US3167353A

US3167353A - Expanded foraminous plastic article

Info

Publication number: US3167353A
Application number: US217344A
Authority: US
Inventors: Samuel P Crane
Original assignee: Individual
Current assignee: Individual
Priority date: 1962-08-16
Filing date: 1962-08-16
Publication date: 1965-01-26
Anticipated expiration: 1982-01-26

Description

Jan. 26, 1965 s. P. CRANE EXPANDED FORAMINOUS PLASTIC ARTICLES Filed Aug. 16, 1962 E INVENTOR.

Samuel P Crane United States Patent 3,167,353 EXPANDED FORAMINOUS PLASTIC ARTICLE Samuel P. Crane, 23 Pine Drive, Great Neck, N.Y. Filed Aug. 16, 1962, Ser. No. 217,344 19 Claims. (Cl. 297453) This invention relates to fabricated foraminous and expanded articles of plastic material and particularly to ventilated seat spacers or cushions or the like made of such material.

One of the objects of the invention is the provision of a one piece foraminous expanded plastic sheet or molded member having net-like imperforate linear and coplanar bracing portions of substantial area and having closely spaced arch shaped laterally outstanding elements adapted to serve as a support when relatively rigid or as a cushion when more or less resilient, the elements when formed from a sheet being pressed from the sheet material between a suitable series of discontinuous slits, the sheet or molded member being so fabricated as to leave ventilating openings bridged by the elements and communicating with the spaces in the elements.

A further object of the invention is the provision of a foraminous member of relatively thin material but of relatively great overall thickness, having spaced apart raised elements separated by continuous imperforate planar bracing strips integral with the member and capable of supporting considerable stress while dimensionally stable and generally self-adjusting to the contour of the surface against which it is pressed.

A further object of the invention is the provision of an inexpensive durable foraminous seat-ventilating cushion or spacer primarily of a single piece of laterally expanded plastic braced in two substantially perpendicular directions against objectional distortion when in use, but sufliciently flexible to adjust itself, under load, to the shape of its supporting surface, such as an automobile cushion.

A further object of the invention is the provision of a shaped ventilating cushion or spacer made of the foraminous member above mentioned and having an integral substantially imperforate marginal portion provided with reinforcement against undue distortion, the cushion being adapted for manufacture with integral or with separate seat and back portions which are relatively adjustable.

A still further object of the invention is the provision of a one piece plastic ventilating cushion or spacer which is rigid enough and includes enough seating or bearing areas for comfortable support of the user, while flexible enough to conform to the shape of its supporting seat cushion and which requires no covering material on either face thereof and which is adapted to have friction or antislip strips and flat edge springs woven thereinto.

The various objects of the invention will further become clear from the following description and from the accompanying drawings, in which FIG. 1 is a fragmentary perspective view of an expanded fabricated sheet or molded member, some of the outstanding arched elements being omitted to show more clearly the ventilating openings and the integral imperforate rows of net-like cross bracing strips, which create a foraminous member.

FIG. 2 is a fragmentary top plan view of a ventilating spacer utilizing the member of FIG. 1 and showing the marginal reinforcement as well as the under friction or anti-slip strips woven into the elements.

FIG. 3 is a vertical sectional view taken on the line 33 of FIG. 2.

FIG. 4 is a fragmentary top plan view of a modified form of the expanded member.

FIG. 5 is a vertical sectional view taken on the line 5-5 of FIG. 4.

FIG. 6 is a fragmentary top plan view of another form of the arch-like elements of the member, showing an integral strengthening rib therein.

FIG. 7 is a plan view of half of a modified form of the cushion or spacer, in which the arch-like elements are arranged in a series of concentric circles instead of parallel rows, the other half being the same as that shown.

FIG. 8 is a plan view of a cushion or spacer in which the arch-like elements alternate and in which the seat part and back part are made from a single sheet and are normally held in a coplanar position by strip springs loosely woven into the sides of the cushion.

