WO2006047142A2 - Article en fragments de bois moules comprenant des elements ressorts flexibles imbriques presentant des protuberances de detection - Google Patents

Article en fragments de bois moules comprenant des elements ressorts flexibles imbriques presentant des protuberances de detection

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Publication number
WO2006047142A2
WO2006047142A2 PCT/US2005/037427 US2005037427W WO2006047142A2 WO 2006047142 A2 WO2006047142 A2 WO 2006047142A2 US 2005037427 W US2005037427 W US 2005037427W WO 2006047142 A2 WO2006047142 A2 WO 2006047142A2
Authority
WO
WIPO (PCT)
Prior art keywords
section
article
spring members
springs
molded
Prior art date
Application number
PCT/US2005/037427
Other languages
English (en)
Other versions
WO2006047142A3 (fr
Inventor
Jeff R. Britton
Samuel S. Conte
Original Assignee
J. R. Britton & Associates, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by J. R. Britton & Associates, Inc. filed Critical J. R. Britton & Associates, Inc.
Publication of WO2006047142A2 publication Critical patent/WO2006047142A2/fr
Publication of WO2006047142A3 publication Critical patent/WO2006047142A3/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C5/00—Chairs of special materials
    • A47C5/14—Chairs of special materials characterised by the use of laminated wood
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C3/00—Chairs characterised by structural features; Chairs or stools with rotatable or vertically-adjustable seats
    • A47C3/02—Rocking chairs
    • A47C3/021—Rocking chairs having elastic frames
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/024—Seat parts with double seats
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/025—Springs not otherwise provided for in A47C7/22 - A47C7/35
    • A47C7/027—Springs not otherwise provided for in A47C7/22 - A47C7/35 with elastomeric springs
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/025—Springs not otherwise provided for in A47C7/22 - A47C7/35
    • A47C7/028—Springs not otherwise provided for in A47C7/22 - A47C7/35 with wooden springs, e.g. slated type
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/36—Support for the head or the back
    • A47C7/40—Support for the head or the back for the back
    • A47C7/405—Support for the head or the back for the back with double backrests
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/36—Support for the head or the back
    • A47C7/40—Support for the head or the back for the back
    • A47C7/44—Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame
    • A47C7/445—Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame with bar or leaf springs

