WO1991001664A1

WO1991001664A1 - Unitary chair, formed from fiberboard

Info

Publication number: WO1991001664A1
Application number: PCT/US1989/003369
Authority: WO
Inventors: James Lewis Kelley; James Richard Volpe
Original assignee: Individual
Current assignee: Individual
Priority date: 1989-08-04
Filing date: 1989-08-04
Publication date: 1991-02-21
Anticipated expiration: 1992-02-04

Abstract

This chair is made from one simple blank of five rectangular panels. Its lower part, a rectangular glued tube, contains a preglued vertical seat-support panel parallel to two outer walls, that folds and unfolds with the tube. The upper part of the chair is an extension of the tube, but the front panel (24) folds in, back and down to form a seat spanning the tube, held up by the front (3) and seat-supports panels. The back and seat are both scored (18, 20) to buckle for added comfort and more-convenient set up; and an instantly deployable holder (40) for beverages or implements is formed in a side panel (5). Scoring (20) of the seat (24) permits a user to initiate positioning of the seat panel (24) by pushing the side panels inward. A scored seat also provides additional comfort.

Description

UNITARY CHAIR, FORMED FROM FIBERBOARD

BACKGROUND

1. FIELD OF THE INVENTION

This invention relates generally to economical, easily transported and rapidly set up chairs suitable for large gatherings such as sporting events, lawn parties or parades; and i&ore particularly to a collapsible, disposable chair of corrugated fiberboard or like generally planar recyclable material.

2. PRIOR ART

The most relevant corrugated-product chair of which we are aware is disclosed in our United States Patent 4,811,987. That patent contains an extensive discussion of prior patents and other art, and their limitations — which discussion is incorporated by reference herein. We have found the chair of that patent to be extremely satisfactory. The present document addresses only certain refinements which we have found desirable under special circumstances or for special applications. The recognition of these special circumstances and special applications is itself a part of the inventive process related to the present invention, and so will be discussed in the following section of this document.

