U.S. patent number 3,841,704 [Application Number 05/344,851] was granted by the patent office on 1974-10-15 for chair.
This patent grant is currently assigned to Steelcase Inc.. Invention is credited to Stephen B. Kolk, Warren Platner, Earl G. Ursul, Ronald L. Whitewam.
United States Patent |
3,841,704 |
Platner , et al. |
October 15, 1974 |
CHAIR
Abstract
A contoured, molded plastic shell chair whose exterior shell is
segmented into arm, back and seat shell segments so that, while
each segment is contoured somewhat, each segment is free of any
sharp contours. Each segment is separately upholstered by an
unseamed upholstery segment. Adjacent shells are joined together
along abutting, inwardly turned flanges which extend generally
aroung the periphery of each shell segment. Separate back and arm
cushions hook into hangers positioned on the interior of their
corresponding shell segments. Both the back cushion and the arm
cushions include flanges projecting downwardly and inwardly into
position beneath the seat cushion such that when the seat cushion
is fastened in place by bolts, the back and arm cushions are
positively held in place in their respective hangers.
Inventors: |
Platner; Warren (New Haven,
MI), Whitewam; Ronald L. (Caledonia, MI), Kolk; Stephen
B. (Grand Rapids, MI), Ursul; Earl G. (Grand Rapids,
MI) |
Assignee: |
Steelcase Inc. (Grand Rapids,
MI)
|
Family
ID: |
23352325 |
Appl.
No.: |
05/344,851 |
Filed: |
March 26, 1973 |
Current U.S.
Class: |
297/452.55;
297/DIG.1; 297/440.2; D6/366; 297/DIG.2; 297/452.14 |
Current CPC
Class: |
A47C
3/12 (20130101); A47C 31/02 (20130101); Y10S
297/02 (20130101); Y10S 297/01 (20130101) |
Current International
Class: |
A47C
31/00 (20060101); A47C 31/02 (20060101); A47c
007/02 () |
Field of
Search: |
;297/358,DIG.1,DIG.2,440,445,416,421,422 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gilliam; Paul R.
Attorney, Agent or Firm: Price, Heneveld, Huizenga &
Cooper
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. In a contoured, molded plastic shell chair, the improvement
comprising: the exterior shell of said chair defining a seat, back
and arms and being segmented along the lines of sharpest contour
thereof, including at least along the juncture between the seat of
the shell and back of the shell and along the junctures between the
arms of the shell and the seat and back of the shell, such that
said shell is compised of a plurality of separate segments; each
said segment being contoured somewhat in accordance with a desired
aesthetic design, but being free of sharp angle contours whereby
each segment can be separately upholstered with unseamed upholstery
segments; an unseamed upholstery segment covering the exterior of
each of said shell segments; attachment means joining said shell
segments togther to provide an upholstered exterior shell for said
chair.
2. The chair of claim 1 in which each of said exterior shell
segments includes a flange located generally at the periphery
thereof, at least in the vicinity of an adjacent shell segment; at
least portions of said flanges of adjacent shell segments abutting;
said attachment means joining said abutting portions of said
flanges together, thereby joining adjacent shell segments to create
a unitary exterior shell.
3. The chair of claim 2 in which each said upholstery segment for
each said shell segment wraps around the periphery of said shell
segment whereby the edges of said upholstery segment are disposed
on the interior of said shell segment and are thereby hidden from
view.
4. The chair of claim 3 in which each of said exterior shell
segments is relatively thin, each of said flanges for each of said
shell segments being inwardly turned and extending generally all of
the way around the periphery of its shell segment; said upholstery
segment for each of said shell segments wrapping around the
perphery of said shell segment and onto said inwardly turned
flange.
5. The chair of claim 1 in which said shell segments include tongue
and groove means cooperating to facilitate securance of said shell
segments to one another; said attachment means extending between
adjacent shell segments for securing said shell segments
together.
6. The chair of claim 5 in which said attachment means including
joining bars extending at least from some of said shell segments to
others of said shell segments; means securing each said joining bar
to each of two adjacent shell segments.