Definitions

  • Wood flake molding also referred to as wood strand molding
  • wood strand molding is a technique invented by wood scientists at Michigan Technological University during the latter part of the 1970s for molding three-dimensionally configured objects out of binder coated wood flakes having an average length from about 1 1 A to about 6 inches, preferably from about 2 to about 3 inches; an average thickness of about 0.005 to about 0.075 inches, preferably from about 0.015 to about 0.030 inches; and an average width of 3 inches or less, most typically 0.25 to 1.0 inches, and never greater than the average length of the flakes.
  • These flakes are sometimes referred to in the art as "wood strands.”
  • This technology is not to be confused with oriented strand board technology (see e.g., U.S. Patent No. 3,164,511 to Elmendorf) wherein binder coated strands of wood are pressed into planar objects.
  • the flakes are molded into three-dimensional, i.e., non-planar, configurations.
  • flakes of wood having the dimensions outlined above are coated with methylene diisocyanate (MDI) or a similar binder and deposited onto a metal tray having one open side, in a loosely felted mat, to a thickness of about eight or nine tunes the desired thickness of the final part.
  • MDI methylene diisocyanate
  • the loosely felted mat is then covered with another metal tray, and the covered metal tray is used to carry the mat to a mold.
  • top metal tray is removed, and the bottom metal tray is then slid out from underneath the mat, to leave the loosely felted mat resting in position on the bottom half of the mold.
  • the top half of the mold is then used to press the mat into the bottom half of the mold at a pressure of approximately 600 psi, and at an elevated temperature, to "set” (polymerize) the MDI binder and to compress and adhere the compressed wood flakes into a final three-dimensional molded part.
  • the excess perimeter of the loosely felted mat that is, the portion extending beyond the mold cavity perimeter, is pinched off where the part defining the perimeter of the upper mold engages the part defining the perimeter of the lower mold cavity. This is sometimes referred to as a pinch trim edge.
  • Patent U.S. 4,469,216 best illustrate the manner in which the ⁇ vood flakes are deposited to form a loosely felted mat, although the metal trays are not shown.
  • loosely felted it is meant that the wood flakes are simply lying one on top of the other hi overlapping and interleaving fashion, without being bound together in any way.
  • the binder coating is quite dry to the touch, such that there is no stickiness or adherence which hold them together hi the loosely felted mat.
  • the drawings of Patent U.S. 4,440,708 best illustrate the manner in which a loosely felted mat is compressed by the mold halves into a three- dimensionally configured article (see Figs. 2-6, for example).
  • the molded wood flakes can be formed in any desired three-dimensional configuration, this discovery allows the material to be used for deflectable weight supporting articles, such as in the seating environment.
  • a clear benefit of using such spring material as opposed to typical coil springs or sinuous wire springs is that they are not subject to rust nor do they require the intense labor necessary when manufacturing a chair or other seating object utilizing conventional springs. Further, the feel of the seat utilizing such springs is improved inasmuch as the springs do not require preloading, as with typical sinuous or coil springs.
  • the use of molded wood flake springs will revolutionize the manufacture of supports which, in past years, required the use of sinuous or coil springs.
  • a support article in the present invention, includes a pair of molded wood flake supports which can be arranged on a frame member in an interleaved pattern.
  • the supports are spaced-apart linearly extending molded wood flake springs with ends that are free to flex.
  • each support integrally includes a plurality of spaced-apart linearly extending spring members which are integrally formed at an angle from a connecting end piece.
  • the pair of supports can be mounted on opposite sides of a support frame with the alternatively staggered molded wood flake springs interleaved to provide cantilevered springs extending from opposite edges of trie support frame to evenly balance a weight load.
  • the free ends of the springs include convexly raised projections which serve as sensors to initiate dynamic loading on the springs as a load is placed on the support.
  • the longitudinal orientation of the molded ⁇ vood flake springs can be from front-to-back or side-to-side in an application. Such construction can be employed in a variety of applications, including but not limited to chairs, sofas, benches, and beds.
  • FIG. 1 is a fragmentary perspective view of a chair, partly in phantom form, having a plurality of interleaved molded wood flake spring members in the seat and back areas according to the present invention
  • Fig. 2 is a fragmentary front view, partly in cross section, of a molding apparatus for manufacturing molded wood flake components with a wood flake mat positioned therebetween before compression;