SUMMARY OF THE DISCLOSURE

We have found that when our chairs are to be set up by retail customers or other people without any benefit of personal instruction in setting them up, some of the motions required are slightly counterintuitive. In particular we have noted that such people attempting to set up our chairs want to push inward, rather than pulling outward, on the side panels. Such an error usually causes no damage but sometimes causes frustration, annoyance or delay before the error is discovered by reference to the pictorial and/or textual instructions. This sort of experience can interfere unduly with full enjoyment of the advantages of a corrugated- product chair. We have also found that some people are unusually sensitive to bodily discomfort, and of course such extraordinary sensitivity is particularly aggravated by protraction of discomfort. Accordingly for such people an especially comfortable variant of a corrugated-product chair is desirable. In addition we have noted that some people who are not agile or well coordinated have difficulty in putting beverage containers — or perhaps other items such as implements — onto the ground or on their laps, or on the chair itself, while seated in our chairs. Furthermore the ground is often dirty, uneven or hot — and thus an unde- sirable place for cool beverages or the like. Thus for various reasons provision for holding beverages or the like in cooperation with other features of a chair is desirable. Our invention is a disposable chair, though it may be reused many times if desired. In only a few seconds — as few as two or three seconds — our invention, if already set up for use as a chair, can be folded flat for storage and shipment; or if in that latter condition can be unfolded and configured for use. The chair includes four contiguous and rectangular panels. The panels should be of material that is of generally planar character. By that we mean that the material is extended in only two dimensions and very thin in a third dimension. Thus it may alternatively be called "sheet material." The material should, however, be sufficiently stiff and strong in the aggregate, when configured for use, to support a person. The four rectangular panels define generally vertical edges of equal length. That length is the overall height of the chair. One pair of the four rectangular panels is mutually of equal width. That is the width of the chair when in use. One panel of this particular pair forms the back of the chair. The other panel of this pair has portions that respectively form the front and seat of the chair. Another pair of the four rectangular panels is mutually of equal width, which width is the front-to-back depth of the chair when it is in use. Each panel of this other pair forms one of the sides of the chair. These four rectangular panels are joined along the entire lengths of their equal-length edges. The side panels alternate with the front and back panels, to form a continuous four-panel row. The opposite ends of this four-panel row, in turn, can be joined to form a continuous upstanding tube of rectangular plan. A fifth rectangular panel is disposed erect within the tube, and defines two vertical edges and a horizontal upper edge. This fifth panel is joined along its two vertical edges to either of the two pairs of rectangular panels mentioned above; it is parallel, and nearly equal in width, to the remaining pair of rectangular panels. The fifth panel, like the others, is of generally planar material — but sufficiently stiff and strong to significantly aid in supporting, and in distributing to the other four panels for support thereby, a person's weight. The seat-forming p-rtion of the panel that forms the front and seat of the chair is folded downwardly and inwardly, with respect to the tube, against the back of the chair. In that position it is supported by the horizontal upper edge of the fifth panel. Each side panel is doubled over and inward, with respect to the tube. This folding-over of each side panel is along a line extending generally from the top rear corner of the chair downward and forward to intersect the transverse fold in the panel that forms the front and seat. In addition, the seat panel is scored — or otherwise adapted for folding — along additional intermediate angled lines. These additional fold lines are provided to permit temporary buckling deformation of upper portions of the tube out of rectangular plan. Such deformation is useful to facilitate the folding of the side panels inward and downward, relative to the tube — this single motion also simultaneously folding the seat panel into position for use. Conversely, the same deformation comes into play in unfolding of the seat-forming portion upward and outward from its seat-forming orientation, preparatory to flattening the entire structure for shipment and storage. This mode of setting up or reflattening the structure is accordingly much easier for people who do not have available any personal instruction in the procedure. It is much more consistent with a person's intuitive expectations than the setup and reflattening mode of our earlier chairs. The foregoing may be a description of our invention in its broadest or most general form. There are several features, however, which we consider highly desirable and prefer to incorporate into the structure for enhancement of the advantageous performance of our invention. One such preferred feature is a beverage or implement holder, formed in the corrugated material of the chair by die-cutting at the same time all other parts of the chair are formed. The holder is simply pulled out into position, and greatly alleviates the previously mentioned difficul- ties of some users in handling beverages or other articles while seated in a corrugated-product chair, as well as avoiding the necessity of placing beverages or the like on dirty, uneven or hot surfaces. Another preferred feature is that the fifth panel satisfy certain conditions. In particular, we prefer that the height of the fifth panel generally defines the height of the chair seat, and that that height generally equals the difference between the overall height of the chair and the front-to-back depth of the chair. The reason for this condition upon the height of the fifth panel will be explained in the detailed description that follows. Yet another preferred feature is an intermediate, generally planar vertical strip interconnecting one of the two vertical edges of the fifth panel with a vertical edge of one of the other four panels. This strip stands parallel to and in generally planar contact with some one of the other four panels, and is of a width that is very generally half the width or depth of the chair. The main function of this intermediate strip is to interconnect the fifth panel with a corner edge of the continuous row of panels that forms the tube. T^* e inter- connection makes it possible for the fifth panel to be part of the same unitary blank that forms the rectangular tube. Another preferred feature is a generally vertical tab, unitary with the other of the two vertical edges of the fifth panel. This vertical tab secures that "other" vertical edge to a rectangular panel which is opposite the intermediate strip. In this way the fifth panel can be positioned parallel to either the front and back panels, or the side panels, of the rectangular-plan tube. We also prefer to provide the fifth panel with an extension panel, which is folded at ninety degrees — just below the seat — to a horizontal orientation. The fold itself functions to very greatly stiffen the fifth panel; hence the extension panel may instead be called a "stiffening-angle tab." In this case the fold line may be regarded as the previously mentioned "horizontal upper edge" of the fifth panel, since the seat is supported on this fold line. All of the five panels, and the intermediate strip and the vertical tab as well, can thus be formed of a single unitary blank. One of the four first-mentioned rectangular panel^'s is at one end of the blank, and the tab is at the other end ©i ' he blank. The panel that is at one end of the blank is secured to the intermediate strip, as a convenient arrangement for completing the continuity of the tube. Another particularly important group of features of our invention is in the nature of detailed refinements to the stiffening-angle tab already mentioned. We have found that by introducing these refinements it is possible to make ^"assembly and disassembly even easier. Most significantly, these refinements also permit a controlled deformation of the seat panel and stiffening- angle tab, when the seat panel and the tab have been folded to their generally horizontal positions. This deformation of the seat panel and the stiffening-angle tab permit the support surface of the seat to conform to a user's body. The refinements which provide these advantages include (1) a lengthening of the stiffening-angle tab itself so that when folded down it contacts the rear panel of the chair, (2) addition of a notch at the extreme edge of the panel, and (3) adding to the panel a through-cut, parallel to but offset slightly below the folding score. The lengthening of the stiffening tab increases a user's leverage in folding down the tab. A user can insert fingers into the notch, to grasp and raise both the seat panel and the tab at once for disassembly. The through-cut converts a shallow part of the fifth panel from being part of the vertical-support column to being part of the horizontal tab. The result is to moder- ate the stiffening action of the tab, and at the same time create a shallow depression — in effect a cavity below the horizontal tab —*"at the top end of the vertical column. These two effects in turn permit a slight sagging of the seat panel into the cavity in the top of the vertical part of the reinforcement panel. This slight controlled sag very greatly enhances the user's comfort, particularly in protracted use. - 7 -

1 At the same time a useful fraction of the stiffening

2 action of the tab is retained, so that the structural

3 advantages of the fifth panel and its stiffening tab are

4 maintained. By extensive trial and error we have learned

5 how to dimension the offset cut to optimize the tradeoff

6 between stabilization of the structure and enhancement of

7 the user's comfort, and we do not in the slightest

8 sacrifice the economy, ease of manufacture, compactness, or

9 any other beneficial property of our invention.

