U.S. patent number 3,669,496 [Application Number 05/094,725] was granted by the patent office on 1972-06-13 for chair and seat and back unit therefor.
This patent grant is currently assigned to American Desk Manufacturing Company. Invention is credited to William A. Chisholm.
United States Patent |
3,669,496 |
Chisholm |
June 13, 1972 |
CHAIR AND SEAT AND BACK UNIT THEREFOR
Abstract
A chair comprises a frame, which may be somewhat flexible, and a
unitary blow-molded plastic seat and back unit including a hollow,
relatively non-bendable seat portion, a hollow, relatively
non-bendable back portion, and a relatively bendable portion
intervening between and connecting the seat and back portions. The
seat and back unit is blow-molded in substantially, i.e. generally,
flat, over-all condition, in which it may be stored and shipped,
and is conditioned for mounting on the chair frame by bending about
the intervening connecting portion. The latter is formed to provide
for controlled bending with avoidance of sharp localized bends, and
to provide for such lateral flexing of the seat and back portions
as to conform to a sitter's position, such as a slouched position,
and to prevent stress-induced edge cracks. The seat and back unit
is attached to the chair frame by bolts engaging internally
threaded fastening elements molded in situ in the plastic unit, the
bolts extending through and beyond the fastening elements and
biting into the plastic to lock the bolts against unintentional
unscrewing.
Inventors: |
Chisholm; William A. (Temple,
TX) |
Assignee: |
American Desk Manufacturing
Company (Temple, TX)
|
Family
ID: |
22246798 |
Appl.
No.: |
05/094,725 |
Filed: |
December 3, 1970 |
Current U.S.
Class: |
297/448.1;
297/452.15; 297/452.65; 297/451.1; 297/451.13; 297/DIG.2;
D6/375 |
Current CPC
Class: |
B29C
49/0031 (20130101); A47C 7/16 (20130101); A47C
5/12 (20130101); Y10S 297/02 (20130101) |
Current International
Class: |
A47C
5/00 (20060101); A47C 5/12 (20060101); A47C
7/02 (20060101); A47C 7/16 (20060101); B29C
49/00 (20060101); A47c 004/02 (); A47c
007/00 () |
Field of
Search: |
;297/445,451,452,454-458
;264/89,93,96,98,294,295,339 ;150/.5 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Nunberg; Casmir A.
Claims
I claim:
1. A chair comprising a supporting frame; an integral blow-molded
seat and back unit comprising a relatively non-bendable hollow seat
portion, a relatively non-bendable hollow back portion, and a
relatively bendable portion intervening between and connecting said
seat and back portions, said relatively bendable portion being of
the same material as and being substantially less in cross section
than said relatively non-bendable seat and back portions; and means
attaching said unit to said frame.
2. A chair according to claim 1 in which said bendable portion is
solid, that is not hollow.
3. A chair according to claim 2 in which said seat portion includes
opposed spaced inner and outer major walls, said back portion
includes opposed spaced inner and outer major walls, and said
bendable portion is constituted by an extension of said inner major
walls from one to the other and an extension of said outer major
walls from one to the other, said extensions being united to each
other to provide said solid bendable portion.
4. A chair according to claim 3 in which said solid bendable
portion is substantially twice as thick as the inner and outer
major walls of said seat and back portions.
5. A chair according to claim 3 in which said solid bendable
portion has a plurality of spaced grooves extending transversely
with respect to the chair.
6. A chair according to claim 5 in which said grooves are in the
part of said solid bendable portion constituted by the extension of
said outer major walls of said seat and back portions.
7. A chair according to claim 5 in which said grooves extend close
to but terminate short of the edges of said solid bendable portion
respectively at the sides of the chair.
8. A chair according to claim 1 in which said seat portion includes
opposed spaced inner and outer major walls, said back portion
includes spaced inner and outer major walls, and said bendable
portion is constituted by an extension of said inner walls from one
to the other and an extension of said outer major walls from one to
the other; and in which the outer major wall of said seat portion
is of undulating peak-and-valley formation, the peaks and valleys
extending transversely with respect to the chair.
9. A chair according to claim 8 in which said frame comprises two
laterally spaced fore-and-aft extending seat portion supporting
members; and in which said seat portion outer major wall has
similarly laterally spaced fore-and-aft extending grooves
respectively receiving said supporting members.
