Molded Wood Flake Article with Integral Flexible Spring Member
A molded wood flake support is fabricated to include at least one flexible spring member which is narrower then the width of the molded wood flake support and integrally formed therewith or secured thereto, wherein the flexible spring member can flex independently from the molded wood flake support.
Wood flake molding, also referred to as wood strand molding, is a technique invented by wood scientists at Michigan Technological University during the latter part of the 1970s for molding three-dimensionally configured objects out of binder coated wood flakes having an average length from about 1¼ to about 6 inches, preferably from about 2 to about 3 inches; an average thickness of about 0.005 to about 0.075 inches, preferably from about 0.015 to about 0.030 inches; and an average width of 3 inches or less, most typically 0.25 to 1.0 inches, and never greater than the average length of the flakes. These flakes are sometimes referred to in the art as “wood strands.” This technology is not to be confused with oriented strand board technology (see e.g., U.S. Pat. No. 3,164,511 to Elmendorf) wherein binder coated strands of wood are pressed into planar objects. In wood flake or wood strand molding, the flakes are molded into three-dimensional, i.e., non-planar, configurations.
In wood flake molding, flakes of wood having the dimensions outlined above are coated with methylene diisocyanate (MDI) or similar binder and deposited onto a metal tray having one open side, in a loosely felted mat, to a thickness eight or nine times the desired thickness of the final part. The loosely felted mat is then covered with another metal tray, and the covered metal tray is used to carry the mat to a mold. (The terms “mold” and “die”, as well as “mold die”, are sometimes used interchangeably herein, reflecting the fact that “dies” are usually associated with stamping, and “molds” are associated with plastic molding, and molding of wood strands does not fit into either category.) The top metal tray is removed, and the bottom metal tray is then slid out from underneath the mat, to leave the loosely felted mat in position on the bottom half of the mold. The top half of the mold is then used to press the mat into the bottom half of the mold at a pressure of approximately 600 psi, and at an elevated temperature, to “set” (polymerize) the MDI binder and to compress and adhere the compressed wood flakes into a final three-dimensional molded part. The excess perimeter of the loosely felted mat, that is, the portion extending beyond the mold cavity perimeter, is pinched off where the part defining the perimeter of the upper mold engages the part defining the perimeter of the lower mold cavity. This is sometimes referred to as a pinch trim edge.
U.S. Pat. Nos. 4,440,708 and 4,469,216 disclose this technology. The drawings in U.S. Pat. No. 4,469,216 best illustrate the manner in which the wood flakes are deposited to form a loosely felted mat, though the metal trays are not shown. By loosely felted, it is meant that the wood flakes are simply lying one on top of the other in overlapping and interleaving fashion, without being bound together in any way. The binder coating is quite dry to the touch, such that there is no stickiness or adherence which hold them together in the loosely felted mat. The drawings of U.S. Pat. No. 4,440,708 best illustrate the manner in which a loosely felted mat is compressed by the mold halves into a three-dimensionally configured article (see
The above described process is a different molding process as compared to a molding process one typically thinks of, in which some type of molten, semi-molten or other liquid material flows into and around mold parts. Wood flakes are not molten, are not contained in any type of molten or liquid carrier, and do not “flow” in any ordinary sense of the word. Hence, those of ordinary skill in the art do not equate wood flake or wood strand molding with conventional molding techniques.