10 Our invention, as defined by the appended claims, also

11 encompasses the novel blank for making the chair.

12 It also encompasses methods for using the chair. One

13 such method is for reusing or disposing of the chair: 14

15 (1) providing the chair configured for use in supporting a

16 person on the seat-forming portion; 17

18 (2) after such use is completed and a person no longer oc-

19 cupies the chair, inserting a hand from above through

20 the hand-access cutout of the seat-forming portion; 21

22 (3) then grasping the seat-forming portion (and also the

23 stiffening-angle tab), and lifting it away from the

24 back of the chair; 25

26 (4) generally simultaneously with the grasping and lifting

27 step, deforming the upper portions of the side and

28 seat panels by buckling the seat-forming portion

29 upward and outward, relative to the tube; 30

31 (5) continuing the motion of the seat-forming portion (and

32 the stiffening tab) '.ard and forward, and then

33 debuckling _ i. e.. restoring to planarity) the

34 seat-forming portion until it is generally vertical; 35

36 (6) then folding the tube from its rectangular plan

37 condition to its generally flat condition; and; (7) then shipping the folded chair as a flat tube to a subsequent point of use or storage.

Another method within the scope of our invention is the converse method for placing the chair in use. It includes these steps:

(1) shipping the folded and secured blank as a flat tube to a point of use;

(2) then unfolding the tube to its rectangular plan condition;

(3) then deforming the upper portions of the four first-mentioned rectangular panels by buckling the upper left and right front corners inward, relative to the tube, and thereby the central portion of the seat along the angled scores outward or forward;

(4) then pushing the side and seat-forming portions back, in and down against the inside, so that the seat is supported by the upper edge of the fifth panel;

(5) either before or during the deforming and pushing steps, pushing the stiffening-angle tab backward, inward relative to the tube, and downward toward a generally horizontal orientation; and

(6) then providing the chair for use in supporting a person on the seat-forming portion thereof.

As will now be clear, our invention provides a very light but strong, reinforced disposable (or reusable) chair that may be made of corrugated fiberboard very inexpensively, with negligible waste. It requires extremely little preliminary assembly — and even that can all be performed by very simple machine operations. The chair takes a very minimum of space for shipment and storage, and only a very few seconds of unskilled labor for setup or knockdown. It has not even one assembly tab to slow either task — or to wear or be damaged. It is improved over our earlier chair in that it is more comfortable, more readily set up and refolded by people working without personal demonstration of the tehnique, and more accommodating of elderly or other people who lack coordination needed for managing drinks or other articles while seated in the chair. The principles and advantages of our invention will be more fully appreciated upon consideration of the following details, with reference to the appended drawings, of which:

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is an isometric drawing of a preferred embodiment of our invention, shown configured for use in supporting a person. Fig. 2 is a front elevation of the same embodiment. Fig. 3 is a side elevation, in section, of the same embodiment — taken in a plane that is just inside either side wall. Fig. 4 is a perspective drawing of the same embodiment folded flat for storage or shipment (or disposal), but stood up on edge as if just removed from a pallet. Fig. 5 is a like view, but taken from below (with respect to the chair). It shows the same embodiment, still standing on ed*?^~, but now in the process of being opened from the Fig. 4 condition into a vertical rectangular-tube condition for use. Fig. 6 is a like drawing, also taken from below and showing the same embodiment at an intermediate stage of assembly — namely, folded open to a rectangular tube, with the seat panel not yet in position for use. Fig. 7 is a like drawing, but taken from above, showing the same embodiment at generally the same stage but now standing erect. Fig. 8, a like drawing, shows the same embodiment at the next intermediate stage of assembly, with the rectangu- lar tube still vertical and the seat now started inward. Fig. 9 is a like view with the seat folded almost fully down into position for sitting. Fig. 10 is an isometric view, similar to Fig. 1, but showing the various panels as if transparent, and with the seat folded fully down into position for sitting. Fig. 11 is an orthographic drawing of the single unitary blank (in its initial flat condition) from which the same embodiment is assembled. Fig. 12 is an enlarged perspective view of the beverage holder deployed for use with a beverage container or the like. Fig. 12a is a like view of holder in use.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in Figs. 1 through 3, a preferred form of our invention when set up for use is a chair with a generally horizontal rectangular seat panel 24 (including three subpanels or portions 24', 26 and 29), and generally vertical rectangular front and rear panels 3 and 7-25-31-32 respectively. The chair also has generally vertical trapezoidal left and right side panels 1 and 5 respectively. (All references to lateral direction in this despription are as viewed from in front of the chair. ) These are the four rectangular panels first-mentioned in the brief description above. The upper portions of the sides of the chair (the portions above the seat 24) are double walled, with inner side panels 30 on the left side and 27 on the right. These inner side panels 30 and 27 ar continuous with the outer side panels 5 and 1 respectively, being folded over at double folds 19, and they suspend the seat 24. As shown in Fig. 3, the seat also rests upon an internal cross-panel 11 (the "fifth panel" mentioned earlier), which is stabilized by a right-angle fold 15 at the base of part of its extension panel or stiffening-angle tab 14. Thus the seat is triply supported — in compression by the front panel 3 and internal panel 11, and in tension by the inner side panels 27, 30. It will be appreciated that the major part of the weight of a person occupying the seat typically will be borne by the internal cross-panel 11. The front panel 3 typically bears the next largest fraction of the weight. The tension effect of the inner side panels 27, 30 in suspending the seat 24 normally comes into play only if the occupant enters the seat in such a way as to slightly damage the internal cross-panel 11 or to slightly disrupt the stiffening effect provided by the right-angle fold 15 — or if the occupant sits in the seat in a skewed fashion that tends to slightly lift the seat away from the internal cross-panel 11. The chair has a handhole 17 for convenience in carrying. It also has a hand-access slot 21 for use in preparing the chair for shipment, storage, or disposal as will be explained shortly. In the rear panel, the upper portions 25-31-32 of the erected chair are generally coplanar with the lower portion 7, and the same is true of these portions even when the chair is folded flat for shipment, storage or disposal. Nevertheless, the upper portions 25-31-32 are separated from the lower portion 7 by a horizontal fold line 16; and the upper central portion 25 is separated from the upper side portions 31 and 32 by diagonal fold lines 18. Similarly the seat panel 24 central portion 24' is separated from its corresponding generally coplanar side portions 26 and 29 by intermediate diagonal fold lines 20. - 12 -