10. A chair according to claim 8 in which said peaks and valleys of
said peak-and-valley formation extend close to but terminate short
of the edges of said seat portion respectively at the sides of the
chair.
11. A chair according to claim 8 in which, in an intermediate part
of said seat portion fore-and-aft of said chair, said seat portion
inner and outer major walls are united or at least touch one
another and in which other parts of said seat portion inner and
outer major walls are spaced from one another.
12. A chair according to claim 1 in which said seat portion
includes inner and outer major walls, said seat portion inner and
outer major walls being united or at least touching one another in
a fore-and-aft intermediate part of said seat portion, said inner
and outer major walls being spaced from and in non-contacting
relation in other parts of said seat portion.
13. A chair according to claim 1 in which each of said seat and
back portions comprises opposed mainly spaced inner and outer major
walls, and said bendable portion is constituted by an extension of
said inner major walls from one to the other and an extension of
said outer major walls from one to the other; and in which the
inner and outer major walls of said back portion are spaced from
one another throughout most of the area of said back portion, said
back portion inner and outer major walls being united in a
relatively small area adjacent to but spaced from the free edge of
said back portion opposite said bendable portion, thereby to
provide a reinforcing box structure extending along said free edge
of said back portion.
14. A chair according to claim 13 in which said extensions of said
inner and outer major walls are united to each other to provide
said bendable portion.
15. A chair according to claim 1 in which said means attaching said
unit to said frame comprises an internally screw threaded member
molded in the material of said unit in axial alignment with an
opening in said material having a diameter less than the diameter
of the screw threads at their roots and substantially equal to the
diameter of said screw threads at their crests; and an externally
threaded fastening screw extending through said frame, threaded
into said internally screw threaded member, and projecting beyond
the latter and into said opening, the threads on the projecting
part of said screw biting into the wall of said opening and thereby
locking said screw against unintentional unscrewing.
16. A chair according to claim 1 in which said frame comprises a
rear upstanding back supporting part and two laterally spaced
fore-and-aft extending seat portion supporting members; and in
which both the seat portion and the back portion of said seat and
back unit include opposed spaced inner and outer major walls, and
said bendable portion is constituted by an extension of said inner
walls from one to the other and an extension of said outer walls
from one to the other; said seat portion being of undulating
peak-and-valley formation with the peaks extending transversely
with respect to the chair, the outer major wall of said seat
portion having two laterally spaced fore-and-aft extending grooves
respectively receiving said seat portion supporting members of said
frame; the outer major wall of said back portion being grooved
vertically to receive said frame rear upstanding back supporting
part; and said bendable portion being flexible substantially in all
directions, whereby to enable said seat portion to adjust in
position so as comfortably to accommodate a sitter sitting in such
position that the sitter's weight would not otherwise be evenly
distributed on said seat portion, as when sitting in a slouched or
non-erect position.
17. A chair according to claim 16 in which said chair frame is
resilient.
18. A chair according to claim 16 in which the inner and outer
major walls of said back portion are more widely spaced from each
other in sections extending along the side and top edges of said
back portion than in the area surrounded by said sections and said
bendable portion.
19. A chair according to claim 16 in which said solid bendable
portion has a plurality of spaced grooves in the part of said
bendable portion constituted by the extension of said outer major
walls, said grooves extending transversely with respect to the
chair and terminating close to but short of the sides of said
bendable portion, thereby leaving ungrooved marginal edge lips
providing for evenly resisted bending of said bendable portion
without localized sharp bending thereof.
20. An integral blow-molded seat and back unit for a chair, said
unit comprising a relatively non-bendable hollow seat portion; a
relatively non-bendable hollow back portion; and a relatively
bendable portion intervening between and connecting said seat and
back portions, said relatively bendable portion being of the same
material as and being substantially less in cross section than said
relatively non-bendable seat and back portions.
21. Seat and back unit according to claim 20 in which said bendable
portion is solid, that is not hollow.
22. Seat and back unit according to claim 21 in which said seat
portion includes opposed spaced inner and outer major walls, said
back portion includes opposed spaced inner and outer major walls,
and said bendable portion is constituted by an extension of said
inner major walls from one to the other and an extension of said
outer major walls from one to the other, said extensions being
united to each other to provide said solid bendable portion.
23. Seat and back unit according to claim 22 in which said solid
bendable portion is substantially twice as thick as the inner and
outer major walls of said seat and back portion.
