Abstract:
Some embodiments of the present invention provide a method and apparatus for a novel double sling chair. The double sling chair simplifies the manufacture of sling chairs affording efficient and speedy construction. The double sling chair comprises a chair frame having a back section with an upper rail and a lower cross member, a decorative cross member, and a seat section, a seat panel coupled to the seat section of the chair frame, a first fabric back panel having length is coupled to the upper rail and the decorative cross member without having to thread the first fabric back panel to the decorative cross member, a second fabric back panel having length is coupled to the lower cross member and the decorative cross member without having to thread the second fabric back panel to the decorative cross member to form a back rest for the back section.

Description:
RELATED APPLICATION 
     This is a continuation-in-part of U.S. Ser. No. 13/065,731 filed Mar. 28, 2011 (HMSC110328) which is incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Technical Field 
     This disclosure generally relates to sling chairs, and more particularly to a double-sling chair wherein insertion of the sling fabric is greatly simplified. 
     2. Related Art 
     Conventional outdoor furniture of the type intended for use on decks and patio are very popular. Manufacturers of outdoor patio furniture are constantly called upon to offer new innovative designs that provide practical, comfortable products to the consumer. Manufacturers on one hand are interested in offering the innovative designs, but are also interested in reducing manufacturing cost by simplifying and reducing the time to manufacture the outdoor patio furniture. 
     As the outdoor patio furniture industry has developed, a popular design for chairs, loungers, and the like is a supporting web that is suspended between a frame of a chair to support the user of the chair. These supporting web style chairs are commonly known as sling chairs. Although the sling chair construction arose since it is easier and less expensive to construct the sling and the chair frame separately, however, it has become apparent that there are short comings to the conventional construction and manufacture of sling-style chairs. 
     What is needed is a sling chair that simplifies conventional sling chair construction and reduces waste and effort associated with the manufacture and construction of sling chairs while still offering attractive designs with many variations. 
     SUMMARY OF INVENTION 
     A method and apparatus for a novel double sling chair are disclosed which overcome disadvantages of previous sling chair construction. The novel double sling chair construction reduces waste associated with ripping sling fabric panels and mis-fitting sling fabric panels. The manufacturing steps are simplified by reducing the incidence of having to thread the fabric panels along the length of the sling fabric groove. Instead of having to attach the sling fabric early in the construction, the sling fabric can be attached near the end of construction when the entire frame of the chair is completed which greatly reduces the incidence of the sling fabric being cut or marred. Accordingly, the double sling chair comprises a chair frame, a seat panel coupled to the chair frame, a first fabric back panel having length and first and second terminating loops at opposing ends with a first rod inserted through the first terminating loop and a second rod inserted through the second terminating loop for attaching the fabric back panel to the chair frame, and a second fabric back panel having length and first and second terminating loops at opposing ends with a first rod inserted through the first terminating loop and a second rod inserted through the second terminating loop for attaching the fabric back panel to the chair frame wherein the chair frame includes a decorative cross member having an upper back center sling rail and a lower back center sling rail, the upper back center sling rail configured to forceably receive the first rod and the first terminating loop of the first fabric panel and the lower back center sling rail configured to forceably receive the first rod and the first terminating loop of the second fabric panel, an upper back cross member having a back top sling rail with an interior side configured to slidably receive the second rod and the second terminating loop of the first fabric panel wherein the back top sling rail is separate from the upper back cross member and configured to securely attach to the upper back cross member to form a section of a back rest, and a lower back cross member having a lower back sling rail having an interior side configured to slidably receive the second rod and the second terminating loop of the second fabric panel wherein the lower back sling rail is separate from the lower back cross member and configured to securely attach to the lower back cross member forming another section of the back rest. 
     In accordance to another embodiment of the present invention, the upper back cross member is configured with screw threads and receives a screw that secures the back top sling rail to the upper back cross member of the chair frame. 