7. The chair of claim 6 in which one of said joining bars joins
each of said arm shell segments to said back shell segment; said
chair including a back cushion, said back cushion including a
cushion supporting pan having recessed channels therein generally
at each side thereof and in the vicinity of said joining bars
whereby said joining bars which join said arm segments to said back
segment are received within said recess.
8. The chair of claim 1 in which: a seat cushion and a back cushion
are positioned on said seat segment and said back segment
respectively; said back cushion and said back segment including
means for releasably securing said back cushion to said back
segment whereby said back cushion is held against said back
segment; said back cushion including flange means projecting
downwardly therefrom and inwardly towards the center of said seat;
said seat cushion including means engaging said flange means and
seating on top thereof; means for securing said seat cushion to
seat segment whereby removal of said back cushion is prevented and
said back cushion is firmly held in place on said exterior
shell.
9. The chair of claim 8 which comprises: an arm cushion for each of
said arm segments; each of said arm cushions and said arm segments
including means cooperating for releasably securing said arm
cushion to said arm segment whereby said arm cushion is held
against said arm segment; each of said arm cushions including
flange means projecting downwardly therefrom and inwardly towards
the center of said seat; said seat cushion including means engaging
said flange means of said arm cushions and seating on top thereof
whereby said arm cushions are also positively secured to said
exterior shell.
10. The chair of claim 9 in which said back cushion includes side
flanges adjacent said arm cushions and extending behind said arm
cushions whereby said arm cushions act to further hold said back
cushion against said exterior shell of said chair.
11. The chair of claim 10 in which each of said exterior shell
segments includes a flange located at the periphery thereof, at
least in the vicinity of an adjacent shell segment; at least
portions of said flanges of adjacent shell segments abutting; said
attachment means joining said abutting portions of said flanges
together, thereby joining adjacent shell segments to create a
unitary exterior shell.
12. The chair of claim 9 in which said means cooperating for
releasably securing said arm and back cushions to said exterior
shell comprise: each of said back and arm cushions including a hook
projecting rearwardly therefrom; said exterior shell including a
hanger thereon for each of said hooks, each of said hooks hooking
into said hangers; said shell segments are molded sufficiently
thick that hook receiving recesses can be integrally molded
therein; said back and arm shell segments including integrally
molded hook receiving recesses for receiving said hooks of said
back and arm cushions; said hangers comprising generally flat
straps extending across said recesses whereby said hooks hook into
said recesses behind said straps.
13. The chair of claim 12 in which said exterior shell segments are
of rigid urethane foam.
14. The chair of claim 11 in which each of said back, arm and seat
cushions comprises a plastic pan; cushion means adhered to said
plastic pan; said flange means for each of said back and arm
cushions comprising a flange integrally formed with said plastic
pan; upholstery covering said cushion means for each said back, arm
and seat cushions and extending onto said flanges and being secured
to said flanges; said upholstery wrapping around behind said pan at
points where there are no flanges; each said upholstery segment for
each said shell segment wrapping around the periphery of said shell
segment whereby the edges of said upholstery segment are disposed
on the interior of said shell segment and are thereby hidden from
view.
15. The chair of claim 8 in which said means for releasably
securing said back cushion to said back shell segment is
directionally oriented in a downward direction whereby said back
cushion can be readily removed from said back segment by an upward
movement of said back cushion.
16. The chair of claim 9 in which said means for releasably
securing said back cushion to said back shell segment is
directionally oriented in a downward direction whereby said back
cushion can be readily removed from said back segment by an upward
movement of said back cushion; said means for releasably securing
said arm cushions to said arm segment being directionally oriented
in a downward direction whereby said arm cushions are removable
from said arm segments by an upward movement of said arm cushions
with respect to said arm segments.
17. A chair comprising: a shell including seat, back and arms; a
seat cushion, a back cushion and two arm cushions for mounting on
said shell; said back cushion and said back including means
cooperating to releasably secure said back cushion to said back
whereby said back cushion is held against said back; each of said
arm cushions and said arm including means cooperating to releasably
secure said arm cushion to said arm whereby said arm cushion is
held against said arm; said back cushion and each of said arm
cushions each including flange means projecting downwardly
therefrom and inwardly towards the center of said seat; said seat
cushion including means engaging said flange means and seating on
top thereof; means securing said seat cushion to said seat whereby
removal of said back cushion and said arm cushions is prevented
when said seat cushion is secured in place.