24. Seat and back unit according to claim 22 in which said solid
bendable portion has a plurality of spaced grooves extending
transversely with respect to said unit.
25. Seat and back unit according to claim 24 in which said grooves
are in the part of said solid bendable portion constituted by the
extension of said outer major walls of said seat and back
portions.
26. Seat and back unit according to claim 25 in which said grooves
extend close to but terminate short of the longitudinal edges of
said solid bendable portion.
27. Seat and back unit according to claim 20 in which said seat
portion includes opposed spaced inner and outer major walls, said
back portion includes spaced inner and outer major walls, and said
bendable portion is constituted by an extension of said inner walls
from one to the other and an extension of said outer major walls
from one to the other; and in which the outer major wall of said
seat portion is of undulating peak-and-valley formation, the peaks
and valleys extending transversely with respect to said unit.
28. Seat and back unit according to claim 27 in which said peaks
and valleys of said peak-and-valley formation extend close to but
terminate short of the edges of said seat portion respectively at
the sides of said unit.
29. Seat and back unit according to claim 27 in which, in an
intermediate part of said seat portion fore-and-aft of said chair,
said seat portion inner and outer major walls are united or at
least touch one another and in which other parts of said seat
portion inner and outer major walls are spaced from one
another.
30. Seat and back unit according to claim 20 in which said seat
portion includes inner and outer major walls, said seat portion
inner and outer major walls being united or at least touching one
another in a fore-and-aft intermediate part of said seat portion,
said inner and outer major walls being spaced from and in
non-contacting relation in other parts of said seat portion.
31. Seat and back unit according to claim 20 in which each of said
seat and back portions comprises opposed mainly spaced inner and
outer major walls, and said bendable portion is constituted by an
extension of said inner major walls from one to the other and an
extension of said outer major walls from one to the other; and in
which the inner and outer major walls of said back portion are
spaced from one another throughout most of the area of said back
portion, said back portion inner and outer major walls being united
in a relatively small area adjacent to but spaced from the free
edge of said back portion opposite said bendable portion, thereby
to provide a reinforcing box structure extending along said free
edge of said back portion.
32. Seat and back unit according to claim 20 in which said seat and
back portions both include opposed spaced inner and outer major
walls and said bendable portion is constituted by an extension of
said inner walls from one to the other and an extension of said
outer walls from one to the other, said inner and outer major walls
of said back portion being more widely spaced from each other in
sections extending along the side and free end edges of said back
portion than in the area surrounded by said sections and said
bendable portion, whereby to provide more stiffness in the
periphery of said back portion than in portions of the central area
thereof.
33. Seat and back unit according to claim 31 in which said
extensions of said inner and outer major walls are united to each
other to provide said bendable portion.
Description
This invention relates to chairs and more particularly to chairs of
the general class comprising a supporting frame and molded plastic
seat and back means mounted on the frame. Chairs of this general
class have been in wide use for many years, one important field
being that of schoolroom furniture. In some previously known chairs
of this general class, the plastic seats and backs have been molded
separately and attached separately to the frames. In others, the
seats and backs have been molded unitarily in such angular relation
to each other as to conform to the relative angularity of the frame
seat and back supporting structures. One disadvantage of the known
unitary molding of seats and backs at an angle to one another has
been the size and cost of the molds required. Another and attendant
disadvantage has been the large amount of space required for
storing and/or shipping the unitary seat and back structures before
being assembled to frames. Still further, prior art unitary molded
seat and back structures known to the applicant have lacked the
coexistent properties of flexibility and conformability to certain
positions, such as slouched positions, of sitters, and resistance
to structural failure, such as formulation of stress-induced edge
cracks resulting from flexing.
An object of the invention is to provide a unitary blow-molded
chair seat and back unit free or substantially free from the above
pointed out disadvantages.
Another object of the invention is to provide such unit including a
hollow, relatively non-bendable seat portion, a hollow, relatively
non-bendable back portion, and a relatively bendable portion
intervening between and connecting the seat and back portions.
Another object of the invention is to provide an improved chair
construction including a chair frame and a blow-molded seat and
back unit of the character outlined above.
Another object is to provide an improved, self-locking attachment
of a chair frame to a unitary blow-molded seat and back unit.
