U.S. patent application number 11/760331 was filed with the patent office on 2007-12-13 for chair having removable back or seat cushion assemblies and methods related thereto.
Invention is credited to Nicholas M. Christianson, Mark B. Emge, Shawn R. Harvill.
Application Number | 20070284930 11/760331 |
Document ID | / |
Family ID | 38821161 |
Filed Date | 2007-12-13 |
United States Patent
Application |
20070284930 |
Kind Code |
A1 |
Christianson; Nicholas M. ;
et al. |
December 13, 2007 |
CHAIR HAVING REMOVABLE BACK OR SEAT CUSHION ASSEMBLIES AND METHODS
RELATED THERETO
Abstract
A chair comprising a chair base, a chair frame mounted to the
chair base, a back cushion assembly, and a seat cushion assembly,
along with related methods, is described. The chair frame includes
an upper and lower frame portion. One or both of the back cushion
assembly or the seat cushion assembly can be releasably coupled to
the upper frame portion or the lower frame portion, respectively.
Such releasable coupling can be achieved via one or more
quick-release connectors brought into coupling engagement or
disengagement via a rotational, sliding, or push-button movement.
In varying examples, the back and seat cushion assemblies each
comprise at least one support member and a foam cushion attached
thereto. A downward-oriented surface of the seat cushion support
member can comprise an integrated tool housing to store a connector
actuator tool when not in use.
Inventors: |
Christianson; Nicholas M.;
(Fairway, KS) ; Emge; Mark B.; (Lawrence, KS)
; Harvill; Shawn R.; (Kansas City, KS) |
Correspondence
Address: |
SCHWEGMAN, LUNDBERG & WOESSNER, P.A.
P.O. BOX 2938
MINNEAPOLIS
MN
55402
US
|
Family ID: |
38821161 |
Appl. No.: |
11/760331 |
Filed: |
June 8, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60804363 |
Jun 9, 2006 |
|
|
|
Current U.S.
Class: |
297/440.2 ;
297/440.22 |
Current CPC
Class: |
A47C 31/11 20130101;
A47C 7/742 20130101 |
Class at
Publication: |
297/440.2 ;
297/440.22 |
International
Class: |
A47C 4/02 20060101
A47C004/02 |
Claims
1. A chair comprising: a chair base; a chair frame mounted to the
chair base, the chair frame including an upper frame portion and a
lower frame portion; a back cushion assembly including at least one
back support member and a back cushion attached to the back support
member; and a seat cushion assembly including at least one seat
support member and a seat cushion attached to the seat support
member, the seat cushion assembly releasably attached to the lower
frame portion with at least a first quick-release connector brought
into coupling engagement via a rotational, sliding, or push-button
movement.
2. The chair of claim 1, wherein the back cushion assembly is
releasably attached to the upper frame portion using at least a
second quick-release connector.
3. The chair of claim 2, wherein one or both of the first or second
quick-release connectors are configured to be brought into coupling
engagement via a rotational movement amount of about 720-degrees or
less.
4. The chair of claim 3, wherein one or both of the first or second
quick-release connectors include a 1/4-turn, 1/2-turn, or 3/4-turn
fastener assembly.
5. The chair of claim 1, wherein the first quick-release connector
includes a cam fastener assembly.
6. The chair of claim 1, wherein the first quick-release connector
includes a sliding fastener assembly.
7. The chair of claim 1, wherein the first quick-release connector
includes a push-button fastener assembly.
8. The chair of claim 1, wherein the upper frame portion comprises
a ring-shaped region disposed with a central opening extending
therethrough; and wherein the back cushion assembly is supported
around a peripheral edge by, and coupled to, the ring-shaped frame
region.
9. The chair of claim 1, wherein one or both of the upper frame
portion or the lower frame portion are configured to receive and
support cushion assemblies of at least two different sizes.
10. The chair of claim 1, wherein at least one of the back support
member or the seat support member comprise a cushion stiffener
panel and an outer protective shell.
11. The chair of claim 10, further comprising a lumbar support
assembly, the lumbar support assembly projecting from, and coupled
to, an inward-oriented surface of the outer protective shell
associated with the back support member.
12. The chair of claim 1, further comprising an actuator tool, a
distal end of which is configured to be received by a non-circular
void in a head portion of the first quick-release connector.
13. The chair of claim 12, wherein the at least one seat support
member comprises an integrated tool housing configured to retain
the actuator tool when not in use.
14. A method of manufacture, comprising: forming a chair base;
forming a chair frame, including forming an upper frame portion and
forming a lower frame portion; coupling the chair frame to the
chair base; forming a back cushion assembly, including forming at
least one back support member and forming a back foam cushion;
forming a seat cushion assembly, including forming at least one
seat support member and forming a seat foam cushion; and releasably
coupling one or both of the back cushion assembly to the upper
frame portion or the seat cushion assembly to the lower frame
portion, including rotating, sliding, or push-button activating at
least a first quick-release connector in an engaging direction.
15. The method of claim 14, further comprising forming an actuator
tool having a distal end configured to be received by a head
portion of the first quick-release connector.
16. The method of claim 14, further comprising forming a lumbar
support assembly; and coupling the lumbar support assembly to a
portion of the back cushion assembly.
17. The method of claim 14, wherein forming the chair frame
includes forming an upper frame portion configured to receive and
support a plurality of back cushion assembly sizes.
18. The method of claim 14, wherein forming the chair frame
includes forming a lower frame portion configured to receive and
support a plurality of seat cushion assembly sizes.
19. A method of use, comprising: removing one or both of a first
back cushion assembly or a first seat cushion assembly from a chair
frame, including rotating, sliding, or push-button deactivating at
least one quick-release connector in a disengaging direction; and
releasably coupling at least one of a second back cushion assembly
or a second seat cushion assembly to the chair frame, including
rotating, sliding, or push-button activating at least one
quick-release connector in an engaging direction.
