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Publication numberUS2847061 A
Publication typeGrant
Publication dateAug 12, 1958
Filing dateMar 18, 1955
Priority dateMar 18, 1955
Publication numberUS 2847061 A, US 2847061A, US-A-2847061, US2847061 A, US2847061A
InventorsHerschel B Morton
Original AssigneeHerschel B Morton
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Chair and method for making same
US 2847061 A
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Description  (OCR text may contain errors)

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United States Patent 2,847,061 CHAIR AND METHOD FOR MAKING SAME Herschel B. Morton, Lincoln, Nebr.

Application March 18, 1955, Serial No. 495,085 1 Claim. (Cl. 155-191) The present invention relates to a chair conformably shaped to fit an individual and to a method for making the same. i

The primary, object of the present invention is to provide a method for making a chair in which the portion of the seat and back occupied by an individual is conformably shaped to fit the back, buttocks, and posterior thighs of such individual.

Another object of the present invention is to provide a method for making a chair which is simple in execution, and commercially feasible.

A further object of the present invention is to provide a chair for individuals deformed by reason of injury, arthritis, poliomyelitis, or due to surgical amputation, and which supports with even pressure the back, buttocks, and posterior thighs of the individual.

A still further object of the present invention is to provide a chair which may be constructed with interchangeable seats and backs and which may be produced in several sizes and shaped to fit individuals of varying stature and which afiords to the occupying individual the maximum amount of comfort and rest consistent with correct posture.

These and other objects and advantages of the present invention will be fully apparent from the following description when taken in connection with the annexed drawings, in which:

Figure 1 is a view in perspective of a chair frame provided with a separate seat cushion and a separate back cushion, both filled with air to provide a resilient support.

Figure 2 is a view in perspective showing the seat and back cushion of the chair frame of Figure 1 covered with a mesh fabric coated with a settable material.

Figure 3 is a view in perspective showing the fabric web of the assembly of Figure 2 covered with a sheet of rubber protective material.

Figure 4 is a side view in cross section of the assembly of Figure 3 showing in dotted lines the figure of a person seated upon such assembly before the settable material has hardened.

Figure 5 is a view in perspective of the assembly of Figure 4 showing the application of a stiffening material thereto.

Figure 6 is a view in perspective showing the formed impression separated from the assembly of Figure 5.

Figure 7 is a view in perspective of a mold having the impression of Figure 6 incorporated therein, with the moldable material in process of being poured into such mold.

Figure 8 is a view in perspective showing the cast form removed from the mold of Figure 7.

Figure 9 is a view in perspective showing the cast form of Figure 8 with a rigid supporting backing applied thereto.

Figure 10 is a view in perspective showing the form of Figure 9 wholly encased in an upholstery fabric.

Figure 11 is a view in perspective showing the assem- 2,847,061 Patented Aug. 12, 1958 bly of Figure 10 with a heading applied to the corner edges of the upholstery fabric.

Figure 12 is a view in position on a chair frame.

Figure 13 is a sectional view taken on the line lit-13 of Figure 12.

In carrying out the method of making a chair having a seat and back conformably shaped to fit the back, buttocks and posterior thighs of an individual, an impression of the back, buttocks and posterior thighs of an individual is first formed. This is done by providing, Figure l, a chair frame 16 having a flexible seat cushion 14 and a flexible back cushion 15, both preferably air filled and with the seat cushion 14 under appreciably more air pressure than the back cushion 15. The seat cushion 14 and the back cushion 15 are arranged in whatever position is desired in the finished chair, in an erect position if an office chair is to be constructed, for instance, or more or less in a reclining position if a reclining chair is to be constructed.

A coating of a settable impression forming material is next applied to the seat cushion 14 and and the back cushion 15. This is done by applying a web of mesh fabric 17 impregnated with the impression forming material, such as plaster of Paris, to the portion of the seat cushion 14 and the back cushion 15 occupied by a seated individual, as shown in Figure 2, whereupon a flexible waterproof sheet 18 of rubber, or the like, is immediately stretched over the impregnated fabric web while still in its unset stage, as seen in Figure 3.

An individual whose impression is desired is then seated upon the sheet 18 as shown in Figure 4 in dotted lines and indicated by the reference numeral 19, and such individual is permitted to remain so seated until the plastic material in the impregnated mesh fabric 17 has set or hardened. At this point the individual arises from the sitting posture of Figure 4, and the rubber sheeet l8 promptly removed. Next, a layer of plastic settable at room temperature in a liquid state is applied to the impression containing fabric 17 in quantity to form a rigid impression of the desired thickness, as by spraying indicated by the numeral 20 in Figure 5. After the plastic has set, the thus formed impression is removed from the chair frame 16, Figure 5, such formed impression being indicated by the reference numeral 21, Fig ure 6.