18. The chair of claim 17 in which said back cushion includes side
flanges adjacent said arm cushions and extending behind said arm
cushions whereby said arm cushions further act to hold said back
cushion against said shell of said chair.
19. The chair of claim 17 in which upholstery covers said cushion
means for each said back, arm and seat cushions and extends onto
said flanges and is secured to said flanges; said upholstery
wrapping around behind said pan at points where there are no
flanges.
20. The chair of claim 17 in which each of said back, arm and seat
cushions comprises a plastic pan; cushion means adhered to said
plastic pan; said flange means for each of said back and arm
cushions comprising a flange integrally formed with said plastic
pan.
21. The chair of claim 17 in which said means for releasably
securing said back cushion to said back shell segment is
directionally oriented in a downward direction whereby said back
cushion can be readily removed from said back segment by an upward
movement of said back cushion said means for releasably securing
said arm cushions to said arm segment being directionally oriented
in a downward direction whereby said arm cushions are removable
from said arm segments by an upward movement of said arm cushions
with respect to said arm segments.
22. The chair of claim 17 in which said means cooperating for
releasably securing said arm and back cushions to said exterior
shell comprise: each of said back and arm cushions including a hook
projecting rearwardly therefrom; said exterior shell including a
hanger thereon for each of said hooks, each of said hooks hooking
into said hangers; said shell segments are molded sufficiently
thick that hook receiving recesses can be integrally molded
therein; said back and arm shell segments including integrally
molded hook receiving recesses for receiving said hooks of said
back and arm cushions; said hangers comprising generally flat
straps extending across said recesses whereby said hooks hook into
said recesses behind said straps
23. The chair of claim 22 in which said exterior shell segments are
of rigid urethane foam.
24. A chair comprising: a shell including seat and back; a seat
cushion and a back cushion for mounting on said shell; said back
cushion and said back including means cooperating to releasably
secure said back cushion to said back whereby said back cushion is
held against said back; said back cushion including flange means
projecting downwardly therefrom and inwardly towards the center of
said seat; said seat cushion including means enaging said flange
means and seating on top thereof; means securing said seat cushion
to said seat whereby removal of said back cushion is prevented when
said seat cushion is fastened in place.
25. The chair of claim 24 in which said means for releasably
securing said back cushion to said back shell segment is
directionally oriented in a downward direction whereby said back
cushion can be readily removed from said back segment by an upward
movement of said back cushion.
26. The chair of claim 24 in which said means cooperating for
releasably securing said arm and back cushions to said exterior
shell comprise: each of said back and arm cushions including a hook
projecting rearwardly therefrom; said exterior shell including a
hanger thereon for each of said hooks, each of said hooks hooking
into said hangers; said shell segments are molded sufficiently
thick that hook receiving recesses can be integrally molded
therein; said back and arm shell segments including integrally
molded hook receiving recesses for receiving said hooks of said
back and arm cushions; said hangers comprising generally flat
straps extending across said recesses whereby said hooks hook into
said recesses behind said straps.
27. The chair of claim 1 comprising: at least some of said shell
segments including a rigid anchor plate integrally molded therein
at least at selected joining points; said anchor plates being
joined to one another by means of joining bars extending
therebetween; fastening means joining each said joining bar to each
of said anchor plates in each of a pair of adjacent shell segments
having said anchor plates.
Description
BACKGROUND OF THE INVENTION
The present invention relates to contoured, plastic shell chairs.
Plastic shell chairs are popular because of the attractive contours
which can be molded into the exterior supporting shell. The plastic
not only fulfills the structural requirements of the chair, but
also provides an attractive exterior surface. Generally, the shells
are somewhat difficult to upholster since the contours which are
usually designed into such shells are extremely difficult to cover
with upholstery.