All these fold lines are provided for purposes to be made clear below, The preferred form of our invention can also assume the flattened or "closed" configuration of Fig. 4. In this condition it is extremely compact. More specifically, the overall thickness is only at maximum three layers of the fiberboard or other material, while the overall "height" (that is, the lengths of the glued edges 8, 33) is only equal to the height of the back panel of the erect chair. Furthermore, the width of the flattened chair is the sum of the widths of only two panels — e. g.. front panel 3 and side panel 1, as shown. In Fig. 4 the chair, though still in its "closed" configuration, is on edge — as if, for example, it has just been removed from a horizontal disposition on a shipping pallet, and rotated ninety degrees onto one of its edges. Figs. 5 and 6 represent two configurations of the chair. These configurations are intermediate between the flattened or "closed" condition of Fig. 4 and the opened condition of Figs. 1 through 3. In the first intermediate configuration, the flattened or "closed" chair of Fig. 4 is still erect, but now partially unfolded, or "folded open," into a parallelogram- shaped tube. To obtain this condition from that of Fig. 4, one first allows the natural springiness of the 180-degree folds 4 and 33 to very slightly open the tube from its completely flattened or "closed" condition, so that the bottom two panels 5 and 7 are no longer substantially coplanar — and similarly with the top two panels. It will be understood that this "first step" takes virtually no time at all. It occurs, without effort on the part of the person assembling the chair, as soon as the chair is placed on edge or even earlier. Next one moves the fold line 4 that is at the left edge of the flattened or "closed" chair (as viewed in Figs. 4 and 5) toward the right relative to the glued seam 8, 33 that is at the right edge. The latter part of this motion is indicated by the arrows 41 and 42. As can be seen in Fig. 5, the internal "fifth panel" 11 (with its extension panel 1 j is parallel to the front and back panels 3-24 and 7. Thus the fifth panel 11, 14 folds open as a parallelogram along with the front and back panels 3-24 and 7. Fig. 5 also illustrates attachment of this panel 11 to the left side panel 5 by a glue tab 13 and to the right side panel by intermediate panel 9. By continuing to unfold the parallelogram-shaped tube until the angles between adjacent panels (e. g.. at the principal fold lines 2, 4 and 6 and at the glue seam 8-33) are all substantially right angles, one eventually brings the chair to the substantially rectangular-tube condition shown in Fig. 7. The chair is now already standing on its bottom end. Next, as shown in Fig. 8 the top edge of the center portion 24' of the seat panel 24 is pulled outward, while its top left and right corners are pushed inward — thus passing through the "lost motion" phase. To accomplish this the side portions 26, 29 of the seat panel are folded back along the diagonal scores 20. Next as shown in Fig. 9 the entire seat panel 24 is pushed backward, inward and downward to approach the position rep sented in Fig. 1. In this process the seat panel 24 is reflattened at its diagonal scores 20; and the original outer-corner scores 2 and 4 (above the seat-forming score 22) are reversed, becoming inner corners, and are tucked into position against the inner side walls of the chair. The height of the seat panel 24 above any supporting surface of course equals the difference between the overall height of the chair and the length of the seat panel 24 — i. e.. its vertical length before it is pushed back. Since the seat panel 24 spans the front-to-back depth of the chair, its length substantially equals the common widths of the side panels 1 and 5. (The angle of the double-fold lines 19 to the horizontal is thus forty-five degrees). The height of the seat panel above any support surface is therefore, as previously mentioned, generally equal to the difference between the overall height of the chair and the front-to-back- depth of the chair. It will be appreciated that if the seat panel 24 were rigidly planar, it would not be physically possible to move the seat panel 24 from its Fig. 7 position to its Fig. 1 position. This is so even though, as previously mentioned- the seat panel is generally planar after the chair has been erected. The reason is that if the seat panel 24 were rigid and planar its left and right edges would have to pass directly adjacent to the upper diagonal double fold lines 19, but rigid upper side portions 30 and 27 would force the seat panel 24 away from the fold lines 19 in the intermediate portions of the motion. To permit lowering of the seat, the seat panel 24 is divided into central portion 24' and side portions 26 and 29. These are separated by respective auxiliary or intermediate fold lines 20, which allow the upper side-panel portions 27 and 30 and the seat-panel side portions 26 and 29 to buckle inward as indicated in Fig. 7. The rear panel is also provided with diagonal fold lines 18 and a horizontal fold line 16. These fold lines allow some flexing of the seat in response to application of a user's weight, to more comfortably accommodate the user's back. It will now be seen that the entire assembly process reduces to just three simple motions: standing the tube on end, opening it to rectangular form, and