Flexible substrate assembly and associated furniture using the same

Abstract

A novel, flexible substrate assembly including a flexible substrate member having an inner surface and an outer surface, and a plurality of rigid or semi-rigid ribs associated with at least one of the inner and outer surfaces of the flexible substrate member. A chair assembly including a seat member, a back support member with an optional headrest, an optional left arm, an optional right arm, a floor-engaging base member which may form part of a frame assembly, a left side, a right side, a front side, and a back side, and a novel, flexible substrate assembly, wherein the novel flexible substrate assembly comprises a flexible substrate member having an inner surface and an outer surface, and a plurality of rigid or semi-rigid ribs associated with at least one of the inner and outer surfaces of the flexible substrate member.

Claims

1. A flexible substrate assembly, comprising: a plurality of rigid or semi-rigid ribs, wherein each one of the plurality of rigid or semi-rigid ribs include a length, a left end and a right end; a flexible substrate member having an inner surface and an outer surface, wherein the flexible substrate member is over-molded onto at least a portion of the plurality of rigid or semi-rigid ribs such that the left end and the right end of each one of the plurality of rigid or semi-rigid ribs are not over-molded with the flexible substrate member; and wherein the flexible substrate assembly is flexible and articulable along a first axis that is orthogonal to the length of each one of the plurality of rigid or semi-rigid ribs, but non-flexible and non-articulable along a second axis that is orthogonal to the first axis.

2. The flexible substrate assembly according to claim 1, wherein the ribs comprise ball ribs.

3. The flexible substrate assembly according to claim 1, wherein the ribs comprise half-ball bottom ribs.

4. The flexible substrate assembly according to claim 1, wherein the ribs comprise half-ball top ribs.

5. The flexible substrate assembly according to claim 1, wherein the ribs comprise hook ribs.

6. The flexible substrate assembly according to claim 1, wherein the ribs comprise block ribs.

7. The flexible substrate assembly according to claim 1, wherein the ribs comprise slide ribs.

8. The flexible substrate assembly according to claim 1, wherein the ribs comprise pin ribs.

9. The flexible substrate assembly according to claim 1, wherein the ribs comprise at least one of ball ribs, half-ball bottom ribs, half-ball top ribs, hook ribs, block ribs, slide ribs, pin ribs, and combinations thereof.

10. A chair assembly, comprising: a seat member, a back support member with an optional headrest, an optional left arm, an optional right arm, a floor-engaging base member which may form part of a frame assembly, a left side, a right side, a front side, and a back side; a flexible substrate assembly, wherein the flexible substrate assembly comprises a plurality of rigid or semi-rigid ribs, wherein each one of the plurality of rigid or semi-rigid ribs include a length, a left end and a right end, and a flexible substrate member having an inner surface and an outer surface, wherein the flexible substrate member is over-molded onto at least a portion of the plurality of rigid or semi-rigid ribs such that the left end and the right end of each one of the plurality of rigid or semi-rigid ribs are not over-molded with the flexible substrate member; wherein the flexible substrate assembly is flexible and articulable along a first axis that is orthogonal to the length of each one of the plurality of rigid or semi-rigid ribs, but non-flexible and non-articulable along a second axis that is orthogonal to the first axis; wherein the seat member and the back support member comprise the flexible substrate assembly; wherein the flexible substrate assembly of the seat member is displaceable between a non-extended configuration and an extended configuration proximate a front end thereof; and wherein the flexible substrate assembly of the back support member is displaceable between a non-extended configuration and an extended configuration proximate an upper end thereof.

11. The chair assembly according to claim 10, wherein the ribs comprise at least one of ball ribs, half-ball bottom ribs, half-ball top ribs, hook ribs, block ribs, slide ribs, pin ribs, and combinations thereof.