It has been discovered that wood flake molded parts have a very well defined spring constant. Sections of molded wood flake articles having a thickness of ½, 9/16, and ⅝ inches and a width of 2 inches and an effective length of 16 inches were mounted to define a cantilevered spring and were tested. It was discovered that the spring constant for the respective thickness of ½ inch was 10 pounds per inch deflection; 9/16 inch was 11 pounds per inch deflection; and ⅝ inch thick was 14 pounds per inch deflection. It was further discovered that the molded wood flake spring so formed returned to its original position within two minutes of a load being removed and displays only a 5 percent to 8 percent hysteresis over time. In view of the fact that the molded wood flakes can be formed in any desired three-dimensional configuration, this discovery allows the material to be used for deflectable weight supporting articles, such as in the seating environment. A clear benefit of using such spring material as opposed to typical coil springs or sinuous wire springs is that they are not subject to rust nor do they require the intense labor necessary when manufacturing a chair or other seating object utilizing conventional springs. Further, the feel of the seat utilizing such springs is improved inasmuch as the springs do not require preloading, as with typical sinuous or coil springs. Thus, the use of molded wood flake springs will revolutionize the manufacture of supports which, in past years, required the use of sinuous or coil springs.
SUMMARY OF THE INVENTIONIn the present invention a molded wood flake support article includes at least one flexible spring. The support may include a plurality of integral spaced-apart linearly extending springs with second ends opposite said first ends that are free to flex, wherein the support is coupled to a frame member. In one embodiment, a plurality of spaced-apart linearly extending spring members are integrally formed from a connecting end piece. The end piece can, in one embodiment, be a curved edge of a seat frame. In one embodiment, an elastomeric mesh is coupled over free ends of the spring members to loosely interconnect the ends of said springs. In yet another embodiment, a seat is formed employing a plurality of spaced-apart linearly extending spring members integrally formed with one end of the seat base having sides coupled thereto, and an elastomeric web extends between the sides underlying said spring members to limit their deflection. In one embodiment also, the elastomeric web can be vertically and horizontally adjusted on the base with respect to the spring members to change the deflection characteristics of said spring members and, thus, the feel of the seat so-formed.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as orientated in
In a preferred embodiment of the present invention, a molded wood flake article (
Process Details:
As best illustrated by
As illustrated by
The molded wood flake part 12 may include additional features such as “T” nut fastener holes 34 (
As seen in
The wood flakes 22 used in creating the molded wood flake part 12 can be prepared from various species of suitable hardwoods and softwoods. Representative examples of suitable woods include aspen, maple, oak, elm, balsam fir, pine, cedar, spruce, locust, beech, birch and mixtures thereof, although aspen is preferred.
Suitable wood flakes 22 can be prepared by various techniques. Pulpwood grade logs, or so-called round wood, are converted into wood flakes 22 in one operation with a conventional roundwood flaker. Logging residue or the total tree is first cut into fingerlings having an average length from about 1¼ to about 6 inches, preferably from about 2 to about 3.5 inches with a device, such as the helical comminuting shear disclosed in U.S. Pat. No. 4,053,004, and the fingerlings are subsequently flaked in a conventional ring-type flaker. Roundwood wood flakes generally are higher quality and produce stronger parts because the lengths and thickness can be more accurately controlled. Also, roundwood wood flakes tend to be somewhat flatter, which facilitates more efficient blending and the logs can be debarked prior to flaking which reduces the amount of less desirable fines produced during flaking and handling. Acceptable wood flakes can be prepared by ring flaking fingerlings. This technique is more readily adaptable to accept wood in poorer form, thereby permitting more complete utilization of certain types of residue and surplus woods.
Irrespective of the particular technique employed for preparing the wood flakes 22, the size distribution of the wood flakes 22 is quite important, particularly the length and thickness. The wood flakes should have an average length from about 1¼ to about 6 inches, preferably from about 2 to about 3½ inches; an average thickness of about 0.005 to about 0.075 inches, preferably from about 0.015 to about 0.030 inches and more preferably about 0.0020 inch; and an average width of 3 inches or less, most typically 0.25 to 1.0 inches, and less than the average length of the flakes. In any given batch, some of the wood flakes 22 can be shorter than 1¼ inch, and some can be longer than 6 inches, so long as the overall average length is within the above range. The same is true for the thickness.
