WO2006047143A2 - Article moule en copeaux de bois comprenant des elements ressort flexibles solidaires intercales - Google Patents

Article moule en copeaux de bois comprenant des elements ressort flexibles solidaires intercales Download PDF

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Publication number
WO2006047143A2
WO2006047143A2 PCT/US2005/037428 US2005037428W WO2006047143A2 WO 2006047143 A2 WO2006047143 A2 WO 2006047143A2 US 2005037428 W US2005037428 W US 2005037428W WO 2006047143 A2 WO2006047143 A2 WO 2006047143A2
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WIPO (PCT)
Prior art keywords
section
spring members
article
molded
springs
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Application number
PCT/US2005/037428
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English (en)
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WO2006047143A3 (fr
Inventor
Jeff R. Britton
Samuel S. Conte
Original Assignee
J. R. Britton & Associates, Inc.
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Application filed by J. R. Britton & Associates, Inc. filed Critical J. R. Britton & Associates, Inc.
Publication of WO2006047143A2 publication Critical patent/WO2006047143A2/fr
Publication of WO2006047143A3 publication Critical patent/WO2006047143A3/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
    • 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
    • A47C7/02—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
    • A47C7/028—Springs not otherwise provided for in A47C7/22 - A47C7/35 with wooden springs, e.g. slated type

Definitions

  • Wood flake molding also referred to as 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 V4 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. In wood flake or wood strand molding, 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 times 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 wood 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 in 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 in 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 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 the seat to evenly balance a weight load.
  • the longitudinal orientation of the molded wood 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 ;
  • FIG. 5 is a perspective view of an alternative chair with a plurality of flexible wood flake spring members according to another embodiment of the present invention
  • Fig. 6 is an exploded perspective view of a bed frame employing wood flake spring members according to another embodiment of the invention
  • Fig. 7 is a perspective assembled view of the bed frame of Fig. 6 ;
  • Fig. 8 is a side elevational pictorial view, showing the springs of the seat of Fig.
  • Fig. 9 is a side elevational pictorial view, showing the springs 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 are integrally molded into supports 16 and 18 during the fabrication process thereof and are secured to a 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.
  • the details of chair 10 are described below folio whig a description, of the molding process and materials used.
  • 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 through 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 14 A, 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.
  • the molded wood flake parts 13, 16, and 18 may include additional features, such as holes 34 for T-nuts 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 incJh 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. Therefore, the bottom surface 37 of molded wood flake parts 13, 16, and/or
  • 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.
  • 18 can be prepared from various species of suitable hardwoods and softwoods.
  • 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 fmgerlings 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 fmgerlings 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 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.O30 inch and more preferably about 0.0020 inch; and an average width of about 3 inches or less, most typically from about 0.25 inch to about 1.0 inch, and less than the average length of the flakes, hi any given batch, some of the wood flakes 22 can be shorter thaai 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 thiclmess 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.
  • 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.
  • the majority of the wood flakes 22 should have a width of from about 0.25 to about 1.0 inches.
  • the 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 ajre usually required to adequately remove both the undersize and oversize particles, whereas fingerling 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 wliich 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 polyphenylpolyisocyanates, 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 polyisocyanate 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 hi 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, which 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.
  • 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 thickness of the mat that would optimally have the nominal part thickness T is preferably controlled by closely 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 35O 0 F to about 45O 0 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.
  • MOLDED WOOD FLAKE ARTICLE DETAILS MOLDED WOOD FLAKE ARTICLE DETAILS:
  • 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 44, and a rear wall 46. 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 of sides 40 and 42, 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 also shown in phantom in Fig.
  • the seat 12 and base 15 are mounted to the seat 12 and base 15 in a conventional manner, which may involve the use of the T-nut fastener apertures 34 or other fasteners, such as threaded screws or the like, extending into the sides 40, 42, 44, and 46 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 walls 44 and 46 are preferably molded using the molded wood flake process.
  • the seat 12 of the chair 10 of the present invention includes interleaved spring members 14A and 14B integrally formed in seat sections 6O> and 70, as best seen in Fig. 4.
  • Seat section 60 includes three flexible fingers 14A extending from an integrally formed support section 16 with slots 17 between adjacent fingers and on the outside edge of the rightmost spring member 14A, as viewed in Fig. 4.
  • the mating interleaved seat section 70 of seat 12 also comprises three extending spring members 14B which integrally extend from support 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.
  • 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/2005 /060422, entitled MOLDED WOOD FLAKE ARTICLE WITH INTEGRAL FLEXIBLE SPRING MEMBER, the disclosure of which is incorporated herein by reference.
  • Fig. 8 shows the seat 12 of chair 10 of Figs. 1 and 4 before loading.
  • the dimensions al and a2, 11 and 12 are the same for the similarly sized spring members 14A and 14B.
  • the weight ⁇ 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
  • FIG. 5 An alternative embodiment of the seat shown in Figs. 1 and 4 is shown in Fig. 5 in which a seat 100 is shown.
  • Chair IOO likewise includes a seat 112 made of a pair of seat sections 160 and 170 made by the molded wood flake process described above.
  • Seat sections 160, 170 integrally include flexible spring members 114A and 114B, which are interleaved as shown in the perspective view of Pig. 5.
  • Seat section 160 includes a frame section 144 which is integrally curved downwardly at its front end at an angle ⁇ greater than 90° and integrally includes spaced-apart molded wood flake springs 114A.
  • section 170 is integrally formed and includes a frame section 146 at a downwardly depending angle ⁇ greater than about 90° from integrally extending spaced- apart molded wood flake springs 114B.
  • Chair t>ase 115 is completed by the attachment of side walls 140 and 142 to the integral front ISO and back 170 sections which integrally include the interleaved, alternately staggered spring members 114A and 114B.
  • the forwardly extending spring members 114B have rounded tips 119 at their free ends which extend slightly above the surface 180 of member 160.
  • the similar tips 119' of spring members 114B likewise extends slightly above the surface 118 of member 170.
  • Chair IOO likewise includes a back 111 mounted to a back frame 185 suitably coupled to base 115 by fasteners.
  • Back 111 and frame 185 can likewise be made of molded wood flake sections suitably secured together by conventional threaded fasteners.
  • the back 111 includes a plurality of spaced-apart wood flake spring members 114C defined by slots 117. Members 114C extend upwardly from an integrally molded section 113, as in the embodiment shown in Figs. 1-4.
  • Webbing 190 may extend behind spring members 114C to provide additional support for the flexible spring members while ttie seat 112 may likewise include webbing 191 and 192 mounted between the sides 140 and 142 and underlying the spring members 114A and 114B to provide additional support supplementing the spring action of the flexible spring members of the seat.
  • chair 100 and its legs 150 may be covered by a suitable padding and upholstery material to complete the chair construction.
  • chair 100 like chair 10, includes a seat which benefits from the use of opposed cantilevered spring members defined by slots 117 with the spring members extending from opposite edges of the seat.
  • the seat sections 160, 170 also integrally form a part of the base by extending the integrally formed spring members at an angle downwardly to define a frame or wall of the seat.
  • the junction of the generally vertically extending seat frame section and the flexible springs typically will be at an angle ⁇ greater than 90° and typically between about 100° and about 110°, such that the tips 119, 119' of the flexible springs 114A and 114B, respectively, will extend slightly above the corresponding adjacent surfaces 118, 18O of members 160, 170.
  • 1, 4, and 5 are from about 2 inches to about 3 inches ⁇ vide with slots therebetween slightly wider to leave a gap between adjacent spring members of about .5 inch.
  • 14A, 14B, 114A and 114B may integrally include molded indentations in the form of concave indentations extending longitudinally along the springs and through the angled junction of the springs with the frame forming base sections to stiffen the springs.
  • Bed 200 includes a first support member 210 extending along one side of the longitudinally extending bed and a second support member
  • Each of the members 210 and 220 includes a generally vertically extending frame 212 and 222, respectively, which integralry- include a plurality of spaced- apart flexible spring members 214A and 214B, which are interleaved as seen hi Figs. 6 and
  • the interleaved spring members 214A and 214B are formed in a manner similar to the interleaved spring shown in the chair base of Fig. 5 except that they are significantly longer and have a width of about
  • Bed 200 will also include end members 230 and 232 which serve as a mounting structure and are secured to frame members 212 and 222 utilizing suitable threaded fasteners 233 secured to T-nuts mounted in apertures 234, as seen in the exploded view of
  • Webbing such as longitudinally extending webbing 250 and 252 may extend under spring members 214A and 214B along the longitudinal length of the bed 200 and are attached to end members 230 and 232 by stapling or other suitable attachment means, such as slides 251 and 253 which can be laterally adjusted in slot 231 to adjust the feel of the bed.
  • the bed may also include selected cross-webbing 254 which extends under the free ends of the arcuately curved spring members 214A and 214B at select locations and anchored to sides 212 and 214 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 214 A and 214B 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 thread cross-woven with polypropylene thread which is commercially available from Ultraflex Corporation. As in the embodiment shown in Fig.
  • the spring members 214A and 214B of bed 200 will intersect the integral downwardly extending base sections 212 and 222 at an 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 200, which will be covered by suitable foam pads and ticking to complete the bed frame and integral mattress so-formed.
  • Wood flake members 210 and 220 are formed with molded slots 217 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 214A and 214B of approximately 1/2 inch.
  • a molded wood flake support member which includes an integrally formed molded wood flake flexible spring.
  • 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, however, 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.

