CHAIR CONSTRUCTION

Abstract: A chair (20) is provided including a support member (50), a projecting surface and a chair back (32). The support member having a top portion extends upward from a rear portion of the seat. A projecting surface or insert member (70) is attached to the top portion of the support member. The chair back includes front (64), back (66), top and bottom (62) surfaces. A cavity (60) opens downwardly toward the bottom surface of the chair back. An aperture (92) communicating with the cavity is located within one of the front and back surfaces of the chair back. The top portion of the support member extends into the cavity with the projecting surface or insert member extending into the aperture with the insert being sized to securely mate within the cavity of the chair back.

Description: CHAIR CONSTRUCTION BACKGROUND OF THE INVENTION The present invention relates to chairs. More particularly, the present invention relates to an improved chair back and support structure for use with a wire rod type chair. In auditoriums, schools, and various halls, it is often desired to provide additional seating on a temporary basis. While folding chairs have filled this need in the past, the set up and take down of these types of chairs can be relatively time consuming. In addition, the storage of this type of chair can be cumbersome. For example, a separate rack may be required to maintain the chairs in an upright position. Stackable wire rod type chairs have overcome some of the problems associated with folding chairs. In particular, they can be readily stored in a convenient stacked form. In addition, they can be readily set up in rows for use and then restacked when not in use. However, wire rod chairs can suffer certain drawbacks. First, the assembly of a wire rod chair can be somewhat complicated. Various fastening devices, such as screws or the like, have been required to secure the chair back to the chair base. In addition to adding to the complexity of the chair construction, these additional parts add to the cost of the chair. Second, the installation of the chair back over the wire rods forming the chair base has been troublesome. Obviously, the chair back should be securely attached to the wire rods. Yet, simply extending the chair back over the wire rods may be unsatisfactory because of the failure of the chair back to be adequately secured to the chair base. In SUBSTITUTE SHEET (RULE 2B) addition, the load bearing rods can cause "whiting" of the chair back when in use. In particular, when a user sits on the chair, a force is applied to the chair back through the wire rods. As a result, the plastic chair back can become deformed and therefore, discolored. 5 Accordingly, there is a need for an improved chair construction that will overcome these problems. SUMMARY OF THE INVENTION This invention is directed to an improved chair construction that may 0 be manufactured at low cost while providing a secure assembly of the chair back to the chair base. In addition, this invention is directed to an improved chair construction that reduces deformation or "whiting" of the chair back. According to a first aspect of the present invention, a chair is provided including a support member, a projecting surface and a chair back. A ' 5 support member having a top portion extends upward from a rear portion of the seat. A projecting surface is attached to the top portion of the support member. The chair back includes front, back, top and bottom surfaces. A cavity opens downwardly toward the bottom surface of the chair back. An aperture communicating with the cavity is located within one of the front and back surfaces 0 of the chair back. The top portion of the support member extends into the cavity with the projecting surface extending into the aperture. According to another aspect of the present invention, a chair is provided including a support member, an insert member and a chair back. A support member having a top portion extends upward from a rear portion of a seat. 25 An insert member is connected to the top portion of the support member. The chair back includes a cavity formed in the lower portion thereof. The cavity opens downwardly toward a bottom surface of the chair back. The top portion of the support member extends into the cavity with the insert being sized to securely mate within the cavity of the chair back. !ι0 As used herein, the term "support member" is intended to include various support structures in addition to the preferred embodiment shown in the Figures. In addition to the preferred embodiment where each "support member" includes three support elements, it is intended that this term also include chairs where either one or two support elements extend upward from the rear portion of the seat. As used herein, the term "aperture" should be broadly interpreted so as to include physical configurations in addition to the preferred embodiment shown in the Figures. For example, the aperture could also be a "blind hole" that does not extend completely through the back surface of the chair back. The invention, together with its further objects and attendant advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front perspective view of a fully assembled chair illustrating the preferred embodiments of the present invention; Figure 2 is a rear fragmented view of the lower right side of the chair back with the support member, the support bracket, and the insert member being shown in dashed lines; Figure 3 is a rear fragmented view of the lower right side of the chair back with chair back shown in dashed lines in order to better show the support member, the support bracket, the projecting surface, and the insert member; Figure 4 is an exploded view of the chair back, the insert member and the support member; Figure 5 is an assembled view of the support member and the insert member from the opposite perspective of that shown in Figs. 2-3; Figure 6 is a top view of the insert member; Figure 7 is a cross-sectional view taken through the lines 7-7 of Fig. 2 in order to better show the support member, the projecting surface and the support bracket; and Figure 8 is a front perspective view of the projecting surface and the support bracket. - 4 - DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention is described with reference to the drawings in which like elements are referred to by like numerals. Figure 1 illustrates a chair 20 in accordance