CHAIR WITH FLEXIBLE INTERNAL SUPPORT

Abstract

The present disclosure relates to a chair back assembly with an outer frame and an inner frame, wherein the outer frame is manufactured of different material than the inner frame to allow for a variety in support throughout the chair back assembly, resulting in localized support throughout the back of the chair. The availability of localized support results in an improvement in comfort and may also improve production in embodiments utilizing a foam covering. Specifically, the inner frame of the chair back assembly may include at least one vertical member and at least one horizontal member to provide additional support to the user.

Description

Claims

1. A method of manufacturing a chair back, the method comprising: coupling an inner frame to an outer frame such that the inner frame stretches across an open central region of the outer frame, the inner frame defining a central longitudinal axis and a central latitudinal axis and being formed of a web material including a crossing-pattern of inner frame elements that define a plurality of closed cells that are symmetric in shape about the central longitudinal axis of the inner frame, the web material being relatively less rigid than an outer frame material;placing the inner frame and the outer frame into a chair mold; anddepositing liquid foam into the chair mold to cover the inner frame and the outer frame.

2. The method of claim 1, further comprising allowing the liquid foam to dry for a desired period in the chair mold to form a foam layer, the foam layer conforming to and holding the shape of the chair mold where a chair back is formed by the outer layer, the inner layer, and the foam layer.

3. The method of claim 1, further comprising removing the chair back from the chair mold after allowing the liquid foam layer to dry for a desired period.

4. The method of claim 1, further comprising filling the plurality of closed cells of the inner frame with the liquid foam.

5. The method of claim 1, wherein coupling the inner frame to the outer frame further comprises heat-staking.

6. The method of claim 1, further comprising performing a pulsed-heat process on at least one of the inner frame and the outer frame such that at least one of the inner frame and the outer frame is partially deformed and melted such that the inner frame and the outer frame are bonded together.

7. The method of claim 1, wherein coupling the inner frame to the outer frame further comprises coupling via fasteners.

8. The method of claim 1, wherein depositing liquid foam into the chair mold to cover the inner frame and the outer frame includes performing a casting process.

9. A method of manufacturing a chair back, the method comprising: deforming at least one of an inner frame and an outer frame to bond the inner frame and the outer frame together, the outer frame defining an open central region and being formed of an outer frame material and the inner frame defining a central longitudinal axis and a central latitudinal axis, the inner frame being formed of a web material including a crossing-pattern of inner frame elements that define a plurality of closed cells that are symmetric in shape about the central longitudinal axis of the inner frame, wherein the web material is relatively less rigid than the outer frame material;placing the inner frame and outer frame into a chair mold; anddepositing liquid foam into the chair mold to cover at least a portion of each of the inner frame and the outer frame.

10. The method of claim 9, wherein deforming at least one of the inner frame and the outer frame to bond the inner frame and the outer frame together further comprises melting at least one of the inner frame and the outer frame.

11. The method of claim 10, further comprising cooling the inner frame and the outer frame prior to placing the inner frame and the outer frame in the chair mold.

12. The method of claim 9, wherein deforming at least one of the inner frame and the outer frame to bond the inner frame and the outer frame together further comprises arranging the inner frame such that the inner frame is extended across the open central region of the outer frame.

13. The method of claim 9, further comprising allowing the liquid foam to dry for a desired period in the chair mold to form a foam layer, the foam layer conforming to and holding the shape of the chair mold where a chair back is formed by the outer layer, the inner layer, and the foam layer.

14. The method of claim 9, further comprising removing the chair back from the chair mold after allowing the liquid foam layer to dry for a desired period.

15. The method of claim 9, further comprising allowing the liquid foam to fill the plurality of closed cells of the inner frame.

16. The method of claim 9, wherein depositing liquid foam into the chair mold to cover at least a portion of each of the inner frame and the outer frame further comprises performing a casting process.

17. A method of manufacturing a chair back, the method comprising: coupling an inner frame to an outer frame so that the inner frame stretches across an open central region of the outer frame, the outer frame being formed of an outer frame material and the inner frame defining a central longitudinal axis and a central latitudinal axis, the inner frame being formed of a web material including a crossing-pattern of inner frame elements that define a plurality of closed cells that are symmetric in shape about the central longitudinal axis of the inner frame, wherein the web material is relatively less rigid than the outer frame material;placing the inner frame and the outer frame into a chair mold; anddepositing liquid foam into the chair mold via injection molding to cover the inner frame and the outer frame.

18. The method of claim 17, further comprising allowing the liquid foam to dry for a desired period in the chair mold to form a foam layer, the foam layer conforming to and holding the shape of the chair mold where a chair back is formed by the outer layer, the inner layer, and the foam layer.

19. The method of claim 17, further comprising removing the chair back from the chair mold after allowing the liquid foam layer to dry for a desired period.

20. The method of claim 17, further comprising filling the plurality of closed cells of the inner frame with the liquid foam.