Chairs having upholstered exteriors employ simple, boxy straight
lines and an upholstering envelope. The envelope includes seams
along the sharp contour lines which generally exist between the
back and the arms and the seat, arms and back. In fact, most
manufacturers do not even attempt to upholster the bottom surface
of the chair. It would be very difficult to sew an upholstery
envelope for a chair having a contoured, as opposed to a straight
line appearance.
Some attempt to overcome this difficulty by designing chairs with
very straight backs and with separate arms. The back and the arms
are upholstered separately and then joined together. However, no
effort is made to upholster the bottom of the chair Further, this
approach has the drawback of enabling one to design a chair having
only a conventional, box-like appearance, rather than a striking,
contoured appearance. Yet, another problem with such chairs is that
the means for interconnecting the arms to the rest of the chair are
generally clumsy. Indeed, chairs having separate exterior shell
components suffer from the fact that the edges of the joined
components are left exposed and visible. In each cases, a special
trim piece must be used.
Another problem encountered in the manufacture of contoured plastic
shell chairs is one relating to the manner in which cushions are to
be supported in the shell. The shell does not provide any framework
to which such cushions can readily be attached. Gluing is sometimes
utilized, but this is a time consuming operation in view of the
need to carefully locate each of the separate cushions as it is
adhered to the shell.
These relatd problems tend to restrict the chair designer, both in
giving the chair the contoured lines which he desires and in
selecting the plastic material from which the contoured shell is to
be made.
SUMMARY OF THE INVENTION
The present invention is a molded plastic shell chair whose
exterior shell can be both artistically contored and completely
upholstered. Upholstery envelopes and sewn seams are completely
eliminated. Further, the manner in which the cushions are assembled
to the exterior shell is quick, convenient and positive.
The exterior shell of the chair is segmented along its lines of
sharpest contour. Thus, the shell is comprised of a plurality of
separate segments, each of which is contoured somewhat in
accordance with a desired aesthetic design, but each of which is
free of any sharp angle contours so that each segment can be
separately upholstered with an unseamed upholstery segment. The
shell segments are then joined together to provide a completely
upholstered exterior shell for the chair.
Preferably, each shell includes an inwardly turned peripheral
flange extending generally around the perimeter thereof. Abutting
portions of these flanges are joined together to effect a joining
of the shell segments. Further, the flange provides a surface upon
which the upholstery segements can be secured. Thus, the upholstery
segment can be wrapped completely around the periphery of the shell
segments and stapled or glued along the inwardly turned peripheral
flange.
In order to effect efficient assembly of the cushions to the chair,
the separate back and arm cushions and the exterior shell include
means cooperating to secure each cushion against the shell through
a downward movement of the cushion. Each cushion is readily
removable by an upward movement thereof. Each of the cushions
includes a flange means projecting downwardly and inwardly
therefrom towards the center of the seat. The seat cushion for the
chair sits on top of these flange means so that when it is bolted
in place, it positively locks the arm and back cushions in place.
This aspect of the invention is important not only in conjuntion
with the segmented exterior shell but is also important in and of
itself and could be employed in conjunction with any type of
supporting shell.
These and other features, objects and advantages of the invention
will be more fully understood and appreciated by reference to the
written specification and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a contored, plastic shell chair
body made in accordance with the present invention;
FIG. 2 is a rear elevation of the chair body;
FIG. 3 is a front perspective view of the assembled shell for the
chair body;
FIG. 4 is a rear elevational view of the back cushion of the
chair;
FIG. 5 is a rear elevational view of the arm cushion of the
chair;
FIG. 6 is a bottom plan view of the bottom cushion for the
chair;
FIG. 7 is a front perspective view of the chair shell with the back
cushion in place;
FIG. 8 is a front perspective view of the chair shell with the back
and arm cushions in place;
FIG. 9 is a front perspective view of the chair body with all of
the cushions in place;
FIG. 10 is a cross-sectional view taken along plane X--X of FIG.
1;
FIG. 11 is a cross-sectional view taken along plane XI--XI of FIG.
1;
FIG. 12 is a crss-sectional view taken along plane XII--XII of FIG.