FIG. 9 is a fragmentary vertical sectional view taken on the line 9-9 of FIG. 8.

FIG. 10 is a similar view of the same showing a modified form of the marginal reinforcement.

FIG. 11 is a similar view of the same showing another form of the marginal reinforcement.

FIG. 12 is a fragmentary plan view of a cushion or spacer similar to that of FIG. 8, but showing the back and seat parts as separate pieces held together adjustably by the side springs which are wedged into adjusted positions.

FIG. 13 is a fragmentary vertical sectional view taken on the line 1313 of FIG. 12.

As has been indicated, the fabricated member shown in FIG. 1 has various uses and may be made of various plastics having the characteristics required for special uses. It may also be made by various processes such as shaping a relatively thin sheet of uniform thickness by heat and pressure between suitable dies or by molding or the like. When fabricated from a sheet, selected areas between discontinuous slits are pressed laterally out of the initial plane of the sheet into the outstanding generally arch-shaped elements desired, while permitting linear bracing portions to remain unchanged and thereby to produce a foraminous or net-like member having openings therein bridged by the elements. When expanded to a considerable extent, parts of the elements may decrease in thickness by the excessive lengthening thereof, but such decrease is compensated for by curving the element material, impressing a rib thereinto or otherwise shaping the parts of the element to increase its strength. When made by molding processes, the parts which take the greatest stresses are obviously made thickest. In what follows, the expanded member as well as the articles made therefrom, will be described as though the outstanding elements thereof were made from a sheet, though it will be understood that other appropriate processes may be utilized to attain substantially the same form of the expanded member.

In the form shown in FIG. 1, a series of longitudinally aligned separated slits as 16 are arranged in a row along a straight line. A similar but opposed series of companion slits 26:: parallel to and spaced transversely away from the slits 16 are made in the sheet. The material forced laterally or outwardly from between the companion slits and out of the initial plane of the sheet is shaped as desired, which is preferably in the general form of a trapezoidal arch to form a supporting element bridging the resulting opening in the sheet. As shown, the element has a flat top 17 parallel to the plane of the sheet, and outwardly converging

sides

18 and 19 of substantial height. The flat tops provide discontinuous bearing areas for the support of the load, and are close enough for a user to sit on or lean against without discomfort when the member 15 is incorporated into a ventilating cushion or spacer.

The openings, formed between companion pairs of

slits

16 and 16a by the removal or displacement of material to form the elements, are in spaced relation to each other, being separated by the preferably imperfor-ate bracing strips 22 extending lengthwise of the openings 20 completely across the member. Said openings 20 communicate with the spaces in the elements to permit the circulation through the member of enough air to adequately ventilate the member, while the bracing strips resist bending on lines extending between the ends of adjacent openings thereby avoiding objectionable limpness or distortion of the member in one direction. To stiffen the member as well against bending in a perpendicular direction and thereby to form a net-like area of substantial extent, the slits 16 of each row of such slits, as well as the slits 16a of the companion row, are spaced apart longitudinally so that a substantial area of imperforate material separates the ends of the slits in each row of the entire set of such rows. Such imperforate areas merge into bracing strips 23 extending completely along the member and form a set intersecting the set of strips 22.

It will be understood that the shapes and sizes of the slits, openings and outstanding elements may be varied to a considerable extent. In FIGS. 1-3, the elements alternate in arrangement in a single row to form a set extending upwardly from the general plane of the connecting

bracing strips

22 and 23 and a second set in the same rows extending downwardly. The first set constitutes the crests 24 and the alternate set constitutes the troughs 25. Such crests and troughs also alternate in the transverse set of rows parallel to the bracing strips 23. As a result, the overall thickness of the member 15 is considerable. It is due to the foraminous structure of the member that it is adequately ventilated without sacrifice of its supporting properties and while permitting some flexibility in the member even though it may be made of relatively rigid plastic.

