STACKABLE CHAIR ASSEMBLY

TECHNICAL FIELD

[ 0001] The present invention generally relates to chairs, and more specifically, to a stackable chair.

BACKGROUND

[ 0002] Chairs for extended seating applications, such as conference rooms and school classrooms are preferably durable and comfortable. Often times, these chairs are stackable or nestable for storage and transportation purposes. Typical stackable and/or nestable chairs are formed from a generally L-shaped molded shell that is defined by a generally horizontal seat and a generally vertical back support and includes a pair of inverted U-shaped leg members attached to the generally L-shaped shell.

[ 0003] A stackable chair is stacked by placing the inverted U-shaped leg members of one chair on top of the leg members of another chair such that the seat of the upper chair is supported just above the seat of the lower chair. The rear surface of the back support of the upper chair can be spaced apart from the front surface of the back support of the lower chair. Alternatively, the rear surface of the back support of the upper chair can be rested against the front surface of the back support of the lower chair when in the stacked configuration.

[ 0004] Stackable chairs are generally formed of hard plastic, or other similar material, and are designed to be rigid so that they can be properly stacked. However, these hard shells are uncomfortable to a user when used in extended seating applications and are not aesthetically pleasing to consumers and users of the chairs. In an effort to improve comfort and create aesthetically pleasing design features, the shells can be ergonomically designed and can include, among other things, an intentional flex between the seat and back support. However, while the ergonomic design and intentional flex may improve design and comfort, it creates instability when multiple chairs are stacked on top of each other. Therefore, the rigid chairs fail to provide comfort while the flexible shells do not permit multiple chairs to be stacked safely. The present invention is provided to solve these and other problems.

SUMMARY

[ 0005] The present invention relates to a chair assembly adapted to be nested with a second chair assembly identical to the chair assembly. The chair assembly comprises a seating portion and a back support. The seating portion includes a top seat surface, a bottom seat surface generally parallel to the top seat surface, a first side seat edge, a second side seat edge, and a front edge. The back support is generally perpendicular to the seating portion and includes an inner back support surface, an outer back support surface generally parallel to the inner back support surface, a first side back support edge, a second side back support edge, and a top back support edge. A first return flange is disposed on the first side back support edge of the back support and a second return flange is disposed on the second side back support edge of the back support.

[ 0006] A first recess can be disposed on the inner surface of the back support, and is adapted to receive a first return flange of a second chair assembly nested with the unitary shell. A second recess can be disposed on the inner surface of the back support and is adapted to receive a second return flange of the second chair assembly nested with the unitary shell.

^' [ 0007] The chair assembly may further comprise a first inverted U-shaped leg member secured to the outer surface of the generally horizontal seating surface and a second inverted U- shaped leg member, secured to the outer surface of the generally horizontal seating surface.

[ 0008] When the second chair assembly is nested with the chair assembly, the first inverted U-shaped leg member of the second chair assembly is nested with the first inverted U- shaped leg member of the chair assembly and the second inverted U-shaped leg member of the second chair assembly is nested with the second inverted U-shaped leg member of the chair assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective front view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 2 is a perspective rear view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 3 is a front view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 4 is a rear view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 5 is a side view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 6 is a top view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 7 is a bottom view of a stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 8 is perspective front view of a second stackable chair assembly stacked on top of a first stackable chair assembly in accordance with an embodiment of the present invention;

FIG. 9 is a perspective rear view of the embodiment of the present invention shown in FIG. 8; and,

FIG. 10 is a side view of the embodiment of the present invention shown in FIG. 8.

DETAILED DESCRIPTION

[ 0009] While the present invention is susceptible to embodiments in many different forms, there is shown in the drawings and will herein be described an example of the invention with the understanding that the present disclosure is to be considered as an exemplification of the

principles of the invention and is not intended to limit the broad aspects of the invention to the examples illustrated.