  • FIG. 3 is a view of the molding apparatus of Fig. 2, shown during compression;
  • Fig. 4 is an exploded perspective view of the chair form of Fig. 1;
  • FIGs. 5-7 are fragmentary side elevational views of the chair of Figs. 1 and 4, showing the progressive dynamic loading of the plurality of flexible wood flake spring members as a person is seated;
  • Fig. 8 is a perspective view of a bed according to another embodiment of the invention.
  • FIG. 9 is an exploded perspective view of the bed shown in Fig. 8;
  • Fig. 10 is a side elevational pictorial view, showing the springs of the seat of
  • Fig. 11 is a side elevational pictorial view, showing the spring of the seat of Fig.
  • Fig. 1 such as a chair 10 is fabricated to include a seat 12 with a plurality of spaced- apart interleaved wood flake molded flexible spring members 14A and 14B extending from opposite edges of the seat 12.
  • the flexible spring members 14A and 14B with sensors 46 and 44, respectively are integrally molded into frame supports 16 and 18 during the fabrication process thereof and are secured to sides 40 and 42 completing the frame 15 of chair 10.
  • the seat back 11 likewise includes a plurality of spaced-apart curved wood flake molded flexible spring members 14C extending from an integral mounting support 13 also secured to frame 15.
  • Mold 20 includes a top mold die 26 and a bottom mold die 28.
  • the top mold die 26 includes a surface 21 and at least one extension 23 extending from the surface 21 for forming slots 17 (Fig. 1) in supports 16, 18, and 13 which define the perimeter of flexible spring members 14A, 14B, and 14C.
  • the bottom mold die 28 includes a surface 25 having at least one extension receiving cavity 27.
  • the surface 21 of the top mold die 26 and the surface 25 of the bottom mold die 28 define a part forming cavity 30 therebetween which forms a part, such as 13, 16, or 18, into a desired shape, while extension 23 is configured to extend througli molded wood flake part 13, 16, or 18 and into cavity 27 to form slots 17 between the spring members, thereby defining at least one flexible spring member 14A, 14B, and/or 14C which can flex independently from the molded wood flake support 16, 18, and/or 13, as illustrated in Fig. 1.
  • slots 17 may be fabricated by other methods including sawing, cutting, machining and the like.
  • the molded wood flake parts 13, 16, and 18 are made by positioning a loosely felted mat 32 of wood flakes 22 on the bottom mold die 28.
  • the top mold die 26 and the bottom mold die 28 are then brought together or closed, wherein heat and pressure are applied to felted mat 32.
  • Felted mat 32 is thereby compressed and cured into the molded wood flake part having integral flexible spring members formed therein. In the preferred embodiment, this is accomplished by having extension 23 pass, cut or push through mat 32, forcing wood flakes 22 down into extension receiving cavity 27 to form slots 17.
  • extension 23 is shown in the illustrated example, a plurality of spaced-apart extensions and cavities are typically used to form a plurality of spaced-apart flexible spring members in the chair seat and back, as illustrated in Fig. 1.
  • the molded wood flake parts 13, 16, and 18 may include additional features, such as holes 39 (Fig. 4) for T-nut fasteners, which receive fasteners 38 (Fig. 4).
  • Figs. 2-3 illustrate, for example, an extension 36 may be used to make hole 34 and is received within cavity 33.
  • the resulting hole 34 provides a uniform appearance from the surface of the molded wood flake part and facilitates the insertion of a T-nut for fasteners 38 from either surface.
  • the width of the hole 34 is sufficiently great throughout its length that it will accommodate a sleeve of a T-nut or other fastener to be inserted into the hole 34, without interference.
  • the top surface 35 of the molded wood flake part 13, 16, and/or 18 is adjacent the surface 21 of the top mold die 26 and the bottom surface 37 of the molded wood flake part 13, 16, and/or 18 is adjacent the surface 25 of the bottom mold die 28 after the wood flakes 22 have been consolidated, compressed and cured into the molded wood flake parts.
  • the molded wood flake parts made in this manner will preferably have a nominal thickness T (Fig. 3) of from about 3/8 inch to about 5/8 inch.
  • Felted mat 32 will be compressed to varying thicknesses by mold 20, due to unavoidable inconsistencies of mat 32, such as spring back of the mat, over- compression, or the like.
  • the bottom surface 37 of molded wood flake parts 13, 16, and/or 18 will be located within a zone of variation in part thickness.
  • the zone of variation in part thickness is the area in which the bottom surface 37 of the molded wood flake part could be located, depending on the thickness of the molded wood flake part, compared to a stationary position for the top surface 35 of the molded wood flake part.
  • suitable woods include aspen, maple, oak, elm, balsam fir, pine, cedar, spruce, locust, beech, birch and mixtures thereof, although aspen is preferred.
