0.25'' to provide space between the
interior side of the button head and the interior surface of the
mold in which a skin can form to secure and hold the fastener in
place.
[0028] The proper ratios of MBI isocyanate and resin polyol are
then metered into the mold as would be obvious to one with ordinary
skill in the art to produce a self skinning foam pad of the
specifications indicated above. Prior to metering one or both the
components are also compounded with a desired colorant. The top and
bottom portions of the clam shell mold are married and clamped
together. The mold is warmed to about 100 degrees Fahrenheit to
speed and facilitate the chemical reaction between the two
components.
[0029] The reaction typically requires about 20 minutes to
complete. During the reaction both solid polyurethane and a
reaction gas are produced. The reaction gas causes the polyurethane
to foam. Because the mold is sealed, high pressures build up in the
mold and the polyurethane proximate the mold surfaces is compressed
against the mold surfaces forming a skin. The polyurethane skin
while still viscous is also forced between the bottoms of the
ratchet fasteners and the adjacent corresponding surfaces of the
mold to effective secure the fasteners in place. Once the cure is
complete, the cushioning pad is removed from the mold.
Retrofitting Outdoor Stadium Seating
[0030] One application of embodiments of the cushioning pad 35
& 40 is to retrofit stadium seats that have prior art seat
bottom and seat back cushions installed thereon. Initially, the
current stadium seating is examined to determine the means by which
the prior art cushioning is secured to the seat bottoms and/or
backs. While in many instances, the prior art cushioning will be
attached using ratchet fasteners, it is appreciated that other
means can be used as well including but not limited to snaps,
adhesives, threaded bosses, and screws. The configuration and
number of the attachment means is determined along with the
dimensions of the cushioning.
[0031] Molds for the seat bottom and/or seat back cushioning are
designed and produced based on the information gathered concerning
the prior art cushioning and the associated seats. The molds are
configured to receive and permit the polyurethane material to mold
around the appropriate type of attachment means. In the case where
cushioning for adhesive bonding to the seat is being molded, the
surface of the mold corresponding to the cushioning pad's back or
rear face may be left flat or ridges or other formation may be
placed on the mold surface to provide divots or channels in which
an adhesive can be received to facilitate installation of the new
cushioning pad.
[0032] The appropriate colorant additive is chosen and compounded
with the polyurethane components to give the resulting cushioning
pads a desired color. Typically, although not necessarily, the pads
will be matched to one or both the color of the seats which are
being retrofitted or the cushioning that is being replaced.
[0033] Next, the cushioning pads are produced in the necessary
quantities to retrofit the stadium or a section thereof typically
using the process described above.
[0034] The old cushioning is removed from the applicable seating
and the replacement cushioning pads are installed as a made to fit
replacement. Periodically, the cushioning pads are inspected by the
stadium maintenance crew, but the frequency of such inspection can
be reduced given the greater longevity and durability of the
replacement cushioning pads.
[0035] Embodiments of the cushioning pads can also be used to
retrofit stadium seating that was not previously cushioned. In this
instance, the size and shape of the cushioning pads would be
determined based on the size and shape of the targeted seat backs
and seat bottoms. Also, the number and type of attachment means is
determined based on the seat back's and bottom's configuration.
Typically, where the seat backs and bottoms comprise a hollow
molded plastic material, ratchet fasteners will be utilized;
however, in certain situations or were other types of seat backs
and/or bottoms are used different attachment means may be
necessitated. For instance, when fitting cushioning pads to wood
slat backs or bottoms, ratchet fasteners which are generally
designed to be secured to thin planar substrates may not be
suitable in a thick piece of wood. In such an instance, snap
fasteners or threaded bosses that receive screws therein from the
opposite side of the respective seat back or bottom can be
utilized.
[0036] When the seats have not been previously fitted with
cushioning, the backs and bottoms will have to be configured to
accept the cushioning pads. When ratchet fasteners are utilized,
the surfaces of the seat backs and seat bottoms need only be
drilled in the appropriate locations to correspond to the fasteners
on the associated cushioning pad. However, once the seats are
configured, the cushioning pads can be installed in essentially the
same manner as indicated above when prior art cushioning is being
replaced.
Alternative Embodiments and Other Variations
[0037] The embodiments of the exercise device as illustrated in the
accompanying figures and described above are merely exemplary and
are not meant to limit the scope of the invention. It is to be
appreciated that numerous variations to the invention have been
contemplated as would be obvious to one of ordinary skill in the
art with the benefit of this disclosure. All variations of the
invention that read upon the appended claims are intended and
contemplated to be within the scope of the invention.
[0038] Although self-skinning polyurethane foam is specified, other
types of self-skinning polymeric foam materials can be used in
place of the polyurethane. The type of fasteners molded into the
cushioning pad can vary substantially as well as indicated above.
The process used to fabricate embodiments of the cushioning pads as
indicated above can also vary as would be obvious to one of
ordinary skill in the art with the benefit of this disclosure. In
at least one alternative embodiment, the self-skinning cushioning
can be molded directly to a seat back or seat bottom substructure
such that the cushioning is fully integrated with the respective
back or bottom. In such an embodiment, the design of the seat back
or bottom is designed specifically to securely receive the
cushioning thereon. Further, the molds used to fabricate the
cushioning, is designed to receive the seat back or bottom therein
so that the self-skinning foam can form around the respective seat
back or bottom. In another embodiment the seat can comprise bench
seating wherein individual seat bottom cushioning pads are provided
or an elongated seat bottom cushioning pad is provided that spans
all or a significant portion of the bench.
* * * * *