[ 0010] FIG. 1 is a perspective front view of a stackable chair assembly 10 in accordance with one embodiment of the present invention. In one example, the stackable chair assembly 10 is formed from a generally L-shaped one-piece molded shell 11 and a pair of inverted U-shaped leg members 13, 15 secured to the L-shaped molded shell 11 by suitable means.

[ 0011] The shell 11 is preferably formed from an integral piece of resilient material, such as a polymeric material, and is molded to include a generally horizontal seating portion 17 and a generally vertical back support 19. The shell 11 may also be constructed of other materials such as wood, steel, or such other material known to those of ordinary skill in the art. The seating portion 17 and back support 19 have respective inner surfaces 23, 49 defining a seating surface 20 against which the user is seated. The seating area 20 has a generally concave contour to facilitate engagement with the body of a user seated thereon.

[ 0012] Preferably, the shell 11 is molded to combine the features of rigid and flexible chairs and ensure comfort, performance, and durability. In that manner, the contour of the shell 11 may be manufactured to include an intentional flex between the seating portion 17 and the back support 19 such that the back support 19 flexes rearwardly with respect to the seating portion 17 when it is leaned against by a user. Further, in order to assist balancing structural rigidity with the comfort of flexibility, the shell 11 may include a tall return flange 21 disposed around the perimeter of the shell 11 to ensure the angle between the seating portion 17 and back support 19 will not open far enough to cause failure and/or cause permanent damage to the chair. This allows the stackable chair assembly 10 to be used in a range of postures, including, for example, sitting at a work surface and reclining in a lecture posture.

[ 0013] As shown in FIGS. 1-7, the seating portion 17 includes a top surface 23, a bottom surface 25, a front edge 27, a first side edge 29, and a second side edge 31. The top surface 23 forms a portion of the seating area 20. The seating portion 17 may be in a generally horizontal plane, however, it is contemplated that the seating portion 17 may also be slightly tilted rearward or forward.

[ 0014] As discussed above, a return flange 21 is disposed on the first side edge 29, the front edge 27, and the second side edge 31. The return flange 21 around the edges of the seating portion 17 is generally vertical and perpendicular to the top surface 23 of the seating portion 17. In one example, the first side edge 29, the front edge 27, and the second side edge 31 are molded to form the return flange 21. Typically, the area where the seating portion 17 intersects with the back support 19, also known as the hip area 33, is the area of highest stress when a user is sitting in the chair 11. Therefore, in order assist with structural integrity, the return flange 21 may be formed such that it is has the highest height at the hip area 33 and transitions to a substantially lower height near the front edge 27. In addition, the seating portion 17 may transition from the generally horizontal top surface 23 to the generally vertical return flanges 21 on the periphery of the seating portion.

[ 0015] As shown in FIG. 2, a plurality of support ribs 35 can be disposed on the bottom surface 25 of the seating portion 17. The support ribs 35 are positioned substantially near the front edge 27 of the seating portion 17 and provide additional support for the curvature of the front edge 27. In addition, a plurality of bottom ribs 37 traverse the bottom surface 25 of the seating portion 17 between the front edge 27 and the hip portion 33. The bottom ribs 37 provide additional support when a user is sitting in the chair assembly 10. As will be described herein, the bottom ribs 37 include a C-shaped cut out section 73 for accepting the inverted U-shaped leg members 13, 15.

[ 0016] As described above, the chair assembly 10 is molded to include a back support 19 that flexes rearwardly with respect to the seating portion 17 when it is leaned against by a user. As illustrated in FIGS. 1-6, the back support 19 includes an inner surface 49, an outer surface 51, a top edge 43, a first side edge 45, and a second side edge 47. The inner surface 49 forms the generally vertical portion of the seating area 20. The back support 19 may be in a generally vertical plane, however, it is contemplated that the back support 19 may also be slightly tilted rearward or forward. The back support 19 includes a thoracic support 41 and a lumbar region 39. In one example, the thoracic support 41 is wider than the lumbar region 39 and the back support 19 tapers from the top edge 43 towards the hip area 33.