  • Suitable wood flakes 22 can be prepared by various techniques. Pulpwood grade logs, or so-called round wood, are converted into wood flakes 22 in one operation with a conventional roundwood flaker. Logging residue or the total tree is first cut into fingerlings having an average length from about 1.25 to about 6 inches, preferably from about 2 inches to about 3.5 inches with a device, such as the helical comminuting shear disclosed in U.S. Patent No. 4,053,004, and the fingerlings are subsequently flaked in a conventional ring-type flaker. Roundwood wood flakes generally are higher quality and produce stronger parts because the lengths and thickness can be more accurately controlled.
  • roundwood wood flakes tend to be somewhat flatter, which facilitates more efficient blending and the logs can be debarked prior to flaking which reduces the amount of less desirable fines produced during flaking and handling.
  • Acceptable wood flakes can be prepared by ring flaking fingerlings - This technique is more readily adaptable to accept wood in poorer form, thereby permitting more complete utilization of certain types of residue and surplus woods.
  • the size distribution of the wood flakes 22 is quite important, particularly the length and thickness.
  • the wood flakes should have an average length from about 1 1 A inches to about 6 inches, preferably from about 2 inches to about 3.5 inches; an average thickness of about 0.005 inch to about 0.075 inch, preferably from about 0.015 inch to about 0.030 inch and more preferably about 0.0020 inch; and an average width of about 3 niches or less, most typically from about 0.25 inch to about 1.0 inch, and less than the average length of the flakes.
  • some of the wood flakes 22 can be shorter than about 1.25 inch, and some can be longer than about 6 inches, so long as the overall average length is within the above range. The same is true for the thickness.
  • wood flakes 22 having a thickness greater than about 0.075 inch are relatively stiff and tend to overlie each other at some incline when formed into the felted mat 32. Consequently, excessively high mold pressures are required to compress the wood flakes 22 into the desired intimate contact with each other. For wood flakes 22 having a thickness falling within the above range, thinner ones produce a smoother surface while thick ones require less binder. These two factors are balanced against each other for selecting the best average thickness for any particular application. 028]
  • the width of the wood flakes 22 is less important. The wood flakes 22 should be wide enough to ensure that they lie substantially flat when felted during mat formation. The average width generally should be about 3 inches or less and no greater than the average length. For best results, the majority of the wood flakes 22 should have a width of from about 0.25 to about 1.0 inches.
  • Trie blade setting on a flaker can primarily control the thickness of the wood flakes 22.
  • the length and width of the wood flakes 22 are also controlled to a large degree by the flaking operation. For example, when the wood flakes 22 are being prepared " by ring flaking fingerlings, the length of the fingerlings generally sets the maximum lengths.
  • Other factors, such as the moisture content of the wood and the amount of bark on the wood affect the amount of fines produced during flaking. Dry wood is more brittle and tends to produce more fines. Bark has a tendency to more readily break down into fines during flaking and subsequent handling than wood.
  • the flake size can be controlled to a large degree during the flaking operation as described above, it usually is necessary to use a screening process in order to remove undesired particles, both undersized and oversized, and thereby ensure the average length, thickness and width of the wood flakes 22 are within the desired ranges.
  • a screening process in order to remove undesired particles, both undersized and oversized, and thereby ensure the average length, thickness and width of the wood flakes 22 are within the desired ranges.
  • both screen and air classification are usually required to adequately remove both the undersize and oversize particles, whereas finger ling wood flakes usually can be properly sized with only screen classification.
  • Wood flakes from some green wood can contain up to about 90 percent moisture.
  • the wood flakes 22 are preferably dried prior to classification in a conventional type drier, such as a tunnel drier, to the moisture content desired for the blending step.
  • the moisture content to which the wood flakes 22 are dried usually is in the order of about 6 weight percent or less, preferably from about 2 to about 5 weight percent, based on the dry weight of the wood flakes 22.
  • the wood flakes 22 can be dried to a moisture content in the order of from about 10 to about 25 weight percent prior to classification and then dried to the desired moisture content for blending after classification. This two-step drying may reduce the overall energy requirements for drying wood flakes prepared from green woods in a manner producing substantial quantities of particles which must be removed during classification and, thus, need not be as thoroughly dried.
  • a known amount of the dried, classified wood flakes 22 is introduced into a conventional blender, such as a paddle-type batch blender, wherein predetermined amounts of a resinous particle binder, and optionally a wax and other additives, is applied to the wood flakes 22 as they are tumbled or agitated in the blender.
