CHAIR

Description

FIELD OF THE INVENTION

The present invention relates to a chair having a suspension assembly, and more particularly, a chair having a suspension material with a molded edge.

BACKGROUND OF THE INVENTION

Some chairs, such as office chairs or task chairs, include frames and that support suspension materials. The suspension materials may be coupled to the frames by various mechanisms.

SUMMARY OF THE INVENTION

The present invention provides, in one aspect, a seating structure including a frame defining an opening, a suspension material extending across the opening, and a molded strip encapsulating an edge of the suspension material and coupled to the frame. The molded strip defines a plurality of windows. A portion of the suspension material is exposed through at least some of the plurality of windows.

The present invention provides, in another aspect, a suspension assembly for a seating structure. The suspension assembly includes a suspension material configured to extend across an opening defined by the seating structure and a strip molded to an edge of the suspension material. The strip is configured to be coupled to a portion of the seating structure. The strip defines a plurality of windows. A portion of the suspension material is exposed through at least some of the plurality of windows.

The present invention provides, in another aspect, a method of manufacturing a seating structure. The seating structure includes a frame defining an opening. The method includes providing a suspension material, molding a strip to an edge of the suspension material such that a portion of the suspension material is exposed through a plurality of windows defined within the strip, and coupling the strip to the frame such that the suspension material extends across the opening of the frame.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of a chair according to an embodiment of the present invention.

FIG. 2 is a side view of a portion of the chair of FIG. 1.

FIG. 3 is an enlarged view of a portion of the chair of FIG. 1, illustrating a suspension assembly of the chair.

FIG. 4 is a perspective view of a molded strip of the suspension assembly of FIG. 3.

FIG. 5 is an enlarged view of a first side strip of the molded strip at section 5-5 of FIG. 4.

FIG. 6 is another enlarged view of the first side strip of the molded strip at section 6-6 of FIG. 4.

FIG. 7 is a cross-sectional, perspective view of the first side strip of the molded strip of FIG. 4.

FIG. 8 is an enlarged front view of a portion of the molded strip of FIG. 4.

FIG. 9 is an enlarged rear view of a portion of the molded strip of FIG. 4.

FIG. 10 is a schematic diagram of an injection mold assembly operable to form the molded strip of FIG. 4 on a suspension material.

FIG. 11 is a perspective view of a first mold portion of the injection mold assembly of FIG. 10.

FIG. 12 is an enlarged view of a portion of the first mold portion of FIG. 11.

FIG. 13 is a flowchart depicting a method of manufacturing the chair of FIG. 1.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

FIG. 1 illustrates a chair 10. More specifically, the illustrated chair 10 is an office chair or a task chair. The illustrated embodiment is only one example of a configuration of a chair. The chair 10 may have other shapes and/or configurations or may be a different type of seating structure. The illustrated chair 10 includes a base 14, a support column 16 coupled to the base 14, a frame 18, and a suspension assembly 22 coupled to the frame 18. In other embodiments, the chair 10 may include a tilt mechanism coupled to and supported by the support column 16. The frame 18 is movably coupled to the support column 16 or the base 14. In other embodiments, the frame 18 may be rigidly coupled to the support column 16 or the base 14. In the illustrated embodiment, the base 14 includes five arms 26 that surround a central hub. Each of the arms 26 is coupled to a caster wheel 30. In some embodiments, the base 14 may have three arms, four arms, or more than five arms. In other embodiments, the base 14 may include a plurality of legs. In such embodiments, the support column 16 and/or a tilt mechanism may be omitted. In another embodiment, the base 14 may include glides instead of the caster wheels 30. In addition, the illustrated chair 10 may include armrests 32 as shown in FIG. 2 or may not have armrests (as shown in FIG. 1).