20. The method of claim 19, wherein rotating the at least one
quick-release connector in the disengaging or engaging direction
includes rotating the connector an amount of about 720-degrees or
less.
21. The method of claim 19, wherein rotating the at least one
quick-release connector includes using an actuator tool storable
beneath the first or second seat cushion assembly.
22. The method of claim 21, further comprising storing the actuator
tool on a downward-orientated surface of the first or second seat
cushion assembly.
23. The method of claim 19, wherein releasably coupling at least
one of the second back cushion assembly or second seat cushion
assembly to the chair frame includes releasably coupling at least
one new back or seat cushion assembly to the chair frame.
24. The method of claim 23, wherein releasably coupling the at
least one new back or seat cushion assembly to the chair frame
includes coupling a back or seat cushion assembly having a
different size than a removed back or seat cushion assembly.
25. The method of claim 19, further comprising performing
maintenance on the first back or seat cushion assembly after
removal, including one of cleaning or refurbishing the cushion
assembly.
26. The method of claim 19, wherein releasably coupling at least
one of the second back or seat cushion assembly to the chair frame
includes coupling a cleaned or refurbished cushion assembly to the
chair frame.
Description
PRIORITY OF INVENTION
[0001] This non-provisional application claims the benefit of
priority under 35 U.S.C. .sctn. 119(e) to U.S. Provisional Patent
Application Ser. No. 60/804,363, filed Jun. 9, 2006, which is
herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This patent document pertains generally to office-type
furniture. More particularly, but not by way of limitation, this
patent document pertains to an office-type chair having removable
back or seat cushion assemblies and methods related thereto.
BACKGROUND
[0003] Modern chairs, and particularly office-type chairs, are
typically provided with fabric-covered cushions designed to provide
comfort to an occupant sitting thereon. One problem associated with
fabric-covered cushions is that over time the cushions get dirty,
worn, or damaged, such that they need to be cleaned, repaired, or
replaced. Still other times, the replacement of fabric-covered
cushions may be desired for size-changing, remodeling, or upgrading
purposes. Unfortunately, the fabric-covered cushions of typical
office chairs are permanently attached to an associated chair
frame, and therefore are not easily removable, if at all, for one
or more of the aforementioned desired purposes. For this reason,
currently used chair constructions are often discarded in their
entirety when repair or replacement of the cushions is necessary or
desired.
[0004] Yet another problem associated with many office-type chairs
is that constructions thereof do not allow air to travel through
the associated chair cushions. As a result, the chair occupant may
be left feeling uncomfortably hot at their back or seated regions.
As a further result of no air flow, the cushions may develop a foul
smell over time, such as a stale or musty smell.
[0005] What is needed is a chair having back or seat cushion
assemblies that are easily, quickly, and reliably removable from,
and attachable to, an associated chair frame. What is further
needed is a chair having a conformable, breathable cushion
assembly.
OVERVIEW
[0006] A chair comprising a chair base, a chair frame mounted to
the chair base, a back cushion assembly, and a seat cushion
assembly, along with related methods, is described. The chair frame
includes an upper and lower frame portion. One or both of the back
cushion assembly or the seat cushion assembly can be releasably
coupled to the upper frame portion or the lower frame portion,
respectively. Such releasable coupling can be achieved via one or
more quick-release connectors brought into coupling engagement or
disengagement via a rotational, sliding, or push-button movement.
In varying examples, the back and seat cushion assemblies each
comprise at least one support member and a foam cushion attached
thereto. A downward-oriented surface of the seat cushion support
member can comprise an integrated tool housing to store a connector
actuator tool when not in use.
[0007] In Example 1, a chair comprises a chair base; a chair frame
mounted to the chair base, the chair frame including an upper frame
portion and a lower frame portion; a back cushion assembly
including at least one back support member and a back cushion
attached to the back support member; and a seat cushion assembly
including at least one seat support member and a seat cushion
attached to the seat support member, the seat cushion assembly
releasably attached to the lower frame portion with at least a
first quick-release connector brought into coupling engagement via
a rotational, sliding, or push-button movement.
[0008] In Example 2, the chair of Example 1 is optionally
configured such that the back cushion assembly is releasably
attached to the upper frame portion using at least a second
quick-release connector.
[0009] In Example 3, the chair of Example 2 is optionally
configured such that one or both of the first or second
quick-release connectors are configured to be brought into coupling
engagement via a rotational movement amount of about 720-degrees or
less.
[0010] In Example 4, the chair of Example 3 is optionally
configured such that one or both of the first or second
quick-release connectors include a 3/4-turn, 1/2-turn, or 3/4-turn
fastener assembly.
[0011] In Example 5, the chair of at least one of Examples 1-4 is
optionally configured such that the first quick-release connector
includes a cam fastener assembly.
[0012] In Example 6, the chair of at least one of Examples 1-5 is
optionally configured such that the first quick-release connector
includes a sliding fastener assembly.
[0013] In Example 7, the chair of at least one of Examples 1-6 is
optionally configured such that the first quick-release connector
includes a push-button fastener assembly.
[0014] In Example 8, the chair of at least one of Examples 1-7 is
optionally configured such that the upper frame portion comprises a
ring-shaped region disposed with a central opening extending
therethrough, and the back cushion assembly is supported around a
peripheral edge by, and coupled to, the ring-shaped frame
region.
[0015] In Example 9, the chair of at least one of Examples 1-8 is
optionally configured such that one or both of the upper frame
portion or the lower frame portion are configured to receive and
support cushion assemblies of at least two different sizes.
[0016] In Example 10, the chair of at least one of Examples 1-9 is
optionally configured such that at least one of the back support
member or the seat support member comprise a cushion stiffener
panel and an outer protective shell.
[0017] In Example 11, the chair of Example 10 optionally comprises
a lumbar support assembly, the lumbar support assembly projecting
from, and coupled to, an inward-oriented surface of the outer
protective shell associated with the back support member.