     In accordance to another embodiment of the present invention, the first fabric back panel is tensioned as the screw is tightened against the upper cross member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a single sling chair in accordance with an embodiment of the present invention; 
         FIG. 2  illustrates an upper rail with an upper end of a sling assembly assembled into an interior side of the upper rail in accordance with an embodiment of the present invention; 
         FIG. 3  illustrates a lower rail with a lower end of the sling assembly assembled into an interior side of the lower rail in accordance with an embodiment of the present invention; 
         FIG. 4  illustrates an exemplary cut-out view of the chair back taken along line  3 - 3  of  FIG. 1 ; 
         FIG. 5  illustrates a double sling chair in accordance with an embodiment of the present invention; 
         FIG. 6  illustrates a fabric panel attached between an upper back center sling rail of a decorative cross member and a back top sling rail of an upper back cross member in accordance to an embodiment of the present invention; 
         FIG. 7A-7B  illustrates a fabric panel attached between a lower back center sling rail of a decorative cross member and a back bottom sling rail of an lower back cross member in accordance to an embodiment of the present invention; and 
         FIG. 8  illustrates an exemplary cut-out view of the chair back taken along line A-A of  FIG. 5 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a single sling chair  10  in accordance with an embodiment of the present invention. The single sling chair  10  includes a chair frame  12 , a seat section  13 , and a back section  14 . The general construction of the single sling chair is conventional and well known to those skilled in the art of making patio chairs. A detailed discussion of how of the chair is constructed will detract from the spirit of the present invention. Therefore, a terse discussion of the general construction of the chair is given. Essentially, the chair frame is formed by attaching symmetrical halves of the chair frame that include an arm rest  16 , legs  18  with cross supports  19 . The seat section  13  is attached to the chair frame  12 . The back support  14  includes a decorative cross member  21  and a cross support member  23  to not only give the back support decorative appeal but also added strength. In accordance to a present embodiment, the seat section  13  and the back section  14  are covered with fabric panels. The fabric panel of the seat section  13  is covered using conventional construction. However, the fabric panel of the back section is covered using a novel single sling construction. The back section  14  includes an upper rail  24 , a sling fabric  25 , a lower rail  26 , and lower back cross member  28 . The sling fabric  25  is of conventional construction consisting of a fabric back panel having a length and terminating loops at opposing ends and rods inserted into the loops for attaching the fabric back panel. 
       FIG. 2  illustrates the upper rail  24 , the sling fabric  25  with an upper rod  35  inserted into the sling fabric terminating loop and fitted into an interior side of the upper rail  24 . The interior side of the upper rail  24  is constructed to receive and secure the upper rod  35  of the sling fabric  25 . In accordance with an embodiment of the present invention, the interior side of the upper rail  24  is configured to flex in order to receive the upper rod  35 . In other words, the upper rod  35  is pressed or forced into the interior side of the upper rail  24  with an aid of a small pry device such as a screw driver, pry bar, or the like. Essentially, no threading or sliding is used to insert the upper rod  35 . The entire upper rod  35  is aligned with the length of the interior side of the upper rail  24  and is pressed or forced into the interior side of the upper rail  24  with an aid of a pry instrument, and there is no threading motion that is used to assemble the upper rod  35 . Manufacture of the single sling chair  10  is greatly simplified by not having to thread or slide the upper rod  35  into the interior side of the upper rail  24  from one end of the upper rod  35 . Sling fabric  25  can often rip during the threading or sliding process of the upper rod  35  into the interior side of the upper rail  24 . Using the present embodiment of inserting the upper rod  35  directly into the interior side not only saves time but reduces the likelihood of ripping the fabric during installation. Instead of attaching the sling fabric early during construction, the entire frame of the chair can be constructed and attaching the sling fabric can be one of the last finishing step further reducing the likelihood of damage or soiling of the sling fabric. 
       FIG. 3  illustrates the lower rail  26 , the sling fabric  25  with a lower rod  36  inserted into the sling fabric terminating loop and fitted into an interior side of the lower rail  26 . Contrary to the interior side of the upper rail  24 , the interior side of the lower rail  26  can not be flexed to insert the lower rod  36  into the interior side of the lower rail  26 . Rather, the lower rod  36  is threaded into the interior side of the lower rail  26  using conventional sling construction technique. Since the lower rail  26  is separate and detached from the chair frame, threading or sliding the lower rod  36  into the interior side of the lower rail  26  from either end of the lower rail  26  is simplified and can be accomplished with rather ease. 