12. A chair assembly, comprising: a seat member, a back support member with an optional headrest, an optional left arm, an optional right arm, a floor-engaging base member which may form part of a frame assembly, a left side, a right side, a front side, and a back side; a flexible substrate assembly, wherein the flexible substrate assembly comprises a plurality of rigid or semi-rigid ribs, wherein each one of the plurality of rigid or semi-rigid ribs include a length, a left end and a right end, and a flexible substrate member having an inner surface and an outer surface, wherein the flexible substrate member is over-molded onto at least a portion of the plurality of rigid or semi-rigid ribs such that the left end and the right end of each one of the plurality of rigid or semi-rigid ribs are not over-molded with the flexible substrate member, and wherein the left end and the right end of each one of the plurality of rigid or semi-rigid ribs are positioned within channels of guide plates; wherein the flexible substrate assembly is flexible and articulable along a first axis that is orthogonal to the length of each one of the plurality of rigid or semi-rigid ribs, but non-flexible and non-articulable along a second axis that is orthogonal to the first axis; wherein the seat member and the back support member comprise the flexible substrate assembly; wherein the flexible substrate assembly of the seat member is displaceable between a non-extended configuration and an extended configuration proximate a front end thereof; and wherein the flexible substrate assembly of the back support member is displaceable between a non-extended configuration and an extended configuration proximate an upper end thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Certain embodiments of the present invention are illustrated by the accompanying figures. It will be understood that the figures are not necessarily to scale and that details not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted. It will be further understood that the invention is not necessarily limited to the particular embodiments illustrated herein.

(2) The invention will now be described with reference to the drawings wherein:

(3) FIG. 1 of the drawings is an isometric view illustrating a flexible substrate assembly in a linear configuration in accordance with the present invention;

(4) FIG. 2A of the drawings are isometric, front, and detail views illustrating a ball rib in accordance with the present invention;

(5) FIG. 2B of the drawings are isometric, front, and detail views illustrating a half-ball bottom rib in accordance with the present invention;

(6) FIG. 2C of the drawings are isometric, front, and detail views illustrating a half-ball top rib in accordance with the present invention;

(7) FIG. 2D of the drawings are isometric, front, and detail views illustrating a hook rib in accordance with the present invention;

(8) FIG. 2E of the drawings are isometric, front, and detail views illustrating a block rib in accordance with the present invention;

(9) FIG. 2F of the drawings are isometric, front, and detail views illustrating a slide rib in accordance with the present invention;

(10) FIG. 2G of the drawings are isometric, front, and detail views illustrating a pin rib in accordance with the present invention;

(11) FIG. 3 of the drawings is an isometric view illustrating a flexible substrate assembly in a non-linear, articulated configuration in accordance with the present invention;

(12) FIG. 4 of the drawings is an isometric view illustrating a flexible substrate assembly in a substantially U-shaped configuration in accordance with the present invention;

(13) FIG. 5 of the drawings is an isometric view illustrating a flexible substrate assembly in a non-linear, articulated chair configuration in accordance with the present invention;

(14) FIG. 6 of the drawings is an isometric view illustrating an office chair having a flexible substrate assembly in accordance with the present invention;

(15) FIG. 7 of the drawings is a side elevation view illustrating an office chair having a flexible substrate assembly in a non-extended configuration in accordance with the present invention;

(16) FIG. 8 of the drawings is a side elevation view illustrating an office chair having a flexible substrate assembly in an extended configuration in accordance with the present invention;

(17) FIG. 9 of the drawings is an isometric view illustrating a public and/or mass transit bench having a flexible substrate assembly in accordance with the present invention;

(18) FIG. 10 of the drawings is an isometric view illustrating a theater lounger having a flexible substrate assembly with a seating member in a deployed configuration in accordance with the present invention;

(19) FIG. 11 of the drawings is an isometric view illustrating a theater lounger having a flexible substrate assembly with a seating member in a retracted configuration in accordance with the present invention;

(20) FIG. 12 of the drawings are front and detail views illustrating a flexible substrate assembly associated with a thick foam over-mold member in accordance with the present invention; and

(21) FIG. 13 of the drawings are front and detail views illustrating a flexible substrate assembly associated with a thin foam over-mold member in accordance with the present invention.