[0018] In Example 12, the chair of at least one of Examples 1-11
optionally comprises an actuator tool, a distal end of which is
configured to be received by a non-circular void in a head portion
of the first quick-release connector.
[0019] In Example 13, the chair of Example 12 is optionally
configured such that the at least one seat support member comprise
an integrated tool housing configured to retain the actuator tool
when not in use.
[0020] In Example 14, a method of manufacture comprises forming a
chair base; forming a chair frame, including forming an upper frame
portion and forming a lower frame portion; coupling the chair frame
to the chair base; forming a back cushion assembly, including
forming at least one back support member and forming a back foam
cushion; forming a seat cushion assembly, including forming at
least one seat support member and forming a seat foam cushion; and
releasably coupling one or both of the back cushion assembly to the
upper frame portion or the seat cushion assembly to the lower frame
portion, including rotating, sliding, or push-button activating at
least a first quick-release connector in an engaging direction.
[0021] In Example 15, the method of Example 14 optionally comprises
forming an actuator tool having a distal end configured to be
received by a head portion of the first quick-release
connector.
[0022] In Example 16, the method of at least one of Examples 14-15
optionally comprises forming a lumbar support assembly; and
rotatably coupling the lumbar support assembly to a portion of the
back cushion assembly.
[0023] In Example 17, the method of at least one of Examples 14-16
is optionally configured such that forming the chair frame includes
forming an upper frame portion configured to receive and support a
plurality of back cushion assembly sizes.
[0024] In Example 18, the method of at least one of Examples 14-17
is optionally configured such that forming the chair frame includes
forming a lower frame portion configured to receive and support a
plurality of seat cushion assembly sizes.
[0025] In Example 19, a method of use comprises removing one or
both of a first back cushion assembly or a first seat cushion
assembly from a chair frame, including rotating, sliding, or
push-button deactivating at least one quick-release connector in a
disengaging direction; and releasably coupling at least one of a
second back cushion assembly or a second seat cushion assembly to
the chair frame, including rotating, sliding, or push-button
activating at least one quick-release connector in an engaging
direction.
[0026] In Example 20, the method of Example 19 is optionally
configured such that rotating the at least one quick-release
connector in the disengaging or engaging direction includes
rotating the connector an amount of 720-degrees or less.
[0027] In Example 21, the method of at least one of Examples 19-20
is optionally configured such that rotating the at least one
quick-release connector includes using an actuator tool storable
beneath the first or second seat cushion assembly.
[0028] In Example 22, the method of Example 21 optionally comprises
storing the actuator tool on a downward-orientated surface of the
first or second seat cushion assembly.
[0029] In Example 23, the method of at least one of Examples 19-22
is optionally configured such that releasably coupling at least one
of the second back cushion assembly or second seat cushion assembly
to the chair frame includes releasably coupling at least one new
back or seat cushion assembly to the chair frame.
[0030] In Example 24, the method of Example 23 is optionally
configured such that releasably coupling the at least one new back
or seat cushion assembly to the chair frame includes coupling a
back or seat cushion assembly having a different size than a
removed back or seat cushion assembly.
[0031] In Example 25, the method of at least one of Examples 19-24
optionally comprises performing maintenance on the first back or
seat cushion assembly after removal, including one of cleaning or
refurbishing the cushion assembly.
[0032] In Example 26, the method of at least one of Examples 19-25
is optionally configured such that releasably coupling at least one
of the second back or seat cushion assembly to the chair frame
includes coupling a cleaned or refurbished cushion assembly to the
chair frame.
[0033] The chair constructions and method discussed herein may
overcome many deficiencies of current chair constructions and
methods. As one example, the present chair constructions provide a
chair having back or seat cushion assemblies that are easily,
quickly, and reliably removable from, or attachable to, an
associated chair frame. In addition, the present chair
constructions advantageously provide a breathable seat cushion
assembly. A breathable seat cushion assembly allows air to flow
through a foam seat cushion, and thereby may provide conforming
comfort and cooling to an occupant. Further, the breathable seat
cushion assembly allows fresh air to flow therethrough. These and
other examples, advantages, and features of the present chair
constructions and methods will be set forth, in part, in the
detailed description that follows, and in part, will become
apparent to those skilled in the art by reference to the following
description, claims, and appended drawings or by practice of the
same.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] In the drawings, which are not necessarily drawn to scale,
like numerals describe similar components throughout the several
views. The drawings illustrate generally, by way of example, but
not by way of limitation, various embodiments discussed in the
present document.
[0035] FIG. 1A is a front isometric view of a chair, as constructed
in accordance with at least one embodiment.
[0036] FIG. 1B is a rear isometric view of a chair, as constructed
in accordance with at least one embodiment.
[0037] FIG. 2 is a front isometric view of another chair, as
constructed in accordance with at least one embodiment.
[0038] FIG. 3 is a rear isometric view of a back cushion assembly,
an upper chair frame portion, and one or more quick-release
connectors, as constructed in accordance with at least one
embodiment.
[0039] FIG. 4A is a rear view of a back cushion assembly and an
upper chair frame portion, as constructed in accordance with at
least one embodiment.
[0040] FIG. 4B is a side exploded view of a back cushion assembly,
an upper chair frame portion, and one or more quick-release
connectors, as constructed in accordance with at least one
embodiment.
[0041] FIG. 5 is an underside isometric view of a seat cushion
assembly, a lower frame portion, and one or more quick-release
connectors, as constructed in accordance with at least one
embodiment.
[0042] FIG. 6A is a side exploded view of a seat cushion assembly,
a lower chair frame portion, and one or more quick-release
connectors, as constructed in accordance with at least one
embodiment.
[0043] FIG. 6B is an underside view of a seat cushion assembly, as
constructed in accordance with at least one embodiment.
[0044] FIG. 6C is an underside view of a seat cushion assembly and
a lower chair frame portion, as constructed in accordance with at
least one embodiment.