[ 0017] The return flange 21 is disposed on the top edge 43, the first side edge 45, and the second side edge 47 of the back support 19. The return flange 21 around the edges of the back support 19 is generally perpendicular to the inner surface 49 of the back support 19. In one example, the back support 19 transitions from the generally vertical back support 19 to the generally perpendicular return flange 21 on the periphery of the back support 19. As with the seating portion 17, the return flange 21 can be taller in the hip area 33 and can transition to a substantially lower height near the top edge 43. In addition, as with the return flange 21 disposed on the seating portion, 17, the top edge 43, the first side edge 45, and the second side edge 47 may be molded to form the return flange 21.

[ 0018] As shown in FIG. 2 and FIG. 4, a plurality of spaced apart longitudinal ribs 53 may be disposed on the outer surface 51 proximate the hip area 33 of the chair assembly 10. Preferably, the outer surface 51 includes 15 longitudinal ribs 53 which are spaced apart approximately 1-1/2 inches from each other, however any suitable spacing distance may be used. The outer surface 51 of the seating portion 17 may be molded to form longitudinal ribs 53. The longitudinal ribs 53 traverse the chair assembly 10 from the bottom surface 25 of the seating portion 17 to the outer surface 51 of the back support 19. The longitudinal ribs 53 may end at different heights on the outer surface 51 of the back support 19.

[ 0019] A cross bow rib 55 may be disposed on the outer surface 51 of the back support

19 and cross-sectionally traverses the plurality of longitudinal ribs 53 on the outer surface 51 of the back support 19. The outer surface 51 of the back support 19 may be molded to form the cross bow rib 55, or the cross bow rib 55 may be attached by suitable means, as known to those of ordinary skill in the art.. The cross bow rib 55 may be a U-shape rib with one end being substantially near the first side edge 45 and the other end being substantially near the second side edge 47. Although a single cross bow rib 55 is shown, any number of cross bow ribs 55 may be used. Along with the return flange 21, the longitudinal ribs 53 and the cross bow rib 55 assist in balancing the structural rigidity, while still providing the intentional flex between the seating portion 17 and the back support 19.

[ 0020] The inner surface 49 of the back support 19 may include a concave stacking recess 63, as shown in FIG. 1 and FIG. 3. When the chair assembly 10 is viewed from the back

side, the stacking recess 63 appears as a convex protrusion on the outer surface 51 of the back support 19. Preferably, the outer surface 51 is molded to form the stacking recess 63. The stacking recess 63 may be a closed recess pocket contour in the back support 19 surface and is shaped to accept and mate with the return flange 21 of a second chair assembly 100 stacked on top of the chair assembly 10. Alternatively, the stacking recess 63 may include an aperture such that a rope, or other securing means, can be fed through to secure the chair to a pallet. The two stacking recesses 63, in combination with return flanges 21 from a second chair assembly 100 stacked on top, creates two points of contact. When multiple chair assemblies 10 are stacked on top of one another, the combination of the stacking recess 63 of the chair below and the return flange 21 of the chair above laterally stabilizes a stack of multiple chair assemblies. The longitudinal ribs 53 and the cross bow rib 55 described above assist in increasing the shell strength of the chair assembly 10 in the areas of the stacking recesses 63.

[ 0021 ] FIGS . 8-10 illustrates a second chair assembly 100 stacked on top of the bottom chair assembly 10. The second chair assembly 100 is identical to the first chair assembly 10. When the second chair assembly 100 is placed on top of the bottom chair assembly, the return flanges 121 on the first side edge 145 and the second side edge 147 of the second chair assembly 100 are received and nested in the stacking recesses 63 of the bottom chair assembly 10.

[ 0022] The back support 19 may also include a hand hole 57 to provide assistance when the chair assembly 10 is lifted. The hand hole 57 is of a generally oval shape and includes a lip 59 around the periphery of the hand hole 57. A company name, or other such logo or indicia, may also be included on the chair assembly 10. For example, the name of the manufacturer 61 of the chair assembly 10 may be molded on the back support 19 above the hand hole 57.