A further object of the invention is to provide an improved method
of blow-molding a unitary chair seat and back unit and mounting it
on a chair frame, wherein the unit is molded in generally flat
form, providing for storage and/or shipping with saving in space,
and is then bent to angular form for mounting on the chair
frame.
Other objects will become apparent from a reading of the following
description, the appended claims, and the accompanying drawings, in
which:
FIG. 1 is a perspective view of a chair including an integral
blow-molded seat and back unit embodying the invention;
FIG. 2 is a side elevational view of the chair shown in FIG. 1;
FIG. 3 is an exploded perspective view showing the chair frame and
integral blow-molded seat and back unit in separated relation, the
blow-molded seat and back unit in separated relation, the
blow-molded unit being shown tipped from its normal position of
assembly on the chair better to show its construction;
FIG. 4 is a diagrammatic fragmentary side elevational view of
portions of the seat and back unit, indicating the bending of the
unit from its substantially flat form as molded to its condition
conforming to the chair frame;
FIG. 5 is a section on the line 5--5 of FIG. 2;
FIG. 6 is a section on the line 6--6 of FIG. 2;
FIG. 7 is a section on the line 7--7 of FIG. 2;
FIG. 8 is an enlarged scale plan view of the seat and back unit as
molded in substantially generally flat over-all condition, i.e.
before being bent to conform to the chair frame, showing the
configuration of outer major walls of a seat portion and a back
portion, the outer major wall of the seat portion being that wall
which is to face downwardly when mounted on the chair, and the
outer major wall of the back portion being that portion which is to
face rearwardly when mounted on the chair frame;
FIG. 9 is a longitudinal section on the line 9--9 of FIG. 8;
FIG. 10 is a transverse section on the line 10--10 of FIG. 8;
FIG. 11 is a cross section on the line 11--11 of FIG. 8;
FIG. 12 is a cross section on the line 12--12 of FIG. 8;
FIG. 13 is a cross section on the line 13--13 of FIG. 8;
FIG. 14 is a cross section on the line 14--14 of FIG. 8;
FIG. 15 is a cross section on the line 15--15 of FIG. 8;
FIG. 16 is a cross section on the line 16--16 of FIG. 8;
FIG. 17 is a cross section on the line 17--17 of FIG. 8;
FIG. 18 is a schematic vertical sectional view of molding apparatus
for blow-molding the unitary seat and back unit, two mold halves
being shown separated and a plastic parison being shown in the
process of being extruded between the mold halves;
FIG. 19 is a view similar to FIG. 18, but showing the mold halves
closed upon one another to encompass the extruded parison which is
shown as being partially blown;
FIG. 20 is a view similar to FIG. 19, but showing the parison fully
blown to produce the integral seat and back unit;
FIG. 21 is a view similar to FIG. 20, but showing the mold halves
separated, and the completed seat and back unit therebetween
suspended from the extruding nozzle;
FIG. 22 is an enlarged scale fragmentary detailed sectional view
through part of one of the mold halves and part of the molded unit,
showing a threaded nut molded in place in the seat and back unit
after having been positioned in the mold cavity by a locating pin
carried by the mold half;
FIG. 23 is an enlarged scale fragmentary detailed sectional view of
part of the chair frame and an adjacent part of the molded seat and
back unit, showing an attaching screw extending through a frame
part and being engaged in the molded-in nut, the screw having
biting engagement with the plastic to lock the screw against
unintentional unscrewing. This section may be considered as being
taken on the line 23--23 of FIG. 7; and
FIG. 24 is a fragmentary sectional view on the line 9--9 of FIG. 8
showing a molded-in groove in the seat and back unit for attachment
of a cushion.
The drawings show a representative embodiment of a chair and
blow-molded seat and back unit, and illustrate a preferred method
of blow-molding the seat and back unit to obtain the advantages of
the present invention. As shown in FIGS. 1, 2 and 3 particularly,
the chair comprises a chair frame CF and an integral blow-molded
seat and back unit generally designated SBU.
In the illustrative embodiment, the supporting frame CF is of the
kind disclosed in U.S. Pat. No. 3,276,818, Sidney A. Durfee et al.,
issued Oct. 4, 1966. The frame components are formed of tubing of
steel or other suitable metal, bent or formed to desired shapes and
then assembled. The chair frame components are semi-rigid,
preferably having a degree of yieldability or resilience such as to
permit adaptation to small unevenness in floor surface and
avoidance of shock when being sat upon.
