Patent Publication Number: US-9408468-B2

Title: Furniture with concealed weld construction

Description:
In the accompanying drawings: 
       FIG. 1  is a perspective view of a swivel chair including concealed weld construction. 
       FIG. 2A  is a side elevation view of the swivel chair shown in  FIG. 1   
       FIG. 2B  is a front elevation view of the swivel chair shown in  FIG. 1   
       FIG. 2C  is a top elevation view of the swivel chair shown in  FIG. 1 . 
       FIG. 3A  is a cross-sectional view of a frame extrusion. 
       FIG. 3B  is an enlarged view of the engagement of a furniture panel with the extrusion. 
       FIGS. 4A-4D  show various embodiments of the swivel chair shown in  FIG. 1 . 
       FIG. 5A  is a rear elevation view of an armchair including concealed weld construction. 
       FIG. 5B  is a side elevation view of the armchair shown in  FIG. 5A . 
       FIG. 5C  is a top elevation view of the armchair shown in  FIG. 5A . 
       FIG. 6A  is a rear elevation view of another armchair including concealed weld construction. 
       FIG. 6B  is a side elevation view of the armchair shown in  FIG. 6A . 
       FIG. 6C  is a top elevation view of the armchair shown in  FIG. 6A . 
       FIG. 7A  is a side view of a lounger including concealed weld construction. 
       FIG. 7B  is a top view of the lounger in  FIG. 7A . 
       FIG. 8A  is a side view of an ottoman including concealed weld construction. 
       FIG. 8B  is front view of the ottoman in  FIG. 8A . 
       FIG. 8C  is a top view of the ottoman in  FIG. 8A . 
    