[ 0023] As shown in FIG. 1 -7, the chair assembly 10 includes legs 67, 69, 75, 79 secured to bottom surface 25 of the shell 11. In one example, a U-shaped back leg member 13 and a U- shaped front leg member 15 are secured to the bottom surface 25 of the seating portion 17 of the chair assembly 10. As discussed above, the bottom ribs 37 may include a C-shaped cut-out 73 to accept the back leg member 13 and the front leg member 15. Typically, the leg members 13, 15 are secured to the bottom surface 25 by a screw, however, any means known to those of ordinary skill in the art may be used.

[ 0024] The back leg member 13 may include a first leg 67 and a second leg 69 that is separated from the first leg 67 by a generally horizontal member 65. The lower ends of the first leg 67 and the second leg 69 may include contacting ends 71 that contact the floor, or other such surfaces. The generally horizontal member 65 extends between and interconnects the upper portions of the first leg 67 and the second leg 69. The back leg member 13 may be a continuous piece of tubing which is bent into the generally inverted U-shaped member. In addition, the first leg 67 and the second leg 69 of the back leg member 13 may be at an outward angle relative to the vertical back support 19.

[ 0025] Similar to the back leg member 13, the front leg member 15 may include a first leg 75 and a second leg 79 that is separated from the first leg 75 by a generally horizontal member 77. The lower ends of the first leg 75 and the second leg 79 may also include contacting ends 71 that contact the floor, or other such surfaces. The generally horizontal member 77 extends between and interconnects the upper portions of the first leg 75 and the second leg 79. As with the back leg member 13, the front leg member 15 may be continuous piece of tubing which is bent into the generally inverted U-shaped member. In addition, the first leg 75 and the second leg 79 of the front leg member 15 may be at an angle generally perpendicular to the bottom surface 25 of the seating portion 17.

[ 0026] With reference again to FIGS. 8-10, a second chair assembly 100 is stacked on top of a first chair assembly 10. When the second chair assembly 100 is placed on top of the bottom chair assembly 10, the front leg members 115 of the second chair assembly 100 nest on top of the front leg members 15 of the bottom chair assembly 10. Preferably, an intentional clearance 81 is created between the front leg members 115 of the second chair assembly 100 and the front leg members 15 of the bottom chair assembly 10. The intentional clearance may be 1/2 inches, however any other suitable clearance may be used. Specifically, the first leg 167 of the second chair assembly 100 is nested on the first leg 67 of the bottom chair assembly 10 and the second leg 169 of the second chair assembly 100 is nested on the second leg 69 of the bottom chair assembly 10. The stacking configuration creates two points of contact on the front leg member 15.

[ 0027] Similarly, the back leg member 113 of the second chair assembly 100 nest on top of the back leg member 13 of the chair assembly 10 when the second chair assembly 100 is placed on top of the chair assembly 10. Specifically, the first leg 175 of the second chair assembly 100 is nested on the first leg 75 of the bottom chair assembly 10 and the second leg 179 of the second chair assembly 100 is nested on the second leg 79 of the bottom chair assembly 10. The stacking configuration creates two points of contact on the back leg member 13.

[ 0028] The two stacking recesses 63, the back leg members 13, and the front leg members 15 allow the chair assembly 10 to stack with six points of contact without distorting the shell 11. Each point of contact improves stack stability and allows for safer transportation and storage of chairs. This configuration can allow for chair assemblies 10 to be stacked and bundled in a safe manner. This further allows more chair assemblies 10 to be placed and transported on a trailer, or other similar storage container, thereby resulting in cost and space savings.

[ 0029] While the foregoing has described what is considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous other applications, combinations and environments, only some of which have been described herein. Those of ordinary skill in that art will recognize that the disclosed aspects may be altered or amended without departing from the true spirit and scope of the subject matter. Therefore, the subject matter is not limited to the specific details, exhibits and illustrated examples in this description. It is intended to protect any and all modifications and variations that fall within the true scope of the advantageous concepts disclosed herein.