Patent Publication Number: US-8123299-B2

Title: Armrest and methods for manufacturing same

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an armrest, and more particularly, to a wooden armrest made with less material and having enhanced structural strength and prolonged service life. The present invention also relates to methods for manufacturing the armrest. 
     2. Description of the Related Art 
     Conventional armrests are generally made of wood materials. However, armrests entirely made of a single piece of timber are a waste in view of limited wood resources. To save precious wood materials while providing the same appearance, it has been proposed to provide an upper veneer layer made of oak for covering an upper surface of an armrest body made of a wood material (such as rubber wood or pinewood from plantation forests) different from oak and to provide two lateral veneer layers made of oak for covering two lateral surfaces of the armrest body. An example of such an armrest is disclosed in U.S. Pat. No. 6,582,021. However, the armrest body and the upper and lateral veneer layers generally fixed to the armrest body by gluing the have different characteristics in fiber density, specific weight, elongation and shrinkage resulting from temperature change. The armrest is liable to break at the gluing section between the armrest body and the veneer layers due to different deformation resulting from temperature change. Furthermore, although the armrest body is not made of oak, use of the upper and lateral veneer layers made oak could still be a waste if the products do not require a quality appearance. 
     Thus, a need exists for a wooden armrest made with less material and having enhanced structural strength and prolonged service life. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention solves this need and other problems in the field of manufacture of high-quality armrests with low costs by providing, in a first aspect, a method for manufacturing an armrest includes making a plurality of core sections. Each of the plurality of core sections is formed by bonding a plurality of waste pieces of high-quality wood together. Outer faces of the plurality of core sections are processed to be smooth and planar. Each of the plurality of the core sections has two lateral faces and top and bottom faces. Each of two adjacent ends respectively of two adjacent core sections is machined to provide a serrated coupling face having a plurality of horizontal grooves and a plurality of horizontal protrusions. The plurality of core sections are bonded together to form a core by applying adhesive to the serrated coupling faces to bond the two adjacent ends respectively of the two adjacent core sections. A surface portion made of a material the same as the plurality of core sections is prepared and bonded to the core. The surface portion includes a plurality of upper boards and a plurality of lateral boards. Each of two adjacent ends respectively of two adjacent upper boards has a first, planar, engaging face. Each of two adjacent ends respectively of two adjacent lateral boards has a second, planar engaging face. Each of the plurality of lateral boards has a height the same as that of the lateral face of each of the plurality of core sections. Each of the plurality of upper boards has a width the same as a sum of a width of the top face of each of the plurality of core sections and two times of a width of a top face of each of the plurality of lateral boards. Inner faces of the plurality of lateral boards are bonded to the lateral faces of the plurality of core sections. Inner faces of the plurality of upper boards are bonded to the top faces of the plurality of core sections and the top faces of the plurality of lateral boards. The first engaging faces of two adjacent upper boards are bonded together, leaving an unobvious rectilinear coupling edge. The second engaging faces of two adjacent lateral boards bonded together, leaving an unobvious rectilinear coupling edge. Serrated coupling edges of the serrated coupling faces of the plurality of core sections are covered by the plurality of lateral boards. The armrest is processed to include a first outline on outer faces of the plurality of upper boards and a second outline on outer faces of the lateral boards, with the top faces of the plurality of core sections still covered by the plurality of upper boards, and with the lateral faces of the plurality of core sections still covered by the plurality of lateral boards. 