[0045] FIG. 7A is an isometric view of a lower chair frame portion,
as constructed in accordance with at least one embodiment.
[0046] FIG. 7B is a top view of a lower chair frame portion, as
constructed in accordance with at least one embodiment.
[0047] FIG. 7C is an underside view of a lower chair frame portion,
as constructed in accordance with at least one embodiment.
[0048] FIG. 8 is an isometric view of an actuator tool for use with
one or more quick-release connectors, as constructed in accordance
with at least one embodiment.
[0049] FIG. 9 is a sectional view of a quick-release connector, a
chair frame portion, and a cushion assembly portion, as constructed
in accordance with at least one embodiment.
[0050] FIG. 10 is an isometric view of a quick-release connector
including a first member integratable with a chair frame portion
and a second member integratable with a cushion assembly, as
constructed in accordance with at least one embodiment.
[0051] FIG. 11 is a sectional view of a quick-release connector, a
chair frame portion, and a cushion assembly portion, as constructed
in accordance with at least one embodiment.
[0052] FIG. 12 illustrates a method of manufacturing a chair, as
constructed in accordance with at least one embodiment.
[0053] FIG. 13 illustrates a method of disassembling and
reassembling a chair, as constructed in accordance with at least
one embodiment.
DETAILED DESCRIPTION
[0054] The following detailed description includes references to
the accompanying drawings, which form a part of the detailed
description. The drawings show, by way of illustration, specific
embodiments in which the present chair constructions and methods
may be practiced. These embodiments, which are also referred to
herein as "examples," are described in enough detail to enable
those skilled in the art to practice the present chair
constructions and methods. The embodiments may be combined, other
embodiments may be utilized or structural and logical changes may
be made without departing from the scope of the present chair
constructions and methods. It is also to be understood that the
various embodiments of the present chair constructions and methods,
although different, are not necessarily mutually exclusive. For
example, a particular feature, structure or characteristic
described in one embodiment may be included within other
embodiments. The following detailed description is, therefore, not
to be taken in a limiting sense, and the scope of the present chair
constructions and methods are defined by the appended claims and
their legal equivalents.
[0055] In this document the terms "a" or "an" are used to include
one or more than one; the term "or" is used to refer to a
nonexclusive or, unless otherwise indicated; the terms "upwardly,"
"downwardly," "inwardly," and "outwardly," or variants thereof,
refer to directions with respect to the geometric center of the
present chair; and the terms "front" and "rear" refer to directions
with respect to an occupant seated in the present chair. In
addition, it is to be understood that the phraseology or
terminology employed herein, and not otherwise defined, is for the
purpose of description only and not of limitation.
[0056] The chair constructions and methods discussed herein
advantageously provide back or seat cushion assemblies that are
easily and quickly removable from, and attachable to, an associated
chair frame. The removability and attachment of the cushion
assemblies from or to the chair frame, respectively, comes by way
of one or more quick-release connectors, such as 1/4-, 1/2-, or
3/4-turn fasteners, cam fasteners, sliding fasteners, or
push-button fasteners. Through simple rotational, sliding, or
push-button activating movement of the one or more quick-release
connectors, for example, the cushion assemblies may be quickly
removed from the chair frame for cleaning, repairing, or
replacement, and thereafter reattached to the chair frame for
occupant use. In addition, the present chair constructions and
methods provide a breathable seat cushion assembly providing the
comfort of foam, while still allowing air to flow into and out of
the foam to and from the surrounding atmosphere. As a result of the
air flow allowance, the seat cushion assembly is able to assume its
preformed configuration when an occupant leaves the seat and
provide a cooling means to the occupant when seated.
[0057] Reference is now made to the drawings, and initially to
FIGS. 1A-1B, which illustrate isometric views of one example of an
office-type chair 100 according to the present subject matter. As
shown, the chair includes a chair base 102, a chair frame 104, a
back cushion assembly 106, and a seat cushion assembly. Optionally,
the chair can further include adjustable arm supports 110, such as
a left and a right adjustable arm support, or a head-rest support
112. As shown, the adjustable arm supports 110 can be disposed on
opposite sides 150, 152 of the chair projecting in an upward
orientation, while the head-rest support can be disposed on a top
side 154 of the back cushion assembly 106.
[0058] In this example, but not limited thereto, the chair base 102
includes a plurality of leg members 114 each having a caster or
roller wheel 116 disposed at a respective outer end thereof. The
caster or roller wheels 116 provide rolling support to the chair
100. In some examples, the chair base 102 includes a simple support
structure without caster or roller wheels. At the center of the
chair base 102 is an upwardly projecting pedestal 120, such as a
pneumatic height-adjusting cylinder. The pneumatic height-adjusting
cylinder can be manipulated via a height-adjusting handle 130. An
upper portion of the pedestal 120 connects to a box-like control
housing 122 to which an upper 124 (FIG. 1B) and a lower 126 (FIG.
1B) portion of the chair frame 104 are mounted. In one example,
portions of the chair frame 104 are composed of aluminum, which is
lightweight, strong, and offers long life. A region substantially
approximating an L-shape 402 (FIG. 4B) couples the upper frame
portion 124 to the control housing 122, while a downward-oriented
surface 702 (FIG. 7A) of the lower frame portion 126 (e.g., a seat
receptacle) couples the lower frame to the control housing 122.
Among other things, the control housing 122 can house therein a
tilt control mechanism, such as a synchro-tilt control mechanism,
permitting vertical rearward tilting of the back cushion assembly
106 and attached upper frame portion 124 via manipulation of a tilt
control handle 132.
[0059] FIG. 2 illustrates an isometric view of another example of
an office-type chair 100, according to the present subject matter.
The chair 100 in this example, unlike the chair examples of FIGS.