With continued reference to FIG. 1, the frame 18 and the suspension assembly 22 form a continuous seat 34a and backrest 34b of the chair 10. In other embodiments, the seat 34a and the backrest 34b may be formed as separate components, or the frame 18 and the suspension assembly 22 may only form one of the seat 34a and the backrest 34b. For example, the backrest 34b may be formed of the suspension assembly 22, while the seat 34a is formed from a foam cushion. The frame 18 includes a first frame member 42a and a second frame member 42b. In the illustrated embodiment, the first frame member 42a and the second frame members 42b are both formed with an arcuate structure to accommodate a user sitting in the chair 10. Each frame member 42a, 42b has a first end 44a, 44b and a second end 46a, 46b opposite the first end 44a, 44b. The first end 44a, 44b and the second end 46a, 46b of each frame member 42a, 42b are formed with a teardrop shape. An aperture 48 (FIGS. 2 and 3) is respectively defined through the first end 44a, 44b and the second end 46a, 46b of each frame member 42a, 42b. The first frame member 42a and the second frame member 42b are spaced from each other in a first direction DA1, DB1 such that a gap 50, or opening, is defined therebetween. Also, the first frame member 42a and the second frame member 42b are each elongated in a second direction DA2, DB2 (FIG. 2) perpendicular to the first direction DA1, DB1.

The illustrated frame 18 also includes a crossbeam 52 disposed at a central portion of backrest 34a. The crossbeam 52 is coupled to the first and second frame members 42a, 42b, and thereby interconnects the frame members 42a, 42b to each other. As such, the crossbeam 52 provides further strength to the backrest 34b to help support a back of the user. In other embodiments, the frame 18 may have two or more crossbeams.

FIG. 2 only illustrates the first frame member 42a of the frame 18. The second frame member 42b is a mirror image of the first frame member 42a. For sake of brevity, only the first frame member 42a is illustrated and described in detail. The first frame member 42a is formed by a front frame member 54a and a rear frame member 56a. The front frame member 54a is configured to be a part of the seat 34a and the backrest 34b. The rear frame member 56a is disposed behind the front frame member 54a and couples the first frame member 42a to the support column 16.

At the first end 44a of the first frame member 42a, the front frame member 54a and the rear frame member 56a are integrally formed together to create the aperture 48. After the first end 44a, the front frame member 54a and the rear frame member 56a separates from each other such that a cavity 55a is defined therebetween. A plurality of links 58 is provided along the first frame member 42a between the front and rear frame members 54a, 56a. The links 58 are configured to interconnect the front frame member 54a and the rear frame member 56a together. As such, an opening or a space 60 is respectively defined between consecutive links 58. The front frame member 54a further elongates in the second direction DA2 to form a part of the seat 34a and the second end 46a of the frame 18. At an end 62 of the rear frame member 54a, the rear frame member 54a is coupled to the support column 16 to couple the first frame member 42a to the support column 16.

The first frame member 42a also includes a support member 64a to provide further structural support to the frame 18 of the chair 10. The support member 64a is disposed between the front frame member 54a and the rear frame member 56a. More specifically, the support member 64a is coupled to the rear frame member 56a at the end 62 and is therefore coupled to the support column 16. The support member 64a is also coupled to the front frame member 42a. As such, the support member 64a is configured to interconnect the front frame member 54a to the support column 16. The illustrated frame 18 is only one example of a frame 18 for use with the chair 10. As noted above, the frame 18 may have other configurations depending on the desired shape, size, functionality, and the like of the chair 10.

With reference to FIG. 3, the suspension assembly 22 includes a suspension material 70 and a strip 74 coupled to edges of the suspension material 70. The illustrated suspension material 70 is configured as a single sheet such that the frame 18 and the suspension material 70 are combined to form the continuous seat 34a and backrest 34b of the chair 10. The suspension material 70 may be made of a woven or knit material, including various elastomeric materials, fabrics, or various molded polymeric materials. The suspension material 70 may include one or more monofilaments interlaced with one or more multifilament strands. In other embodiments, the suspension material 70 can include a single monofilament with a plurality of multifilament strands. Alternatively, the suspension material 70 can include only monofilaments and no multifilament strands.