with the preferred embodiments of the present invention. While a wire rod type chair is shown, it should be understood that the present invention can be used on various other types of chairs. The chair 20 includes a right side frame member 22 and a left side frame member 24. The frame members 22 and 24 are joined together in a substantially congruent, but spaced apart relation by front frame members 26 and a rear frame member 28. In a preferred embodiment, the front frame members 26 have a diameter of 3/8 inch with the other frame members having a diameter of 7/16 inch. As shown in Figure 1 , the chair 20 also includes a seat 30 and a chair back 32. The frame members 22 and 24 include integral base members 36, front risers 38 and rear risers 40. Runners 42 extend from a top portion 44 of the front risers 38 horizontally back to a position adjacent the top portion 46 of the rear risers 40. The seat 30 is secured between the runners 42. The front frame member 26 is secured between the front risers 38 by employing suitable welding techniques known to those of ordinary skill in the art. As will be better explained below, the rear frame member 28 is secured to the runners 42 and the rear risers 40. Therefore, in combination, the frame members 22, 24, 26, 28, the seat 30, and the chair back 32 substantially form the chair 20. In the preferred embodiment, the rear risers 40, the runners 42 and the rear frame member 28 form support members 50 for the chair back 32. As shown in Figs. 2-3 for the right hand side of the chair, the rear riser 40, the runner 42 and the rear frame member 28 include respective top portions 51, 52 and 54. With particular reference to Fig. 3, the rear riser 40 forms an outermost support element with the rear frame member 28 forming the innermost support element and the runner 42 being positioned therebetween. As best seen in Fig. 4, the chair back 32 includes a cavity 60 in a lower portion thereof. The cavity 60 extends downward toward a bottom surface 62. In this manner, an upper portion of the chair back 32 can flexibly support a user. The chair back 32 also includes a front surface 64 and back surface 66. Referring to Figs. 3-6, an insert member 70 is attached to the top portions 51 , 52 and 54 of the rear riser 40, the runner 42 and the rear frame member 5 28. The insert 70 is sized to securely mate with the inner walls that form the cavity 6 within the chair back 32. In this manner, the chair back 32 is securely attached to the support members 50. The insert member 70 includes a first cavity 72 and a second cavity 74. The cavities 72 and 74 form tubular openings in order to securely mate with the rear 10 riser 40 and the runner 42. The first cavity 72 extends further into the insert 70 than the second cavity 74. In a preferred embodiment, the cavity 72 extends inward approximately 1 inch with the second cavity 74 extending inward approximately 0.3 inch. As shown in Figs. 3 and 5, the top portion 51 of the rear riser 40 extends into and mates securely within the first cavity 72. In addition, the top portion 52 of the 15 runner 42 extends into and mates securely within the second cavity 74. As also show in these figures, a downwardly extending lip 75 mates with a part of the top portion 5 of the rear riser 28. As best seen in Figs. 5 and 6, the insert 70 includes a curved outer surface 78 that corresponds with the curvature of the rear surface 66 of the chair back 2.0 32. The insert 70 tapers downward from a top surface 80 to a bottom surface 82. A opening 84 is formed in the top surface 80 in order to mate with a fin (not shown) formed in the top portion of the cavity 60. When these elements mate, the insert 70 i securely fitted within the cavity 60. In a preferred embodiment, the insert 70 has a height of approximately 4 inches, a width of approximately 2 inches, and a thickness 25 of approximately 5/8 inch. Referring to Figs. 2-3 and 7-8, a projecting surface 90 extends through an aperture 92 formed in the back surface 66 of the chair back 32. The projecting surface 90 is integrally formed with a mounting bracket 94. With reference to Fig. 2, the bracket 94 is attached to side portions of the rear riser 40 and the rear frame ;>0 member 28 and to a rear portion of the runner 42. In the preferred embodiment sho in Fig. 8, the bracket 94 includes an aperture 96 that may be filled with a flux materi in order enhance welding of the bracket 94 to the runner 42. In addition, the bracket 94 is also preferably welded to the rear riser 40 and the rear frame member 28. As shown in Figs. 2-3, the projecting surface 90 is curved to correspond with the curved aperture 92 in the back surface 66 of the chair back 32. As also shown in these 5 figures, the projecting surface 90 extends between the runner 42 and the rear frame member 28. Once assembled, the insert 70 is fixedly secured within the cavity 60 of the chair back 32. In addition, the projecting surface 90 extends through the aperture 92 in the back surface 66 of the chair back 32. Accordingly, the chair back 32 is .0 thereby secured to the support members 50. Because the projecting surface 90 extends through the aperture 92, the personnel assembling the chair as well as the user, may clearly identify that the chair back 32 has been secured to the support members 50. While the frame members of the present invention may be formed from various materials known to those of ordinary skill in the art, they are preferably ] 5 formed from cold rolled steel. Similarly, while the seat 30, the chair back 32 and the insert 70 can also be formed in various known manners using various known materials, these elements are preferably injection molded from polypropylene. Accordingly, the present invention provides an office chair construction that is less expensive to manufacture than previous constructions. In addition, the 20 present invention is also easy to assemble by unskilled persons due to the simplified and improved chair back and support members. The present invention may be embodied in other specific forms without departing from the spirit of the invention. For example, the aperture 92 could be located on the front surface 64 of the chair back 32 rather than on the rear surface 66 25 as shown in the drawings. Therefore, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and it is understood that the appended claims, including all equivalents, are intended to define the scope of the invention.