1A, 1B, does not include a head-reset assembly 112. As shown, the
chair 100 includes, among other things, a back cushion assembly
106, a seat cushion assembly 108, and a chair frame 104. As
discussed in greater detail below, particularly with respect to
FIGS. 4B and 6A, both the back cushion assembly 106 and the seat
cushion assembly 108 include at least one back support member and a
cushion, such as a foam cushion, attached to an inward-oriented
surface of the support member. Foam cushions advantageously adjust
to a unique shape of an occupant's body, thereby providing comfort
to the occupant while seated in the chair 100. As also discussed in
greater detail below, at least one of the back and seat cushion
assemblies 106, 108, respectively, are releasably coupled to the
chair frame 104 via one or more quick-release connectors, such as
1/4-, 1/2-, or 3/4-turn fasteners. Other quick-release connectors
include cam fasteners, sliding fasteners, push-button fasteners or
the like.
[0060] The example arrangement of FIG. 3 illustrates an upper
portion of a chair 100 according to the present subject matter, and
particularly illustrates an exploded view of a back cushion
assembly 106, an upper frame portion 124, and one or more
rotational quick-release connectors 302 for coupling between the
same. The back cushion assembly 106, by way of rotating the one or
more quick-release connectors 302, can be releasably attached to
the upper frame portion 124. In various examples, the upper frame
portion 124 is configured to receive and support different sized
back cushion assemblies to accommodate a wide range of users. The
rotation of the one or more quick-release connectors 302 can be
made using an actuator tool 800 (FIG. 8) configured to be stored on
an underside of the chair 100 (see, e.g., FIG. 5).
[0061] One or more connector receptacles 304 are arranged in a
predetermined pattern on an outward-oriented surface 350 of the
back cushion assembly 106 to receive a distal end of the one or
more quick-release connectors 302. The connector receptacles 304
are configured (e.g., include internal threads) to engage the
quick-release connectors 302 when the connectors are rotated in a
first engaging direction (e.g., direction 306 for right-handed
fasteners), such that the back cushion assembly 106 may be securely
attached to the upper frame portion 124. In one example, an amount
of the engaging rotation is 1080-degrees or less, such as about
720-degrees or less or about 360-degrees or less, thereby providing
for quick and easy attachment of the cushion assembly. In a similar
manner, the connector receptacles 304 are configured to disengage
the quick-release connectors 302 when the connectors are rotated in
a second disengaging direction (e.g., direction 308 for
right-handed fasteners), such that the back cushion assembly 106
may be quickly and easily removed for cleaning, repair, or
replacement. In one example, an amount of the disengaging rotation
is 1080-degrees or less, such as about 720-degrees or less or about
360-degrees or less, thereby providing for quick and easy
detachment of the cushion assembly.
[0062] As shown, the upper frame portion 124 can include a
ring-like region 352 disposed in a surrounding relation to a
central opening 312 extending therethrough. In this example, the
back cushion assembly 106 is supported solely around a peripheral
edge thereof by the ring-like frame region. Such construction
transmits transverse loading substantially uniformly outward to the
surrounding ring-like region. Four quick-release connectors 302 and
corresponding receptacles 304 can be disposed at the four corner
locations of the ring-like shape to releasably secure the back
cushion assembly 106 to the upper frame portion 124. A head portion
of the one or more quick-release connectors can include a
non-circular, such as non-standard, void 310 (see also FIG. 4B) to
help prevent unauthorized removal of the back cushion assembly.
Such non-circular void 310 may require a custom-made actuator tool
800 (FIG. 8) to effect rotation of the connectors 302.
[0063] FIG. 4A is a rear unexploded view of an upper portion of a
chair 100 according to the present subject matter, and particularly
illustrates a back cushion assembly 106 and an upper frame portion
124. FIG. 4B illustrates a side exploded view of the back cushion
assembly 106, the upper frame portion 124, and one or more
quick-release connectors 302.
[0064] As shown, the back cushion assembly 106 includes a cushion
404, such as a foam cushion, and at least one back support member,
such as a stiffener panel 406 and an outer protective shell 408.
The cushion 404 is disposed on, and coupled to, an inward-oriented
surface 450 of the stiffener panel 406, such that an
outward-oriented surface 452 of the cushion extends co-extensively
over the panel's inward-facing surface. An outward-oriented surface
454 of the stiffener panel 406 is disposed in abutting relationship
to an inward-oriented surface 456 of the outer protective shell
408. In this example, an outward oriented surface 350 of the outer
protective shell 408 comprises one or more connector receptacles
304 configured to receive and retain a distal portion of one or
more quick-release connectors 302, such as rotatable, slidable, or
push-button fasteners. The connector receptacles 304 can be
separate pieces attached to the outer protective shell 408 via
ultrasonic welding. In this way, the one or more quick-release
connectors 302 can be inserted through the upper frame portion 124
and into the connector receptacles 304, thereby holding the back
cushion assembly 106 to the upper frame portion 124.
[0065] The back cushion assembly 106 can further include a lumbar
support assembly 410. In this example, the lumbar support assembly
410 projects from an inward-oriented surface 456 of the outer
protective shell 408. The lumbar support assembly 410 can provide
the chair 100 with an adjustable arch-shaped lumbar region to help
support an occupant's back. Among other things, the lumber assembly
410 can be pivotally attached to the outer protective shell 408 so
as to fit the occupant's back ergonomically, providing a
comfortable feel to the occupant.
[0066] Material options for the back cushion assembly 106 are
numerous. In one example, the cushion 404 comprises polyurethane
(PU) resilient foam. In another example, the cushion 404 comprises
open-celled foam that is preformed into a specified shape. In yet
another example, the cushion 404 comprises multi-layered foam. The
foam can be aesthetically colored as desired by coloring the foam
itself or covering the foam with a desired colored thin, flexible
upholstery layer. In a further example, one or both of the
stiffener panel 406 and the outer protective shell 408 can comprise
a resilient polymeric material, such a sheet of polypropylene or
similar engineering-type stiff structural material.