       FIG. 4  illustrates a cutout taken along line  3 - 3  of  FIG. 1 . The upper back support  14  is shown with the cross support member  23 , the decorative cross member  21 , the upper rail  24  having the upper rod  35  assembled into the interior side of the upper rail  24 , sling fabric  25 , the lower rail  26  having the lower rod  36  assembled into the interior side of the lower rail  26 , the lower back cross member  28 , threaded screw/bolt  38 , and threads  39 . The lower rail  26  has a threaded hole  39  for receiving the threaded screw/bolt  38 . The threaded screw  38  is screwed into the threaded hole  39  for attaching the lower rail  26  to the lower back cross member  28 . As the threaded screw  38  is tightened, the sling fabric  25  tension can be adjusted. Accordingly, the present embodiment of the single sling chair simplifies the construction of the sling fabric back panel. For example, the entire chair frame can be assembled prior to assembly of the sling fabric back. The assembly of the sling fabric back is simplified by not having to thread the upper rod  35  including the sling fabric  25  into the interior side of the upper rail  24 . According to an embodiment of the present embodiment, there is insufficient space to thread/slide the upper rod  35  into the interior side of the upper rail  24 . By limiting the space and protrusions of the chair construction, more aesthetically appealing designs of sling style chair can be constructed. In addition, using the threaded screw  38  to attach the lower rail  26  with the lower rod  36  assembled to the interior side of the lower back cross member  28  enables tensioning and adjustment of the sling fabric which reduces waste during manufacturing when the sling fabric is not exactly the correct length. Conventional sling chair construction offers very little if any adjustment to the tension of the sling fabric. 
       FIG. 5  illustrates a double sling chair  50  in accordance with an embodiment of the present invention. The double sling chair  50  includes a chair frame  52 , a seat section  53 , and a back section  54 . The general construction of the double sling chair is conventional and well known to those skilled in the art of making patio chairs. A detailed discussion of how of the chair is constructed will detract from the spirit of the present invention. Therefore, a terse discussion of the general construction of the chair is given. In accordance to an embodiment of the present invention, the chair frame  52  is formed by attaching symmetrical halves of the chair frame that include an arm rest  55 , legs  58  with cross supports  59 . The seat section  53  is attached to the chair frame  52 . The back support  54  includes a decorative cross member  61  and an upper back cross member  63  to not only give the back support decorative appeal but also added strength. In accordance to a present embodiment, the seat section  53  and the back section  54  are covered with fabric panels  56 . The fabric panels are constructed using durable man-made materials that are weather resistant and strong. The fabric panel of the seat section  53  is covered using conventional construction. However, the fabric panels of the back section are covered using a novel double sling construction. The back section  54  includes the upper back cross support  63 , sling fabrics  56 , decorative cross member  61  which includes upper back center sling rail  64  (not shown) and lower back center sling rail  65  (not shown), and lower back cross member  68 . The sling fabrics  56  is of conventional construction consisting of a fabric back panel having a length and terminating loops at opposing ends and rods inserted into the loops for attaching the fabric back panel. 
       FIG. 6  illustrates the decorative cross member  61  with the upper back center sling rail  64 . A first end of the sling fabric  56  with a rod  74  is inserted into the sling fabric terminating loop and fitted into an interior side of the upper back center sling rail  64 . In accordance with an embodiment of the present invention, the interior side of the upper back center sling rail  64  is configured to flex in order to receive the rod  74 . In other words, the rod  74  is pressed or forced into the interior side of the upper back center sling rail  64  with an aid of a small pry device such as a screw driver, pry bar, or the like. Essentially, no threading or sliding is used to insert the rod  74 . The entire rod  74  is aligned with the length of the interior side of the upper back center sling rail  64  and is pressed or forced into the interior side of the lower back center sling rail  65  with an aid of a pry instrument, and there is no threading motion that is used to assemble the rod  74 . Manufacture of the single sling chair  50  is greatly simplified by not having to thread or slide the rod  74  into the interior side of the upper back center sling rail  64  from one end of the rod  74 . Sling fabric  56  can often rip during the threading or sliding process of the rod  74  into the interior side of the upper back center sling rail  64 . Using the present embodiment of inserting the rod  74  directly into the interior side not only saves time but reduces the likelihood of ripping the fabric during installation. Instead of attaching the sling fabric early during construction, the entire frame of the chair can be constructed and attaching the sling fabric can be one of the last finishing step further reducing the likelihood of damage or soiling of the sling fabric. Referring to  FIG. 6 , the upper back cross member  63  is shown with a back top sling rail  71  with the sling fabric  56  having an upper rod  74  inserted into the sling fabric terminating loop and fitted into an interior side of the back top sling rail  71 . The interior side of the back top sling rail  71  is constructed to receive and secure the rod  74  of the sling fabric  56  against the upper back cross member  63 . Screws  75  are inserted through the back top sling rail  71  and are screwed into the upper back cross member  63  to secure the rod  74 , sling fabric  56 , and the back top sing rail  71  to the upper back cross member  63 . 