The strip 74 may be molded to the edges of the suspension material 70. As such, the strip 74 may be referred to as a molded strip, a molded member, or a molded edge. The strip 74 may be coupled to all of the edges of the suspension material 70 or only some of the edges of the suspension material 70. In addition, the strip 74 may be a single, continuous strip or may include two or more discrete sections. When coupled (e.g., molded) to the suspension material 70, the strip 74 encapsulates the edges of the suspension material 70. In other embodiments, the strip 74 may be coupled to the suspension material 70 in other ways.

FIGS. 3-9 illustrate the molded strip 74 in more detail. The illustrated molded strip 74 is formed by a first side strip 78a, a second side strip 78b, a top strip 82a, and a bottom strip 82b. The first and second side strips 78a, 78b are spaced from each other such that the side strips 78a, 78b are disposed opposite each other. The top and bottom strips 82a, 82b are disposed between the first and second side strips 78a, 78b and, thereby, interconnect the side strips 78a, 78b to each other at corners 84a-d of the molded strip 74. A first corner 84a of the molded strip 74 is formed at the interconnection of the first side strip 78a and the top strip 82a. A second corner 84b of the molded strip 74 is formed at the interconnection of the second side strip 78b and the top strip 82a. A third corner 84c of the molded strip 74 is formed at the interconnection of the first side strip 78a and the bottom strip 82b. A fourth corner 84d of the molded strip 74 is formed at the interconnection of the second side strip 78b and the bottom strip 82b. Each corner 84a-d is formed with an elongated tab 85 (FIGS. 8 and 9) having a notch 86 defined therein. The notch 86 may cooperate with the frame 18 of the chair 10 when coupling the molded strip 74 to the frame 18.

FIGS. 5 and 6 illustrate the first side strip 78a of the molded strip 74. The second side strip 78b is a mirror image of the first side strip 78a and includes similar features. For sake of brevity, only the first side strip 78a is illustrated and described in detail. The first side strip 78a is defined by a first leg 88a, a second leg 90a spaced apart from the first leg 88a, and an intermediate leg 94a that extends between and connects the first and second legs 86a, 90a together. As such, the first side strip 78a has a generally C-shaped cross-section (as shown in FIG. 7) defined by the first leg 88a, the second leg 90a, and the intermediate leg 94a. In other embodiments, the first side strip 78a and/or the second side strip 78b may have other cross-sectional shapes.

The first side strip 78a further includes a slot 98a and a first plurality of ribs 102a. The slot 98a of the first side strip 78a is defined between the first leg 88a and the second leg 90a. The first plurality of ribs 102a is formed along the first leg 88a and the intermediate leg 94a of the first side strip 78a. In other embodiments, the first plurality of ribs 102a may be formed on each leg 88a, 90a, 94a of the first side strip 78a. The first plurality of ribs 102a and the first leg 88a are arranged to define a first plurality of windows 106a that provide openings within the first side strip 78a of the molded strip 74. In the illustrated embodiment, the first plurality of windows 106a is arranged in a row extending along a length of the first leg 88a. Also, each window 106a has a rectangular shape. In other embodiments, the first plurality of windows 106a may have other shapes (e.g., square, circular, oblong, irregular, etc.) and/or may be arranged in two or more rows along the first leg 88a. Once the strip 74 is molded onto the suspension material 70, the first plurality of windows 106a is configured to expose a portion of the suspension material 70 such that the molded strip 74 does not entirely cover the edges of the suspension material 70. As shown in FIG. 3, the suspension material 70 is visible through every window 106a. However, in practice, the suspension material 70 may only be visible through some of the first plurality of windows 106a. The number and locations of windows 106a through which the suspension material 70 is visible may depend on, for example, how fibers (e.g., monofilaments, multifilament strands, etc.) align with the first plurality of windows 106a during the molding process. Having the suspension material 70 visible through at least some of the first plurality of windows 106a helps aesthetically transition the suspension assembly 22 from the suspension material 70 to the molded strip 74, rather than having an abrupt transition from the suspension assembly 22 to a solid molded strip.