1;
FIG. 1 is a front perspective view of an assembled alternative
embodiment shell for the chair body;
FIG. 14 is a rear elevational view of the back cushion of the
alternative embodiment chair;
FIG. 15 is a rear elevational view of the arm cushion of the
alternative embodiment chair;
FIG. 16 is a fragmentary generally bottom perspective view of the
alternative embodiment chair;
FIG. 17 is a fragmentary bottom plan view of the alternative
embodiment chair; and
FIG. 18 is a generally perspective view of the cover piece for the
bottom of the alternative embodiment chair, the cover piece being
visible on the bottom of the chair as shown in FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, the contoured, exterior shell 10 of
chair 1 is segmented along its lines of sharpest contour into a
separate back segment 11, seat segment 13 and arm segment 15 (FIGS.
1, 2 and 3). While each of these segments is somewhat contoured to
conform to a desired aesthetic appearance, there are no sharp
contours in any given shell segment. Each of these segments is
upholstered and then joined together by suitable fastening means
such as nuts and bolts 30.
A back cushion 40 and a pair of arm cushions 50 are hung by hooks
70 in hanger 71 which are secured to the exterior supporting shell
10 (FIGS. 8, 9, 10 and 11). Back cushion 40 includes a bottom
flange 43 which sits generally beneath bottom cushion 60 and side
flanges 42 which fit behind arm cushions 50 (FIGS. 10, 11 and 12).
Each arm cushion 50 includes a bottom flange 53 which fits beneath
seat cushion 60. Thus, when seat cushion 60 is bolted in place by
bottom bolts 75, back cushions 40 and arm cushions 50 are basically
locked in position and are rendered substantially unremovable.
The back segment 11, seat segment 13 and arm segments 15 of
exterior supporting shell 10 are molded of a glass fiber reinforced
polyester resin. Each segment is contoured to conform to the
overall aesthetic design which is desired. Naturally, this can be
varied substantial.y to suit a particular designer's tastes.
Similarly, the lines of demarcation between connected shell
segments can be made either very pronounced or can be made to
appear very fine and seam-like. In the embodiment shown in the
drawings, the lines of demarcation between the adjacent segments
have been made very pronounced in order to achieve a particular
aesthetic effect.
Each segment, while contoured somewhat, is free of any sharp
contours therein. This makes it possible to cover the exterior
surface of each shell segment with a single piece of unseamed
upholstery 20 (FIGS. 10, 11 and 12). In the preferred embodiment,
there are four separate shell segments. If, however, a designer
wanted a particularly sharp contour in the middle of the seat
segment, the seat segment could be divided into two separate
segments.
Each of the shell segments include an inwardly turned flange 16
extending around the periphery thereof (FIGS. 3, 10, 11 and 12).
When the various shell segments are placed adjacent one another,
portions of these flanges 16 abut. The shells are secured together
by a plurality of nut and bolt combinations 30, the bolts passing
through apertures in the abutting flange portions. Upholstery 20
can be selected to suit a desired aesthetic effect. Upholstery 20
is secured to the exterior of each shell segment by gluing.
Back cushion 40, which is secured to back shell segment 11,
comprises a molded plastic pan 41 to which is adhered a foam
cushion 44 (FIGS. 4 and 10). A piece of upholstery 45 covers foam
cushion 44 and wraps generally around the peripheral edges of pan
41 and is secured on the back side thereof.
Pan 41 is molded of glass fiber reinforced polyester resin and
includes a pair of side flanges 42 projecting to either side
thereof, at the bottom thereof and being formed integrally
therewith. Similarly, a bottom flange 43 is formed integrally with
pan 41 and projects downwardly from the bottom thereof. Bottom
flange 43 slopes forwardly at an angle and seats in beneath seat
cushion 60 (FIG. 10). Side flanges 42 similarly slope forwardly at
an angle and fit in behind arm cushions 50 (FIG. 2). Arm cushions
50 and seat cushions 60 thus cooperate with side flanges 42 and
bottom flange 43, respectively, to aid in positively holding back
cushion 40 in place. Since flanges 42 and 43 are hidden, upholstery
45 is secured to the face thereof and does not have to be wrapped
there around.
Back cushion 40 is held in place at its top by a pair of hooks 70
which are secured to pan 41 and which hook into receiving hangers
71 (FIGS. 3, 4 and 10). Hangers 71 are secured to back segment 11.