pulling and then pushing the seat into place. There is no slot-and-tab fitting step. Accordingly, unskilled personnel can perform this entire final-assembly or erecting procedure in just three seconds, ør perhaps as much as five seconds. Moreover they can do so after only a few minu^J s' training — which generally consists of being shown the procedure once. It will be understood that there is great variability among individuals in the ability to understand and imitate a simple mechanical procedure involving "normal" manual dexterity and "typical" spatial-relations sense. Accordingly our invention is not necessarily limited or defined in terms of the amount of assembly effort or time needed by any particular individual or individuals, except to the extent (if any) specified in the appended claims. Furthermore, such pe^rsonnel can even more rapidly refold the chair for shipment, storage and/or disposal by simply reversing the procedure just described. That is, the seat 24 and extension 14 are first folded forward and upward, and the seat 24 outward, to regain the Fig. 6 rectangular-tube structure. The hand-access slot 21 in the seat 24 facilitates this process. This slot makes it unnecessary to reach through the chair from the bottom to start the seat 24 and extension panel 14 upward from their horizontal positions of Figs. 1 through 3 and Fig. 9. The rectangular structure is then simply allowed to collapse. It passes through the parallelogram condition of Fig. 5 to the flattened cc idition of Fig. 4. As will be understood, the Fig. 4 starting point of the final-assembly process shown in Figs. 4 through 7 is a structure that has already been preliminarily assembled. The preliminary steps include partial folding, securing of the tab 13 to the inside of the lower left-hand side panel 5, and securing of the inside of the right-hand side panel 1 to the intermediate panel 9. We prefer to perform such securing by the use of glue, and preferably by automatic machinery which can fold and glue the blank to obtain the flattened form of Fig. 4. The securing may instead, however, be accomplished with heat-sensitive or chemically sensitive construction materials, staples, etc. Figs. 10 and 11 show how our entire chair can be folded up from a single blank of sheet material. They thus implicitly show also how the flattened form of Fig. 4 of our invention can be prepared from such a blank. The relationship between Figs. 10 and 11 may be con- ceptualized as follows. Starting with Fig. 11, in essence the rear panel 7-25-31-32 remains in position while the other panels fold "forward" or "upward" out of the plane of Fig. 11, and then transversely above that plane toward one another to make the enclosed forms of Fig. 10. More specifically, the intermediate strip 9, the "fifth panel" 11 with its extension 14, and the glue tab (or more generally "securing tab") 13 all fold forward in two right angles at the right-rear-corner vertical fold line 8 and the right-internal-corner vertical fold line 10. As a consequence the "fifth panel" 11 and extension 14 are parallel to and directly forward of the back panel 7-25-31-32. The glue tab 13 folds either in the same or (as illustrated) the opposite sense in another right angle at the left-internal-corner vertical fold line 12. Hence the glue tab 13 and intermediate strip 9 are mutually parallel, but at right angles to the rear panel 7 and "fifth panel" 11. On the other side ^'of the rear panel 7, the side panels 1 and 5 and the front-and-seat panel 3-24 all fold forward in three right angles along the left-rear-corner vertical fold line 6 and the two front-corner vertical fold lines 2 and 4. Consequently, (1) the inside of the left side panel 5 meets the glue tab 13 to form a parallel joint, (2) the front panel is directly in front of and parallel with both the back panel 7-25-31-32 and the "fifth panel" 11, and (3) the inside of the right side panel 1 meets the intermediate strip 9 to form another parallel joint. Specifically, the far left-hand edge 33 of the blank as shown in Fig. 8 meets the right-rear corner fold 8, as shown in Figs. 4 through 6. Now we will describe in more practical terms the assembly procedures leading to the flattened configura- tion of Fig. 4. The sheet stock is first printed by a silkscreen or direct-printing process, and then die-cut, scored and per- forated as shown in Fig. 11 — which shows the blank from the "inside". After that, glue is applied to the tab 13 on the inside of the sheet, and then the blank is folded over along the right edge 8 of the rear panel 7-16-17- 25-31-32 to glue the tab 13 to the left side panel 5. Next, glue is applied to the right side panel 1 in a stripe along its rear edge 33. Finally, the blank is folded along the corner 4 between the left-side panel 5 and the front-and-seat panel 3-24, to secure the right side panel 1 to the outside of the intermediate strip 9. We prefer to have the blank shown in Fig. 11 made from double-wall corrugated fiberboard with a Mullen test of 19.3 to 24.6 kg/cm² (275 to 350 pounds per square inch) bursting strength or liner-weight combination of 538 to 616 g/m² (110 to 126 pounds per thousand square feet). We also prefer B-type medium fluting toward the outside of the glued tube, and C-type fluting inside. Dimensions will vary with the sizes of people to be accommodated. In mass production for use by the general population, we prefer the following:

- overall height of the blank (that is to say, length of edge 33, and of fold lines 2, 4, 6 and 8), 71.1 centimeters; - width of the chair (that is, the fold-centerline-to- fold-centerline length of fold lines 22, 16 and 15), 43.2 centimeters; - front-to-back depth of the chair (that is, the fold-centerline-to-fold-centerline width of panels 1 and 5), 28.4 centimeters; - height of the seat above a support surface (that is, the fold-centerline-to-cut-edge length of that portion of the fold lines 2 and 4 that is below the fold line 22; or the height of the bottom portion 3 of the front panel) 43.2 centimeters; and - width of the glue tab 13 (cut-edge-to-fold-centerline) , 4.6 centimeters, but dependent upon the type of glue (or other securing means) employed.

The width of the intermediate strip 9 and of the front-to-back length (when horizontal) of the extension 14 can be adjusted between rather liberal limits. Very generally speaking, the "fifth panel" 11 should be midway between the front and rear panels 3 and 7. We strongly prefer to select these two dimensions so that the "fifth panel" 11 is somewhat closer to the rear panel 7. In typical or normal use the user's torso and hence the greater fraction of applied weight are placed behind the front-to-back central plane of the chair. We thus prefer to make the intermediate strip 9 approximately 13.3 centimeters. We have recently refined the stiffening-angle tab to optimize a tradeoff between structural stabilization and user comfort. Part of our invention lies in our recognizing that in this type of chair too much stability degrades the comfort of users — especially in protracted use. We have developed a structural feature that moderates the stiffening action provided by the stiffening-angle tab. The amount of this moderation can be quantitatively controlled by selection of the precise dimensions of this feature, so that by trial and error it is possible to optimize the comfort of a user of specified dimensions and weight. This optimization can simply be performed for a typical adult user. If preferred, a corresponding variety of optimal dimensions can be worked out for users of a variety of heights and weights. Blanks for making our chairs ith a variety of dimensions can be prepared for use by different groups of people, when it is feasible to determine in advance the sizes and weights of people who will be using the chairs. These refinements include:

(1) increasing the height of the sti fening-angle tab 14 so that when folded horizontal it just contacts the rear wall panel 7 — as does the folded-down seat panel 24;

(2) adding at the tip of the stiffening-angle tab 14 a notch 14n, which when the chair is assembled will be aligned generally with the notch 21 in the edge of the seat panel 24; and

(3) providing a through-cut 15c that is shaped to have a relatively long segment 15o which is offset from the geometric extension of the fold line 15.