FIGS. 8 and 9 illustrate the top strip 82a disposed between the first and second corners 84a, 84b of the molded strip 74. The bottom strip 82b is substantially similar to the top strip 82a and includes similar features. For sake of brevity, only the top strip 82a will be illustrated and described in detail. The top strip 82a of the molded strip 74 includes a front surface 108a and a rear surface 109a opposite the front surface 108a. A second plurality of ribs 110a are formed along the front surface 108a of the top strip 82. The top strip 82a and the second plurality of ribs 110a are also arranged to define a second plurality of windows 112a configured to expose another portion of the suspension material 70. Similar to the first plurality of windows 106a, the suspension material 70 may only be visible through some of the second plurality of windows 112a. Additionally, multiple tabs 114 extend from the rear surface 109a of the top strip 82. The tabs 114 are embedded into the suspension material 70 to thereby arrange the top strip 82a along the suspension material 70.

With reference to FIG. 4, each side strip 78a, 78b includes a first end 116a, 116b and a second end 118a, 118b opposite the first end 116a, 116b. The first end 116a, 116b and the second end 118a, 118b of each side strip 78a, 78b are substantially similar to each other and include similar features. For sake of brevity, only the first ends 116a, 116b of each side strip 78a, 78b will be illustrated and described in detail.

With reference back to FIGS. 8 and 9, each first end 116a, 116b of the side strips 78a, 78b includes a plurality of slits 120a, 120b defined therein. More specifically, the plurality of slits 120a, 120b define multiple spaces within the intermediate leg 94a, 94b and the second leg 90a, 90b to thereby form a plurality of fingers 122a, 122b along each first end 116a, 116b. The plurality of fingers 122a, 122b is integrally formed with and extend from the first leg 88a, 88b. Additionally, each finger 122a, 122b is L-shaped. As such, each first end 116a, 116b of the side strips 78a, 78b is specifically structured to permit an easier assembling process of the chair 10. The plurality of slits 120a, 120b, defined between each finger 122a, 122b, provide further flexibility to the side strips 78a, 78b. The first ends 116a, 116b of the side strips 78a, 78b are then permitted to easily wrap around and couple to the curved configuration of each end 44, 46 of the frame 18. In embodiments of the chair 10 where the frame 18 does not include tightly curved ends 44, 46, the slits 120a, 120b may be omitted. In other embodiments, the molded strip 74 may include slits in other sections to help flex into tight curves of different frame configurations.

With reference to FIGS. 3 and 10-12, the molded strip 74 is formed along the suspension material 70 by an injection molding process performed within a mold assembly 124. In particular, a plastic material is injected into the mold assembly 124 to form the molded strip 74. The illustrated mold assembly 124 includes a first mold portion 126a and a second mold portion 126b. The first mold portion 126a is formed with an arcuate surface 128 to provide the suspension assembly 22 with a curved profile that is similar to the structure of the first and second frame members 42a, 42b. In other embodiments, the first mold portion 126a may be generally planar or may include other curved or undulated sections, depending on the configuration of the frame 18. A border 130 is defined along a periphery of the arcuate surface 128 and includes a plurality of projections 132 or pads. The second mold portion 126b is structured to have a complementary shape to the first mold portion 126a. The suspension material 70 is configured to lay flat against the second mold portion 126b during the injection molding process. The first mold portion 126a is positioned such that the plurality of projections 132 hold the suspension material 70 against the second mold portion 126b.

During the injection molding process for manufacturing the suspension assembly 22, the suspension material 70 is clamped between the first and second molding portions 126a, 126b. The plastic material is injected into the mold assembly 124 and the molded strap 74 is formed along the edges of the suspension material 70. More specifically, the molded strip 74 is formed to encapsulate the edges of the suspension material 70. The first leg 88a, 88b of each side strip 78a, 78b is molded onto the suspension material 70. The second leg 90a, 90b of each side strip 78a, 78b is molded to remain free of the suspension material 70 for attachment to the frame 18 of the chair 10. The top and bottom strips 82a, 82b are also molded onto the suspension material 70 such that the rear surface 109a contacts the suspension material 70. The first and second plurality of windows 106a, 112a of the molded strip 74 are also formed where the plurality of projections 132 of the first mold portion 126a contacts the suspension material 70. A portion of the suspension material 70 is then exposed or visible through the windows 106a, 112a. The encapsulated edge of the suspension material 70 has a consistent appearance since the suspension material 70 is held down by the projections 132 and not allowed to move within the mold assembly 124 during the injection molding process. As such, it is not necessary to perform a multi-injection molding process to cover the portion of the suspension material 70 that becomes visible for visual consistency.