       FIG. 7A  illustrates the decorative cross member  61  with the lower back center sling rail  65 . A first end of the sling fabric  56  with a rod  74  is inserted into the sling fabric terminating loop and fitted into an interior side of the lower back center sling rail  65 . Similarly configured as the upper back center sling rail  64 , the interior side of the upper back center sling rail  64  is configured to flex in order to receive the rod  74 . In other words, the rod  74  is pressed or forced into the interior side of the lower back center sling rail  65  with an aid of a small pry device such as a screw driver, pry bar, or the like. Essentially, no threading or sliding is used to insert the rod  74 . The lower back cross member  68  is shown with a lower back sling rail  76  with the sling fabric  56  having a rod  74  inserted into the sling fabric terminating loop and fitted into an interior side of the lower back sling rail  76 . The interior side of the lower back sling rail  76  is constructed to receive and secure the rod  74  of the sling fabric  56  against the lower back cross member  68 . 
       FIG. 7B  illustrates screws  75  are inserted through the lower back sling rail  76 . The screws  75  are screwed into the lower back sling rail  76  to secure the rod  74 , sling fabric  56 , and the lower back sling rail  76  to the lower back cross member  68 . 
       FIG. 8  illustrates a cross-sectional view of the back section  54  of the double sling chair  50  taken alone line A-A rotated approximately 20 degrees about the line A-A. The back section  54  shows the upper back cross member  63 , thread block  78 , back top sling rail  71 , rod  74 , screw  75 , sling fabric  56 , upper back center sling rail  64 , decorative cross member  61 , rod  74 , lower back center sling rail  65 , sling fabric  56 , lower back sling rail  76  having a thread block  76 , screw  75 , and lower back cross member  68 . The upper back cross member  63  includes a thread block  78  that is configured to receive a threaded screw  75 . The threaded screw  75  secures the back top sling rail  71  having the rod  74 , sling fabric  56  against the upper back cross member  63 . The other end of the sling fabric  56  and the rod is attached to the interior side of the upper back center sling rail  64 . As the threaded screw  75  is tightened, the sling fabric  56  tension can be adjusted. Similarly, another sling fabric  56  having a rod  74  inserted into the sling fabric terminating loop is inserted into the interior side of the lower back center sling rail  65 . The other end of the sling fabric  56  having a rod  74  inserted into the sling fabric terminating loop is inserted into an interior side of the lower back sling rail  76 . The lower back sling rail  76  includes a thread block  78  configured to receive a threaded screw  75  that secures the lower back sling rail  76  assembly which includes the sling fabric  56  and rod  74  inserted into the sling fabric termination loop to the lower back cross member  68 . As the threaded screw  75  is tightened, the sling fabric  56  tension can be adjusted. 
     The present novel double sling invention is susceptible to minor variations and modifications that may be introduced without departing from the inventive concept. For example, the fabric seat and seat back panel could be switched with the fabric seat incorporating the novel double sling construction. 
     It is further appreciated that designation of furniture as fitting into categories such as chairs, lounges, and other separate and distinct varieties may be inadequate. For example, patio furniture as opposed to furniture designs may show no clear delineation separating the two categories. Moreover, alternative configurations may be within the spirit of the invention if the frame were modified resulting in furniture that can be regarded as a cot, bed, as well as a chair, lounge, sofa, or similar furniture. 
     The foregoing descriptions of embodiments of the present invention have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Moreover, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the claims.