From the thus formed impression 21, Figure 6, a flexible casting is next formed. This is effected by forming a seat and back mold 22, Figure 7, having the impression 21 incorporated in the front face thereof. Into the mold 22 is poured a flexible material, such as foam rubber 23 in a liquid uncured state, as also shown in Figure 7, in quantity sufficient to fill the mold, and the mold then subjected to a curing treatment. When the foam rubber has been cured, the thus formed casting is removed from the mold 22, the casting being shown in Figure 8 and indicated by the reference numeral 24. It is to be noted that the front face of the casting 24 has the shaping of the impression 21, namely, a shaping conformably shaped to fit the back, buttocks, and posterior thighs of the individual 19. To the casting 24 is next applied a rigid supporting backing 25 which may be either of metal, wood, or like rigid material, as shown in Figure 9 to form a seat and back assembly. The seat and back assembly of Figure 9 is then totally encased in a sheet of upholstering fabric 26, as shown in Figure 10, and suitable edging or trim 27 is applied to the corners of the fabric 26, as shown in Figure 11'. The encased seat and back assembly is then mounted in a chair frame 28, as shown in Figures 12 and 13 and here shown to be constructed of tubes or solid metal rods and bars fabricated of such materials as aluminum, magnesium, wrought iron, steel, or the like.

The foam rubber seat and back assembly thus formed by the method of the present invention as seen in Figure 12 has depressions 29, 30 and 31 conformably shaped to fit the posterior thighs,'buttocks, and the back, respectively, of the individual and providing points of equal pressure between such portions of the body so as to result in a comfortable chair giving perfect posture to the body of such individual.

In the case of individuals deformed by disease, surgery, or due to other conditions, the seat and back assembly of the present invention may provide such support to the individual as will permit him to engage in his normal occupation.

It is contemplated that the seat and back assembly of the present invention may be made in a variety of shapes and sizes, and may be interchangeably mounted within the chair frame 28, permitting economical manufacture and sale of perfectly contoured chairs conformably shaped to several sizes of persons of various statutes.

In place of forming a casting of the impression 21, a layer of flexible material may be applied to the front face of the impression. the layer being applied in a thickness such to give the resultant impression flexibility without destroying or altering the formed shaping in the front face of the impression. The layer of flexible material may be made of foam rubber or any like material giving flexibility to the impression when applied thereto. The impression may then be totally incased in the upholstering fabric 26. suitable edging or trim 27 applied to the corners of such fabric, and thence mounting in a chair frame 28.

If desired, the impression 21 may be employed without further treatment as a seat and back for a chair.

What is claimed is:

A chair comprising a frame including a seat and a back, and a one-piece foam rubber casting fltted in said frame and including a seat portion supported on the frame seat and a back portion supported against the frame back. the front of said one-piece foam rubber casting having formed therein a single continuous impression, said impression conforming to the shape of a person's back, buttocks, and posterior thighs, the thickness of said foam rubber casting throughout its entire extent being sufficient to give full, comfortable support to the back, buttocks and posterior thighs of a person seated in said chair.

References Cited in the flle of this patent UNITED STATES PATENTS D. 142,800 Watson Nov. 6, 1945 672,193 McKinley Apr. 16, 1901 1,716,871 Weldon June ll, 1929 1,917,264 Kellogg July ll, 1933 2,251,318 Reynolds et al. Aug. 5, 1941 2,259,534 Blair et al. Oct. 21, 1941 2,542,931 Lightfoot Feb. 20, 1951 2,565,758 Covino Aug. 28, 1951