The chair frame CF comprises two unitary combination leg and
under-seat frame members LUF, and one back and under-seat frame
structure BUF formed and assembled as described below.
The two leg and under-seat frame members LUF are identical, but are
reversed relatively to one another when assembled. Each member LUF
is formed of a unitary, elongated element so as to have a bight 1
intermediate its ends. Each bight comprises a curved central
connecting portion 1a and two side portions 1b which extend from
opposite ends of the connecting portion 1a and terminate in
downwardly extending leg portions 2a and 2b. The leg portions
diverge relatively to one another fore and aft from the center of
the chair frame considered as a whole.
In assembling the two leg and under-seat frame members LUF, the
curved connecting portions 1a of the bights 1 are brought into
contact with one another and are secured together for example by
welding indicated at 3. The legs of the two assembled members LUF
diverge from each other transversely of the chair frame, as well as
fore and aft.
The back and under-seat frame structure BUF is formed integrally
from a unitary, elongated element, e.g. of steel tubing, so as to
have a rear upstanding back supporting part or post 4 in the shape
of an inverted V, and two laterally spaced portions 5, 5 which
extend forwardly respectively from the bottom portions of the
upstanding inverted V shaped post part 4.
In assembling the back and under-seat frame structure BUF and the
sub-assembly of the two leg and under-seat frame members LUF, the
back and under-seat frame structure BUF is so positioned that each
of its laterally spaced portions 5, 5 crosses over the two side
portions 1b of the associated bight 1. Adjacent to their rear ends,
the laterally spaced portions 5, 5 are welded at 5a to the rear
side portions 1b of the bights 1.
Adjacent their front ends, the laterally spaced portions 5, 5 of
the structure BUF are suitably secured to the respective front side
portions 1a of the bights 1. Preferably, this securing is effected
through spacers 6 interposed between and connected to the foremost
bight side portions 1b, 1b and the forward ends of the transversely
spaced portions 5, 5 of the BUF structure. Each spacer 6 is of
inverted U shape as shown in FIG. 5, and provides a seat for the
associated portion 5 of the structure BUF. Welds secure the spacers
6 respectively to the portions 5 and the bight portions 1b.
With its components formed and assembled as described above, the
chair frame CF has such an over-all configuration that a number of
chair frames may be stacked and supported one upon another. This
stackability of the chair frame per se is frequently convenient
when a number of chair frames must be held awaiting application of
back and seat structures.
Preferably, glides 9, which may be of conventional form, are
applied to the lower ends of the legs 2a and 2b.
The integral blow-molded seat and back unit SBU is molded from any
of a number of known thermoplastic materials, such as polyethylene
and polypropylene, having the property of being extrudable in the
form of a parison while hot and molded to predetermined shape. A
suitable material is that known commercially by the trademark
MARLEX 5202, a high density linear polyethylene obtainable from
Phillips Petroleum Company, Bartlesville, Oklahoma.
As shown in FIGS. 8 and 9, the unit SBU comprises a relatively
non-bendable hollow seat portion HSP, a relatively non-bendable
hollow back portion HBP, and a bendable connecting portion BCP
intervening between and connecting the portions HSP and HBP.
Preferably, the connecting portion BCP is solid as distinguished
from being hollow.
Considering the configuration of the flat molded unit SBU, the
hollow back portion HBP comprises an inner major wall 10 and an
opposed outer major wall 11 spaced from the wall 10, the walls 10
and 11 being connected by a free end edge wall 12, side edge walls
13, 13 and the bendable connecting portion BCP. The wall 10 is
designated the inner major wall because it is to face inwardly
toward the sitter in the assembled chair, and the wall 11 is
designated the outer major wall because it is to face away from the
sitter in the assembled chair. The outer surface of the inner major
wall 10 may be textured in molding, if desired.
To enable nesting or partial nesting of the upstanding frame parts
4, 4 in the outer wall 11 of the hollow back part HBP, the latter
is molded to have an inverted V shaped recess 14 which receives the
upstanding frame parts 4, 4 as shown in FIG. 2, thus contributing
to the appearance of the assembled chair.