The hooks 70 hook downwardly so that back cushion 40 is assembled
by sliding it downwardly. It is held against back segment 11 in
this manner, but it is readily removable by moving it upwardly. It
is the cooperation of seat cushion 60 and bottom flange 43 which
prevents such upward movement in the finally assembled chair.
The construction of each arm cushion 50 is similar (FIGS. 5, 11 and
12). Each arm cushion 50 includes a molded plastic pan 51 molded of
glass fiber reinforced polyester resin. Pan 51 includes a forwardly
sloping sidewall 52 which matingly abuts a side flange 42 of back
cushion 40. It also includes a downwardly and inwardly projecting
bottom flange 53 which seats beneath bottom cushion 60.
Pan 51 includes a pair of hooks 70 thereon which hook downwardly
into receiving hangers 71 which are mounted on the inside of arm
segments 15 of shell 10 (FIGS. 3 and 11). As with back cushion 40,
arm cushions 50 are initially positioned by sliding them downwardly
into hooks 71 and are readily removable upwardly except for the
interaction of their bottom flanges 53 and seat cushion 60.
A suitable foam cushion material 54 is adhered to the surface of
pan 51 and is covered by upholstery 55 which wraps generally around
the edges of pan 51 and is secured therebehind. At flange 53, the
upholstery merely goes down the surface thereof and is adhered
thereto.
Bottom cushion 60 is also similarly constructed, including a molded
plastic pan 61, a foam cushion 66 adhered thereto and upholstering
67 covering foam cushion 66 and wrapping around pan 61 (FIGS. 6, 10
and 12). The rear wall 63 and side walls 62 of pan 61 slope
downwardly and inwardly generally to the same degree as bottom
flange 43 of back cushion 40 and bottom flange 53 of arm cushions
50, respectively. In this manner, back wall 63 matingly abuts bttom
flange 43 to positively lock that cushion 40 in position and side
walls 62 matingly abut bottom flanges 53 to positively lock arm
cushions 50 in position. The bottom of pan 61 includes several
threaded apertures 65 therein which receive bottom bolt 75 to
positively secure seat cushion 60 to seat shell segment 13 (FIGS. 6
and 10). A suitable aperture 68 is provided in the bottom of pan 61
for venting purposes.
In assembling the chair, the molded segments of exterior supporting
shell 10 are first upholstered by seamless upholstery segments 20.
This is effected by gluing, stapling or the like. The segments are
then joined together along their abutting flange portions 16 by
nuts and bolts
With supporting shell 10 thus assembled, back cushion 40 is joined
to back shell segment 11 by hooking its hooks 70 into the hangers
71 mounted on back shell segment 11 (FIG. 7). Next, the arm
cushions 50 are similarly mounted to arm shell segments 15, their
sidewalls 52 overlapping and abutting side flanges 42 of back
cushion 40 (FIG. 8). Finally, seat cushion 60 is lowered into
position, its sidewalls 62 overlapping and abutting bottom flanges
53 of arm cushions 50 and its back wall 63 overlapping and abutting
bottom flange 43 of back cushion 40. Bolts 75 are passed through
the bottom of bottom shell segment 13 and are threaded into
threaded apertures 65 in bottom cushion 60 to thereby positively
hold all of the cushions in place (FIGS. 9 and 10).
ALTERNATIVE EMBODIMENT
FIGS. 13 through 18 show an alternative embodiment 2 of the
invention. The basic differences between chair body 2 and chair
body 1 arise from the fact that chair body 2 is molded from rigid
urethane foam rather than glass fiber reinforced polyester resin.
Because of the nature of rigid urethane foam, the various exterior
shell segments of alternative embodiment chair 2 are thicker than
their corresponding counterparts in chair body 1. Various rigid
urethane foams are commercially available for use in the furniture
industry and they have heretofore been used specifially in the
construction of chairs.
To the extent that the components of chair body 2 are substantially
identical in function to the components of chair body 1, they have
been identified with the same last two digits as their
corresponding counterparts in chair body 1, the two digits being
preceded by the numeral 1. For example, the assembled exterior
shell of chair body 2 has been designated 110 while the overall
assembled exterior shell of chair body 1 bears the identification
numeral 10.
