Roll-up furniture leg floor protector
The present invention relates to a furniture leg floor protector. The invention is an improvement over the prior art in that firstly it has a flexible upper sleeve which is stretchable and adapted to receive a leg of many dimensions. This overcomes previous problems with floor protectors which after a certain age and wear, and because of semi-rigid construction, tend to fall off the furniture legs. The invention also presents a method of installing the felt pad on the bottom of the floor protector by means of molding around the pad during molding of the floor protector. This not only fixedly secures the pad to the rest of the floor protector in an integral manner; but also alleviates applying the pads to the floor protector by means of adhesive as a second step in the manufacturing process after molding.
This application claims priority from Canadian Patent Application no. 2,585,597, filed in Canada Apr. 20, 2007.
FIELD OF THE INVENTIONThis invention relates to furniture leg floor protectors, and more particularly those adapted for use with chair, table, stool, sofa, or any other furniture leg.
BACKGROUNDFurniture leg floor protectors have commonly been in use for many years. These are used to avoid damage to for example hardwood floors when a chair or table is moved. They also reduce noise in the classroom where children tend to move their desks and chairs around often making an irritating noise.
Almost all furniture leg floor protectors suffer from two problems which the present invention seeks to solve. Most present day floor protectors are injector molded out of a transparent, rubber-like material such as plasticized thermo-plastic elastomer. The product is semi-rigid, including the upper sleeve with circular side walls. The upper sleeve is adapted to receive a leg of furniture such as a chair or table. After the molding process, a pad is applied to the bottom of the elastomer rubber-like body on the bottom thereof. The pad may be constructed of wool or felt. The pad can also be formed of a deformable resilient material to stabilize the object to give a support surface. The pad is usually secured to the floor protector body by mechanical bonding or adhesive bonding.
The addition of the pad is an extra step in the manufacturing process, which must sometimes be done by hand and thus is labor intensive. Moreover, overtime the adhesives tend to wear out, and by constant movement of the furniture leg, the pad finally becomes detached and a new pad must be added. The other problem with the semi-rigid elastomer protectors is that the upper sleeve, after significant use, becomes somewhat enlarged and the protector tends to fall off the chair or table leg.
Attempts to increase friction and long life of the upper sleeve of a floor protector have been mildly successful. For example, in United States Publication No. 2004/0123421 A1, a corrugated sleeve having folds therein to increase friction has been utilized. It would appear however that the complexity of the molding process could make this option uneconomical.
The present inventor has set out to remedy these two problems. With regard to the first, the present inventor has found by surprise that if, a for instance, a 100% wool felt is placed in a mold in a centralized position on the bottom of the mold with some frictional fit within the mold, that when the injection molding process takes place, the thermo-plastic elastomer is injected in the mold and surrounds the felt on its top planar surface and also forms a circumferential lip around the pad. Once set, cooled and removed from the mold, the pad becomes an integral part of floor protector, and cannot be separated therefrom without damage. That is to say, it is permanently affixed.
With regard to the second problem, by molding the floor protector with an upper flexible, stretchable sleeve, i.e. a circular side wall, the protector can be rolled up or folded up the chair leg during installation and frictionally stretches and adheres to the chair leg, constantly exerting an inward force towards the leg and thus preventing the floor protector from falling off the furniture leg. Moreover, in the folded down or rolled down sleeve position, the protector is smaller and easier to ship and handle, as it takes up a smaller volume.
Therefore, it is the first object of this invention as to provide an easier way to attach a pad of felt to the bottom of a floor protector. The second object of the present invention is to increase friction between the upper sleeve or circular side wall of the protector and the furniture leg.
Therefore, this invention seeks to provide a furniture leg floor protector adapted for use with chair and table legs comprising: a semi-rigid body of rubber-like material; said body including a lower, circular side wall, a bottom wall, and a lower circumferential lip; said protector further comprising a stretchable flexible circular upper side wall; said lower circular side wall, said bottom wall, said circumferential lip, and said stretchable flexible circular upper side wall being integrally formed together as one during molding; said protector further comprising a pad; said pad being adapted to fit below said bottom wall and within said circumferential lip and be permanently affixed to said semi-rigid body during said molding.
This invention also seeks to provide a method of manufacturing a furniture leg floor protector comprising the steps of: (a) placing said pad in a friction-fitted centralized position on the bottom of an injection mold; (b) injecting a transparent rubber-like material, such as plasticized thermoplastic elastomer, into said mold over and around said pad; and (c) removing said protector with said permanently affixed pad from said mold after cooling and setting.