As shown in FIGS. 9-13, the major walls 10 and 11 of the hollow
back portion HBP are spaced from each other more widely in a
section 15 extending along the top or free end edge 12, and in
hollow sections 16 extending along the side edges 13, 13 than in
some parts of the area surrounded by the sections 15, 16 and the
bendable connecting portion BCP. This construction provides
relatively greater stiffness and strength throughout the periphery
of the back portion HBP with relatively more yieldability
throughout the central area so as to provide for comfortable
resting of the sitter's back against the back portion HBP. As shown
in FIGS. 9 and 10, the inner and outer major walls 10 and 11 are
united in molding at 17 in a relatively narrow strip area extending
transversely and just below the enlarged top edge section 15,
opposite the bendable portion BCP, from one side section 16 to the
other section 16. The uniting of the inner and outer major walls 10
and 11 in the narrow area 17 is effected by pushing opposite parts
of the molding parison against each other and welding them together
to form a reinforcing box structure during the molding operation,
which is described more particularly hereinafter with reference to
FIGS. 18-21.
FIGS. 7, 9, 11 and 12 show fastening nuts 18 molded in situ in the
outer major wall 11 for attaching the hollow back portion HBP to
the chair frame CF. The method of molding the nuts 18 in situ is
described hereinafter with reference to FIG. 22.
The form of the hollow seat portion HSP may best be understood by
reference to FIGS, 3, 5, 6, 8, 9, 15, 16 and 17. The seat portion
comprises an inner major wall 19 and an outer major wall 20, side
edge walls 21, 21, and a front or free edge wall 22 which is curved
as shown in FIGS. 2 and 9 to provide a comfortable drop-off contour
at the front of the seat portion.
As shown in FIGS. 3, 8, 15, 16 and 17, the outer major wall 20 of
the seat portion HSP is molded to provide two fore and aft
extending grooves 23, 23 which are spaced suitably respectively to
receive the fore and aft extending parts 5, 5 of the frame CF. The
wall 20 is of undulating peak-and-valley formation, the peaks 24
and valleys 25 of which extend transversely and die out and
terminate close to but short of the edge walls 21, 21. The
peak-and-valley formation provides additional stiffness of the
outer major wall 20 which, in assembly, rests on the frame CF. The
inner major wall 19 is of smoothly dished contour so as to be
relatively yieldable and comfortable when sat upon. Additional
strength of the hollow seat portion HSP in its entirety is provided
by mold-welding the major walls 10 and 20 together in two
relatively small intermediate areas 26, 26, as shown in FIG. 16, or
so as to touch in those areas.
As shown in FIGS. 5, 6, 8, 15, and 17, fastening nuts 27 are molded
in situ in the outer major wall 20 similarly to the molding of the
nuts 18 in the outer major wall 11 of the hollow back portion
HBP.
The bendable connecting portion BCP is molded unitarily with the
hollow seat portion HSP and the hollow back portion HBP in such
manner that the connecting portion BCP is solid, i.e. not hollow,
as shown in FIGS. 8 and 9, and so as to be somewhat flexible in all
directions. The molding steps followed for so forming the
connecting portion BCP are described hereinafter with reference to
FIGS. 18-21. At this point, it is sufficient to state that opposite
sides of the parison being molded are pressed together while hot so
as to be heat-united or welded together. The construction of the
connecting portion BCP thus produced is constituted by an extension
of the inner major walls 10 and 19 respectively of the hollow back
portion HBP and the hollow seat portion HSP from one to the other,
and an extension of the outer major walls 11 and 20 respectively of
the hollow back portion HBP and the hollow seat portion HSP from
one to the other. These extensions are merged or united in molding
to provide the solid bendable connection BCP between the hollow
back portion HBP and the hollow seat portion HSP. As shown in FIG.
9, the bendable portion BCP is twice as thick, or substantially
twice as thick, as the inner and outer major walls 10, 19, 11 and
20. As also shown in FIG. 9, the relatively bendable portion BCP is
substantially less in cross section than the hollow seat portion
HSP and hollow back portion HBP.
When the molded seat and back unit SBU is to be mounted on the
chair, it is bent from its substantially flat as molded condition
as indicated in FIG. 4 to position the portions HSP and HBP for
being connected respectively to the frame under-seat members 5, 5
and the frame back-supporting member 4. Bending about the
connecting portion BCP is facilitated by providing molded-in
grooves 28 extending transversely with respect to the chair close
to but terminating short of the side edges of the bendable portion
BCP. Terminating the grooves 28 short of the side edges leaves
ungrooved marginal or lip portions 29 which provide for controlled
bending of the connecting portion BCP and avoidance of sharp
localized bending. The grooves 28 are formed in the part of the
bendable portion BCP which is constituted by extensions of the
outer major walls 11 and 20.