In chair 1, the various exterior shell segments 11, 13 and 15 are
joined by bolts passing through their respective peripheral
inwardly turned flanges 16. While shell segments 111, 113 and 115
of shell 110 do not have inwardly turned flanges, they are molded
to be of a generally dished configuration whereby peripheral
flanges 116 are defined at least in areas where adjacent shell
segments must be joined (FIG. 13). Bolts 130 pass from flange 116
in back segment 111 and arm segment 115 into a peripheral flange
116 in seat segment 113.
Chair 2 additionally employs a tongue and groove arrangement (FIG.
13). Back segment 111 includes a downwardly extending tongue 112
which fits into a receiving notch or groove 118 along the back edge
of seat segment 113. The center bolt 130 holding back segment 111
extends specifically through flange 116 and behind tongue 112 and
into seat segment 113. Similarly, each arm segment 115 includes a
downwardly extending tongue 117 which fits into a notch or groove
119 along the side edge of seat shell segment 113.
In addition, each arm segment 115 is joined to back segment 111 by
means of an arm-to-back joining bar 131 (FIG. 13). Bolts 133 extend
through arm-to-back joining bar 131 and are threadably received in
arm segment 115 and back segment 111. In order to provide a firm
anchoring point for bolts 133 back segment 111 and arm segment 115
each include a steel reinforcing or anchoring plate 134 integrally
molded into the rigid urethane foam. Suitable holes are prepunched
into the embedded steel anchor plate 134 in order to receive bolts
133. In order to show one such embedded steel plate 134, a portion
of the urethane foam in back segment 111 has been broken away.
Similarly, each arm segment 115 is joined to seat segment 113 by
means of an arm-to-seat joining bar 132. Bolts 133 pass through
holes in joining bar 132 and are anchored in embedded anchor plates
such as anchor plate 134. As with arm-to-back joining bar 131,
arm-to-seat joining bar 132 is bent so that it conforms somewhat to
the inner contour of shell 110 and thereby extends readily from one
shell segment to the other.
The hanger brackets 171 on back segment 111 and on arm segments 115
are somewhat different than hanger brackets 71 of shell 10. Back
segment 111 and arm segments 115 are thicker than back segment 11
and arm segments 15, and they include integrally formed recesses
172 along their respective upper regions. Hangers 171 constitute
flat pieces of steel bolted to back shell segment 111 or seat shell
segment 115 as the case may be, across the various recesses 172.
The various hooks 170 on back cushion 140 and arm cushion 150 fit
into recesses 172 behind hangers 171.
The back cushion 140 and arm cushion 150 of alternative embodiment
chair 2 are constructed substantially similar to back cushion 40
and arm cushion 50 of chair 1. Indeed, the same material is used in
both instances. The basic difference between back cushion 140 of
chair 2 and back cushion 40 of chair 1 is that the pan 141 of back
cushion 140 includes channel shaped recesses 146 therein in order
to accommodate the arm-to-back joining bars 131. Channels 146 allow
one to provide sufficient bulk, particularly in back segment 111,
in the vicinity of arm-to-back joining bar 131 to give adequate
strength to shell 110 in this area.
Another variation of only minor importance is that the hooks 170
for back cushion 140 are positioned closer to the top periphery of
back cushion 140 than are the hooks 70 of back cushion 40. This
insures a tighter fit of back cushion 140 against back shell
segment 111 along the top periphery thereof. Also, the hooks 170
open upwardly instead of downwardly as do hooks 70 in first
embodiment chair 1. Similarly, the hooks 170 of arm cushion 150 are
positioned somewhat higher on arm cushion 150. Naturally, this also
requires that the hangers 171 and recesses 172 on back shell
segment 111 and arm shell segments 115 be located higher than the
hangers 71 on back shell segment 11 and arm shell segments 15 of
chair 1.