When the plastic used is of greater resiliency than that required for seat ventilators, the member may be employed in shipping packages as a protecting packing cushion, or for other cushioning purposes where a resilient supporting pad is desirable.

In FIGS. and 6 is shown a member 26 in which only outstanding crests are provided as elements, the troughs having been omitted in order to attain denser or more closely spaced bearing areas than would be possible if the troughs were present. The arch-shaped crests are aligned in rows lengthwise of the openings 20 similarly to those shown in FIGS. 1-3, but the crests differ in arrangement, those of FIGS. 5-6 having adjacent rows which are relatively staggered. The transverse bracing strips 28 between the ends of adjacent elements in each row consequently are not continuous or straight, but are undulating. The flat tops 17 of elements in adjacent rows overlap somewhat and decrease the spacing of the bearing areas as compared to the form of FIGS. 1-3. In addition, or optionally, the converging

outstanding sides

29, 30 of the elements are curved in cross section better to resist bending or collapse under load than when flat.

In the form of the element shown in FIG. 6, all three sides are provided with suitable outstanding ribs as 31 to strengthen said sides, it being understood that such ribs may be provided, if desired, in any of the elements hereinbefore described.

The expanded plastic member, no matter how it is fabricated, is particularly useful in a ventilating cushion or spacer for an automobile seat. For such use, the marginal portion 33 of the sheet (FIGS. 2 and 3) preferably remains imperforate for stiffening purposes and may be additionally reinforced or stiffened in a number of ways. In FIGS. 2 and 3, the peripheral portion 34 is curved underneath and around the preferably plastic welt or core 35 and heat sealed to the marginal portion 33.

In FIG. 7, the outstanding elements are arranged in concentric rows as 36, 37 to form a disc shaped cushion or spacer, leaving concentric bracing strips 39 between the radial rows of elements. It will be understood that the arrangement of the rows of elements does not neces sarily depend on the outline of the shape selected for the cushion, provided that at least two sets of intersecting bracing strips separate and stiffen the elements and the member. As shown in FIG. 7, radial bracing strips 38 remain between adjacent radial rows of the elements. The curved marginal flange 40 serves to retain the border stiffening member 41 in place.

In FIG. 8 is illustrated the application of the member as 15 or the like to a generally rectangular one piece seat cushion or spacer having a seat part 42 and a back part 43 integral therewith. The area 44 between said parts remains imperforate. Through the side

marginal portions

45, 46 short transverse spaced apart slits are made as 47, through which suitable fiat springs as 49 (FIG. 9) are woven. The springs are normally flat spring strips shaped to maintain the parts in coplanar positions when unloaded and unstressed, but are soft enough to yield readily and to permit the parts to assume mutually perpendicular positions whereby the seat part may be arranged to rest on the seat cushion of an automobile and the back part against the back cushion. The edges of the cushion or spacer, regardless of the shape of its outline or of the shape or arrangement of the rows of outstanding elements thereof, terminate in outstanding flanges as 50 substantially perpendicular to the general plane of the expanded member and serves as a means for stiffening the cushion against undue bending and aiding the longitudinal and transverse bracing strips between the elements to attain the required resistance to bending.

In FIG. 10, the edge stiffening means takes the form of an inturned springy cylindrical edge portion 51 enclosing a socket-like space 52 having a flared lip 53 constricting the entrance opening to said space and adapted to receive the border frame 54 of suitable stiffening material. The frame is forced past the lip, which yields to enlarge the entrance opening and to permit the frame to move therepast and into the furthermost part of the socket 52, the lip being released and again restricting the opening after the passage of the frame therepast.

As shown in FIG. 11, the edge reinforcing or stiffening means comprises corrugations or ribs as 55 in the marginal portion of the cushion, optionally combined with the outstanding flange 56.