[0067] The example arrangement of FIG. 5 illustrates a lower
portion of a chair 100 according to the present subject matter, and
particularly illustrates an exploded view of a seat cushion
assembly 108, a lower frame potion 126, an actuator tool 800, and
one or more quick-release connectors 302. The seat cushion assembly
108, by way of rotating, sliding, or push-button activating the one
or more quick-release connectors 302, can reliably be attached to
the lower frame portion 126. In various examples, the lower frame
portion 126 is configured to receive and support different sized
seat cushion assemblies to accommodate a wide range of users. The
rotation of the one or more quick-release connectors 302 can be
brought about using the actuator tool 800, which is configured to
be stored on an underside of the chair 100 in an integrated tool
housing 502. In one example, the tool housing 502 includes one or
more detents arranged to hold the actuator tool 800. In another
example, the actuator tool is magnetized and is held within the
tool housing 502 using one or more magnets. In yet another example,
the actuator tool 800 is held within the tool housing 502 using a
hook-and-loop arrangement.
[0068] One or more connector receptacles 304 are arranged in a
predetermined pattern on a downward-oriented surface 550 of the
seat cushion assembly 108 to receive a distal end of the one or
more quick-release connectors 302. The connector receptacles 304,
in one example, are configured (e.g., include internal threads) to
engage the quick-release connectors 302 when the connectors are
rotated in a first engaging direction (e.g., direction 306 for
right-handed fasteners), such that the seat cushion assembly 108
may be securely attached to the lower frame portion 126. In a
similar manner, the connector receptacles 304 are configured to
disengage the quick-release connectors 302 when the connectors are
rotated in a second disengaging direction (e.g., direction 308 for
right-handed fasteners), such that the seat cushion assembly 108
may be quickly and easily removed for cleaning, repair, or
replacement. In this example, two quick-release connectors 302 and
corresponding receptacles are disposed at a front edge of the seat
cushion assembly 108, while two tabs 508 (see also FIG. 6C) are
disposed at a back edge of the seat assembly to releasably secure
the seat cushion assembly 108 to the lower frame portion 126.
[0069] As shown and further discussed below, the lower frame
portion 126 includes one or more air-venting passages 504 allowing
surrounding air to enter and exit the seat cushion assembly 108,
and more specifically a cushion 602 (FIG. 6C) of the assembly. As
discussed, a breathable seat cushion assembly 108, among other
things, allows air to flow through a foam seat cushion, and thereby
may provide conforming comfort and cooling to an occupant. In
addition, the breathable seat cushion assembly 108 allows fresh air
to flow therethrough. Further, the breathability of the seat
cushion assembly 108 allows the foam cushion 602 to return to a
preformed configuration when an occupant leaves the seat (i.e.,
after conforming to a unique profile of the occupant).
[0070] FIG. 6A illustrates a side exploded view of an air-permeable
seat cushion assembly 108, a lower frame portion 126, and one or
more quick-release connectors 302. As shown, the seat cushion
assembly 108 includes a cushion 602, such as a foam cushion, and at
least one seat support member, such as a stiffener panel 604 and an
outer protective shell 606. The foam cushion 602 includes a
plurality of projections 608 extending downward, each of the
projections separated by a valley-like region 610. Among other
things, the projections 608 facilitate the breathability of the
seat cushion 602, specifically the intake and discharge of air from
and to the surrounding atmosphere. The cushion 602 is disposed on,
and coupled to, an upward-oriented surface 650 of the stiffener
panel 604, such that a downward-oriented surface 652 of the cushion
602 extends co-extensively over the panel's upward-oriented surface
650. The stiffener panel 604 includes a plurality of voids 612
sized and shaped to allow the plurality of projections 608 to
extend therethrough and into projection mating cavities 614 of the
outer protective shell 606. As shown in FIG. 6B, the downward most
portions of the projection mating cavities 614 include one or more
air-venting passages 616.
[0071] A downward-oriented surface 656 of the stiffener panel 604
is disposed in abutting relationship to an upward-oriented surface
658 of the outer protective shell 606. In this example, a
downward-oriented surface 660 of the outer protective shell 606
comprises one or more connector receptacles 304 configured to
receive and retain a distal portion of one or more quick-release
connectors 302. The connector receptacles 304 can be attached to
the outer protective shell 606 via ultrasonic welding or similar
techniques. In this way, the one or more quick-release connectors
302 can be inserted through the lower frame portion 126 and into
the connector receptacles 304, thereby holding the seat cushion
assembly 108 to the lower frame portion 126.
[0072] Material options for the seat cushion assembly 108 are
numerous. In one example, the cushion 602 comprises polyurethane
(PU) resilient foam. In another example, the cushion 602 comprises
open-celled foam that is preformed into a specified shape. In yet
another example, the cushion 602 comprises multi-layered foam. The
foam can be aesthetically colored as desired by coloring the foam
itself or covering the foam with a desired thin, flexible
upholstery layer. In a further example, one or both of the
stiffener panel 604 and the outer protective shell 606 can comprise
a resilient polymeric material, such a sheet of polypropylene or
similar engineering-type stiff structural material.
[0073] FIG. 6B is an underside unexploded view of the seat cushion
assembly 108. As shown, the downward-oriented surface 660 of the
outer protective shell 606 can include an integrated tool housing
502 to retain the actuator tool 800 when not in use. FIG. 6B also
illustrates one or more air-venting passages 616 which, in
combination with the stiffener panel voids 612 and the air-venting
passages 504 of the lower frame portion 126 (FIG. 6C), allow the
seat cushion 602 to breath (i.e., intake and discharge air), as
shown by the air-flow lines 670 in FIG. 6A. FIG. 6C is an underside
unexploded view of the seat cushion assembly 108 and the lower
chair frame portion 126. Advantageously, the seat cushion assembly
108 and lower frame portion 126 illustrated in FIGS. 6A-6C and
discussed in the text associated therewith, allow for a removable
and breathable foam seat cushion.