The presence of major quantities of wood flakes 22 having a length shorter than about 1¼ inch tends to cause the felted mat 32 to pull apart during the molding step. The presence of some fines in the felted mat 32 produces a smoother surface and, thus, may be desirable for some applications so long as the majority of the wood flakes, preferably at least 75 percent, is longer than 1⅛ inch and the overall average length is at least 1¼ inch.
Substantial quantities of wood flakes 22 having a thickness of less than about 0.005 inches should be avoided, because excessive amounts of binder are required to obtain adequate bonding. On the other hand, wood flakes 22 having a thickness greater than about 0.075 inch are relatively stiff and tend to overlie each other at some incline when formed into the felted mat 32. Consequently, excessively high mold pressures are required to compress the wood flakes 22 into the desired intimate contact with each other. For wood flakes 22 having a thickness falling within the above range, thinner ones produce a smoother surface while thick ones require less binder. These two factors are balanced against each other for selecting the best average thickness for any particular application.
The width of the wood flakes 22 is less important. The wood flakes 22 should be wide enough to ensure that they lie substantially flat when felted during mat formation. The average width generally should be about 3 inches or less and no greater than the average length. For best results, the majority of the wood flakes 22 should have a width of from about 0.25 to about 1.0 inches.
The blade setting on a flaker can primarily control the thickness of the wood flakes 22. The length and width of the wood flakes 22 are also controlled to a large degree by the flaking operation. For example, when the wood flakes 22 are being prepared by ring flaking fingerlings, the length of the fingerlings generally sets the maximum lengths. Other factors, such as the moisture content of the wood and the amount of bark on the wood affect the amount of fines produced during flaking. Dry wood is more brittle and tends to produce more fines. Bark has a tendency to more readily break down into fines during flaking and subsequent handling than wood.
While the flake size can be controlled to a large degree during the flaking operation as described above, it usually is necessary to use a screening process in order to remove undesired particles, both undersized and oversized, and thereby ensure the average length, thickness and width of the wood flakes 22 are within the desired ranges. When roundwood flaking is used, both screen and air classification usually are required to adequately remove both the undersize and oversize particles, whereas fingerling wood flakes usually can be properly sized with only screen classification.
Wood flakes from some green wood can contain up to 90 percent moisture. The moisture content of the mat must be substantially less for molding as discussed below. Also, wet wood flakes tend to stick together and complicate classification and handling prior to blending. Accordingly, the wood flakes 22 are preferably dried prior to classification in a conventional type drier, such as a tunnel drier, to the moisture content desired for the blending step. The moisture content to which the wood flakes 22 are dried usually is in the order of about 6 weight percent or less, preferably from about 2 to about 5 weight percent, based on the dry weight of the wood flakes 22. If desired, the wood flakes 22 can be dried to a moisture content in the order of 10 to 25 weight percent prior to classification and then dried to the desired moisture content for blending after classification. This two-step drying may reduce the overall energy requirements for drying wood flakes prepared from green woods in a manner producing substantial quantities of particles which must be removed during classification and, thus, need not be as thoroughly dried.
To coat the wood flakes 22 prior to being placed as a felted mat 32 within the cavity 30 of mold 20, a known amount of the dried, classified wood flakes 22 is introduced into a conventional blender, such as a paddle-type batch blender, wherein predetermined amounts of a resinous particle binder, and optionally a wax and other additives, is applied to the wood flakes 22 as they are tumbled or agitated in the blender. As such, the article fabricated from wood flakes 22 is substantially rather than entirely comprised of wood flakes, as other additives as described above are added to create mat 32. Of course, other base materials may also be added to the wood flakes to form a mat 32 comprising a blend of wood flakes 22 and other suitable materials. Suitable binders include those used in the manufacture of particle board and similar pressed fibrous products and, thus, are referred to herein as “resinous particle board binders.” Representative examples of suitable binders include thermosetting resins such as phenolformaldehyde, resorcinol-formaldehyde, melamine-formaldehyde, urea-formaldehyde, urea-furfuryl and condensed furfuryl alcohol resins, and organic polyisocyantes, either alone or combined with urea- or melamine-formaldehyde resins.