Should it be desired to have separate seat and back parts for the cushion, as shown in FIGS. 12 and 13, such parts are adjustably connected by the flat springs 49 woven through the slits 47 of said parts as in FIGS. 8 and 9. The seat and back parts are slid along the springs until the space 57 therebetween is adjusted to the required width, whereafter the springs are secured to the parts in any suitable manner as by Wedging them into the slits, or by snap fasteners or the like. Wedges as 58 are shown diagrammatically in FIG. 13 to prevent undesired movement of the seat and back parts relatively to each other and to the springs.

To resist slippage of the cushion on its seat, suitable anti-friction (such as rubber) strips as 60 (FIGS. 2 and 3) are woven through the spaces in the elements in position to contact the seat on which the cushion rests. In the form of FIGS. 5 and 6, the strips may be woven through the openings 20 in a similar manner.

It will now be seen that the expanded member herein described may assume a variety of forms by the proper spacing sizes and arrangements of the elements, openings and bracing strips thereof; that such member has various uses and may be made of various plastics by various processes depending on the type of load thereon and the desired rigidity strength flexibility and resilience thereof, that when used in cushions, such cushions are made in any desired shape of a single piece of plastic other than the edge reinforcing means added thereto, that adequate provision is made for ventilation through the openings and communicating spaces in the member and that the various objects of the invention have been adequately attained.

While certain specific forms of the invention have herein been shown and described, various obvious changes may be made therein without departing from the spirit of the invention defined by the appended claims.

I claim:

1. In a fabricated expanded plastic member of greater overall height than the thickness of the material thereof, a foraminous generally planar one piece portion having integral sets of intersecting stiffening strips surrounding and defining rows of longitudinally and transversely spaced apart openings in said portion, and outstanding generally arch-shaped elements integral with said portion and each bridging one of the openings and having a top of substantial area, the elements being sufiiciently rigid and closely spaced enough to support a load, there being spaces in the elements communicating with the openings and of suflicient volume for the circulation of air through the member.

2. The plastic member of claim 1, the member being sufiiciently flexible to conform, when loaded, to the contour of the surface on which the member rests, one set of strips comprising parallel rows in transverse spaced relation to each other, and the intersecting set of strips comprising rows in longitudinal spaced relation to each other.

3. The plastic member of claim 1, alternate elements outstanding laterally at the openings in opposite directions.

4. The plastic member of claim 1, the tops of the elements being flat, the elements being arranged in transversely and longitudinally extending sets of rows, each of the stiffening strips of one set being parallel to and between a pair of adjacent elements of adjacent transversely extending rows, each of the strips of the other set of stiffening strips being interposed between a pair of adjacent rows of the longitudinally extending set of rows.

5. The plastic member of claim 4, each strip of one set of stilfening strips being straight and continuous and each strip of the other set being discontinuous, adjacent rows of elements of one of the sets of said rows being staggered relatively to each other.

6. A ventilating cushion comprising the member of claim 1, an integral coplanar extension of the foraminous portion constituting a substantially imperforate marginal part around the periphery of the cushion, said extension being curved to extend laterally and thereby to stitfen said marginal part.

7. The cushion of claim 6, and a reinforcing border member held by and Within the marginal part.

8. A one piece plastic ventilating cushion sufiiciently flexible to conform, when loaded, to the contour of a seat on which the cushion rests or leans, comprising a marginal portion, reinforcing means at the periphery of said portion, and a laterally expanded portion integral with the marginal portion and comprising a net-like part having longitudinally and transversely extending and spaced apart rows of openings therein and laterally outstanding elements of arch-like shape each bridging one of the openings and thereby being spaced longitudinally away from adjacent elements in the same row and transversely away from adjacent elements in adjacent rows.

9. The cushion of claim 8, the cushion having a seat part and a back part separated by an imperforate portion integral with the seat and back parts, the marginal portion of the seat and back parts having short parallel slits therein, and springs Woven through the slits and urging the seat and back parts into coplanar relation to each other.

