Seat box with drop-in webbing assembly

Patent metadata

Field	Value
Publication number	US-9420892-B2
Application number	US-201414293339-A
Country	US
Kind code	B2
Filing date	Jun 2, 2014
Priority date	May 31, 2013
Publication date	Aug 23, 2016
Grant date	Aug 23, 2016

Abstract

A seat box assembly and method of fabricating utilizing a drop-in webbing assembly secured into a main box and back frame assembly. The webbing assembly has a rectangular frame with elongate members and shorter members and a central girder with a cutout extending between mid-portions of the elongate members. The central girder attachable to the seat box and a central vertical frame member of the back frame assembly. The elongate members having stub portions that fit into slots in the main seat box. A method of repair includes replacing a damaged drop-in assembly with a different drop-in assembly.

First claim

What is claimed is:

1. A seat box assembly, comprising:
a main box including a front rail and a back rail separated by a pair of side rails to define an interior space;
a back frame assembly extending vertically from said main box, said back frame assembly including a pair of side uprights and a middle upright, each of the uprights being affixed to an interior face of said back rail, each of the side uprights of said pair of side uprights extending upwards from a respective one of said pair of side rails of said main box to define an apex at an intersection of the side upright and said side rail; and
a drop-in webbing assembly comprising:
a webbing frame including a forward spring rail and a rearward spring rail separated by a pair of cross rails, wherein each end of said rearward spring rail extends laterally beyond each of said cross rails to define a pair of protruding portions of said rearward spring rail;
a central girder attached to mid-portions of each of said elongate frame members; and
a webbing spanning between said forward spring rail and said rearward spring rail,

wherein said pair of side rails and said pair of side uprights cooperate to define a pair of rearward notches, one at each apex, each of said rearward notches including a first lead-in structure defined by the respective side upright of the respective apex and a second lead-in structure defined by the respective side rail of the respective apex; and
wherein said protruding portions of said rearward spring rail are disposed in said pair of rearward notches.

2. The seat box of claim 1 , wherein said second lead-in structure of each rearward notch is a chamfered lead-in structure.

3. The seat box of claim 1 , wherein said webbing comprises a plurality of webbing straps.

4. The seat box of claim 1 , wherein said drop-in webbing assembly is removably attached to said main box and back frame as a unit with said webbing and said central girder attached thereto.

5. The seat box of claim 1 , wherein said central girder comprises a wooden material.

6. The seat box of claim 2 , wherein each of the side rails of said pair of side rails further comprises structure defining a forward notch proximate said front rail.

7. The seat box of claim 6 , wherein each of said forward notches includes a third lead-in structure.

8. The seat box of claim 7 , wherein said third lead-in structure comprises chamfered lead-in structure.

9. The seat box of claim 8 , wherein a tapered face said chamfered lead-in structure of said second lead-in structure faces in a direction towards said back rail and a tapered face of said chamfered lead-in structure of said third lead-in structure faces in a direction towards said front rail.

10. The seat box of claim 1 , wherein:
said central girder includes a forward block and a rearward block connected by a cross member, said forward block including a first notch formed thereon, said rearward block including a second notch formed thereon;
said forward spring rail is disposed in said first notch of said forward block; and
said rearward spring rail is disposed in said second notch of said rearward block.

11. The seat box of claim 10 , wherein:
said forward block includes an extension portion that extends beyond said forward block in a forward direction;
said front rail defines a notch that is open to an upper edge of said front rail; and
said extension portion of said forward block is registered in said notch of said front rail.

12. The seat box of claim 10 , wherein:
said rearward block includes an extension portion that extends beyond said second notch of said rearward block in a rearward direction;
said back rail defines a notch that is open to a lower edge of said back rail; and
said extension portion of said rearward block is registered in said notch of said back rail.

13. The seat box of claim 10 , wherein a lateral face of said rearward block is affixed to a lateral face of said middle upright.

14. The seat box of claim 13 , wherein:
a back end of the central girder includes a rearward face having a rearward face area;
an overlapping contact area is defined between said lateral face of said rearward block and said lateral face of said middle upright; and
said overlapping contact area is greater than said rearward face area of said central girder.

15. The seat box of claim 14 , wherein an area ratio of said overlapping contact area to said rearward face area of said central girder is between 2 and 20 inclusive.

16. The seat box of claim 15 , wherein said area ratio is between 2 and 10 inclusive.

17. The seat box of claim 16 , wherein said area ratio is between 4 and 10 inclusive.

18. A method of assembling a seat box, comprising:
providing a sub assembly comprising:
a main box including a front rail and a back rail separated by a pair of side rails to define an interior space, said main box including upper edges that substantially define a plane; and
a back frame assembly extending vertically from said main box, said back frame assembly including a pair of side uprights and a middle upright, each of the side uprights of said pair of side uprights extending upwards from a respective one of said pair of side rails of said main box to define an apex at the intersection of the side upright and said side rail,
wherein said pair of side rails and said pair of side uprights cooperate to define a pair of rearward notches, one at each apex, each of said rearward notches including a first lead-in structure defined by the respective side upright of the respective apex and a second lead-in structure defined by the respective side rail of the respective apex;

providing a drop-in webbing assembly comprising:
a webbing frame including a forward spring rail and a rearward spring rail separated by a pair of cross rails, wherein each end of said rearward spring rail extends laterally beyond each of said cross rails to define a pair of protruding portions of said rearward spring rail;
a central girder attached to mid-portions of each of said elongate frame members, said central girder including a rearward block affixed to said rearward spring rail of said webbing frame; and
a webbing spanning between said forward spring rail and said rearward spring rail,

inserting said drop-in webbing assembly into said interior space of said main box so that said rearward block of said central girder is immediately adjacent a lateral face of said middle upright of said back frame assembly, said drop-in webbing assembly being inserted at an acute angle relative to said plane of said upper edges of said main box;
disposing each protruding portion of said pair of protruding portions into a respective one of said rearward notches via said at least one lead-in structure;
rotating said drop-in webbing assembly about said rearward spring rail when said pair of protruding portions are lodged within said rearward notches, so that said forward spring rail is rotated towards said main box; and
registering said drop-in webbing assembly within said main box, so that said rearward spring rail is registered against the support faces of said rearward notches.

19. The method of claim 18 , further comprising:
sliding said pair of protruding portions over said at least one lead-in structure to stretch said webbing frame.

20. The method of claim 19 , wherein said at least one lead-in structure of each of said rearward notches of said subassembly provided in the step of providing a subassembly are chamfered lead-in structures.

Assignees

• Ashley Furniture Ind Inc

Inventors

• Lejcher Christopher Jon
• Brandtner Timothy A
• Boe Aaron

Classifications

• Y10T29/49904

  Assembling a subassembly, then assembling with a second subassembly · CPC title

• A47C4/028

  Upholstered chairs, e.g. metal, plastic or wooden chairs · CPC title

• A47C7/22 Primary

  Straps or the like for {direct user support or for} carrying upholstery · CPC title

• A47C7/02

  Seat parts · CPC title

• A47C4/02

  Dismountable chairs · CPC title