Particularly suitable polyisocyanates are those containing at least two active isocyanate groups per molecule, including diphenylmethane diisocyanates, m- and p-phenylene diisocyanates, chlorophenylene diisocyanates, toluene di- and triisocyanates, triphenylmethene triisocyanates, diphenylether-2,4,4′-triisoccyanate and polyphenylpolyisocyanates, particularly diphenylmethane-4,4′-diisocyanate. So-called MDI is particularly preferred.
The amount of binder added to the wood flakes 22 during the blending step depends primarily upon the specific binder used, size, moisture content, type of the wood flakes and the desired characteristics of the part being formed. Generally, the amount of binder added to the wood flakes 22 is from about 3½ to about 15 weight percent, preferably from about 4 to about 10 weight percent, and most preferably about 5 percent. When a polyisocyanate is used alone or in combination with a urea-formaldehyde resin, the amounts can be more toward the lower ends of these ranges.
The binder can be admixed with the wood flakes 22 in either dry or liquid form. To maximize coverage of the wood flakes 22, the binder preferably is applied by spraying droplets of the binder in liquid form onto the wood flakes 22 as they are being tumbled or agitated in the blender. When polyisocyantes are used, a conventional mold release agent preferably is applied to the die or to the surface of the felted mat prior to pressing. To improve water resistance of the part, a conventional liquid wax emulsion is also sprayed on the wood flakes 22 during the blinding step. The amount of wax added generally is about 0.5 to about 2 weight percent, as solids, based on the dry weight of the wood flakes 22. Other additives, such as one of the following: a coloring agent, fire retardant, insecticide, fungicide, mixtures thereof and the like may also be added to the wood flakes 22 during the blending step. The binder, wax and other additives, can be added separately in any sequence or in combined form.
The moistened mixture of binder, wax and wood flakes 22 or “furnish” from the blending step is formed into a loosely-felted, layered mat 32, which is placed within the cavity 30 prior to the molding and curing of the felted mat 32 into molded wood flake part 12. The moisture content of the wood flakes 22 should be controlled within certain limits so as to obtain adequate coating by the binder during the blending step and to enhance binder curing and deformation of the wood flakes 22 during molding.
The presence of moisture in the wood flakes 22 facilitates their bending to make intimate contact with each other and enhances uniform heat transfer throughout the mat during the molding step, thereby ensuring uniform curing. However, excessive amounts of water tend to degrade some binders, particularly urea-formaldehyde resins, and generate steam which can cause blisters. On the other hand, if the wood flakes 22 are too dry, they tend to absorb excessive amounts of the binder, leaving an insufficient amount on the surface to obtain good bonding and the surfaces tend to cause hardening which inhibits the desired chemical reaction between the binder and cellulose in the wood. This latter condition is particularly true for polyisocyanate binders.
Generally, the moisture content of the furnish after completion of blending, including the original moisture content of the wood flakes 22 and the moisture added during blending with the binder, wax and other additives, should be about 5 to about 25 weight percent, preferably about 8 to about 12 weight percent. Generally, higher moisture contents within these ranges can be used for polyisocyanate binders because they do not produce condensation products upon reacting with cellulose in the wood.
The furnish is formed into the generally flat, loosely-felted, mat 32, preferably as multiple layers. A conventional dispensing system, similar to those disclosed in U.S. Pat. Nos. 3,391,223 and 3,824,058, and 4,469,216 can be used to form the felted mat 32. Generally, such a dispensing system includes trays, each having one open side, carried on an endless belt or conveyor and one or more (e.g., three) hoppers spaced above and along the belt in the direction of travel for receiving the furnish.
When a multi-layered felted mat 32 is formed, a plurality of hoppers usually are used with each having a dispensing or forming head extending across the width of the carriage for successively depositing a separate layer of the furnish as the tray is moved beneath the forming heads. Following this, the tray is taken to the mold to place the felted mat within the cavity of bottom mold 28, by sliding the tray out from under mat 32.