FIGS. 18-21 schematically illustrate apparatus for molding the seat
and back unit SBU, and the step-by-step molding procedure. The
molding apparatus is of generally known or conventional
construction including two mold halves M1 and M2 mounted for
relatively horizontal reciprocation from the open positions shown
in FIGS. 18 and 21 to the closed positions shown in FIGS. 19 and
20, and vice versa. The mold halves M1 and M2 are actuated
respectively by hydraulic rams R1 and R2.
The mold half M1 is contoured as a reverse image of the outer major
walls 11 and 20 of the unit SBU and the extension of these walls
into the bendable connecting portion BCP. The mold half M2 is
contoured as a reverse image of the inner major walls 10 and 19 of
the unit SBU and the extension of these walls into the bendable
connecting portion BCP.
An extrusion nozzle N is mounted in fixed position directly above
the molding apparatus so that when the mold halves M1 and M2 are
open as shown in FIG. 18 the extrusion nozzle N will be directly
above the space between the two mold halves. The nozzle N is of
known or conventional construction having an annular orifice
through which heated plastic material is extruded between the mold
halves in the form of a closed bottom end, cylindrical parison P as
shown in FIG. 18. The parison P is shown in full lines as partly
extruded with the complete extent of extrusion indicated in dotted
lines.
The mold half M1 is provided with an upper blowing needle 30 and a
lower blowing needle 31 as commonly used in blow-molding
operations.
When the mold is open and the parison is being extruded between the
mold halves, the needles 30 and 31 are retracted so as not to
extend inwardly beyond the cavity forming walls of the mold half
M1, as shown in FIG. 18.
When the extrusion of the parison P has been completed, the mold
halves are closed to the position shown in FIG. 19 and the needles
30 and 31 are projected so as to extend inwardly beyond the cavity
wall of the mold half M1, through the adjacent wall of the tubular
parison, but to terminate short of the opposite wall of the
parison. Air or other gas is then injected through the needles 30
and 31 and thus into the parison P so as to force the walls of the
latter into contact with and to assume the contour of the mold
walls. The partially blown parison is shown in FIG. 19, and the
completely blown parison forming the seat and back unit SBU is
shown in FIG. 20.
As seen in FIGS. 19 and 20, the top needle 30 is positioned to blow
into the enlarged section 15 extending along the top of the hollow
back portion HBP and above the narrow area 17 in which the inner
and outer major walls 10 and 11 are united by being pressed
together while hot. However, the hollow section 15 communicates
with the hollow sections 16 extending along the sides of the hollow
back portion HBP so that air blown into the section 15 by the
needle 30 flows into the hollow side sections 16 and thence in
between the inner and outer major walls 10 and 11 so as completely
to expand the parison in forming the hollow back portion HBP, thus
maintaining the inner and outer major walls spaced from one another
throughout most of their areas.
Substantially vertically midway of the parison and mold, the mold
halves press opposite sides of the parison into contact with one
another while hot, thus welding or uniting them to form the solid
bendable connecting portion BCP having the grooves 28.
After the parison has been blown completely to form the blow-molded
seat and back unit SBU, the mold halves M1 and M2 are opened as
shown in FIG. 21. The molded unit SBU is then severed from the
following extruded material at 32 and removed from the mold.
Thereafter, the scrap or flash at the bottom of the molded unit may
be trimmed off at 33. The unit SBU will then be ready to be bent to
the configuration shown in FIGS. 1-3 and mounted on the chair
frame.
FIG. 22 illustrates how one of the fastening nuts 18 is molded in
situ in the outer major wall 11 of the hollow back portion HBP. The
mold half M1 is locally bulged to provide an enlargement 34 formed
with a recess or bore 35. A positioning pin 36, fitted snugly in
the recess 35, has a reduced diameter end generally designated 37
providing a shoulder 38 at its juncture with the larger diameter
part of the pin. The pin 36 is inserted into the recess 35 with a
moderate friction fit so as normally to remain in the bore 35, but
to be removable for replacement if damaged. When the mold is open
the nut member 18 is slipped onto the reduced diameter pin portion
37, the crests of the nut threads clearing the pin portion 37 just
enough to prevent binding while still maintaining the nut
substantially axially aligned with the pin 36. The mold is then
closed and the parison P blown into molded form as previously
explained. During the blow-molding operation the parison material
will surround the part of the pin 36 extending beyond the bulged
mold enlargement 34, the nut 18 and the reduced diameter part 37 of
the pin 36. Pressure exerted by the plastic against the outer face
39 of the nut 18 due to blowing forces the nut against the shoulder
38. When the mold is opened, the pin 36 will remain in the mold
half M1, and will be withdrawn from the nut 18 and the surrounding
blow-molded material. This will leave the nut 18 securely embedded
in the mold outer major wall 11 of the hollow back portion HBP.