    
     Various embodiments of furniture having common construction techniques are disclosed herein. Referring to  FIG. 1 , chair  10  comprises a frame  11  and a seatback panel  12 . In some embodiments, the frame  11  comprises a plurality of elements such as, for example, base frame element  11 ′ and upper frame element  11 ″. In  FIG. 1 , the base frame element  11 ″ is generally U-shaped delimiting a seat  15 . The upper frame element  11 ″ extends upward from the front edges  111  of the base frame element  11 ′ and then curves upward and around to define armrests  13  and top rail  14 . Seat  15  is disposed between adjacent portions of the upper frame element  11 ″ at an elevation above the base frame elements  11 ″. Seatback panel  12  is disposed inside frame  11  between base frame element  11 ′ and upper frame element  11 ″ and is attached thereto to form the side and rear supporting portions of the chair  10 . In some embodiments, the seatback panel  12  is perforated, punched, cut, or stamped with any desired design. Cutting may be accomplished by a CNC machine, waterjet, laser cutter or other known precision cutting means. Shown also is seat cushion  20  disposed on seat frame  15  and back cushion  21  disposed against an interior aspect of the seatback panel  12 . 
       FIGS. 2A-2C  show various views of the chair  10 . Referring to the side view in  FIG. 2A , the orientation and configuration of frame  11  is shown in more detail. Here it is seen that the base frame element  11 ′ is generally oriented on a single plane whereas the upper frame element  11 ″ extends in curvilinear fashion from the base frame element  11 ′. Also shown is swivel base  16  on which chair  10  is mounted. Swivel base  16  is generally configured as a ball-bearing or similar rotating mount that allows chair  10  to at least partially swivel or rotate about its central axis  17 . Referring to the front view in  FIG. 2B , shown in more detail is seat frame  15  that extends horizontally across frame  11  to provide vertical support for an individual using the chair  10 . Referring to the top view in  FIG. 2C , shown in more detail is the upper frame element  11 ″ which in a plain view has a U-shaped profile matching that of bottom frame element  11 ′. Here it is more easily seen how upper frame element  11 ″ is shaped to form the opposing armrests  13  and top rail  14  from a single, contiguous frame member. 
     Referring to  FIGS. 3A and 3B , the frame  11  of chair  10  comprises an extrusion  30  having certain features advantageous to the construction of the furniture items disclosed herein. In some embodiments, extrusion  30  has a generally rectangular cross-section with rounded or beveled edges. In some embodiments, extrusion  30  includes a longitudinally oriented insertion channel  31  that is configured to receive the panel  12  as shown in  FIG. 3B  and further described herein. In some embodiments, extrusion  30  may have one or more longitudinally oriented relief channels  32  provided therethrough that reduce the weight and increase the bendability of extrusion  30  to allow for the design of a multitude of furniture configurations in accordance with the present disclosure. Referring to  FIG. 3B , chair  10  is assembled by inserting at least a portion of the perimeter edge  121  of the seatback panel  12  into the insertion channel  31  of extrusion  30 . In some embodiments, the entire perimeter edge of the seatback panel  12  is seated in the insertion channel, such that the frame  11  encircles the perimeter of the panel. 
     In some examples, the thickness of the panel  12  is somewhat smaller than the width of insertion channel  31 , resulting in a small gap  33  that provides sufficient space for the application of a weld on an interior aspect of, i.e. inside, insertion channel  31  to secure panel  12  to extrusion  30 . In some embodiments, the gap  33  allows the weld to be at least partially concealed from view and, in some embodiments, the welds are disposed within the gap  33  such that the welds are not visible from an exterior aspect of chair  10 , i.e. when viewed from the outside, resulting in an unobstructed and smooth finish to the chair  10 . In some embodiments, welds can be placed only on one side of the panel  12 , for example on the interior side, such that there are no welds at all on the exterior side of the panel  12  with respect to the extrusion  30 , providing a clean unobstructed view from the exterior of the chair  10 . 
       FIGS. 4A through 4D  depict various embodiments of the chair  10  having seatback panels  12  of various designs and embellishment assembled in accordance with the present disclosure. Accordingly, it is appreciated and understood that the seatback panel  12  can be manufactured through a variety of means such as stamping, punching, die cutting, and the like, to provide a multitude of designs and features as desired. For exemplary purposes only, chair  10  in  FIG. 4A  shows a seatback panel  12  having fish designs, chair  10  in  FIG. 4B  has a filigree design, chair  10  in  FIG. 4C  has a punched circle design, and chair  10  in  FIG. 4D  has a grass design. 
     Referring to  FIG. 5 , shown is dining armchair  50  assembled in accordance with the present disclosure. Armchair  50  comprises a frame  51  and a back panel  52 . Frame  51  is constructed from extrusion  30  and comprises base frame element  51 ′ and upper frame element  51 ″. Base frame element  51 ′ is, in some embodiments, generally U-shaped and delimits the seat  55  for the barstool  50 . Upper frame element  51 ″ extends upward from the base frame element  51 ′ and is curved to form the armrests and top rail of the armchair  50 . In some embodiments, as shown in  FIG. 5B  (back panel  52  omitted for clarity), a vertically oriented seatback  54  is disposed between the upper frame element  51 ″ and seat  55 . In such embodiments, the user rests against seatback  54  instead of back panel  52  (which otherwise surrounds the armchair  50 ), which may be somewhat more comfortable for the user depending on the overall shape and dimension of the armchair  50 . Here, the bottom of seat  55  is mounted to a pedestal  53 . In some embodiments, armchair  50  swivels or rotates about pedestal  53 . Back panel  52  is configured to be inserted into frame  51  in accordance with the above description of the extrusion  30  wherein the welds attaching same are at least partially concealed inside the insertion channel  31  of extrusion  30 . In some embodiments, the welds are entirely concealed. 
     Referring to  FIGS. 6A-6C  shown is an alternative armchair  60  assembled with a traditional four-legged bottom. Here armchair  60  comprises a frame  61  and a back panel  62 . Frame  61  is constructed from extrusion  30  and comprises a base frame element  61 ′ that is generally U-shaped and that delimits the seat  63 . Upper frame element  61 ″ is attached at the front of base frame element  61 ′ and forms the front two legs  64  and  65  of the armchair  60 . Upper frame element  61 ″ continues upward to define the armrests  66  and top rail  67  of the armchair  60 . Back panel  62  is configured to be inserted into frame  62  in accordance with the above description of the extrusion  30  wherein the welds attaching same are at least partially concealed inside the insertion channel  31  of extrusion  30 . In some embodiments, the welds are entirely concealed. Rear legs  677  and  68  extend from the base frame element  61 ′ to form the bottom supporting structure for the armchair  60 . In some embodiments, one or more stretchers  69  are attached to adjacent legs to provide additional rigidity. 
     Referring to  FIGS. 7A and 7B , shown is lounger  70  comprising an upper frame  71 , a lower frame  72 , and a circumferential panel  73 . Panel  73  is disposed between the upper frame  71  and lower frame  72  to form an outer encasement of the lounger. The upper frame  71  delimits an upper lounging surface  74 . Further included in some embodiments is an adjustable seatback  75  attached to lounger  70  at pivot point  76 . In some embodiments, the lounging surface  74  comprises a grid-like structure that is adapted to spread out the weight of a load placed thereon,  5  such as by an individual laying or sitting on the lounger  70 . Upper and lower frame  71  and  72  are comprised of extrusion  30  and panel  73  is attached thereto in the manner shown in  FIG. 3B , namely by inserting the perimeter edges of the panel  73  into the insertion channel  31  of the extrusion  30  and welding the components at an interior aspect of the insertion channel  31 . This allows the welds to be at least partially concealed and, in some embodiments, to be entirely concealed. 
     Referring to  FIGS. 8A-8C  shown is ottoman  80 . Side view  8 A shows ottoman  80  comprising upper frame element  81 , lower frame element  82 , and side panel  83 . Side supports  84  and  85  are perpendicular to upper frame  81  and lower frame  82 . Upper frame  81  and side supports  84  and  85  delimit a resting surface  86  for the ottoman  80 .  FIG. 8B  is an end view showing top rail  87  and stretcher  88  disposed between respective side supports  84  and  84 ″ wherein side support  84 ″ is parallel to side support  84 . Shown in top view  8 C are opposing top rails  87  and  87 ′ as well as opposing upper frame elements  81  and  81 ′. Side panel  83  is disposed between upper frame element  81  and lower frame element  82 . The frame elements  81  and  82  are comprised of extrusion  30  and receive the edges of side panel  83  substantially as described above and shown in  FIG. 3B . In some embodiments, side panel  83  is provided on both sides of ottoman  80  between respective upper and lower frame elements. 
     It is appreciated and understood that the present disclosure contemplates a multitude of furniture designs and configurations including without limitation chairs, tables, loungers, ottomans, and barstools, each incorporating one or more frame elements comprising extrusion  30  and at least one panel configured to be received by extrusion  30  and welded thereto in a concealed fashion. To that end, extrusion  30  may comprise any suitable material including metals such as steel and aluminum provided such material is sufficiently strong and bendable for the desired application. In some embodiments, the panel or panels utilized may comprise a variety materials including aluminum, which is particularly suitable because it is relatively lightweight, strong, and malleable. Further still, it is appreciated and understood that panel or panels are capable of being stamped, punched, or otherwise cut into a variety shapes and sizes with a variety of design elements for the desired application. As is evident from the present disclosure, the panel-extrusion construction technique provides sturdy and secure furniture with minimal visible welds and joints. The present disclosure is not limited to the specific furniture embodiments disclosed herein, rather the construction technique can be applied to virtually any piece of furniture conceivable. 
     While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, those with ordinary skill in the art will appreciate that various modification and alternative to those details could be developed in the light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.