  • a conventional blender such as a paddle-type batch blender
  • predetermined amounts of a resinous particle binder, and optionally a wax and other additives is applied to the wood flakes 22 as they are tumbled or agitated in the blender.
  • the article fabricated from wood flakes 22 is substantially rather than entirely comprised of wood flakes, as other additives as described above are added to create mat 32.
  • other base materials may also be added to the wood flakes to form a mat 32 comprising a blend of wood flakes 22 and other suitable materials.
  • Suitable binders include those used in the manufacture of particle board and similar pressed fibrous products and, thus, are referred to herein as "resinous particle board binders.”
  • suitable binders include thermosetting resins such as phenolformaldehyde, resorcinol-formaldehyde, melamine-formaldehyde, urea- formaldehyde, urea-furfuryl and condensed furfuryl alcohol resins, and organic polyisocyantes, either alone or combined with urea- or melamine-formaldehyde resins.
  • Particularly suitable polyisocyanates are those containing at least two active isocyanate groups per molecule, including diphenylmethane diisocyanates, m- and p- phenylene diisocyanates, chlorophenylene diisocyanates, toluene di- and triisocyanates, triphenylmethene triisocyanates, diphenylether-2,4 ,4'-triisoccyanate and polypheny lpolyisocyanates, particularly diphenylmethane-4,4'-diisocyanate. So-called MDI (methylene diphenyl diisocyanate) is particularly preferred.
  • the amount of binder added to the wood flakes 22 during the blending step depends primarily upon the specific binder used, size, moisture content, type of the wood flakes and the desired characteristics of the part being formed. Generally, the amount of binder added to the wood flakes 22 is from about 3.5 to about 15 weight percent, preferably from about 4 to about 10 weight percent, and most preferably about 5 percent. When a poly isocyanate is used alone or in combination with a urea- formaldehyde resin, the amounts can be more toward the lower ends of these ranges.
  • the binder can be admixed with the wood flakes 22 in. either dry or liquid form.
  • the binder preferably is applied by spraying droplets of the binder in liquid form onto the wood flakes 22 as they are being tumbled or agitated in the blender.
  • a conventional mold release agent preferably is applied to the die or to the surface of the felted mat prior to pressing.
  • a conventional liquid wax emulsion is also sprayed on the wood flakes 22 during the blinding step .
  • the amount of wax added generally is about 0.5 to about 2 weight percent, as solids, based on the dry weight of the wood flakes 22.
  • additives such as one of the following: a coloring agent, fire retardant, insecticide, fungicide, mixtures thereof and the like may also be added to the wood flakes 22 during the blending step.
  • a coloring agent such as one of the following: a coloring agent, fire retardant, insecticide, fungicide, mixtures thereof and the like may also be added to the wood flakes 22 during the blending step.
  • the binder, wax and other additives can be added separately in any sequence or in combined form.
  • the moistened mixture of binder, wax and wood flakes 22 or "furnish" from the blending step is formed into a loosely-felted, layered mat 32, ⁇ vhich is placed within the cavity 30 prior to the molding and curing of the felted mat 32 into molded wood flake parts, such as those used to form seat 12.
  • the moisture content of the wood flakes 22 should be controlled within certain limits so as to obtain adequate coating by the binder during the blending step and to enhance binder curing and deformation of the wood flakes 22 during molding.
  • the moisture content of the furnish after completion of blending should be from about 5 to about 25 weight percent, preferably from about 8 to about 12 weight percent.
  • higher moisture contents within these ranges can be used for polyisocyanate binders " because they do not produce condensation products upon reacting with cellulose in the wood.
  • the furnish is formed into the generally flat, loosely-felted, mat 32, preferably as multiple layers.
  • a conventional dispensing system similar to those disclosed in U.S. Pat. Nos. 3,391,223 and 3,824,058, and 4,469,216 can be used to form the felted mat 32.
  • a dispensing system includes trays, each having one open side, carried on an endless belt or conveyor and one or more (e. g. , three) hoppers spaced above and along the belt in the direction of travel for receiving the furnish.
  • a plurality of hoppers usually are used with each having a dispensing or forming head extending across the width of the carriage for successively depositing a separate layer of the furnish as the tray is moved beneath the forming heads. Following this, the tray is taken to the mold to place the felted mat within the cavity of bottom mold 28, by sliding the tray out from under mat 32.
  • molded wood flake parts such as 13, 16, and 18 (Figs. 1 and