After manufacturing the suspension assembly 22, the suspension assembly 22 may be attached to the chair 10 to support a user sitting on the chair 10. The first side strip member 78a may be coupled to the first frame member 42a such that the first end 116a of the first side strip member 78a is coupled to the first end 44a of the first frame member 42a and the second end 118a of the first side strip member 78a is coupled to the second end 46a of the first frame member 42a. The second side strip member 78b may be coupled to the second frame member 42b such that the first end 116b of the second side strip member 78b is coupled to the first end 44b of the second frame member 42b and the second end 118b of the second side strip member 78b is coupled to the second end 46b of the second frame member 42b. The second leg 90a, 90b of each side strip 78a, 78b is configured to be received within a slot 136 respectively defined within the first and second frame members 42a, 42b of the frame 18. As such, the first and second frame members 42a, 42b are disposed within a corresponding slot 98a of each side strip 78a, 78b. In some embodiments, an adhesive may be used to secure the molded strip 74 within the first and second frame members 42a, 42b. Additionally or alternatively, fasteners (e.g., screws, rivets, etc.) may be used to the secure the molded strip 74 to the frame members 42a, 42b.

The top strip member 82a extends between the first end 44a of the first frame member 42a and the first end 44b of the second frame member 42b. The bottom strip member 82b extends between the second end 46a of the first frame member 42a and the second end 46b of the second frame member 42b. Once the suspension assembly 22 is coupled to the first and second frame members 42a, 42b, the suspension material 70 is arranged to extend across the gap 50 of the chair 10. In other embodiments, the suspension assembly 22 may be coupled to other parts of the chair 10 (e.g., armrests). In further embodiments, the frame 18 may form a closed configuration such that the molded strip 74 is coupled to the frame 18 and extends continuously around a seat and a backrest of a chair. In other embodiments, the frame 18 may form a closed configuration that only extends continuously around a seat or that only extends continuously around a backrest.

FIG. 13 illustrates a method 200 of manufacturing the chair 10 of FIG. 1. At step 204, the suspension material 70 is provided. The suspension material 70 may be manufactured by, but not limited to, a weaving process or a knitting process using an elastomeric material (e.g., one or more monofilaments). At step 208, the suspension material 70 is inserted into the mold assembly 124 and securely clamped therein. The plurality of projections 132 of the first mold portion 126a holds the suspension material 70 against the second mold portion 126b. At step 212, the molded strip 74 is molded onto the suspension material 70 by an injection molding process to form the suspension assembly 22. Plastic material is injected into cavities defined within the mold assembly 124 such that the molded strip 74 is formed to encapsulate the edges of the suspension material 70. The plastic material may be injected into the mold assembly 124 as a single shot process or as a multi-shot process. The plastic material hardens around the plurality of projections 132 to form the first and second plurality of windows 106a, 112a of the molded strip 74 such that a portion of the suspension material 70 is exposed through the windows 106a, 112a. At step 216, the suspension assembly 22 is removed from the mold assembly 124 for attachment to the frame 18 of the chair 10. At step 220, the molded strip 74 of the suspension assembly 22 is coupled to the frame 18 of the chair 10. Each side strip member 78a, 78b is respectively coupled to the first and second frame members 48a, 48b such that the suspension material 70 extends across the gap 50 of the chair 10.

Ultimately, the molded strip 74 is configured to protect the edges of the suspension material 70 from damage. For example, a suspension material directly coupled to the frame of a chair without the molded strip 74 may tear or unravel when the chair continuously bumps into various objects (e.g., a table edge). As such, the molded strip 74 reduces the possibility of the suspension material 70 tearing or being removed from the frame 18 of the chair 10.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. Various features and advantages of the invention are set forth in the following claims.