In order to produce molded wood flake parts 12 having the desired edge density characteristics without excessive blistering and spring back, the felted mat should preferably have a substantially uniform thickness and the wood flakes 22 should lie substantially flat in a horizontal plane parallel to the surface of the carriage and be randomly oriented relative to each other in that plane. The uniformity of the mat thickness can be controlled by depositing two or more layers of the furnish (i.e., wood flakes and binder) on the carriage and metering the flow of furnish from the forming heads.
Spacing the forming heads above the carriage so the wood flakes 22 must drop from about 1 foot to about 3 feet from the heads en route to the carriage can enhance the desired random orientation of the wood flakes 22. As the flat wood flakes 22 fall from that height, they tend to spiral downwardly and land generally flat in a random pattern. Wider wood flakes within the range discussed above enhance this action. A scalper or similar device spaced above the carriage can be used to ensure uniform thickness or depth of the mat, however, such means usually tend to align the top layer of wood flakes 22, i.e., eliminate the desired random orientation. Accordingly, the thickness of the mat that would optimally have the nominal part thickness T (
Following the production of the felted mat 32 and placement of the felted mat 32 within the cavity 30 of the mold 20, the felted mat 32 is compressed and cured under heat and pressure when the top mold die 26 engages the bottom mold die 28. Mat 32 is compressed preferably to a density of from about 40 to about 45 pounds per cubic foot, more preferably about 43 pounds per cubic foot. During this molding process, the extension 23 pushes through the binder coated wood flakes 22 of the felted mat 32 and is received by the extension receiving cavity 27. This action forms the slots 18 which defines the perimeter of flexible spring members 14. Any holes 34 will also be created during this molding step as detailed above.
The felted mat 32 is thus compressed and cured between the top mold die 26 and the bottom mold 28 to become the molded wood flake part 12. After the molded wood flake part 12 is produced, any flashing and any plugs are removed by conventional means to reveal flexible spring members 14 and holes 34.
Molded Wood Flake Article Details:
The process as described above can be used to fabricate three-dimensional articles, such as represented by the molded wood flake back 12 of chair 10 shown in
Cantilevered flexible spring member 14 can be used in any article or situation wherein an independently flexible spring member is desired. For example, article 12 may be a molded chair back, as seen in
In a first embodiment as shown in
The presence of flexible members 14 allow for turning movement to take place within the chair without having to move the seat thereof. Additionally, flexible members 14 permit back portion 12 to conform to the shape of the user, thereby promoting greater comfort. Further, the back 12 and rear edge of seat 11, as well as flexible members 14, can be curved as shown in
In this embodiment, because the total weight disposed against back 12 is supported by a plurality of flexible spring members 14, the total load and/or deflection experienced by a given flexible member 14 will be divided over the total number of flexible members 14 supporting the weight.
The following equations define the expected amount of deflection and sheer stress that a given flexible member 14 should experience. In each equation n=number of flexible members.
where:
-
- D=deflection;
- w=0.18×(weight of user);
- l=length or height of member;
- E=elastic modulus of engineered wood;
- I=moment of inertia;
- B=member thickness; and
- H=member height.
For the seat only, use the following formula to calculate deflection and to consider the different location of the weight of the user.
where:
-
- D=deflection of flexible member (14A′, 14F, 14I);
- W=0.82×W, where W is the weight of user;
- a=distance from the front end of spring member (i.e., toward the back of the chair) to a point where the concentrated load is applied. This point is usually =⅓ l.