  • the felted mat should preferably have a substantially uniform thickness and the wood flakes 22 should lie substantially flat in a horizontal plane parallel to the surface of the carriage and be randomly oriented relative to each other in that plane.
  • the uniformity of the mat thickness can be controlled by depositing two or more layers of the furnish (i.e. , wood flakes and binder) on the carriage and metering the flow of furnish from the forming heads.
  • the mat thickness that would optimally have the nominal part thickness T will vary depending upon such factors as the size and shape of the wood flakes 22, the particular technique used for forming the mat 32, the desired thickness and density of the molded wood flake part 12 produced, the configuration of the molded wood flake parts, and the molding pressure to be used.
  • felted mats 32 will be compressed to varying thicknesses by mold 20 due to unavoidable inconsistencies from mat 32, spring back, over-compression, or the like.
  • the felted mat 32 is compressed at a pressure of up to about 600 psi and cured under heat of from about 350°F to about 450°F when the top mold die 26 engages the bottom mold die 28.
  • Mat 32 is compressed preferably to a density of from about 40 to about 45 pounds per cubic foot, more preferably about 43 pounds per cubic foot.
  • the extension 23 pushes through the binder coated wood flakes 22 of the felted mat 32 and is received by the extension receiving cavity 27. This action forms the slots 17 which define the perimeter of flexible spring members 14A, 14B, and 14C of the structure shown in Fig. 1. Any holes 34 will also be created during this molding step as detailed above.
  • the felted mat 32 is thus compressed and cured between the top mold die 26 and the bottom mold 28 to become the molded wood flake parts 13, 16, and 18. After the molded wood flake parts are produced, any flashing and any plugs are removed by conventional means to reveal flexible spring members 14A, 14B, and 14C integrally extending from supports 16, 18, and 13, respectively, and holes 34.
  • the molded wood flake process as described above can be used to fabricate three-dimensional weight bearing supports, such as represented by the molded wood flake back 11 and seat 12 of chair 10 shown in Figs. 1 and 4.
  • the chair 10 includes a generally rectangular base 15 having sides 40 and 42, a front wall 16, and a rear wall 18. Side walls 40 and 42 extend rearwardly behind rear wall 46 and include slots 41 and 43, respectively, therein for receiving the back 11 which includes notches 45 (Fig. 4) allowing the back to interfit within the slots 41 and 43 of sides 40 and 42, respectively, as shown in the assembled view of Fig. 1.
  • Chair 10 may be covered by a suitable padding and upholstery 48, as shown in phantom form in Fig. 1.
  • Legs 50 are mounted to the seat 12 and base 15 in a conventional manner, which may involve the use of the T-nut fasteners placed in apertures 34 and threaded screws 38 or the like, extending into the sides 16, 18, 40, and 42, to complete the base 15 and into apertures formed in the edges of notches 45 of back 11 and into legs 50 to assemble the chair 10.
  • the sides 40 and 42 and back 11 are preferably molded using the molded wood flake process described above.
  • the seat 12 of the chair 10 of the present invention includes interleaved spring members 14A and 14B integrally formed in seat sections 60 and 70, as best seen in Fig. 4.
  • Seat section 60 includes four flexible fingers 14A extending from an integrally formed angled support frame section 16 with slots 17 between adjacent fingers.
  • the mating interleaved seat section 70 of seat 12 also comprises three extending spring members 14B which integrally extend from angled support frame section 18 in alternately staggered relationship with respect to the orientation of spring members 14A, such that they interleave as shown in Fig. 1, to provide continuous, spaced-apart parallel extending cantilevered springs 14A and 14B which extend from opposite edges of seat 12.
  • the angle ⁇ (Fig.
  • leg area of body form 56 first engages sensors 46 on spring arms 14B which initiates the deflection of spring arms 14B, as seen in Fig. 6, presenting an initial, relatively soft feel to the seat inasmuch as only three spring arms in the preferred embodiment, as shown in Figs. 1 and 4, are initially involved.
  • the members 14A begin to deflect, as also seen in Fig. 6, and, as the person is fully seated, as shown in Fig.
  • the sensors 44 cause the deflection of spring arms 14A to provide significant support for the full weight of the body form 56, while the lighter leg section sensors 46 allow spring arms 14B to deflect upwardly and provide continuous support for the legs.
  • Padding 48 of the upholstery is also illustrated in Figs. 5-7, which may include upholstery fabric and suitable foam padding to provide a more uniform feel to the user as the spring arms 14B initially deflect, followed by spring arms 14A, and subsequently all of the spring arms to divide the weight of the user over the interleaved springs.
  • FIG. 1 This shows use of cantilevered springs extending from opposite edges of a support, such as a seat, and, in the case of Figs. 1 and 4, front to back orientation.