Landscapes

  • Dry Formation Of Fiberboard And The Like (AREA)
  • Springs (AREA)

Abstract

L'invention concerne un support formé de manière à comprendre deux supports flexibles en copeaux de bois moulés, comprenant chacun une pluralité d'éléments ressort flexibles espacés, ces supports étant montés face à face de sorte que les éléments ressort flexibles sont mutuellement intercalés. Les supports en copeaux de bois moulés peuvent comprendre une partie cadre solidaire, les ressorts flexibles s'avançant à partir de la partie cadre en formant un angle avec cette dernière.
PCT/US2005/037428 2004-10-22 2005-10-19 Article moule en copeaux de bois comprenant des elements ressort flexibles solidaires intercales WO2006047143A2 (fr)

Applications Claiming Priority (2)

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US62115104P 2004-10-22 2004-10-22
US60/621,151 2004-10-22

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WO2006047143A2 true WO2006047143A2 (fr) 2006-05-04
WO2006047143A3 WO2006047143A3 (fr) 2007-02-22

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9560917B2 (en) 2014-11-26 2017-02-07 Steelcase Inc. Recline adjustment system for chair

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6427261B1 (en) * 1999-05-18 2002-08-06 David Chadbourn Furniture devices and methods

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6427261B1 (en) * 1999-05-18 2002-08-06 David Chadbourn Furniture devices and methods

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9560917B2 (en) 2014-11-26 2017-02-07 Steelcase Inc. Recline adjustment system for chair

Also Published As

Publication number Publication date
WO2006047143A3 (fr) 2007-02-22

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