Claims: WE CLAIM: 1. A chair including a seat comprising: a support member extending upward from a rear portion of said seat, said support member having a top portion; 5 a projecting surface attached to said top portion of said support member; and a chair back having front, back, top and bottom surfaces, said chair back having a cavity opening downwardly toward said bottom surface and an aperture within one of said front and back surfaces, said aperture communicating with said 0 cavity, said top portion of said support member extending into said cavity, and said projecting surface extending into said aperture. 2. The chair of claim 1 wherein said back surface of said chair back includes said aperture. .5 3. The chair of claim 2 wherein said support member includes first, second and third rods. 4. The chair of claim 3 wherein said projecting surface extends between 0 said second and third rods. 5. The chair of claim 4 wherein said projecting surface is curved. 6. The chair of claim 3 wherein said projecting surface is integrally formed 5 with a support bracket. 7. The chair of claim 6 wherein said support bracket has an aperture adjacent said projecting surface. [•0 8. The chair of claim 6 wherein said support bracket is attached to said first, second and third rods. 9. The chair of claim 8 wherein said support bracket is attached to a rear portion of said second rod and opposing sides of said first and third rods. 10. A chair including a seat comprising: a support member extending upward from a rear portion of said seat, said support member having a top portion; an insert member connected to said top portion of said support member; and a chair back having inner walls that form a cavity in a lower portion of said chair back, said cavity opening downwardly toward a bottom surface thereof, said top portion of said support member extending into said cavity and said insert sized to securely mate with said inner walls of said cavity. 1 1. The chair of claim 10 wherein said support member comprises first, second and third rods. 12. The chair of claim 11 wherein said insert member is attached to said first, second and third rods. 13. The chair of claim 12 wherein said insert member has first and second cavities opening from a bottom surface, said cavities receiving said first and second rods. 14. The chair of claim 13 wherein said first cavity of said insert has a depth greater than that of said second cavity of said insert. 15. The chair of claim 12 wherein said insert includes a downwardly extending lip that is attached to said third rod. 16. The chair of claim 15 wherein an outer surface of said insert is curved to correspond with a back surface of said chair back. 17. A chair including a seat comprising: a support member extending upward from a rear portion of said seat, said support member including a top portion; an outwardly projecting surface attached to said top portion of said 5 support member; an insert member connected to said top portion of said support member; and a chair back having front, back, top and bottom surfaces, said chair back having inner walls that form a cavity opening downwardly toward said bottom surface ' 0 and an aperture within said back surface, said aperture communicating with said cavity, said top portion of said support member extending into said cavity, and said insert sized to securely mate with said inner walls of said cavity. 18. The chair of claim 17 wherein said support member comprises first, 5 second and third rods. 19. The chair of claim 18 wherein said insert member is attached to said first and second rods. 20 20. The chair of claim 18 wherein said projecting surface is integrally formed with a support bracket that is attached to said first, second and third rods beneath said insert.

Inventors: GIERZ MARC A, NEWHOUSE THOMAS J, GIERZ, MARC, A., NEWHOUSE, THOMAS, J.
Applicants: GIERZ MARC A, MILLER HERMAN INC, NEWHOUSE THOMAS J, GIERZ, MARC, A., HERMAN MILLER, INC., NEWHOUSE, THOMAS, J.
Application year: 1997
Main classification: A47C7
IPC codes: A47C5