  • the spring members 14A and 14B can be oriented to extend from trie sides of base 15 (i.e. , laterally) as well. This design thus provides a uniform progressively increasing spring feel for the seat by providing opposed interleaved cantilevered sensor springs for the seat.
  • the back 11 of seat 10 may include curved spring members 14C formed by slots 17 to provide a back-conforming comfortable configuration for the seat 10.
  • the seat 10, shown in Figs. 1 and 4 may include additional support webbing or foam blocks, as disclosed in International Publication No.
  • WO/2005AO60422 entitled MOLDED WOOD FLAKE ARTICLE WITH INTEGRAL FLEXIBLE SPRING MEMBER, the disclosure of which is incorporated herein by reference.
  • the free ends of the back springs 14C may be intercoupled by a polymeric mesh sheath 52 (Fig. 1) coupled by staples 54, if desired.
  • the mesh sheath 52 extends about 2 inches to 3 inches over the front and rear surfaces of members 14C.
  • the sheath 130 is an open mesh elastomeric stretch material made of polyester or vinyl.
  • One webbing which has been used is commercially available from Bruin Plastics Company, Inc. as 9x9 vLnyl coated mesh.
  • Fig. 10 shows the seat 12 of chair 10 of Fig. 1 before loading.
  • the dimensions ai and 32, Ii and h. are the same for the similarly sized spxing members 14A and 14B. As seen in Fig. 1 1, the weight W of a person sitting on seat 12 deflects the spring members 14A and 14B . The amount of deflection of the interleaved members can be determined according to the following formulas.
  • W weight of load
  • a the length of the springs from the center to their free end
  • Bed 100 includes a first elongated support member 110 extending along one side of the longitudinally extending bed and a second elongated support member 120 on the opposite side.
  • Each of the members 110 and 120 includes a generally vertically extending frame section 112 and 122, respectively, which integrally include a plurality of spaced- apart flexible spring members 114A and 114B, which are interleaved as seen in Figs.
  • Bed 100 will also include mounting structure, such as end frame members 130 and 132, which are secured to frame members 110> and 120 by utilizing suitable threaded fasteners 133 secured to T-nuts mounted in apertures 134, as seen in the exploded view of Fig. 9.
  • Webbing such as longitudinally extending webbing 150 and 152 may extend under spring members 114A and 114B along the longitudinal length of the bed 100 and are attached to end members 130 and 132 by stapling or other suitable attachment means, such as slides 151 and 153 which can be laterally adjusted in laterally extending slot 131 to adjust the feel of the bed.
  • the bed may also include selected cross-webbing 154 which extends under the free ends of the arcuately curved spring members 114A and 114B at select locations and anchored to sides 112 and 114 where the body weight load may be focused.
  • the web may have a width of about 3 inches and limits the deflection of the members 114A and 114B from about 20 to about 40 percent depending on the positioning of the web or whether one or more webs are used.
  • One 3 inch wide web material which has been used is a polypropylene spiral wrap natural extruded rubber threads cross-woven with polypropylene thread which is commercially available from Ultraflex Corporation. As in the embodiment shown in Fig.
  • the spring members 114A and 114B of bed 100 will intersect the integral downwardly extending base sections 112 and 122 at an obtuse angle ⁇ of greater than 90° and preferably from about 100° to about 110° to provide a generally convexly curved crowned bed surface to the upper surface of bed 100, which will be covered by suitable foam pads and ticking to complete the bed and integral mattress so-formed.
  • Wood flake members 110 and 120 are formed with molded slots 11 ⁇ 7 which are alternately staggered to align with the spring members of the mating opposed cantilevered springs so they are nestably received with a gap between adjacent spring members 114A and 114B of approximately 1/2 inch.
  • Each of spring members 114A and 11433 includes a convexly curved raised sensor 142 and 144, respectively, near their free ends. As a person sits on the edge of the bed during ingress and egress therefrom, from either side, initially the sensors 144 or 146 will be engaged, providing a softer initial feel to ease the entry onto the bed.
  • molded wood flake support members which include an integrally formed molded wood flake flexible spring having raised sections forming tactile sensors.
  • the flexible spring member acts as a cantilevered spring thereby flexibly supporting the user that is positioned thereon.
  • the above embodiments have been particularly directed to the furniture industry and more particularly to the seating and bed industries. These embodiments, howevex, represent only the preferred embodiments and are not meant to be limiting in any manner.
  • the above inventive integral flexible spring can be utilized in various ways and be fabricated into varied articles. Hence, the above description is that of the preferred embodiments only. 53] Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment described above is merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.