The through-cut 15c advantageously can be formed with two short end segments 15e, relatively sharply angled to the fold line 15, that substantially connect the through-cut 15c to the fold line 15. The through-cut 15c if preferred can be instead tapered back to the fold line 15. The configuration of the cut which we prefer is a hybrid of these two possibilities — a five-segment path. A central segment 15o parallels the fold line 15, two very short end segments 15e are perpendicular to the fold line 15, and two intermediate very shallowly tapered segments 15t connect the short e segments 15e with the central segment 15o. It is not absolutely necessary that the connection of the through-cut 15c to the fold 15 be completed by die-cutting; reliance can instead be placed on a very slight amount of tearing or buckling to complete this connection. We prefer, however, to control the manner and location of this connection by die-cutting the through-cut back to the fold line. As can be seen from the drawings, when the seat is folded for use the offset through-cut creates a short forward horizontal extension 15f of the horizontal panel 14, and a shallow declivity or cavity 15d in the top of the associated vertical panel 11. The user's weight is supported in part on the combined horizontal surface 15f-14 of the fifth panel. This combined horizontal surface spans the declivity or cavity 15d. In use the user's weight deforms the seat panel 24 and the combined horizontal surface 15f-14. In this deformation the user's weight presses the combined horizontal surface 15f-14 partly or completely (depending upon the user's weight and dimensions) downward into the declivity 15d. For a user of medium or greater size and weight, the chair by this deformation tends to conform to the user's shape. For a smaller and lighter user, the combined horizontal surface tends not to "bottom out" in the declivity 15d and thus, instead retains some springiness. This configuration thus promotes comfort for both users. The previously mentioned five-segment cut configuration causes the declivity in the vertical portion 11 of the fifth panel to be gently tapered for comfortable conformance to the body of a middle-size, middle-weight user, but still provides a small vertical drop at each end of the declivity to create a springy "span" effect for smaller, lighter users. (Our invention does not depend on the accuracy of these analyses or theories.) The front-to-back length (when horizontal) of the extension 14 should be approximately 13 to 13.3 centimeters to match the intermediate strip 9. For actults in a normal range of size and weight, we prefer to make the length of the offset cut 15c approximately.23 centimeters, and the maximum offset roughly 1.9 centimeters. The finger notch 21 in the back panel can be approximately 4.4 centimeters wide, and the corresponding notch 14n in the stiffening-angle tab 14 can be approximately 5.7 centimeters wide. Both notches can be approximately 1.9 centimeters deep. It is possible to adjust the chair design for users' size and weight. Both the length of the offset cut 15c and the maximum offset distance (the distance from the offset segment 15o of the cut and the extension of the fold line 15) may be progressively decreased for relatively larger, heavier people. Such users seem to slightly deform the structure for themselves, without the need for a built-in stiffening- moderation (or "weakening") feature. For such people it is accordingly preferable to trade away some comfort and gain greater stability. Fig. 12 shows how a holder 40 for beverages etc. is formed. Die-cuts 43, 44 form inner and outer cut edges of a separated loop 41, which folds upward and outward along score lines 42, as indicated by the broad arrow 48 — so that the loop 41 stands out at generally a right angle, i. e.. in a generally horizontal orientation, from the surface of the vertical side (or other) panel 5. The inner and outer cuts 43, 44 also form respective inner and outer cut edges 47, 49 of a "U"-shaped aperture 46. At the bottom of his aperture 46, the outer cut edge 49 forms a platform for supporting a beverage container or the like. Left behind when the loop 41 is folded upward and outward is a stiff flap or tab 45, defined by the inner edges 47 of the aperture 46. A score 42' across the top of this flap 45 facilitates bending of the flap 45 inward by h.. pressure, or by pressure from a beverage container or the like. This inward bending makes it easier for a person to grasp the loop 41 to pull it out into position, and also makes a more definite space available for resting of a container on the "platform" 49. Yet the flap 45 continues to resiliently exert some counterpressure outward on the container to help hold it against the inner cut edge 43 of the loop 41. Fig. 12a shows how a beverage container 50 or the like fits into the holder 40. The loop 41 encircles the container 50, and the container 50 presses the flap 45 inward. The inward displacement of the flap 45 — caused by manual pressure when the holder 40 is first put into use, or by pressure from a container 50, or by both — allows the bottom portion of the container 50 to rest upon the platform formed by the outer edge 49 of the aperture 46. The flap 45 meanwhile presses outward against the beverage container 50 or the like — increasing the frictional force between the container 50 and the loop 41, to keep the container from slipping out of the loop. In practice when using the holder 40 with a standard can 50 for beverages, the friction between the can and the loop is high enough to hold the can in place even without reliance on the platform 47. The latter, however, always provides some assurance to the user who is uncertain of the adequacy of the frictional support alone; and of course may add significant support for a container whose diameter is smaller than that of a standard can. The foregoing disclosure is intended to be merely exemplary, not to limit the scope of the invention — which is to be determined by reference to the appended claims.