The seat cushion 60 of chair body 1 is adequate as already
disclosed for use in chair 2 and therefore is not shown separately
in conjunction with chair 2. The seat, back and arm cushions for
chair 2 include the same cooperating flanges and surfaces as have
been heretofore described in conjuncion with chair 1 for purposes
of holding the various back cushions within shell 110. One
advantage to using rigid urethane as the construction material for
shell 110, however, is that additional securing means can be
employed as insurance. Back cushion 140 and arm cushions 150 can
actually be bolted to back shell segment 111 and arm shell segments
115, respectively, along the bottom flanges 143 and 153 thereof,
respectively. The rigid urethane shell segments 111 and 115 are
sufficiently thick that one does not need to worry about the
fastening screw coming through the exterior side of the shell. This
provides an added margin of safety with respect to holding back
cushion 140 and arm cushions 150 in place.
FIGS. 16, 17 and 18 disclose a feature of chair 2 which can also
readily be incorporated into alternative embodiment 1. A unique
cover 180 is located on the bottom of shell 110 for the purpose of
hiding the chair tilting control. Where no control is empoyed, the
fastening of the chair base 200 to chair shell 110 is covered by
cover 180. Seat segment 113 of chair shell 110 includes a recess
190 in the bottom exterior thereof (FIG. 17). Mounting holes 191
are provided for receiving bolts 75 which fasten a suitable base
200 to shell 110 (FIGS. 17 and 16). Recess 190 is sufficiently
large to receive a chair tilt control in the event that one is
desired. Because of recess 190, the chair control is recessed
upwardly within shell 110 and is therby somewhat hidden from view.
Cover 180 then further hides the chair control and indeed hides any
fastening hardware from view.
Positioned on the side walls of recess 190 are three outwardly
projecting pins 192. Two pins 192 are located at the sides and
towards the rear of recess 190 while a third pin 192 is located at
the front of recess 190. Cover 180 is molded of plastic or the like
to a desired design configuration. It includes three upwardly
projecting tabs 181, each including a hole 182 therein for
cooperating with pins 192. One tab 181 is located at the front of
cover 180, and the other two are located on the sides and generally
at the rear of cover 180.
Cover 180 includes a large aperture 183 in the bottom thereof in
order to accommodate the spindle or supporting post 201 of a chair
supporting base 200. A slot 184 extends from the rear of aperture
183 through to the back edge of cover 180. Cover 180 should be made
of a material which is somewhat flexible and resilient so that it
can be separated at slot 184 a sufficient distance to allow one to
slip cover 180 around a spindle or post 201 of a chair base 200.
Then, with the chair base secured to shell 110 through suitable
bolts in holes 191, one can move cover 180 upwardly and slip the
hole 182 of front tab 181 over the front pin 192 in recess 190.
Then, by compressing the rear portions of cover 180 slightly
inwardly, one can fit each of the side tabs 11 over its respective
side pin 192. In this manner, cover 180 is positively secured to
the bottom of shell 110 and, for all practical purposes, completely
seals any hardware or fastenings at the top of a chair base from
view.
In the broader aspects of this feature of the invention, the slot
184 could be eliminated. In such a construction, cover 180 would
have to be slipped over the post 201 of base 200 before any control
or chair mounting plate were secured thereto. This would be
somewhat clumsy during manufacture however.
This aspect of alternative embodiment 2 can be as readily used with
alternative embodiment 1. In alternative embodiment 2, the pins 192
can be embedded in the molded rigid urethane and thereby anchored
in place. In alternative embodiment 1, some type of nut and bolt
fastening would probably have to be used for pins 192.
CONCLUSION
The result of this invention is a chair which is both extremely
attractive and reasonably economically manufacturable. The
upholstered exterior of the contoured plastic shell guarantees an
extremely rich, luxurious appearance. The designer is free to
contour the appearance of this shell to suit his taste. He is free
to provide for very pronounced lines of demarcation between
adjacent shell segments or to render them almost invisible,
depending on the aesthetic effect which he seeks to achieve.
Economy is effected not only by ease of upholstering, but by the
ease with which the various cushions are assembled to the
structural shell.
Of course, it is understood that the above are merely preferred
embodiments of the invention and that various changes and
alterations can be made thereof without departing from the spirit
and broader aspects of the invention.
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