Removal of the pin 36 from the nut 18 leaves an unthreaded opening
41 in the molded material beyond the nut 18. The wall of the
opening 41 has a diameter less than the diameter of the roots of
the nut 18 threads and substantially equal to the diameter of the
nut thread crests.
FIG. 23 shows the attachment of the hollow back portion HBP to the
chair frame CF. The upstanding post 4 of the frame shown in part in
FIG. 23 is apertured to receive a bolt 42 which is screwed into the
nut 18 to clamp the back portion HBP to the post 4 securely. The
threaded end of the bolt 42 extends beyond the nut 18 and bites
into the plastic molding at 43 so as to cut its own threads and
thus lock the bolt against unintentional unscrewing. Other nuts 18
are similarly molded in situ in the outer major wall 11 of the back
portion HBP and are similarly engaged by other frame-connected
bolts 42. The nuts 27 previously referred to for fastening the
hollow seat portion HSP to the frame are molded in situ in the
outer major wall of the portion HBP similarly to the molding in of
the nuts 18 described above. Bolts 44 cooperate with the nuts 27
for securing the hollow seat portion HSP to the parts 5, 5 of the
chair frame.
FIG. 24 shows a modified hollow seat portion HSP which is molded to
provide a groove 45 adapted to receive a projection 46 on a seat
cushion 47 for holding the cushion in place on the seat portion
HSP.
A blow-moulded unitary seat and back unit, exemplified by the unit
SBU in the present disclosure, has a number of advantages and
improvements as compared to previously known chair seat and back
equipments. The hollow blow-molded forms of the seat portion HSP
and the back portion HBP provide sufficient yieldability and
cushioning effect for increased comfort, while still being strong
and durable. Strength and durability are provided, inter alia, by
the perimetral stiffness or reinforcement afforded the back portion
HBP by the enlarged marginal hollow sections 15 and 16, and the
bendable connecting portion BCP. The undulating peak-and-valley
formation of the outer major wall 20 of the hollow seat portion HSP
provides for relative stiffness of the lower or outer wall 20 of
the seat and for thus firmly supporting the seat unit on the frame
members 5, 5, while the grooves 28 and edge lips 29 in the bendable
portion BCP provide for evenly resisted bending from flat, as
molded, form to the angular form required for mounting the unit SBU
on the chair frame CF. Very importantly, the bendable connecting
portion BCP is sufficiently flexible to allow the seat portion HSP
to flex laterally to conform to a slouched position of a sitter so
that the sitter's buttocks still will contact and be supported by
the seat, thus affording comfort through good weight distribution.
Similarly, the flexibility of the bendable portion BCP also allows
the lower part of the back portion HBP to shift or flex laterally
to conform to a slouched position while still contacting the
sitter's lower back or pelvic area, thus affording better support
and comfort through weight distribution. In short, the formation of
the unit SBU permits the flexing required for maximum comfort
without, however, creating such stress, particularly in the waist
area, as would be likely to cause structural failure, such as edge
cracks.
Aside from the above mentioned advantages in the chair construction
as such, there is a very important practical advantage in the
molding of the entire unit BSU unitarily in a generally flat
condition and then bending it to shape for mounting on the chair
frame CF. The blow-molding of the unit SBU in generally flat
condition permits the use of molding equipment which is less
cumbersome, less heavy, and therefore less expensive than if the
unit SBU were to be molded with the seat and back portions in such
angular relation to one another as to be mountable on the chair
frame. Additionally, the generally flat blow-molded unit SBU is
compact and may be stored and/or shipped with considerable saving
in space. The economic advantage is apparent.
The construction and method disclosed are preferred and are
representative of the invention; but the disclosure is intended to
be illustrative rather than definitive of the invention.
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