     According to a second aspect, a method for manufacturing an armrest includes making a plurality of core sections. Each of the plurality of core sections is formed by bonding a plurality of waste pieces of high-quality wood together. Outer faces of the plurality of core sections are processed to be smooth and planar. Each of the plurality of the core sections has two lateral faces and top and bottom faces. Each of two adjacent ends respectively of two adjacent core sections is machined to provide a first serrated coupling face having a plurality of horizontal grooves and a plurality of horizontal protrusions. The plurality of core sections are bonded together to form a plurality of longer core sections by applying adhesive to the first serrated coupling faces to bond the two adjacent ends respectively of the two adjacent core sections. Serrated coupling edges of the first serrated coupling faces are located in two lateral sides of the plurality of longer core sections. A surface portion made of a material the same as the plurality of core sections is prepared. The surface portion includes a plurality of upper boards and a plurality of lateral boards. Each of two adjacent lateral boards has a planar engaging face. Each of the plurality of lateral boards has a height the same as that of the lateral face of each of the plurality of longer core sections. A length of each of the plurality of lateral boards is equal to a length of each of the plurality of longer core sections. Inner faces of the plurality of lateral boards are bonded to the two lateral faces of the plurality of longer core sections. The engaging faces of two adjacent lateral boards are bonded together, leaving an unobvious rectilinear coupling edge. The serrated coupling edges of the first serrated coupling faces of the longer core sections are covered by the plurality of lateral boards. Each of two adjacent upper boards has a planar, engaging face. Each of the plurality of upper boards has a width the same as a sum of a width of the top face of each of the plurality of longer core sections and two times of a width of a top face of each of the plurality of lateral boards. Each of two adjacent ends respectively of two adjacent longer core sections is machined to provide a second serrated coupling face having a plurality of horizontal grooves and a plurality of horizontal protrusions. The plurality of longer core sections are bonded together to form a core by applying adhesive to the second serrated coupling faces to bond the two adjacent ends respectively of the two adjacent longer core sections. Serrated coupling edges of the second serrated coupling faces are located in the two lateral faces of the plurality of longer core sections. The plurality of upper boards are bonded to the core with inner faces of the plurality of upper boards bonded to the top faces of the plurality of core sections and the top faces of the plurality of lateral boards. The engaging faces of two adjacent upper boards are bonded together, leaving an unobvious rectilinear coupling edge. The serrated coupling edges of the second serrated coupling faces are covered by the plurality of upper boards. The armrest is processed to include a first outline on outer faces of the plurality of upper boards and a second outline on outer faces of the plurality of lateral boards, with the top faces of the plurality of core sections still covered by the plurality of upper boards, and with the lateral faces of the plurality of core sections still covered by the plurality of lateral boards. 
     According a third aspect, an armrest includes a core comprised of a plurality of core sections formed by bonding a plurality of waste pieces of high-quality wood. Each of two adjacent ends respectively of two adjacent core sections includes a serrated coupling face having a plurality of horizontal grooves and a plurality of horizontal protrusions. Each of the plurality of core sections includes two lateral faces and top and bottom faces. Adhesive is applied to the serrated coupling faces to bond the plurality of core sections together, leaving serrated coupling edges of the serrated coupling faces in the lateral faces of the plurality of core sections. The armrest further includes a surface portion made of a wood material the same as the plurality of core sections and including an upper side comprised of a plurality of upper boards and two lateral sides each of which is comprised of a plurality of lateral boards. Each of the plurality of lateral boards and the plurality of the upper boards is a parallelepiped. Each of two adjacent ends respectively of two adjacent upper boards has a first, planar, engaging face. Each of two adjacent ends respectively of two adjacent lateral boards has a second, planar, engaging face. Each of the plurality of lateral boards has a height the same as that of the lateral face of each of the plurality of core sections. Each of the plurality of upper boards has a width the same as a sum of a width of the top face of each of the plurality of core sections and two times of a width of a top face of each of the plurality of lateral boards. Inner faces of the plurality of upper boards are bonded to the top faces of the plurality of core sections and the top faces of the plurality of lateral boards. The first engaging faces of two adjacent upper boards are bonded together, leaving a rectilinear coupling edge. The second engaging faces of two adjacent lateral boards are bonded together, leaving a rectilinear coupling edge. The serrated coupling edges of the core sections of the plurality of core sections are covered by the plurality of lateral boards. 
     The present invention will become clearer in light of the following detailed description of illustrative embodiments of this invention described in connection with the drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The illustrative embodiments may best be described by reference to the accompanying drawings where: 
         FIG. 1  shows a flowchart of a method for manufacturing an armrest of a first example according to the preferred teachings of the present invention. 
         FIG. 2  shows an exploded, perspective view of a core of an armrest blank formed by bonding a plurality of core sections according to the method of  FIG. 1 . 
         FIG. 3  shows an exploded, perspective view of an armrest blank including the core sections of  FIG. 2  and a surface portion. 
         FIG. 4  shows a perspective view of the armrest blank of  FIG. 3  after bonding. 
         FIG. 5  shows a cross sectional view of the armrest blank of  FIG. 4  according to section line  5 - 5  of  FIG. 4 . 