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US672193 *Dec 30, 1897Apr 16, 1901Duncan Mckenzie MckinlayMethod of finding surface forms for cycle-saddles.
US1716871 *Nov 23, 1925Jun 11, 1929Earl Thompson Posture SeatingChair
US1917264 *Jan 17, 1931Jul 11, 1933Harvey Kellogg JohnChair
US2251318 *Dec 17, 1937Aug 5, 1941Mishawaka Rubber & Woolen MfgCushioning facility for seats and the like
US2259534 *Sep 12, 1938Oct 21, 1941Arthur T ReynoldsSeat and mattress construction
US2542931 *Feb 4, 1949Feb 20, 1951Karl M LightfootChair
US2565758 *Aug 10, 1950Aug 28, 1951Covino SalvatorePreparation of orthopedic appliances
USD142800 *Mar 8, 1945Nov 6, 1945 Design for a chair seat-back unit
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US2970638 *Jan 6, 1958Feb 7, 1961Halter LudwigSeat and backrest construction
US2985889 *Jul 10, 1958May 30, 1961Fain Archie IBathing recliner
US3027195 *Dec 1, 1958Mar 27, 1962Miller Herman IncMulti-piece formed furniture construction
US3043624 *Nov 7, 1958Jul 10, 1962Mason Ernest GilbertSeat for public use
US3081129 *Dec 16, 1960Mar 12, 1963Ann Ridder ClaraChairs and seats
US3091497 *Jul 12, 1961May 28, 1963Houser Raymond JosephPew construction
US3111345 *May 25, 1961Nov 19, 1963RenaultUpholstery of seats and seat-backs, in particular for the seats of automobile vehicles
US3120407 *Jun 5, 1961Feb 4, 1964Miller Herman IncNet seating
US3124389 *Sep 7, 1961Mar 10, 1964 mi kan
US3138404 *Jul 29, 1963Jun 23, 1964Relaxo Bak IncAuxiliary body support for vehicle seats
US3147997 *Sep 20, 1961Sep 8, 1964Mason Ernest GilbertSeat for public use
US3361471 *Aug 18, 1966Jan 2, 1968Warren S. RadfordBack support
US3729752 *Jul 6, 1971May 1, 1973H HugginsOrthodontic cradleboard
US4828325 *Sep 29, 1987May 9, 1989University Of Tennessee Research CorporationMethod of making a custom fitted composite foamed cushion, a preform kit and the resultant product of the process
US4852945 *Aug 18, 1987Aug 1, 1989Rowles John WComprehensive contour chair apparatus
US5141285 *Feb 24, 1989Aug 25, 1992Brian ParkRelaxation chair
US5164536 *Nov 19, 1990Nov 17, 1992Societe Europeenne De PropulsionComposite armored seat, and method of manufacture
US5695406 *Feb 14, 1996Dec 9, 1997Park; Brian V.Immersive cyberspace system
US6357829 *Apr 25, 2000Mar 19, 2002Colby EnterprisesContoured body cushion
US6533971 *Sep 12, 2000Mar 18, 2003Synthetic Tubular Socks, Inc.Custom molded orthopedic impression shirt, kit and method
US7216388 *Jul 28, 2003May 15, 2007Aspen Seating, LlcContoured seat cushion and method for offloading pressure from skeletal bone prominences and encouraging proper postural alignment
US7422290 *Nov 18, 2004Sep 9, 2008Honde Access CorporationBody support assembly
US7918510 *Jul 25, 2007Apr 5, 2011Van Den Nieuwboer Johanna HendrikaPathology related individual modular orthopedic seating system
US8398170 *Oct 5, 2007Mar 19, 2013Brock WalkerActive response seating system
US8733843Jul 19, 2011May 27, 2014Bayerische Motoren Werke AktiengesellschaftProcess for producing a supporting shell for a seat
US20100140998 *Oct 5, 2007Jun 10, 2010Brock WalkerActive response seating system
US20130190869 *Jan 24, 2012Jul 25, 2013Wendy A. SmithMethod of Forming a Prosthesis From a User Kit
EP0957719A1 *Aug 16, 1996Nov 24, 1999Alan J. PowellSupporting seat
EP1878644A2 *Jul 9, 2007Jan 16, 2008Dirk BinderMethod and apparatus of individually manufacturing bicycle saddle
WO1990009751A1 *Feb 17, 1990Sep 7, 1990Edwin ArnoldSeat in the form of a chair, bench or the like
WO2008127266A1 *Aug 7, 2007Oct 23, 2008Vries Jacob DePathology related individual modular orthopedic seating system
WO2010112219A1 *Mar 31, 2010Oct 7, 2010Bayerische Motoren Werke AktiengesellschaftProcess for producing a supporting shell for a seat
U.S. Classification297/452.28, 219/217, 297/284.1, 297/DIG.200, 297/DIG.100
International ClassificationA61B5/107, A47C3/12, B29C44/12
Cooperative ClassificationY10S297/02, B29C44/1204, A47C31/126, A61B5/1078, Y10S297/01, A47C3/12
European ClassificationA61B5/107L2, B29C44/12B, A47C3/12, A47C31/12C