[0074] FIGS. 7A-7C illustrate various views of one example of a
lower frame portion 126, as constructed in accordance with at least
one example of the present subject matter. More particularly, FIG.
7A illustrates an isometric view of the lower frame portion 126,
FIG. 7B illustrates a top view of the lower frame portion 126, and
FIG. 7C illustrates an underside view of the lower frame portion
126. The upward-oriented portion of the lower frame assembly 126
(FIG. 7B) is configured to receive the seat cushion assembly 108.
The downward-oriented surface of the lower frame assembly 126 (FIG.
7C) is configured to couple to a chair base 102 (FIGS. 1A, 1B),
such as a control housing 122. In one example, but as may vary, the
lower frame portion 126 can comprise aluminum or other metal having
similar characteristics.
[0075] FIG. 8 is an isometric view of one example of an actuator
tool 800, which may be used, for instance, to rotate one or more
quick-release connectors 302 (FIG. 3) and thereby remove or attach
a back or seat cushion assembly 106,108 (FIGS. 1A, 1B) from and to,
respectively, a chair frame 104. As shown, the actuator tool 800
can include a distal driving portion 802 configured to mate with a
non-circular void 310 (FIG. 3, FIG. 4B) in a head portion of the
one or more rotatable quick-release connectors 302. In one example,
the distal driving portion 802 includes a non-standard shape (e.g.,
non-flat-head screwdriver like or non-Phillips screwdriver like) to
prevent unauthorized removal of the back or seat cushion assembly
from the chair frame. In another example, but as may vary, the
actuator tool 800 includes a metal insert and a plastic over-mold.
When not in use, the actuator tool 800 can be stored on an
underside of the chair 100 (FIGS. 1A, 1B), such as a
downward-oriented surface of a seat cushion assembly 108 (FIG. 5)
in an integrated tool housing 502.
[0076] FIG. 9 is a sectional view of a quick-release connector, and
more specifically a rotatable cam fastener assembly 900 example,
which can be used to couple a back cushion assembly 106 or a seat
cushion assembly 108 to an upper 124 or lower 126 chair frame
portion, respectively. As shown, the cam fastener assembly 900 can
include a control rod 902, a cam lever 904, and a connector
receptacle nut 906. Attached to one end of the control rod 902 is
the cam lever 904. Attached to the other end of the control rod 902
is the connector receptacle nut 906. In this example, the connector
receptacle nut 906 is embedded in a portion of the back 106 or seat
108 cushion assemblies and includes internal threads configured to
receive external threads of the control rod 902. The back 106 or
seat 108 cushion assemblies are removed from the upper 124 or lower
126 chair frame portion in a quick-release manner by opening the
cam lever 904, such as in direction 908. A similar, but reversed
operation is used for cushion assembly attachment. Other cam
fastener assemblies including one or both of a rotating or sliding
component which transforms rotary motion into linear motion or vice
versa can also be used to couple a back cushion assembly 106 or a
seat cushion assembly 108 to an upper 124 or lower 126 chair frame
portion, respectively.
[0077] FIG. 10 is an isometric view of a quick-release connector,
and more specifically a slidable fastener assembly 1000 example,
which can be used to couple a back cushion assembly 106 or a seat
cushion assembly 108 to an upper 124 or lower 126 chair frame
portion, respectively. As shown, the slidable fastener assembly
1000 includes an elongated track portion 1002 and a slidable
fastener portion 1004. In one example, the elongated track portion
1002 can be integrated with the upper 124 or lower 126 chair frame
portions, while the slidable fastener portion 1004 can be
integrated with the back 106 or seat 108 cushion assemblies. In
this example, the elongated track 1002 is configured to slidably
receive an intermediate portion 1006 of the slidable fastener 1004
between its track rails 1008 and is configured to slidably receive
a retaining portion 1010 of the slidable fastener 1004 within its
track body 1012. The retaining portion 1010 of the slidable
fastener 1004 is sized and shaped to be retained within the track
body 1012, thereby securing the back 106 or seat 108 cushion
assemblies to an upper 124 or lower 126 chair frame portion,
respectively, in a quick and easy manner.
[0078] FIG. 11 is a sectional view of a quick-release connector,
and more specifically a push-button fastener assembly 1100 example,
which can be used to couple a back cushion assembly 106 or a seat
cushion assembly 108 to an upper 124 or lower 126 chair frame
portion, respectively. As shown, the push-button fastener assembly
1100 can include a female portion 1102 and a male portion 1104. In
this example, but not limited thereto, the female portion 1102 is
integrated with the back 106 or seat 108 cushion assemblies, while
the male portion 1104 is integrated with the upper 124 or lower 126
chair frame portion. The female portion 1102 can include a
cylindrical housing 1106 having an open upper end 1108, a closed
lower end 1110, and a cylindrical side wall therebetween 1112. A
bolt 1114 having a seating recess 1116 and a spring 1118
therearound can extend from the closed lower end 1110.
[0079] The male portion 1104 can likewise include a cylindrical
housing 1120 having an open upper end 1122, a closed lower end
1124, and a cylindrical side wall 1126 therebetween. In this
example, the closed lower end 1124 has an aperture therethrough
which connects to an inner cylinder 1128. A movable cam 1130 is
slidably disposed within the open upper end 1122 of the cylindrical
housing 1120.
[0080] The movable cam 1130 has an open lower end 1132 for
receiving the inner cylinder 1128 and a spring 1132 on an upper end
thereof. A set of retaining balls 1234 are disposed within the
movable cam 1130 for engaging the seating recess 1116 of the bolt
1114 of the female portion 1102 when the bolt extends through the
inner cylinder 1128 in the locked orientation. In order to release
the male portion 1204 from the female portion 1202 in a
quick-release manner, and thus release the back 106 or seat 108
cushion assemblies from the upper 124 or lower 126 chair frame
portion, the cam 1130 can be pushed inwardly against the urging of
the spring 1132 so that the retaining balls 1234 slide outwardly
and subsequently disengage the seating recess 1116 of the bolt
1114.