10. The cushion of claim 8, the cushion having separate seat and back parts and means adjustably connecting said parts comprising springs loosely woven through the adjacent marginal portions of the seat and back parts and means for securing the springs in adjusted positions in said portions.

11. In a ventilating cushion having rows of aligned openings therethrough and laterally extending supporting members bridging the openings, a member of anti-friction material woven through each of a number of selected rows of openings, the member having longitudinally spaced apart portions thereof exposed at a surface of the cushion for contact with a supporting surface thereby to resist slippage of the cushion on said supporting surface.

12. The cushion of claim 11, the member being a strip of fiat elastomer material.

13. In a ventilating cushion, a substantially imperforate marginal portion, stiffening means increasing the overall thickness of the periphery of said portion, rows of transversely and longitudinally spaced apart supporting elements projecting laterally from the cushion and integral therewith, there being openings in the cushion at each of said elements, and elongate anti-friction members woven through respective selected rows of said openings.

14. The cushion of claim 13, the anti-friction members being flat rubber strips.

15. A fabricated plastic member comprising a sheet of substantially uniform initial thickness having a first set of parallel longitudinally extending continuous rows of strips of substantially uniform width,

a second set of parallel transversely extending rows of strips of substantially uniform width intersecting the first set,

said sets of strips constituting a planar net-like stiffening web of the initial uniform thickness of the sheet,

there being openings arranged in rows through the sheet between the rows of both sets of strips,

the openings between adjacent rows of strips and in each row of openings being spaced apart, and

a laterally outstanding arch-like element integral with the sheet material of the strips at each end of each opening and bridging said opening and having a top of slightly less length than and of substantially the same width as that of said opening and in lateral spaced relation thereto, and

outwardly converging sides on the element integrally joining the top to the adjacent strips of the second set.

16. The plastic member of claim 15, the strips of the second set being of substantially undulating form.

17. The plastic member of claim 15, the sides of each element being of lesser thickness than that of the web.

18. The plastic member of claim 15, the elements at alternate openings outstanding laterally in one direction from the web and the elements at the remaining openings outstanding laterally in the opposite direction from the web.

19. The plastic member of claim 14, the top of the element being flat, the sides of each element being of lesser thickness than that of the web, the elements being sufficiently rigid and spaced closely enough to support a load.

References Cited in the file of this patent UNITED STATES PATENTS 198,421 Smith Dec. 18, 1877 1,067,521 Jones July 15, 1913 1,490,554 Bashkow et a1 Apr. 15, 1924 1,577,331 Lopez Mar. 16, 1926 2,454,912 Cunningham Nov. 30, 1948 2,734,556 Hebrank Feb. 14, 1956 2,931,427 Goldstein Apr. 5, 1960 2,948,333 Goldstein Aug. 9, 1960 2,948,334 Goldstein Aug. 9, 1960 3,006,688 Ouellette Oct. 31, 1961

Claims

1. IN A FABRICATED EXPANDED PLASTIC MEMBER OF GREATER OVERALL HEIGHT THAN THE THICKNESS OF THE MATERIAL THEREOF, A FORAMINOUS GENERALLY PLANAR ONE PIECE PORTION HAVING INTEGRAL SETS OF INTERSECTING STIFFENING STRIPS SURROUNDING AND DEFINING ROWS OF LONGITUDINALLY AND TRANSVERSELY SPACED APART OPENINGS IN SAID PORTION, AND OUTSTANDING GENERALLY ARCH-SHAPED ELEMENTS INTEGRAL WITH SAID PORTION AND EACH BRIDGING ONE OF THE OPENINGS AND HAVING A TOP OF SUBSTANTIAL AREA, THE ELEMENTS BEING SUFFICIENTLY RIGID AND CLOSELY SPACED ENOUGH TO SUPPORT A LOAD, THERE BEING SPACES IN THE ELEMENTS COMMUNICATING WITH THE OPENINGS AND OF SUFFICIENT VOLUME FOR THE CIRCULATION OF AIR THROUGH THE MEMBER.