         FIG. 6  shows a perspective view of a final product of an armrest after processing the armrest blank of  FIG. 4 . 
         FIG. 7  shows a cross sectional view of the armrest of  FIG. 6  according to section line  7 - 7  of  FIG. 6 . 
         FIG. 8  shows a flowchart of a method for manufacturing an armrest of a second example according to the preferred teachings of the present invention. 
         FIG. 9  shows an exploded, perspective view of two armrest portions of an armrest including a core comprised of a plurality of core sections and a plurality of lateral boards. 
         FIG. 10  is an exploded, perspective view illustrating bonding of the armrest portions of  FIG. 9  according to the method of  FIG. 8 . 
         FIG. 11  shows a partial, top view of the armrest portions of  FIG. 10  after bonding. 
         FIG. 12  is an exploded, perspective view illustrating bonding of upper boards according to the method of  FIG. 8 . 
         FIG. 13  is a perspective view illustrating the armrest of  FIG. 12  after bonding. 
     
    
    
     All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiments will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a flowchart of a method for manufacturing an armrest of a first example according to the preferred teachings of the present invention.  FIG. 2  shows an exploded, perspective view of a core of an armrest blank formed by bonding a plurality of core sections  1  according to the method of  FIG. 1 .  FIG. 3  shows an exploded, perspective view of an armrest blank including the core sections  1  of  FIG. 2  and a surface portion  2 . 
     Specifically, the method for manufacturing an armrest of the first example according to the preferred teachings of the present invention includes making a plurality of core sections  1 . Each core section  1  has rectangular cross sections and includes two lateral faces  11  spaced in a width direction, a top face  12  extending between the lateral faces  11 , and a bottom face  13  extending between the lateral faces  11  and spaced from the top face  12  in a height direction perpendicular to the width direction. Each core section  1  further includes two ends each extending between the top and bottom faces  12  and  13  and between the lateral faces  11 . Each of two adjacent ends respectively of two adjacent core sections  1  is machined to provide a serrated coupling face  14  having a plurality of horizontal grooves and a plurality of horizontal protrusions. Each core section  1  has a height H 1  between the top and bottom faces  12  and  13  and a width W 1  between the lateral faces  11  ( FIG. 5 ). Each core section  1  is formed by bonding a plurality of waste pieces  10  of high-quality wood together (see A 1  of  FIG. 1 ). The waste pieces  10  are wastes of cutting a high quality wood and generally not utilized in conventional methods for manufacturing armrests. The high quality wood can be oak, beech, maple, cheery tree, Brazil cheery tree, mahogany, etc. The core sections  1  do not have to be of equal length in a length direction perpendicular to the width and height directions. 
     Next, the top and bottom faces  12  and  13  and the lateral faces  11  of each core section  1  are processed to be smooth and planar. The core sections  1  are bonded together to form a core of a length L 1  by applying adhesive to and engaging the serrated coupling faces  14  of the core sections  1  (see B 1  of  FIG. 1  and  FIG. 3 ). The serrated coupling faces  14  increase the coupling force between the core sections  1  by increasing the coupling area. After bonding, the serrated coupling edges  15  of the serrated coupling faces  14  are located on the lateral faces  11  of the bonded core sections  1 . 
     Next, a surface portion  2  made of a high quality wood the same as the core sections  1  is prepared and bonded with the core sections  1  (see C 1  of  FIG. 1 ). The surface portion  2  includes a plurality of upper boards  22  and a plurality of lateral boards  21 . Each of the lateral boards  21  and the upper boards  22  are in the form of a parallelepiped. Each upper board  22  and each lateral board  21  are processed to have a specific size in the length, width, and height. Each of two adjacent ends respectively of two adjacent lateral boards  21  has a planar engaging face  211 . Each of two adjacent ends respectively of two adjacent upper boards  22  has a planar engaging face  221 . Each lateral board  21  has a height H 1  equal to that of each core section  1 . Each upper board  22  has a width equal to a sum of the width W 1  of the top face  12  of each core section  1  and two times of the width W 2  of a top face  213  of each lateral board  21 . Inner faces of the lateral boards  21  abut and are bonded by adhesive to the lateral faces  11  of the core sections  1 . The planar engaging faces  211  of two adjacent lateral boards  21  are also bonded together. After bonding, the coupling edges  212  of the lateral boards  21  are not obvious, and the lateral boards  21  cover the serrated coupling edges  15  of the core sections  1 , providing an aesthetic appearance. Likewise, the upper boards  22  abut and are bonded by adhesive to the top faces  12  of the core sections and the top faces  213  of the lateral boards  21 . After bonding, the coupling edges  222  of the upper boards  22  are not obvious, providing an aesthetic appearance. The planar engaging faces  221  of two adjacent upper boards  22  are also bonded together (see  FIG. 5 ). 
