Patent ID: 8257642

Claim:
A method for forming a chair comprising: (A) disposing at least a portion of a first plastic strip into an open first forming mold, the first forming mold defining a first mold cavity for chair legs and having a first blow hole extending into the first mold cavity; (B) closing the first forming mold and blowing air into the forming mold; wherein molds of the first forming mold are closed together to cut off and seal the first plastic strip in the first forming mold, and an end of the first blow hole passes through the first plastic strip and is used for blowing the first plastic strip to expand the first plastic strip to conform to the shape of the first mold cavity and form the chair legs; (C) opening the first forming mold and removing the chair legs; wherein the chair legs are removed from the first forming mold, and the chair legs have a securing portion with a plurality of through apertures; (D) placing at least two of the chair legs into a second forming mold, the second forming mold comprising plural matching molds and defining a second mold cavity for a chair seat and having a second blow hole, at least one of the matching molds having a space for accepting leg portions of the chair legs such that the chair legs are partially disposed within the second mold cavity; (E) disposing at least a portion of a second plastic strip into the second forming mold; and (F) closing the second forming mold and blowing air into the second forming mold; wherein the molds of the second forming mold are closed together to cut off and seal the second plastic strip in the second forming mold, an end of the second blow hole passing through the second plastic strip and used for blowing the second plastic strip to expand the second plastic strip to conform to the shape of the second mold cavity and form the chair seat; wherein the second plastic strip covers the securing portion of the chair legs to provide plastic material that permeates into the through apertures to expand to form at least a stop edge, such that the chair seat and the chair legs are engaged together.