SUMMARY OF THE INVENTION

(22) The present invention is directed to, in one embodiment, a novel, flexible substrate assembly comprising: (a) a flexible substrate member having an inner surface and an outer surface; and (b) a plurality of rigid or semi-rigid ribs associated with at least one of the inner and outer surfaces of the flexible substrate member.

(23) In a preferred embodiment of the present invention, the ribs comprise at least one of ball ribs, half-ball bottom ribs, half-ball top ribs, hook ribs, block ribs, slide ribs, pin ribs, and combinations thereof.

(24) The present invention is further directed to, in one embodiment, a chair assembly comprising: (a) a seat member, a back support member with an optional headrest, an optional left arm, an optional right arm, a floor-engaging base member which may form part of a frame assembly, a left side, a right side, a front side, and a back side; and (b) a novel, flexible substrate assembly, wherein the novel flexible substrate assembly comprises: (1) a flexible substrate member having an inner surface and an outer surface; and (2) a plurality of rigid or semi-rigid ribs associated with at least one of the inner and outer surfaces of the flexible substrate member.

DETAILED DESCRIPTION OF THE INVENTION

(25) While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described herein in detail, one or more specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

(26) It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of one or more embodiments of the invention, and some of the components may have been distorted from their actual scale for purposes of pictorial clarity.

(27) The present invention generally relates to flexible substrate assemblies and, more particularly, to articles of furniture utilizing such flexible substrates, including, but not limited to, office, residential, theater, and cinema furniture, as well as, automotive, aerospace, and mass transit seating that are configured to provide a patron or occupant with a flexible and adjustable experience not seen heretofore.

(28) Referring now to the drawings, and to FIG. 1 in particular, flexible substrate assembly 10 is shown in a linear configuration as generally comprising flexible substrate member 12 having an inner surface and an outer surface, and a plurality of rigid or semi-rigid ribs 14 associated with at least one of the inner and outer surfaces of the flexible substrate member. Rigid or semi-rigid ribs 14 preferably include cap members 16 which are used during production, as well as sometimes subsequently serve as tabs and/or guides in, for example, a channel of a chair, desk, drawer, and/or door.

(29) Flexible substrate member 12 is preferably fabricated from, for example, an at least partially elastomeric and/or flexible material including natural and/or synthetic plastics and/or rubbers, saturated and/or unsaturated rubbers such as polyisoprene, butyl rubber, polyacrylic rubber, silicone, flurosilicone, flexible foams, I-skin type foams, self-skinning foamsjust to name a few.

(30) Rigid or semi-rigid ribs 14 are preferably fabricated from natural and/or synthetic plastic forming resins, rigid and/or semi-rigid plastics, metals (both ferrous and non-ferrous, alloys, natural materials (e.g., wood, bamboo, etcetera). As is best shown FIGS. 2A-2G ribs 14 may comprise, for example, ball ribs, half-ball bottom ribs, half-ball top ribs, hook ribs, block ribs, slide ribs, pin ribs, and combinations thereof.

(31) Referring now to FIG. 3 of the drawings, flexible substrate assembly 10 is shown in a non-linear, articulated configuration. It will be understood that flexible substrate assembly 10 is flexible and articulable along the X-axis, but generally not along the Y-axis (see FIG. 1) due to the structural configuration and association of rigid or semi-rigid ribs 14.

(32) Referring now to FIG. 4 of the drawings, flexible substrate assembly 10 is shown in a substantially U-shaped configuration that is optimal for utilization in an article of furniture.

(33) Referring now to FIG. 5 of the drawings, flexible substrate assembly 10 is shown in a configuration that is optimal for utilization as a chair having a base member and a backrest.