     Then, the armrest blank is processed to provide a final product of an armrest having a desired shape (see D 1  of  FIG. 1 ). The lateral faces  11  and the top faces  12  of the core sections  1  are still covered by the lateral boards  21  and the top boards  22  after processing, providing an outline  214  on outer faces of the upper boards  22  and an outline  223  on outer faces of the lateral boards  21  (see  FIGS. 6 and 7 ). Thus, the armrest can have a desired appearance after processing. 
     Although the bottom side of the armrest made by the method of the first example according to the teachings of the present invention is not covered, it is not seen in normal situations. Thus, the armrest made by the method of the first example according to the teachings of the present invention can be made with lower costs while meeting the practical needs. Furthermore, the core sections  1 , the upper boards  22 , and the lateral boards  21  are made of the same material and, thus have the same density and bonding strength as well as the same characteristics in expansion and shrinkage. Disengagement between the core sections  1 , the upper boards  22 , and the lateral boards  21  due to heat expansion and cold shrinkage is, thus, less likely to occur, providing enhanced structural strength and prolonging the service life of the armrest. Further, the whole armrest including the core sections  1  and the upper and lateral boards  22  and  21  is made of waste wood pieces, avoiding waste of high quality wood and saving the precious forests. 
       FIG. 8  shows a flowchart of a method for manufacturing an armrest of a second example according to the preferred teachings of the present invention. The method of the second example can be utilized to manufacture a longer armrest. Specifically, at A 2 , a plurality of core sections  1  ( FIG. 9 ) is made in a manner the same as A 1  of the method of the first example. At B 2 , the faces of each core section  1  are processed to be smooth, and the core sections  1  are bonded together to form a plurality of longer core sections, which is substantially the same as B 1  of the method of the first example. Each longer core section includes two lateral faces  11  and top and bottom faces  12  and  13 . After bonding, the serrated coupling edges  15  of the serrated coupling faces  14  are located on the lateral faces  11  of the core sections  1 . It can be appreciated that the core sections  1  can be bonded as many as required for the length of the longer core section. 
     At C 2 , a surface portion  2  made of a high quality wood the same as the core sections  1  is prepared and bonded with the longer core sections. The surface portion  2  includes a plurality of upper boards  22  and a plurality of lateral boards  21 . Each lateral board  21  has a height equal to the height of the lateral face  11  of each longer core section. The length of each lateral board  21  is equal to the length of the longer core section. Each of two adjacent ends respectively of two adjacent lateral boards  21  has a planar engaging face  211 . Inner faces of the lateral boards  21  abut and are bonded by adhesive to the lateral faces  11  of longer core section. After bonding, the coupling edges  212  of the lateral boards  21  are not obvious, and the lateral boards  21  cover the serrated coupling edges  15  of the core sections  1 , providing an aesthetic appearance. Each upper board  22  is in the form of a parallelepiped and has a width equal to a sum of the width of the top face of each longer core section (which is the same as the width of the top face of the core section  1  in the second example) and two times of the width of a top face of each lateral board  21 . Each of two adjacent ends respectively of two adjacent upper boards  22  has a planar engaging face  221 . Furthermore, each upper board  22  has a length not equal to that of each lateral board  21 . 