[0081] FIG. 12 illustrates one example of a method 1200 of
manufacturing a chair. At 1202, a chair base is formed. In one
example, the chair base includes multiple legs and a pedestal
projecting upward from a center of the multitude of legs. Forming
the chair base can further include forming a control housing
mounted to the top of the pedestal. In another example, each leg
includes a wheel at an outer end thereof for providing rolling
support to the chair. At 1204, a chair frame including an upper
frame portion and a lower frame portion is formed. In one example,
forming the upper frame portion comprises forming a ring-shape
region and a substantially L-shape region. In another example,
forming the lower frame portion comprises forming a seat receptacle
having one or more air-venting passages. At 1206, the chair frame
is coupled to the chair base. In one example, the upper frame
portion is coupled to the control housing by way of the
substantially L-shaped frame region. In another example, the lower
frame portion is coupled to the control housing by way of the seat
receptacle.
[0082] At 1208, a back cushion assembly is formed and releasably
coupled to the chair frame. Forming the back cushion assembly
includes forming at least one back support member and forming a
back foam cushion. In one example, forming the at least one back
support member includes forming a stiffener panel and an outer
protective shell. Releasably coupling the back cushion assembly to
the chair frame can include rotating, sliding, or push-button
activating one or more quick-release connectors in a first engaging
direction. In another example, releasably coupling the back cushion
assembly to the chair frame includes releasably coupling the back
cushion assembly to the ring-shaped frame region.
[0083] In a similar manner to the back cushion assembly, at 1209, a
seat cushion assembly is formed and releasably coupled to the chair
frame. Forming the seat cushion assembly includes forming at least
one seat support member having an integrated tool housing and
forming a seat foam cushion. In one example, forming the at least
one seat support member includes forming a stiffener panel and an
outer protective shell. Releasably coupling the seat cushion
assembly to the chair frame includes rotating, sliding, or
push-button activating one or more quick-release connectors in the
first engaging direction. In another example, forming the seat foam
cushion includes forming a plurality of projections extending from
a downward-oriented surface of the cushion. In yet another example,
releasably coupling the seat cushion assembly to the chair frame
includes releasably coupling the seat cushion assembly to the seat
receptacle.
[0084] At 1210, an actuator tool is optionally formed. Forming the
actuator tool includes forming a shaft distal end configured to be
received by a head portion of the one or more quick-release
connectors. In addition, forming the actuator tool includes forming
the tool to be received in and retained by the tool housing
integrated with the at least one seat support member. At 1212, a
lumbar support assembly is optionally formed and coupled to the
back cushion assembly, and particularly to an inward-oriented
surface of the outer protective shell associated with the back
cushion assembly. At 1214, a left and a right adjustable arm-rest
assembly are optionally formed and coupled to the chair base, and
particularly to the control housing. At 916, a head-rest assembly
is optionally formed and coupled to the back cushion assembly.
[0085] FIG. 13 illustrates one example of a method 1300 of using a
chair, particularly disassembling and reassembling the chair. At
1302, one or both of a first back cushion assembly (if present) or
a first seat cushion assembly is removed from a chair frame.
Removing the first back or seat cushion assembly from the chair
frame includes rotating, sliding, or push-button deactivating one
or more quick-release connectors in a second disengaging direction,
such as by using an actuator tool--a distal end of which is
configured to be received by a head portion of the one or more
quick-release connectors. In one example, the chair includes a
stool or other like structure without an upper back frame portion.
In such an example, it is a first seat cushion assembly which is
removed from the chair frame at 1302. At 1304, maintenance, such as
cleaning or refurbishing, is optionally performed on the first back
and first seat cushion assembly removed from the chair frame.
[0086] At 1306, one or both of a second back cushion assembly or a
second seat cushion assembly is releasably coupled to the chair
frame. Releasably coupling the second back or seat cushion assembly
to the chair frame includes rotating, sliding, or push-button
deactivating the one or more quick-release connectors in a second
disengaging direction using the actuator tool. In one example, the
second back or seat cushion assembly comprises a new cushion
assembly of different size. In another example, the second back or
seat cushion assembly comprises a cleaned or refurbished cushion
assembly. At 1308, the actuator tool is stored on a
downward-oriented surface of the first or second seat cushion
assembly attached to the chair frame.
[0087] The chair constructions and method discussed herein may
overcome many deficiencies of current chair constructions and
methods. As one example, the present chair constructions provide a
chair having back or seat cushion assemblies that are easily,
quickly, and reliably removable from, or attachable to, an
associated chair frame. In addition, the present chair
constructions advantageously provide a breathable seat cushion
assembly. A breathable seat cushion assembly allows air to flow
through a foam seat cushion, and thereby may provide conforming
comfort and cooling to an occupant. Further, the breathable seat
cushion assembly allows fresh air to flow therethrough. As
discussed, the breathable seat cushion assembly may be achieved by
an outer protective shell and lower frame portion, each having one
or more air-venting passages.
[0088] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For instance,
although a majority of the foregoing discusses chair components
individually or in specific combinations, any combination of the
chair components described herein is within the scope of the
present subject matter. In addition, while the above text discusses
and figures illustrate office-type chairs, the present subject
matter is not so limited. Many other chair embodiments and
contexts, such as for non-office environments, will be apparent to
those of skill in the art upon reviewing the above description.
Further, the present chair constructions can include mesh cushion
assemblies in ways similar to their foam counterparts discussed
herein. The scope should, therefore, be determined with reference
to the appended claims, along with the full scope of legal
equivalents to which such claims are entitled.
[0089] The Abstract of the Disclosure is provided to comply with 37
C.F.R. .sctn.1.72(b), requiring an abstract that will allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims.
* * * * *