Landscapes

  • Dry Formation Of Fiberboard And The Like (AREA)
  • Measurement Of The Respiration, Hearing Ability, Form, And Blood Characteristics Of Living Organisms (AREA)
  • Springs (AREA)

Abstract

L'invention concerne un support comprenant une paire de supports de fragments de bois moulés, flexible, chaque support comprenant une pluralité d'éléments ressorts flexibles, espacés présentant des détecteurs bombés à proximité de leurs extrémités libres, lesdits supports étant montés de manière opposée par rapport aux éléments ressort flexibles imbriqués. Les supports en fragments de bois moulés peuvent comprendre intégralement un élément cadre présentant des ressorts flexibles s'étendant sur un angle de l'élément cadre.
PCT/US2005/037427 2004-10-22 2005-10-19 Article en fragments de bois moules comprenant des elements ressorts flexibles imbriques presentant des protuberances de detection WO2006047142A2 (fr)

Applications Claiming Priority (2)

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US62153004P 2004-10-22 2004-10-22
US60/621,530 2004-10-22

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WO2006047142A2 true WO2006047142A2 (fr) 2006-05-04
WO2006047142A3 WO2006047142A3 (fr) 2006-09-08

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2130456A1 (fr) * 2008-06-04 2009-12-09 Vitra Patente AG Siège doté d'un dossier élastique
EP2277414A1 (fr) * 2009-07-20 2011-01-26 Actiu Berbegal y formas, s.a. Chaise de bureau
GB2494247A (en) * 2011-08-30 2013-03-06 Sunny Wheel Ind Company Ltd Bicycle child carrier with elastic seat structures
US20200214916A1 (en) * 2019-01-04 2020-07-09 Haworth, Inc. Adjustable ergonomic chair

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3931384A (en) * 1972-10-02 1976-01-06 Plexowood, Inc. Method of making end frames for upholstered furniture
WO1983000654A1 (fr) * 1981-08-27 1983-03-03 Univ Michigan Tech Produits moules avec des particules de bois comprenant des organes d'intersection assembles de maniere solidaire
US4440708A (en) * 1978-12-21 1984-04-03 Board Of Control Of Michigan Technological University Method for molding articles having non-planar portions from matted wood flakes
US6761844B1 (en) * 2000-05-30 2004-07-13 Bruce A. Haataja Spring-loaded ejectors for wood strand molding

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3931384A (en) * 1972-10-02 1976-01-06 Plexowood, Inc. Method of making end frames for upholstered furniture
US4440708A (en) * 1978-12-21 1984-04-03 Board Of Control Of Michigan Technological University Method for molding articles having non-planar portions from matted wood flakes
WO1983000654A1 (fr) * 1981-08-27 1983-03-03 Univ Michigan Tech Produits moules avec des particules de bois comprenant des organes d'intersection assembles de maniere solidaire
US6761844B1 (en) * 2000-05-30 2004-07-13 Bruce A. Haataja Spring-loaded ejectors for wood strand molding

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2130456A1 (fr) * 2008-06-04 2009-12-09 Vitra Patente AG Siège doté d'un dossier élastique
EP2277414A1 (fr) * 2009-07-20 2011-01-26 Actiu Berbegal y formas, s.a. Chaise de bureau
GB2494247A (en) * 2011-08-30 2013-03-06 Sunny Wheel Ind Company Ltd Bicycle child carrier with elastic seat structures
GB2494247B (en) * 2011-08-30 2014-02-19 Sunny Wheel Ind Company Ltd Bicycle child carrier with a plurality of elastic structures
US20200214916A1 (en) * 2019-01-04 2020-07-09 Haworth, Inc. Adjustable ergonomic chair
US10780003B2 (en) * 2019-01-04 2020-09-22 Haworth, Inc. Adjustable ergonomic chair
US11471345B2 (en) 2019-01-04 2022-10-18 Haworth, Inc. Adjustable ergonomic chair

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