     At D 2 , each of two adjacent ends respectively of two adjacent longer core sections bonded with the lateral boards  21  is machined to provide a serrated coupling face  16  having a plurality of vertical grooves and a plurality of vertical protrusions. The planar engaging faces  211   a  and  211   b  of the lateral boards  21  on opposite side of each longer section are on opposite sides of the serrated coupling face  16  and perpendicular to the lateral boards  21 . Furthermore, the engaging face  211   a  of one of the lateral boards  21  has a spacing to the engaging face  211   b  of the other lateral board  21  in the length direction. The longer core sections comprised of the core sections  1  and the lateral boards  2  are bonded together to form a core of a desired length by applying adhesive to the serrated coupling face  16  and the engaging faces  211   a  and  211   b . The planar engaging faces  211  of two adjacent lateral boards  21  are bonded together. After bonding, the rectilinear coupling edges  212  of the lateral boards  21  are not obvious, providing an aesthetic appearance. Furthermore, since each serrated coupling face  16  extends in a direction different from that of each serrated coupling edge  15  and since the engaging face  211   a  of one of the lateral boards  21  has a spacing to the engaging face  211   b  of the other lateral board  21  in the length direction, the anti-deformation capability of the armrest is increased (see  FIGS. 10 and 11 ). 
     At E 2 , the upper boards  22  are bonded by adhesive to the core. Inner faces of the upper boards  22  are bonded to the top faces  12  of the core sections  1  and the top faces  213  of the lateral boards  21 . After bonding, the serrated coupling edges  17  of the longer core sections are covered by the upper boards  22 . The planar engaging faces  221  of two adjacent upper boards  22  are also bonded together by adhesive (see  FIGS. 12 and 13 ). After bonding, the rectilinear coupling edges  222  of the upper boards  22  are not obvious, providing an aesthetic appearance. An armrest having core sections  1  whose top face  12  and lateral faces  11  are covered by upper boards  22  and lateral boards  21  is provided. The armrest can have square cross sections. Although the serrated coupling edges can be seen from the bottom side of the armrest, it is usually not seen in normal situations. Thus, the armrest made by the method of the second example according to the teachings of the present invention can be made with lower costs while meeting the practical needs. 
     Next, at F 2 , the armrest can be processed to provide a final product of an armrest having a desired shape. The lateral faces  11  and the top faces  12  of the core sections  1  are still covered by the lateral boards  21  and the top bards  22  after processing, providing an outline  214  on outer faces of the upper boards  22  and an outline  223  on outer faces of the lateral boards  21 . Thus, the armrest can have a desired appearance after processing. 
     It can be appreciated that the outer faces of the upper boards  22  and the lateral boards  21  can be processed to include the outlines  214  and  223  before bonded to the core sections  1 . 
     Thus, the armrests manufactured by the methods according to the teachings of the present invention are environmentally friendly and high quality and can be made at low costs. In the preferred forms shown, the armrest manufactured by the methods according to the teachings of the present invention includes a core and a surface portion. The core is comprised of a plurality of core sections  1  formed by bonding a plurality of waste pieces  10  of high-quality wood. Each of two adjacent ends respectively of two adjacent core sections  1  includes a serrated coupling face  14  having horizontal grooves and horizontal protrusions. Adhesive is applied to the serrated coupling faces  14  to bond the core sections  1  together, leaving serrated coupling edges  15  in the lateral faces  11  of the core sections  1 . The core sections  1  can have rectangular cross sections. The surface portion is made of a wood material the same as the core sections  1  and includes an upper side comprised of a plurality of upper boards  22  and two lateral sides each of which is comprised of a plurality of lateral boards  21 . Each of the lateral boards  21  and the upper boards  22  are in the form of a parallelepiped. Each of two adjacent ends respectively of two adjacent upper boards  22  has a planar engaging face  221 . Each of two adjacent ends respectively of two adjacent lateral boards  21  has a planar engaging face  211 . Each lateral board  21  has a height the same as that of the lateral face  11  of each core section  1 . Each upper board  22  has a width the same as a sum of the width of the top face  12  of each core section  1  and two times of the width of a top face  213  of each lateral board  21 . The inner faces of the upper boards  22  are bonded to the top faces  12  of the core sections  1  and the top faces  213  of the lateral boards  21 . The engaging faces  221  of two adjacent upper boards  22  are bonded together, leaving unobvious rectilinear coupling edges  222 . The engaging faces  211  of two adjacent lateral boards  21  are bonded together, leaving unobvious rectilinear coupling edges  212 . The serrated coupling edges  15  of the core sections  1  are covered by the lateral boards  22 . Outlines  214  and  223  can be provided on the lateral boards  21  and the upper boards  22 . The core sections  1  can include serrated coupling faces  16  having vertical grooves and vertical protrusions when the core sections  1  are to be assembled to a longer core section. 
     Thus since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.