Chair 10, and more particularly back 12, is fabricated from the aforementioned wood flake molding process. In the preferred embodiment flexible spring members 14 are integrally formed by molding appropriate slots or channels 18 into seat back 12 during the molding process. However, the channels 18 for flexible spring members 14 can be fabricated by numerous other methods, such as cutting, machining, sawing, or the like. Thus, when referring to the spring members as being “integrally formed” with a support, this refers to spring members which are integral with the surrounding support, such as base section or end 16 (
As seen in
D=Wl3/3EI÷n
where:
-
- D=deflection;
- W=0.18×(w) where w is the weight of user;
- l=length or height of member;
- E=elastic modulus of engineered wood;
- n=number of springs (n=1 in
FIG. 8 ); and - I=moment of inertia,
- and
I=BH3/12
where;
-
- B=member thickness; and
- H=member height.
As can be seen from the above equations, D1 and D2 will vary relative to one another based solely upon their effective length or height, as all other variables are the same for each equation. The potential total deflection of flexible member 14B is determined by adding D1 and the opposite direction D2 together. Their effects are cumulative because main back sections 59 act as a secondary floating cantilever. Chair 50 also can be upholstered, as shown by the upholstery and padding shown in phantom in the embodiment of
The chair 50′ of
In the embodiments described above, the springs are formed from the molded wood flake material preferably by integrally molding channels to define one or more springs. The channel or channels typically have a width of about ½ inch, while the thickness of the cantilevered spring material is from about ⅜ inch to about ⅝ inch. Frequently, when springs are made for seating, such as shown in
A sofa 80 embodying the present invention is shown in
In the preferred embodiment of a sofa back 84, interconnecting each flexible member 14E and located approximately • to ½ of the distance up from base 83 is lumbar foam support 88. Lumbar foam support 88 is connected by a suitable adhesive to each of the plurality of flexible members 14E and couples the springs to one another to provide co-joint back support and offers the additional advantage of providing a lumbar support for the back of a user. Additionally, a foam sheet 89 covers flexible members 14D and lumbar foam member 88. Foam material 89 is formed from a flat sheet of foam, which is relatively inexpensive as it does not need to be pre-shaped or provided with a particular contour. During the course of mounting material 89 in place with fabric covering 90, it takes the appropriate shape needed. An additional advantage associated with foam material 89 is that is can be manufactured to any desired size and length and/or can be cut from a larger sheet of foam. The “cushiony” feel provided by the combination of foam sheet 89, lumbar foam member 88, top foam member 86 and flexible members 14E eliminates the need for batting to achieve the desire degree of softness. This is especially advantageous since the elimination of the batting between the foam slab and the fabric reduces the material and/or labor costs of constructing sofa back 84.
In a preferred embodiment, a single foam member is used for members 86 and 88 which extends across flexible members 14E. These members may be fabricated from numerous materials which are commonly known within the art. However, the type of foam ideally used is a 2.5-3.0 pound foam. Base 83 and back member 87 may also be molded of wood flake material and may include support blocks 92 (
The back 120 likewise includes three integrally molded spring members 14G which are defined by channels 108 extending therebetween downwardly to the integral lower section 122 of back 120. The sides 102 and 104, back member 106, seat section 110, and seat back 120 are secured to one another by threaded fasteners 101 which extend through the apertures 103 formed at various locations in the respective members, as best seen in
The chair design, as shown in
Another modification to the chair 100 shown in
In
In the above embodiments, a molded wood flake support member has been described which includes an integrally formed molded wood flake flexible spring. The flexible spring member acts as a cantilevered spring thereby flexibly supporting the user that is seated therein. The above embodiments have been particularly directed to the furniture industry and more particularly to the seating industry. However, these embodiments represent only the preferred embodiments and are not meant to be limiting in any manner. The above inventive integral flexible spring can be utilized in various ways and be fabricated into varied articles. Hence, the above description is that of the preferred embodiments only.
Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment described above is merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.
Claims
1-99. (canceled)
100. A support comprising:
- a support member having a width; and
- at least one molded wood flake flexible spring which is narrower than said width of said support member, said flexible spring including a free end and a joined end, said joined end being integrally formed with said support member, wherein said flexible spring can flex independently from said support member.