General DescriptionThe furniture leg protector of the present invention is a one piece plastic elastomer body with a felt pad, preferably 100% wool, embedded in the bottom during the molding process. The protector can take many shapes, providing that there is sufficient friction between the upper sleeve/circular side wall and the chair leg. The pad can be rounded or have an aperture therein or simply one piece with planar top and bottom surfaces. After molding, the pad must protrude slightly from the elastomer body in order to have proper contact with the floor. The upper sleeve is generally constructed to be much thinner than the lower circular wall, which must be more rigid to support the bottom of the chair leg. The thickness of the sleeve can diminish from the bottom to the top, i.e. the remote end which provides access for the chair leg during installation. It may also be tapered or in some cases cone-shaped. In other embodiments, the sleeve upper side wall can have a concave outer side and a convex inner side. It is of course possible to also have an upper sleeve or upper side wall of equal thickness in the form of a cylinder.
The invention will be described in detail in conjunction with the following, wherein:
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In conclusion, it is to be understood that the two specific improvements in this invention are (1) the flexible, stretchable upper side wall, circular in form, adapted to frictionally engage a furniture leg of any dimension, and (2) the manufacture of the integrally molded furniture leg protector, wherein the injection molding takes place on and around the pad or felt. It is a novel and effective way to ensure fixation of the pad or felt to the thermoplastic elastomer body to ensure long life of the product.
Claims
1. A furniture leg floor protector adapted for use with furniture, comprising: a semi-rigid body of rubber-like material; said body including a lower, circular side wall, a bottom wall, and a lower circumferential lip; said protector further comprising a stretchable flexible circular upper side wall; said lower circular side wall, said bottom wall, said circumferential lip, and said stretchable flexible circular upper side wall being integrally formed together as one during molding; said protector further comprising a pad; said pad being adapted to fit below said bottom wall and within said circumferential lip and be permanently affixed to said semi-rigid body during said molding.
2. A method of manufacturing a furniture leg floor protector, as claimed in claim 1, comprising the steps of: (a) placing said pad in a friction-fitted centralized position on the bottom of an injection mold; (b) injecting a transparent rubber-like material, such as plasticized thermoplastic elastomer, into said mold over and around said pad; and (c) removing said protector with said permanently affixed pad from said mold after cooling and setting.
3. A furniture leg floor protector as claimed in claim 1 wherein said pad is a felt-like substance comprised of any one of the group of polyester, wool, nylon, rayon, Teflon, and cotton.
4. A furniture leg floor protector as claimed in claim 1 wherein said pad is comprised of a mixture of any two of the group of polyester, wool, nylon, rayon, Teflon, and cotton.
5. A furniture leg floor protector as claimed in claim 1 wherein said flexible stretchable circular upper side wall is thinner than said lower circular side wall.
6. A furniture leg floor protector as claimed in claim 5, wherein said upper side wall in a first position is folded downwardly for shipping and handling, and in a second position is folded upwardly to engage a furniture leg during installation.
7. A furniture leg floor protector as claimed in claim 5 wherein said upper side wall in a first position is rolled down around said lower side wall during shipping and handling; and in a second position is unrolled to engage a furniture leg frictionally during installation.
8. A furniture leg floor protector, as claimed in claim 1, wherein the circumference of a top edge portion of said upper side wall is less than that of said lower side wall.
9. A furniture leg floor protector, as claimed in claim 8, wherein said upper side wall is tapered inwardly and upwardly.
10. A furniture leg floor protector as claimed in claim 1 wherein an upper most portion of said upper side wall is thinner than a lower most portion of said upper side wall.
11. A furniture floor protector as claimed in claim 1, wherein an outer side of said upper side wall is concave and an inner side of said upper side wall is convex; and the circumference of a top portion of said upper side wall is less than the circumference of a bottom portion of said upper side wall.
12. A furniture leg floor protector as claimed in claim 1 wherein a top portion of said upper side wall is of the same thickness as a lower most portion of said upper side wall.
13. A furniture leg floor protector as claimed in claim 1, wherein the thickness of said upper side wall decreases from a lower most position to an uppermost position.
14. A furniture leg floor protector as claimed in claim 1, wherein said pad is round with planar top and bottom surfaces.
15. A furniture leg floor protector as claimed in claim 1, wherein said pad includes a convex lower outer surface.
16. A furniture leg floor protector as claimed in claim 1, wherein said pad includes a central aperture.
Type: Application
Filed: Apr 8, 2008
Publication Date: Oct 23, 2008
Inventor: Pierre Desmarais (Cantely)
Application Number: 12/082,054
International Classification: A47B 91/00 (20060101); A47B 95/00 (20060101);