Claims

WE CLAIM :

1 1. A disposable chair that in a few seconds can be

2 folded substantially flat for storage and shipment or

3 unfolded and configured for use; said chair

4 comprising:

5 four substantially contiguous and substantially

6 rectangular panels of material that is of generally

7 planar character, extended in only two dimensions and

8 substantially very thin in a third dimension but

9 sufficiently stiff and strong in the aggregate, when

10 configured for use, to support a person; said four

11 rectangular panels defining generally vertical edges

12 of substantially equal length, which length is the

13 overall height of the chair;

14 one pair of the four rectangular panels being

15 mutually of substantially equal width, which is

16 substantially the width of the chair when in use; one

17 of the pair forming the back of the chair, and the

18 other of the pair having portions that respectively

19 form the front and seat of the chair;

20 another pair of the four rectangular panels

21 being mutually of substantially equal width, which is

22 substantially the front-to-back depth of the chair

23 when in use; each of this other pair forming one of

24 the sides of the chair;

25 said four rectangular panels being joined along

26 substantially the entire lengths of their

27 equal-length edges, the side panels alternating with

[Claim 1 continues [Claim 1 continued:]

28 the front and back panels to form an upstanding tube

29 of substantially rectangular plan;

30 a fifth rectangular panel that is disposed erect

31 within the tube, and that: 32

33 defines two vertical edges and a horizontal

34 upper edge,

35 is joined along its two vertical edges to

36 one or the other pair of rectangular panels,

37 is parallel and nearly equal in width to

38 the remaining pair of rectangular panels, and

39 is also of generally planar material that

40 is sufficiently stiff and strong to significant-

41 ly aid in supporting, and in distributing to the

42 other four panels for support thereby, the

43 weight of a person; 44

45 the Seat-forming portion of the panel that forms

46 the front and seat of the chair being folded

47 downwardly and inwardly, with respect to the tube,

48 against i.he back of the chair to be supported by the

49 horizontal upper edge of the fifth panel;

50 each-'side panel being doubled over and inwardly,

51 with respect to -the tube, along a line extending

52 generally from the top rear corner downward and

53 forward to intersect the fold in the panel that forms

54 the front and seat; and

55 corner sections of said seat-forming portion

56 being adapted for folding along intermediate angled

57 lines, to permit buckling deformation of the tube out

58 of rectangular plan and thereby to facilitate folding

59 of said seat-forming portion upward and outward

60 relative to the tube for shipment and storage, or

61 downward and inward relative to the tube for use. 2. The chair of claim 1, for use with a beverage container or the like, by a user who has impaired agility or coordination and has difficulty managing such beverage container or the like while seated in a disposable chair; and further comprising: cuts defined in at least a particular one of the panels, said cuts forming in said material:

a thin loop of said material for folding outward away from that particular panel to encircle and thereby retain such beverage container or the like, when said thin loop is folded outward away from the particular panel, a stiff flap of such material extending downward from the loop and bendable inward by pressure from such beverage container or the like when retained in said loop, and when said thin loop is folded outward away from the particular panel, an aperture below said flap, said aperture having a bottom edge for supporting such a beverage container or the like when retained in said loop and pressing inward on said flap;

said cuts cooperating with the seat-forming panel to provide a seating environment in which such a user with impaired coordination or agility can, while seated, successfully manage such beverage container by capturing such container in said loop. 3. The chair of claim 1: wherein the height of the fifth panel defines the height of the seat panel above the bottom of the chair, and very generally equals the difference between the overall height of the chair and said front-to-back depth of the chair; and further .comprising an intermediate generally planar vertical strip interconnecting one vertical edge of the fifth panel with a vertical edge of one of the other four panels; said strip standing parallel to and in generally planar contact with some one of the other four panels and being of a width that is very generally half the width or depth of the chair.

4. The chair of claim 3: further comprising a generally vertical tab, unitary with the other vertical edge of the fifth panel, that secures said other vertical edge to a rectangular panel which is opposite the intermediate strip; all of said five panels, the intermediate strip and the vertical tab being formed of a single unitary blank, one of the four first-mentioned rectangular panels being at one end of the blank and the tab being at the other end of the blank; and the panel that is at one end of the blank being secured to the Intermediate strip.

5. The chair of claim 3: wherein the fifth panel stands parallel to the front and back of the chair, the vertical tab joins the fifth panel to one side of the chair, and the intermediate strip is parallel to and in generally planar contact with the opposite side of the chair; and further comprising a stiffening-angle tab joined to the fifth panel along the horizontal upper edge of that panel, and folded backward and downward toward a generally horizontal orientation.

6. The chair of claim 5, wherein: the fifth panel and the stiffening-angle tab are unitary and are mutually demarcated by, in part, a transverse score along which they are mutually folded and by, in part, a generally transverse through-cut; the through-cut interrupts the score in a region, and is at least in part offset from a projection of the score through that region; the offset through-cut causes part of the fifth panel below the projection of the score through said region to function as a part of the stiffening-angle tab and to be folded toward a generally horizontal orientation together with the stiffening-angle tab generally.

7. The chair of claim 6, wherein: said part of the fifth panel below the projection of the score through said region, being folded toward a generally horizontal orientation, leaves a declivity in an upper vertical edge of the fifth panel below the generally horizontal part of the fifth panel; said declivity and said generally horizontal part of the fifth panel cooperate to enhance such person's comfort.