(34) Referring now collectively to FIGS. 6-8 of the drawings, office chair 100 is shown as generally comprising flexible substrate assembly 10, frame assembly 102, and floor-engaging wheels or casters 104. Office chair 100 is adjustable from a non-extended configuration (see FIG. 7) to an extended configuration (see FIG. 8). It will be understood that the base member and backrest of office chair 100 are independently and essentially infinitely displaceable between their respective non-extended and extended configurations.

(35) In one embodiment of the present invention the purpose of the frame or side rails is to provide structural support to the type tambour seating and/or hold the tambour in its final position. The rib ends can be designed to slide into the rails and/or snap in and/or on the rails/frame during assembly. The rails can act as a guide so the person assembling the chair simply pulls the tambour down the rails to form the seat. The rails or frame can be made out of any conventional structural material including plastics, metals, or other common materials used in seating construction. The rails may be part of the chair frame which reduces the amount of pieces in the chair.

(36) Referring now to FIG. 9 of the drawings, public and/or mass transit bench 200 is shown as generally comprising frame member 202 having flexible substrate assembly 10. Notably, both the base member and the backrest of bench 200 are adjustable due to the flexibility of substrate assembly 10.

(37) Referring now collectively to FIGS. 10-11 of the drawings, theater lounger 300 is shown as generally comprising flexible substrate assembly 10, arm rests 302, and floor-engaging base member 304. Theater lounger 300 is displaceable between a retracted configuration (see FIG. 10) and a deployed configuration (see FIG. 11). Similarly to other embodiments of the present invention, theater lounger 300 includes a base member and a backrest that are adjustable due to flexible substrate assembly 10.

(38) It will be understood that the designs of the present invention are similar in nature to a roll-top desk or a tambour door enclosure. Notably, these novel designs allow the seat to form to almost any contour and simplify manufacturing and assembly. The embodiments of the present invention also offer design flexibility while not sacrificing comfort. In particular, the reduction in parts during assembly reduces materials used, assembly time, weight and allows for potentially smaller shipping containers.

(39) In accordance with the present invention, the seating concept utilizes a multiple shot molding process to accomplish the desired results. Specifically, the process consists of molding structural ribs on the backside of the part with a soft over-mold of one or more materials on the front. The ribs provide some structural support of the chair while supporting the person and the soft rubber(s) or foam(s) provide the desired comfort of the seat. The steps of the process are to mold the rib structure in a rigid or semi-rigid material of one or more materials and then molding the rubber(s) or foam(s) on the front surface. This design reduces the assembly time and materials used in conventional manufacturing methods.

(40) The design of the present invention allows for the seat to flex as the person leans back in the chair. The chair can be a simple one-piece design or a multiple piece design similar to conventional office chairs. The front edge of the chair can be extended out on a simple track to provide additional leg support. A headrest can also be implemented using the same extension method. Additional support can be provided in a lumbar or other areas by simply stiffening the ribs in that area, adding more soft cushion, or other conventional methods such as air bag or mechanical leverage advantages.

(41) In one aspect of the invention, the process can be used in many designs and several industries. Non-limiting examples include office chairs, task chairs, stools, stadium seating, benches, ottomans, foot rests, automotive seating, aircraft seating, outdoor seating, Adirondack chairs, residential seating, couches, theatre seating, etcetera. The materials used can provide as much comfort as most any other form of seating while significantly reducing materials used, weight, and time to manufacture and assemble. The parts are molded in a flat layout which also can reduce the size of the box used for shipping. Indeed, office chairs are typically known for shipping a lot of air because of the overall size vs. weight of the bulky product.

(42) In accordance with the present invention, cushions can also be wrapped post process with fabrics, leather, vinyls or other materials suited for seating applications.

(43) Referring now to FIGS. 12-13, thick and/or thin foam can be over-molded, integrated, associated, and/or form part of flexible substrate assembly 10.

(44) The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.