101. The support as defined in claim 100 wherein said support member and flexible spring are integrally fabricated substantially of wood flakes.
102. The support as defined in claim 100 wherein said support member includes a plurality of spaced-apart molded wood flake flexible springs.
103. The support as defined in claim 100 wherein said at least one molded wood flake flexible spring is defined by a U-shaped channel formed in said support member.
104. The support as defined in claim 100 wherein said support member comprises a seat and said at least one molded wood flake flexible spring is disposed within said seat.
105. The support as defined in claim 100 wherein said support member includes at least one channel disposed therein, said at least one channel defining said at least one molded wood flake flexible spring and said at least one channel is integrally molded within said support member.
106. A molded wood flake support for a seating article which at least partially supports a user seated thereon, said molded wood flake support comprising:
- a base section molded of binder coated wood flakes, said base section including a frame section having a main portion and an integral seating section formed at an angle to said main portion of said frame section; and
- said seating section including at least one molded wood flake flexible spring including a free end and a joined end integrally formed with said frame section, wherein said flexible spring can flex independently from said main portion of said frame section.
107. The molded wood flake support as defined in claim 106 wherein said support is fabricated substantially of wood flakes.
108. The molded wood flake support as defined in claim 107 wherein said seating section includes a plurality of spaced-apart molded wood flake springs.
109. The molded wood flake support as defined in claim 108 wherein said wood flake springs are defined by a channel separating adjacent springs.
110. The molded wood flake support as defined in claim 109 wherein said at least one channel is molded into said support and terminates in said frame section and a circular aperture is formed through said frame section at the junction of said channel and frame section.
111. The molded wood flake support as defined in claim 106 wherein said at least one molded wood flake flexible spring comprises a plurality of spaced-apart molded wood flake flexible springs.
112. The molded wood flake support as defined in claim 106 further including a back molded of binder coated wood flakes connected with said base section, wherein said back includes at least one molded wood flake flexible spring.
113. The molded wood flake support as defined in claim 112 wherein said back includes a seat facing side and said at least one molded wood flake flexible spring extends outwardly from said seat facing side of said back.
114. A molded wood flake support according to claim 106 wherein said support includes at least one channel disposed therein, said at least one channel defining said at least one molded wood flake flexible spring and said at least one channel is integrally molded within said support.
115. The molded wood flake support as defined in claim 110 further including an elastomeric mesh coupled to said springs.
116. A molded wood flake article for a seating member said molded wood flake support comprising:
- a support section molded of binder coated wood flakes including a frame section having a main portion and a plurality of spaced-apart molded wood flake flexible springs including free ends and joined ends integrally formed with said frame section, wherein said flexible springs can flex independently from said main portion;
- a rigid panel mounted in spaced relationship to said support section; and
- a foam pad extending between said rigid panel and said support section and coupled to said molded wood flake flexible springs for supplementing the spring resistance of said flexible molded wood flake springs.
117. The molded wood flake support as defined in claim 116 including a plurality of spaced-apart foam pads extending between said rigid panel and said support section.
118. The molded wood flake support as defined in claim 116 wherein said wood flake springs are defined by a channel separating adjacent springs.
119. The molded wood flake support as defined in claim 118 wherein said at least one channel is molded into said support and terminates in said frame section and a circular aperture is formed through said frame section at the junction of said channel and frame section.
120. The molded wood flake support as defined in claim 107 wherein said flexible spring includes a longitudinal indentation extending into said frame section to stiffen said spring.
Type: Application
Filed: Oct 22, 2004
Publication Date: Nov 22, 2007
Applicant: J. R. Britton & Associates, Inc. (Leo, IN)
Inventors: Jeff Britton (Leo, IN), Samuel Conte (Fort Wayne, IN)
Application Number: 10/581,464
International Classification: A47C 7/16 (20060101); A47C 7/18 (20060101);